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BACKGROUND OF THE INVENTION
1. Field of the Invention
The field of the invention is contaminant oxidation, or, more specifically, oxidizing solutions and processes for oxidizing contaminants.
2. Description of Related Art
The appearance of contaminants, such as hydrocarbons, organics, bacteria, algae, animal oils, vegetable oils, and arabic gums, in various media and on various surfaces, creates a need for effective contaminant removal materials and techniques.
For example, a typical surface water storage facility can be expected to encounter hydrocarbon contaminants in tank bottom materials, and in emulsified layers on the stored water. Similarly, cooling tower installations are known to encounter hydrocarbon based oil layers on water that has accumulated in an adjacent basin, as well as, in the sludge at the basin bottom. Algae will frequently appear in the cooling tower to compound the contamination problem. Hydrocarbon contaminants are also known at crude oil storage tanks which frequently have contaminated soil surfaces proximate the tank, and at wastewater treatment plants, which are often faced with hydrocarbon based grease layers at their lift stations, and undesirable bacteria in their aeration tanks.
Organics, including animal oils and vegetable oils, are a known contaminant on surfaces, such as sidewalks and parking lots near restaurants and other public establishments. Sidewalks are also subjected to contamination with arabic gum.
The prior art includes various oxidizing materials, solutions and processes, as well as, various contaminant remediation methods.
U.S. Pat. No. 6,423,868 is a process for the production of an aqueous monoester peroxycarboxylic acid solution by reaction of a peroxygen compound with at least one dicarboxylic acid and with at least one alcohol optionally in the presence of an acid catalyst. Aqueous monoester peroxycarboxylic acid solution is obtainable by this process. Use of the aqueous monoester peroxycarboxylic acid solution is as a disinfectant. A microbicide is described in the description as a monester percarboxylic acid prepared by reaction between a monoester of an aliphatic dicarboxylic acid and hydrogen peroxide.
U.S. Pat. No. 6,423,236 relates to a method for treating waste water including the steps of: oxidizing the waste water, and then treating the oxidized waste water with a reverse osmosis membrane having high salt rejection rate. By being treated with the reverse osmosis membrane, the waste water is separated into an impermeated liquid which contains an oxidizable substance, and a permeated liquid which contains almost no oxidizable substance. Oxidation by hydrogen peroxide is mentioned.
U.S. Pat. Nos. 6,245,729, 6,384,006, and 6,319,888 include a system for forming and releasing an aqueous peracid solution is disclosed. The system includes a container and a peracid forming composition provided within the container. The container is permeable to the passage of water and aqueous peracid solution. The peracid forming composition includes a peracid precursor and a peroxygen source. Preferably, the peracid forming composition includes a chemical heater capable of releasing heat upon hydration. When placed in water, water enters the container and interacts with the peracid forming composition provided within the container. The water combines with the peracid precursor and peroxygen source to provide an aqueous peracid composition. The presence of a chemical heater within the container provides for the generation of heat within the container which enhances the rate of peracid formation. The peracid solution leaves the container and forms an effective sanitizing amount of sanitizer. A composition for forming and releasing an aqueous peracid solution is disclosed. The composition can include a mixture of peracid forming components or a composite structure containing peracid forming components adhered together. Methods of sanitizing a surface having a population of microorganisms are provided, and methods for manufacturing are provided.
U.S. Pat. No. 5,296,239 provides peracetic acid compositions containing at least one thickening agent and optionally a stabilizer chosen from sequestering agents, free-radical scavengers and mixtures containing two or more of these products. The preferred compositions are obtained by successively incorporating at least one stabilizer and then at least one thickening agent. These compositions are especially capable of being employed for the disinfection of large bulks which are difficult to immerse and of nonhorizontal surfaces, and for detergency or bleaching at low temperature.
U.S. Pat. No. 5,736,497 provides a phosphorus-free and boron-free cleaning composition containing a phosphorus-free aqueous solution containing an active ingredient (e.g., hydrogen peroxide or a compound capable of releasing hydrogen peroxide under the conditions prevailing in use of the composition), at least one organic stannate which is a tetravalent tin complexed with dicarboxylic acid, hydroxy carboxylic acid, or tricarboxylic acid, and optionally at least one organic stabilizer which is a benzoate, a sulfonic acid or salt, or mixtures thereof. The active ingredient is hydrogen peroxide or a percarbonate. The aqueous solution has an alkaline pH.
U.S. Pat. No. 4,051,058 provides Stable peroxy-containing concentrates useful for the production of microbicidal agents consisting essentially of 0.5% to 20% by weight of peracetic or perpropionic acid or their precursors, 25% to 40% by weight of H.sub.2 O.sub.2, 0.25% to 10% by weight of an organic phosphonic acid capable of sequestering bivalent metal cations and their water-soluble acid salts, 0 to 5% by weight of anionic surface-active compounds of the sulfonate and sulfate type, the remainder being water.
U.S. Pat. No. 4,051,059 provides Peroxy-containing concentrates, stable in storage, useful for the production of functional agents consisting essentially of 0.5% to 20% by weight of peracetic or perpropionic acid or their precursors, 25% to 40% by weight of H.sub.2 O.sub.2 0 to 5% by weight of anionic surface-active compounds of the sulfonate and sulfate type, the remainder being water.
U.S. Patent Application No. 20020086903 provides synergistic biocidal oxidant, useful as a sanitizer and disinfectant, is disclosed. The synergistic biocidal oxidant comprises a lower organic peracid, preferably peracetic acid, and chlorine dioxide.
U.S. Pat. No. 5,525,008 provides a method and apparatus for in-situ treatment of soil and groundwater contaminated with organic pollutants. The process involves defining the nature and extent of the contamination; determining the hydrology and geology of the contaminated area; determining the volume and concentration of a reactive solution required to effect treatment of the contaminated area; injecting the reactive solution into one or more injectors that are inserted into the ground, sealed and positioned so as to assure flow of the reactive solution through the contaminated area; allowing the reactive solution to flow through the contaminated area thereby reacting chemically with the contaminants contained within the contaminated area; and determining when the treatment is complete by monitoring by-products of the chemical reaction. Preferably, the reactive solution is an aqueous solution of hydrogen peroxide and metallic salts.
U.S. Pat. No. 5,820,761 involves a process wherein organic pollutants in wastewaters are wet-oxidized by addition of pure oxygen or an oxygen-containing gas at temperatures of 80.degrees to 330 degrees C., under pressures of 1 bar to 200 bar and at a pH value below 7. For the wet oxidation process, iron ions and digested sludge or surplus sludge from a biological sewage treatment plant are added to the wastewater.
U.S. Pat. No. 6,387,278 relates to in situ hydrous pyrolysis/partial oxidation of organics at the site of the organics constrained in a subsurface reservoir produces surfactants that can form an oil/water emulsion that is effectively removed from an underground formation. The removal of the oil/water emulsions is particularly useful in several applications, e.g., soil contaminant remediation and enhanced oil recovery operations. A portion of the constrained organics reacts in heated reservoir water with injected steam containing dissolved oxygen gas at ambient reservoir conditions to produce such surfactants.
U.S. Pat. No. 6,036,849 includes a method of removing hydrocarbons from soils contaminated with various hydrocarbons such as gasoline, diesel fuel, solvents, motor oil and crude oil. The process first screens the soil to remove oversized rocks and debris and to reduce the contaminated soil to uniformly sized particles. The soil particles are moved along a conveyor and first sprayed with an oxidizer diluted with ionized water and then sprayed with only ionized water. The washed particles are then vigorously mixed with their entrained oxidizer and ionized water in an auger mixer for several minutes to oxidize almost all of the remaining hydrocarbons. The washed and hydrocarbon-free soil is then moved by conveyor to a stockpile for storage, testing and drying.
U.S. Pat. No. 6,398,938 includes a process, which includes: electrochemically oxidizing at least one organic compound by bringing the organic compound into contact with an anode, wherein the anode includes: an electrically conductive support; and an electrically conductive, anodically polarized layer on the support; wherein the anodically polarized layer is formed in situ upon the support by precoating; and wherein the organic compound is not phosphonomethyliminodiacetic acid. Another embodiment of the present invention provides a product, produced by the above process.
U.S. Pat. No. 5,948,275 is an integrated method for purifying industrial and/or urban effluents containing a large amount of organic material in solution and/or suspension, wherein said effluents are treated in a wet oxidation reactor. The effluents are oxidized in the presence of at least one oxidizing gas to mineralize a large part of the organic material therein by producing a gas phase and an essentially liquid phase mainly containing soluble residual organic material, as well as an essentially inorganic solid phase in suspension. The essentially liquid phase from the reactor is subjected to liquid/solid separation to separate the solid phase, and at least a fraction of the separated solid phase is recycled in the wet oxidation reactor. Various alternative embodiments of the method include adding a catalyst and/or an agent for acidifying the recycled solid phase fraction. The facility may operate continuously or semi-continuously between interruptions.
U.S. Pat. No. 6,453,914 includes a method for removing organometallic and organosilicate residues remaining after a dry etch process from semiconductor substrates. The substrate is exposed to a conditioning solution of phosphoric acid, hydrofluoric acid, and a carboxylic acid, such as acetic acid, which removes the remaining dry etch residues while minimizing removal of material from desired substrate features. The approximate proportions of the conditioning solution are typically 80 to 95 percent acetic acid, 1 to 15 percent phosphoric acid, and 0.01 to 5.0 percent hydrofluoric acid.
U.S. Pat. No. 6,395,188 is a single step wet oxidation process for treating wastewaters containing organic species, with or without heteroatoms, and anions of strong acids, e.g. sulfate or phosphate ion, or cations of strong bases, e.g., sodium, potassium or calcium ions, and which may contain ammonium ion and/or nitrate ion in addition to added ammonium ion and/or nitrate ion was developed which on thermal treatment near the critical temperature of water removes substantially all the COD and nitrogen through conversion to water, carbon dioxide or carbonate species, nitrogen gas and small amounts of nitrous oxide. Key to the success of the process is the balancing of all reducing species with an equivalent amount of oxidizing species and the balancing of all strong acid anions with strong base cations and including at least 0.06 acetate ion for moles of nitrate in the wet oxidation process.
U.S. Pat. No. 6,426,020 is an etchant for copper or copper alloys comprising 5–50 wt % of an alkanolamine, a copper ion source in the amount of 0.2–10 wt % as copper, a halide ion source in the amount of 0.005–10 wt % as halogen, 0.1–30 wt % of an aliphatic carboxylic acid, and the balance water, wherein the molar ratio of the alkanolamine to one mol of the aliphatic carboxylic acid is two or more. The etchant is free from problems such as instability of the liquid composition and unpleasant odor, has a high etching rate, exhibits only very slight corrosion even if a small amount of residue is left on the surface and is capable of producing a roughened surface when used for microetching.
While the foregoing may function generally with respect to the purposes for which they were designed, they would not be as suitable for the purposes of the present invention, as hereinafter described. For example, such compositions and processes do not provide what is needed, that is effective oxidizing solutions and processes for safely oxidizing the above-described contaminants in a wide variety of locations and media in which they are encountered.
SUMMARY OF THE INVENTION
The present invention overcomes the shortcomings of the prior art by providing oxidizing solutions and processes for safely removing hydrocarbon and other contaminants from a wide variety of media and surfaces.
I have provided an oxidizing solution, comprising an aqueous solution comprising a peroxygen compound and a carboxylic acid selected from the group consisting of glycolic acid, oxalic acid, formic acid, and benzoic acid. In some embodiments, peroxygen compound is selected from the group consisting of hydrogen peroxide, calcium peroxide, magnesium peroxide, and sodium perborate and the solution further comprises a halogen compound selected from the group consisting of sodium bromide, sodium chloride, sodium fluoride, sodium iodide, and periodic acid. In one embodiment, the peroxygen compound is hydrogen peroxide, the carboxylic acid is glycolic acid, and the halogen compound is sodium bromide, and sodium percarbonate is the source of the hydrogen peroxide. In another embodiment, the peroxygen compound is hydrogen peroxide, the carboxylic acid is glycolic acid, and the halogen compound is sodium iodide.
My invention provides a process for oxidizing hydrocarbon contaminants in a media comprising exposing the hydrocarbon contaminants to an aqueous solution comprising a peroxygen compound and a carboxylic acid. The process is applicable when the media is selected from a group consisting of soil, sludge, and water. In some embodiments, the aqueous solution further comprises a halogen compound, and in some the halogen compound is selected from the group consisting of sodium bromide, sodium chloride, sodium fluoride, sodium iodide, and periodic acid. In some embodiments, the peroxygen compound is hydrogen peroxide, the carboxylic acid is glycolic acid, and the halogen compound is sodium bromide. In some embodiments, the media is water and the hydrocarbon contaminant is approximately 1 percent by weight, the hydrogen peroxide is from approximately 3 to 30 percent by weight, the glycolic acid is from approximately 0.0001 to 10 percent by weight, and the sodium bromide is from approximately 0.00005 to 10 percent by weight, and sodium percarbonate can be the source of the hydrogen peroxide. In some embodiments, the carboxylic acid is selected from the group consisting of glycolic acid, oxalic acid, acetic acid, formic acid, and benzoic acid, and in some embodiments the peroxygen compound is selected from the group consisting of hydrogen peroxide, calcium peroxide, magnesium peroxide, and sodium perborate. In other embodiments, exposing the hydrocarbon contaminants to an aqueous solution further comprises exposing the hydrocarbon contaminants to the aqueous solution by mixing the aqueous solution with the media.
I have provided a process for oxidizing hydrocarbon contaminants in a media comprising: exposing at least some of the hydrocarbon contaminants to a peroxygen compound; and exposing the remaining hydrocarbon contaminants to an aqueous solution comprising a carboxylic acid. In some embodiments, the media is selected from a group consisting of soil, sludge, and water. In some embodiments, the aqueous solution further comprises a halogen compound, and in some, the halogen compound is selected from the group consisting of sodium bromide, sodium chloride, sodium fluoride, sodium iodide, and periodic acid. In additional embodiments, the peroxygen compound is hydrogen peroxide, the carboxylic acid is glycolic acid, and the halogen compound is sodium bromide, the media is water and the hydrocarbon contaminant is approximately 1 percent by weight, the hydrogen peroxide is from approximately 3 to 30 percent by weight, the glycolic acid is from approximately 0.0001 to 10 percent by weight, and the sodium bromide is from approximately 0.00005 to 10 percent by weight. In some embodiments, sodium percarbonate is the source of the hydrogen peroxide, and in some the peroxygen compound is hydrogen peroxide, the carboxylic acid is glycolic acid, and the halogen compound is sodium iodide. In additional embodiments, the carboxylic acid is selected from the group consisting of glycolic acid, oxalic acid, acetic acid, formic acid, and benzoic acid. In some embodiments, the peroxygen compound is selected from the group consisting of hydrogen peroxide, calcium peroxide, magnesium peroxide, and sodium perborate. In additional embodiments, the step of exposing at least some of the hydrocarbon contaminants to a peroxygen compound, further comprises exposing at least some of the hydrocarbon contaminants to the peroxygen compound by mixing the peroxygen compound with the media; and the step of exposing the remaining hydrocarbon contaminants to a carboxylic acid, further comprises exposing the remaining hydrocarbon contaminants to a carboxylic acid by mixing the carboxylic acid with the media.
My invention provides a process for oxidizing phosphonic acid contaminants in a media comprising: exposing at least some of the phosphonic acid contaminants to a peroxygen compound; and exposing the remaining phosphonic acid contaminants to an aqueous solution comprising a carboxylic acid. In some embodiments, the media is selected from a group consisting of soil, sludge, and water. In another embodiment, the aqueous solution further comprises a halogen compound, and in some embodiments, the halogen compound is selected from the group consisting of sodium bromide, sodium chloride, sodium fluoride, sodium iodide, and periodic acid. In additional embodiments, the peroxygen compound is hydrogen peroxide, the carboxylic acid is glycolic acid, and the halogen compound is sodium bromide, and in some embodiments, sodium percarbonate is the source of the hydrogen peroxide. In some embodiments, the peroxygen compound is hydrogen peroxide, the carboxylic acid is glycolic acid, and the halogen compound is sodium iodide, and in some, the carboxylic acid is selected from the group consisting of glycolic acid, oxalic acid, acetic acid, formic acid, and benzoic acid, and the peroxygen compound is selected from the group consisting of hydrogen peroxide, calcium peroxide, magnesium peroxide, and sodium perborate. In additional embodiments, the step of exposing at least some of the phosphonic acid contaminants to a peroxygen compound, further comprises exposing at least some of the phosphonic acid contaminants to the peroxygen compound by mixing the peroxygen compound with the media; and the step of exposing the remaining phosphonic acid contaminants to a carboxylic acid, further comprises exposing the remaining phosphonic acid contaminants to a carboxylic acid by mixing the carboxylic acid with the media.
I have provided a process for oxidizing contaminants on a solid surface, wherein the solid surface is selected from the group consisting of brick, concrete, cement, asphalt, clay, and caliche, the process comprising: wetting the solid surface with water; distributing a peroxygen compound onto the surface; and distributing an aqueous carboxylic acid solution onto the surface. In some embodiments, the contaminant is selected from the group consisting of arabic gum, hydrocarbon, animal oil, and vegetable oil. In additional embodiments, the aqueous carboxylic acid solution further comprises a halogen compound, and in some embodiments, the peroxygen compound is hydrogen peroxide, the carboxylic acid is glycolic acid, and the halogen compound is sodium bromide. In some embodiments, sodium percarbonate is the source of the hydrogen peroxide.
My invention provides a process for oxidizing organic compound contaminants in a media, wherein the organic compound is selected from the group consisting of animal oils and vegetable oils, the process comprising: exposing at least some of the organic compound contaminants to a peroxygen compound; and exposing the remaining organic compound contaminants to an aqueous solution comprising a carboxylic acid. In some embodiments, the media is selected from a group consisting of soil, sludge, and water. In additional embodiments, the aqueous solution further comprises a halogen compound, and in some embodiments, the halogen compound is selected from the group consisting of sodium bromide, sodium chloride, sodium fluoride, sodium iodide, and periodic acid. In some embodiments, the peroxygen compound is hydrogen peroxide, the carboxylic acid is glycolic acid, and the halogen compound is sodium bromide, and in some embodiments, sodium percarbonate is the source of the hydrogen peroxide. In additional embodiments, the peroxygen compound is hydrogen peroxide, the carboxylic acid is glycolic acid, and the halogen compound is sodium iodide, and in some embodiments, the carboxylic acid is selected from the group consisting of glycolic acid, oxalic acid, acetic acid, formic acid, and benzoic acid. In some embodiments, the peroxygen compound is selected from the group consisting of hydrogen peroxide, calcium peroxide, magnesium peroxide, and sodium perborate.
A process for oxidizing contaminated sludge underlying water is provided, comprising: distributing a peroxygen compound into the water; and distributing a carboxylic acid into the water. In some embodiments, the step of distributing a carboxylic acid into the water further comprises distributing a solution into the water having the carboxylic acid and a halogen compound. In additional embodiments, the peroxygen compound is hydrogen peroxide, the carboxylic acid is glycolic acid, and the halogen compound is sodium bromide.
My invention provides a process for oxidizing bacteria suspended in wastewater, comprising: exposing at least some of the bacteria to a peroxygen compound by mixing the peroxygen compound with the wastewater; and exposing the remaining bacteria to an aqueous solution comprising a carboxylic acid by mixing the aqueous solution with the wastewater. In some embodiments, the aqueous solution further comprises a halogen compound, and in some embodiments, the halogen compound is selected from the group consisting of sodium bromide, sodium chloride, sodium fluoride, sodium iodide, and periodic acid. In another embodiment, the peroxygen compound is hydrogen peroxide, the carboxylic acid is glycolic acid, and the halogen compound is sodium bromide, and in some embodiments, sodium percarbonate is the source of the hydrogen peroxide. In additional embodiments, the peroxygen compound is hydrogen peroxide, the carboxylic acid is glycolic acid, and the halogen compound is sodium iodide, and in some embodiments, the carboxylic acid is selected from the group consisting of glycolic acid, oxalic acid, acetic acid, formic acid, and benzoic acid. In some embodiments, the peroxygen compound is selected from the group consisting of hydrogen peroxide, calcium peroxide, magnesium peroxide, and sodium perborate.
I have provided a process for oxidizing hydrocarbon contaminants in a subsurface formation, wherein the subsurface formation is in communication with the surface through a well bore, comprising: exposing the hydrocarbon contaminants to an aqueous solution comprising a peroxygen compound and a carboxylic acid, by injecting the solution through the well bore to the subsurface formation. In some embodiments, the aqueous solution further comprises a halogen compound, and in some embodiments, the peroxygen compound is hydrogen peroxide, the carboxylic acid is glycolic acid, and the halogen compound is sodium bromide.
My invention provides an oxidizing solution, comprising an aqueous solution comprising a peroxygen compound, a carboxylic acid, and a halogen compound. In some embodiments, the peroxygen compound is hydrogen peroxide, the carboxylic acid is glycolic acid, and the halogen compound is sodium bromide.
The foregoing features and advantages of my invention will be apparent from the following more particular descriptions of exemplary embodiments of the invention as illustrated, in some embodiments, in the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic, partially sectional view of a surface water storage facility.
FIG. 2 is a schematic, partially sectional view of a cooling tower installation.
FIG. 3 is a schematic, partially sectional view of a crude oil storage tank installation.
FIG. 4 is a schematic, partially sectional view of a restaurant facility and adjacent parking lot.
FIG. 5 is a schematic, partially sectional view of a theater and adjacent sidewalk.
FIG. 6 is a schematic, partially sectional view of a wastewater treatment plant.
DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS
The following discussion describes in detail exemplary embodiments of the invention. This discussion should not be construed, however, as limiting the invention to those particular embodiments. Practitioners skilled in the art will recognize numerous other embodiments as well. For a definition of the complete scope of the invention, the reader is directed to the appended claims.
As used herein, the term “hydrocarbons” means hydrocarbons or halogenated, particularly chlorinated, organic solvents such as trichloroethane (TCA), trichloroethylene (TCE), perchloroethylene (PCE), dichloroethane (DCA) or dichloroethylene (DCE), etc., and include herbicides, insecticides, and fuel hydrocarbons such as those hydrocarbons commonly found in gasoline, diesel fuel, solvents, motor oil, crude oil, aviation fuel, and the like.
Exemplary embodiments of contaminant oxidizing solutions and contaminant oxidation processes of the present invention are illustrated by the examples listed below. In some such examples, the contaminant oxidizing solution is formed in the contaminated media.
EXAMPLE 1
An exemplary embodiment of a solution and process of the present invention is illustrated by a first example with respect to the surface water storage facility 10 shown in schematic section in FIG. 1 . Storm water and washdown water from a remote pumping station and tank truck unloading facility had drained along a slope 12 to trench 14 , where a pump 16 lifted the contaminated water into a storage tank 18 . Over time a sludge 20 , containing clay, sand, and inorganic particulate matter, and contaminated with hydrocarbons, formed on the tank bottom, and a hydrocarbon-based emulsified oil layer 22 formed on the water 24 . A 500 milliliter sample of the emulsified oil layer 22 and a 500 milliliter sample of the sludge 20 were acquired.
In this first example, the emulsified oil layer 22 sample was exposed to approximately 453 grams (1 pound) of sodium carbonate peroxyhydrate (a/k/a sodium carbonate peroxohydrate and hereinafter referred to as sodium percarbonate), resulting in the placement in the sample of a peroxygen compound, i.e. hydrogen peroxide. After approximately five minutes, the emulsified oil layer was exposed to 50 milliliters of an aqueous solution including a carboxylic acid, i.e. glycolic acid, and a halogen salt, i.e. sodium bromide. This aqueous solution, prior to exposure was approximately 14.3 percent glycolic acid by weight and approximately 11.3 percent sodium bromide by weight. After introduction of the aqueous solution into the sample, the solution was approximately 5 percent glycolic acid and 4 percent sodium bromide. After 12 minutes the sample appeared to be clear water with only a trace of an oil slick on top of the water 24 . Prospectively, it is anticipated that the remaining trace would be oxidized by a repetition of the foregoing exposures and/or increased treatment amounts. It is estimated that the sodium percarbonate and the aqueous solution combined to form a solution having a pH of approximately 5.0.
The 500 milliliter sample of the sludge 20 was exposed to approximately 226 grams (0.5 pounds) of sodium percarbonate by stirring the latter into the sample. The sample was then exposed to an aqueous solution containing glycolic acid and sodium bromide in water, by stirring 250 milliliters of the aqueous solution into the sample. The stirring totaled between six and seven minutes, with the sodium percarbonate being stirred in less than two minutes before the aqueous solution was added. This aqueous solution was approximately 14.3 percent glycolic acid by weight and approximately 11.3 percent sodium bromide by weight. The sludge changed color from black to reddish-brown, and all apparent hydrocarbon that acted as a sediment binder was removed, leaving a free flowing sand-like material. It is estimated that the sodium percarbonate and the aqueous solution combined to form a solution having a pH of approximately 6.0.
In a prospective example, the hydrocarbon contaminated sludge is mixed, by stirring, with a pre-mixed solution comprising the foregoing sodium percarbonate and the aqueous solution containing glycolic acid and sodium bromide.
EXAMPLE 2
An exemplary embodiment of a solution and process of the present invention is illustrated by a second example with respect to the cooling tower installation 30 shown in schematic section in FIG. 2 . In this type of installation, the water 32 is aerated as it descends through the cooling tower 34 , and then accumulates in a basin 36 . In this example, a hydrocarbon-based oil layer 38 was present on top of the water and a thick, odorous, and slimy sludge layer 40 , six to eight inches deep, was on the bottom of the basin. An estimated 1.8 kilograms (4 pounds) of a hydrocarbon based oil and 56.7 kilograms (125 pounds) of an organic material were present in the sludge layer. Approximately 25,700 liters (6,800 gallons) of water was present in the basin.
In this second example, the oil layer 38 was exposed to approximately 45 kilograms (100 pounds) of sodium percarbonate by pouring the same into the water 32 having the oil layer 38 . This resulted in the placement in the water of a peroxygen compound, i.e. hydrogen peroxide. After approximately fifteen minutes, the oil layer was exposed to an aqueous solution including a carboxylic acid, i.e. glycolic acid, and a halogen salt, i.e. sodium bromide, the combined volume of the aqueous solution being approximately 38 liters (10 gallons). This aqueous solution was approximately 14.3 percent glycolic acid by weight and approximately 11.3 percent sodium bromide by weight. It is estimated that the sodium percarbonate and the aqueous solution combined to form a solution having a pH of approximately 8.0.
Within 30 minutes the oil layer 38 was removed by oxidation. In the area where the aqueous solution was introduced into the water 32 , the contaminants were removed from the sludge layer 40 leaving a 3.8 cm (1.5 inch layer of sand and clay).
To finish removing the remaining sludge layer 40 , the amounts of sodium percarbonate, glycolic acid and sodium bromide were doubled and the sodium percarbonate and the aqueous solution were distributed more uniformly over the surface area of the water in the basin 36 . The sodium percarbonate was distributed into the water less than two minutes before the aqueous solution. The entire remaining sludge layer was reduced to 1.3 cm. to 5.1 cm. (0.5 to 2.0 inches) of clay, sand and a firm mud material. The previous odor was removed and no odor or fumes were evident from the treatment. Algae growing in the cooling tower 34 were also removed, after treated water was circulated through the system. Prospectively, it is anticipated that an adjustment of the volumes of the sodium percarbonate and the aqueous solution, along with a broader distribution of sodium percarbonate and the aqueous solution into the water overlying the sludge layer, will successfully remove the contaminants from the sludge layer, with no repeated distributions.
EXAMPLE 3
An exemplary embodiment of a solution and process of the present invention is illustrated by a third example with respect to the crude oil storage tank facility 50 shown in schematic section in FIG. 3 , having a crude oil storage tank 52 , along with a mixing machine 54 having a hopper 56 for the reception of the crude oil contaminated soil 58 and a chemical injection port 60 for introducing chemicals to the soil while the soil is being agitated by the machine 54 , prior to being discharged into a truck 62 for hauling.
In this third example, approximately 0.765 cubic meters (1 cubic yard) of the contaminated soil 58 was placed in the mixing machine 54 and exposed to sodium percarbonate, resulting in the placement of a peroxygen compound, i.e. hydrogen peroxide in the contaminated soil. The sodium percarbonate was added through the hopper 56 . Within two minutes, the contaminated soil was exposed to an aqueous solution including a carboxylic acid, i.e. glycolic acid, and a halogen salt, i.e. sodium bromide, by introducing the aqueous solution through the chemical injection port 60 such that the aqueous solution combined with the hydrogen peroxide. This aqueous solution was approximately 14.3 percent glycolic acid by weight and approximately 11.3 percent sodium bromide by weight. During treatment, it is estimated that the sodium percarbonate and the aqueous solution combined to form a solution having a pH of approximately 7.5.
Although amounts of the sodium percarbonate and the aqueous solution were not measured accurately, the contaminated soil 58 was cleaned of the crude oil contaminants, and lost the oil odor previously present on the soil.
EXAMPLE 4
An exemplary embodiment of a solution and process of the present invention is illustrated by a fourth example with respect to the public facility 70 shown in schematic section in FIG. 4 , having a solid cement surfaced parking lot 72 near the building 74 . The cement surface 72 was contaminated with an organic compound, i.e. vegetable oil 76 from a spilled cooking container, but contained by a boundary 78 made of an absorbent material. Approximately 0.95 liters (0.25 gallons) of oil was in the spill area.
In this fourth example, approximately 38 liters (10 gallons) of water was sprayed on the oil 76 . 1.8 kilograms (4 pounds) of sodium percarbonate were then added to the sprayed water on the oil, resulting in the placement of a peroxygen compound, i.e. hydrogen peroxide on the oil. Within approximately two minutes, the oil was exposed to an aqueous solution including a carboxylic acid, i.e. glycolic acid, and a halogen salt, i.e. sodium bromide. This aqueous solution was approximately 14.3 percent glycolic acid by weight and approximately 11.3 percent sodium bromide by weight. During treatment, the sodium percarbonate and the aqueous solution combined to form a solution having a pH of approximately 4.0.
In this fourth example, the oil 76 was completely oxidized within ten minutes and the cement was as clean as new cement. Oil on the edge of the absorbent material was also removed.
EXAMPLE 5
An exemplary embodiment of a solution and process of the present invention is illustrated by a fifth example with respect to a public theater facility 80 shown in schematic section in FIG. 5 , having a solid concrete surface sidewalk 82 near a theater building 84 . The concrete surface 82 was contaminated with an arabic gum compound, i.e. chewing gum 86 over an approximately 3 square meters (32 square feet).
In this fifth example, water was sprayed on the contaminated area until it was dampened. Then 453 grams (1 pound) of sodium percarbonate was sprinkled onto the contaminated area, resulting in the placement of a peroxygen compound, i.e. hydrogen peroxide on the contaminated area. After approximately 20 minutes, the gum was exposed to an aqueous solution including a carboxylic acid, i.e. glycolic acid, and a halogen salt, i.e. sodium bromide by spraying the aqueous solution on the contaminated area. This aqueous solution was approximately 14.3 percent glycolic acid by weight and approximately 11.3 percent sodium bromide by weight. Additional water spray was then used to keep the area wet for approximately 20 minutes. During treatment, it is estimated that the sodium percarbonate and the aqueous solution combined to form a solution having a pH of approximately 7.0.
In this fifth example, after approximately 45 minutes, residue from the oxidized gum broke up in small hard fragments that were easily removed from the concrete surface by sweeping.
EXAMPLE 6
An exemplary embodiment of a solution and process of the present invention is illustrated by a sixth example with respect to the wastewater treatment plant 90 shown in schematic section in FIG. 6 , having a lift station 92 , clarifier 94 , and sludge aeration tank 96 . The lift station had a 76 centimeter (2.5 foot) grease layer 98 floating on and in the wastewater. The grease layer was hydrocarbon based. Filamentous bacteria in the aeration tank 96 were causing excessive foaming and plant effluent was out of specification with respect to ammonia and total suspended solids. The plant had an average dissolved oxygen content of 0.8 ppm.
In this sixth example, the grease layer 98 was exposed to approximately 272 kilograms (600 pounds) of sodium percarbonate resulting in the placement of a peroxygen compound, i.e. hydrogen peroxide in the contaminated water. The amount of sodium percarbonate equated to a 1:1 ratio of the same to the grease layer by weight. Within approximately two minutes, the grease layer was exposed to an aqueous solution including a carboxylic acid, i.e. glycolic acid, and a halogen salt, i.e. sodium bromide, by adding 7.6 liters (2 gallons) of the solution to the contaminated water. The amount of the aqueous solution equated to a 1:2 ratio of the same to the grease layer by weight. This aqueous solution was approximately 14.3 percent glycolic acid by weight and approximately 11.3 percent sodium bromide by weight. During treatment, it is estimated that the sodium percarbonate and the aqueous solution combined to form a solution having a pH of approximately 8.0.
After approximately two hours, the filamentous bacteria in the aeration tank was no longer evident, the plant average dissolved oxygen content rose to 14 ppm, oxidation of the grease in the lift station was visually observed, and the plant was adequately digesting both solids and ammonia. Foaming was under control and the plant aeration could be increased. The plant effluent was improved to good quality.
EXAMPLE 7
An exemplary embodiment of a solution and process of the present invention is illustrated by a seventh example where, in the laboratory, an aqueous solution containing 10 percent by weight isopropyl alcohol was first treated by adding a peroxygen, i.e. hydrogen peroxide such that the resulting solution was 15 percent by weight hydrogen peroxide. A pre-mixed combination of a halogen salt, i.e. sodium bromide with a carboxylic acid, i.e. glycolic acid, was then added such that the resulting solution was 1 percent by weight sodium bromide and 4 percent by weight glycolic acid. The isopropyl alcohol was fully and almost instantaneously oxidized after the pre-mixed sodium bromide and glycolic acid were added.
EXAMPLE 8
An exemplary embodiment of a solution and process of the present invention is illustrated by an eighth example where, in the laboratory, an aqueous solution containing 10 percent by weight isopropyl alcohol was first treated by adding a peroxygen, i.e. hydrogen peroxide such that the resulting solution was 15 percent by weight hydrogen peroxide. A carboxylic acid, i.e. glycolic acid, was then added such that the resulting solution was 2 percent by weight glycolic acid. The isopropyl alcohol was fully oxidized after the glycolic acid was added. The oxidation was rapid, but somewhat slower than in the foregoing seventh example, due to the absence of the halogen salt, and the lowering of the glycolic acid concentration, in this eighth example.
For comparative purposes, the isopropyl alcohol solution was treated in the laboratory, using hydrogen peroxide only, with no halogen salt and no glycolic acid. The isopropyl alcohol and hydrogen peroxide were present in the same proportions as in the above seventh example. Although oxidation did take place the oxidation was unacceptably slow when compared to the additional components described in seventh and eighth examples. Similarly, the isopropyl alcohol solution was treated in the laboratory using sodium percarbonate only, with the same unacceptably slow oxidation performance.
EXAMPLE 9
An exemplary embodiment of a solution and process of the present invention is illustrated by a ninth example where, in the laboratory, an aqueous solution containing 1 percent by weight light machine oil (specific gravity approximately 0.90) was first treated by adding a peroxygen, i.e. hydrogen peroxide such that the resulting solution was 10 percent by weight hydrogen peroxide. A pre-mixed combination of a halogen salt, i.e. sodium bromide with a carboxylic acid, i.e. glycolic acid, was then added such that the resulting solution was 1 percent by weight sodium bromide and 2 percent by weight glycolic acid. The light machine oil was fully and almost instantaneously oxidized after the pre-mixed sodium bromide and glycolic acid were added.
EXAMPLE 10
An exemplary embodiment of a solution and process of the present invention is illustrated by a tenth example where, in the laboratory, an aqueous solution containing 1 percent by weight light machine oil (specific gravity approximately 0.90) was first treated by adding a peroxygen, i.e. hydrogen peroxide such that the resulting solution was 10 percent by weight hydrogen peroxide. A pre-mixed combination of a halogen salt, i.e. sodium chloride with a carboxylic acid, i.e. glycolic acid, was then added such that the resulting solution was 1 percent by weight sodium chloride and 2 percent by weight glycolic acid. The light machine oil was only partially oxidized.
Since all concentrations and components were the same in the ninth and tenth examples, other than the substitution of sodium chloride for sodium bromide, it is clear that sodium chloride, albeit effective, is less preferable than sodium bromide.
EXAMPLE 11
An exemplary embodiment of a solution and process of the present invention is illustrated by an eleventh example where, in the laboratory, an aqueous solution containing 1 percent by weight light machine oil (specific gravity approximately 0.90) was first treated by adding sodium percarbonate such that the resulting solution was 15 percent by weight hydrogen peroxide. A pre-mixed combination of a halogen salt, i.e. sodium bromide with a carboxylic acid, i.e. glycolic acid, was then added such that the resulting solution was 1 percent by weight sodium bromide and 2 percent by weight glycolic acid. The light machine oil was fully and almost instantaneously oxidized after the pre-mixed sodium bromide and glycolic acid were added. This example repeats the conditions of the ninth example, except the peroxygen compound, i.e. hydrogen peroxide, is introduced through the addition of the sodium percarbonate. The ninth example and this example indicate the ability to choose between direct or indirect addition of hydrogen peroxide, without an untoward decline in oxidation efficiency.
EXAMPLE 12
A twelfth example is analogous to the tenth example. Conditions of the eleventh example are repeated other than the substitution of sodium chloride for sodium bromide. As discussed with regard to the tenth example, the sodium chloride is acceptable, but less than optimal when compared to sodium bromide.
EXAMPLE 13
An exemplary embodiment of a solution and process of the present invention is illustrated by a thirteenth example where, in the laboratory, an aqueous solution containing 1 percent by a baby oil, comprising a hydrocarbon based mineral oil (specific gravity approximately 0.90), was first treated by adding hydrogen peroxide such that the resulting solution was 5 percent by weight hydrogen peroxide. A pre-mixed combination of a halogen salt, i.e. sodium bromide with a carboxylic acid, i.e. glycolic acid, was then added such that the resulting solution was 0.5 percent by weight sodium bromide and 2 percent by weight glycolic acid. The baby oil was fully and almost instantaneously oxidized after the pre-mixed sodium bromide and glycolic acid were added.
EXAMPLE 14
An exemplary embodiment of a solution and process of the present invention is illustrated by a fourteenth example where, in the laboratory, an aqueous solution containing 1 percent by weight baby oil (specific gravity approximately 0.90) was first treated by adding sodium percarbonate such that the resulting solution was 5 percent by weight hydrogen peroxide. A pre-mixed combination of a halogen salt, i.e. sodium bromide with a carboxylic acid, i.e. glycolic acid, was then added such that the resulting solution was 0.5 percent by weight sodium bromide and 2 percent by weight glycolic acid. The baby oil was fully and almost instantaneously oxidized after the pre-mixed sodium bromide and glycolic acid were added. This example repeats the conditions of the thirteenth example, except the peroxygen compound, i.e. hydrogen peroxide, is introduced through the addition of the sodium percarbonate. The thirteenth example and this example again indicate the ability to choose between direct or indirect addition of hydrogen peroxide, without an untoward decline in oxidation efficiency.
EXAMPLE 15
An exemplary embodiment of a solution and process of the present invention is illustrated by a fifteenth example where, in the laboratory, an aqueous solution containing 1 percent by weight baby oil was first treated by adding sodium percarbonate such that the resulting solution was 5 percent by weight hydrogen peroxide. A carboxylic acid, i.e. glycolic acid, was then added such that the resulting solution was 2 percent by weight glycolic acid. The baby oil was partially oxidized after the glycolic acid was added. This example repeats the conditions of the fourteenth example, except that the halogen salt is omitted. The oxidation was rapid, but somewhat slower than in the foregoing fourteenth example, due to the absence of the halogen salt.
COMPARATIVE EXAMPLE A
For comparative purposes, the baby oil solution was treated in the laboratory, using sodium percarbonate and sodium bromide only, with no glycolic acid. The baby oil, sodium percarbonate and sodium bromide were present in the same proportions as in the above fourteenth example. Although partial oxidation did take place the oxidation was unacceptably slow when compared to the fourteenth example, which included the glycolic acid with the sodium bromide.
EXAMPLE 16
An exemplary embodiment of a solution and process of the present invention is illustrated by a sixteenth example where, in the laboratory, an aqueous solution containing 1 percent by weight baby oil (specific gravity approximately 0.90) was first treated by adding sodium percarbonate such that the resulting solution was 5 percent by weight hydrogen peroxide. A pre-mixed combination of a halogen salt, i.e. sodium chloride with a carboxylic acid, i.e. glycolic acid, was then added such that the resulting solution was 0.5 percent by weight sodium chloride and 2 percent by weight glycolic acid. The baby oil was only partially oxidized. Since all concentrations and components were the same in the fourteenth and sixteenth examples, other than the substitution of sodium chloride for sodium bromide, it is clear that sodium chloride, albeit effective, is less preferable than sodium bromide.
EXAMPLE 17
An exemplary embodiment of a solution and process of the present invention is illustrated by a seventeenth example where, in the laboratory, an aqueous solution containing 1 percent by weight of a phosphonic acid, i.e. HEDP (1-hydroxyethane-1, 1-diphosphonic acid) was first treated by adding sodium percarbonate such that the resulting solution was 10 percent by weight hydrogen peroxide. A pre-mixed combination of a halogen salt, i.e. sodium bromide with a carboxylic acid, i.e. glycolic acid, was then added such that the resulting solution was 0.5 percent by weight sodium bromide and 2 percent by weight glycolic acid. The HEDP was fully and almost instantaneously oxidized to phosphate, carbon dioxide and water, after the pre-mixed sodium bromide and glycolic acid were added.
EXAMPLE 18
An exemplary embodiment of a solution and process of the present invention is illustrated by an eighteenth example where, in the laboratory, an aqueous solution containing 1 percent by weight of a phosphonic acid, i.e. HEDP (1-hydroxyethane-1, 1-diphosphonic acid) was first treated by adding sodium percarbonate such that the resulting solution was 10 percent by weight hydrogen peroxide. A pre-mixed combination of a halogen salt, i.e. sodium chloride with a carboxylic acid, i.e. glycolic acid, was then added such that the resulting solution was 0.5 percent by weight sodium chloride and 2 percent by weight glycolic acid. The HEDP was partially oxidized to phosphate, carbon dioxide and water, after the pre-mixed sodium chloride and glycolic acid were added. Since all concentrations and components were the same in the seventeenth and eighteenth examples, other than the substitution of sodium chloride for sodium bromide, it is clear that sodium chloride, albeit effective, is less preferable than sodium bromide.
EXAMPLE 19
An exemplary embodiment of a solution and process of the present invention is illustrated by a nineteenth example where, in the laboratory, an aqueous solution containing 1 percent by weight of a phosphonic acid, i.e. HEDP (1-hydroxyethane-1, 1-diphosphonic acid) was first treated by adding sodium percarbonate such that the resulting solution was 10 percent by weight hydrogen peroxide. A pre-mixed combination of a halogen salt, i.e. sodium bromide with a carboxylic acid, i.e. acetic acid, was then added such that the resulting solution was 0.5 percent by weight sodium bromide and 2 percent by weight acetic acid. The HEDP was partially oxidized to phosphate, carbon dioxide and water, after the pre-mixed sodium bromide and acetic acid were added. Since all concentrations and components were the same in the seventeenth and nineteenth examples, other than the substitution of acetic acid for glycolic acid, it is clear that acetic acid, albeit effective, is less preferable than glycolic acid.
EXAMPLE 20
An exemplary embodiment of a solution and process of the present invention is illustrated by a twentieth example where, in the laboratory, an aqueous solution containing 1 percent by weight of a phosphonic acid, i.e. PBTC (2-phosphonobutane-1,2,4-tricarboxylic acid) was first treated by adding sodium percarbonate such that the resulting solution was 10 percent by weight hydrogen peroxide. A pre-mixed combination of a halogen salt, i.e. sodium bromide with a carboxylic acid, i.e. glycolic acid, was then added such that the resulting solution was 0.5 percent by weight sodium bromide and 2 percent by weight glycolic acid. The PBTC was partially oxidized to phosphate, carbon dioxide and water, after the pre-mixed sodium bromide and glycolic acid were added.
EXAMPLE 21
An exemplary embodiment of a solution and process of the present invention is illustrated by a twenty-first example where, in the laboratory, an aqueous solution containing 1 percent by weight of a phosphonic acid, i.e. PBTC (2-phosphonobutane-1,2,4-tricarboxylic acid) was first treated by adding sodium percarbonate such that the resulting solution was 5 percent by weight hydrogen peroxide. A pre-mixed combination of a halogen salt, i.e. sodium bromide with a carboxylic acid, i.e. glycolic acid, was then added such that the resulting solution was 0.5 percent by weight sodium bromide and 2 percent by weight glycolic acid. The PBTC was partially oxidized to phosphate, carbon dioxide and water, after the pre-mixed sodium bromide and glycolic acid were added, however, less oxidation occurred than in the twentieth example. Since all concentrations and components were the same in the twentieth and twenty-first examples, other than the reduced concentration of sodium percarbonate, it is clear that a change in the concentration of the peroxygen compound will have a corresponding change in the amount of oxidation.
EXAMPLE 22
An exemplary embodiment of a solution and process of the present invention is illustrated by a twenty-second example where, in the laboratory, an aqueous solution containing 1 percent by weight of a phosphonic acid, i.e. PBTC (2-phosphonobutane-1,2,4-tricarboxylic acid) was first treated by adding hydrogen peroxide such that the resulting solution was 10 percent by weight hydrogen peroxide. A pre-mixed combination of a halogen salt, i.e. sodium bromide with a carboxylic acid, i.e. glycolic acid, was then added such that the resulting solution was 0.5 percent by weight sodium bromide and 2 percent by weight glycolic acid. The PBTC was partially oxidized to phosphate, carbon dioxide and water, after the pre-mixed sodium bromide and glycolic acid were added. The twentieth example and this example again indicate the ability to choose between direct or indirect addition of hydrogen peroxide, without an untoward decline in oxidation efficiency.
EXAMPLE 23
An exemplary embodiment of a solution and process of the present invention is illustrated by a twenty-third example where, in the laboratory, an aqueous solution containing 1 percent by weight of a phosphonic acid, i.e. PBTC (2-phosphonobutane-1,2,4-tricarboxylic acid) was first treated by adding hydrogen peroxide such that the resulting solution was 10 percent by weight hydrogen peroxide. A pre-mixed combination of a halogen salt, i.e. sodium chloride with a carboxylic acid, i.e. glycolic acid, was then added such that the resulting solution was 0.5 percent by weight sodium chloride and 2 percent by weight glycolic acid. The PBTC was partially oxidized to phosphate, carbon dioxide and water, after the pre-mixed sodium chloride and glycolic acid were added. The amount of oxidation was, however, less than that in the twentieth example which used sodium bromide. It is clear that sodium chloride, albeit effective, is less preferable than sodium bromide.
COMPARATIVE EXAMPLE B
For comparative purposes, the PBTC solution was treated in the laboratory, under the conditions of the twentieth example, except for the substitution of sulfamic acid for glycolic acid. Only negligible oxidation took place, providing a clear indication that non-carboxylic acids are unacceptable substitutes for the carboxylic acids used in the present invention. This remained true in an additional laboratory test wherein the concentrations of sodium bromide and sulfamic acid were at least doubled. The oxidation remained negligible and unacceptable.
The foregoing exemplary embodiments of the present invention that reference phosphonic acid has a slower oxidation rate than those exemplary embodiments involving hydrocarbons. However, because the presence of phosphonic acids as a contaminant is often hard to determine, the present invention is useful as an indicator of the presence of one or more of the phosphonic acids.
EXAMPLES 24–25
An exemplary embodiment of a solution and process of the present invention is illustrated by a twenty-fourth example where, in the laboratory, an aqueous solution containing 1 percent by weight baby oil (specific gravity approximately 0.90) was first treated by adding sodium percarbonate such that the resulting solution was 5 percent by weight hydrogen peroxide. A pre-mixed combination of a halogen compound, i.e. periodic acid with a carboxylic acid, i.e. glycolic acid, was then added such that the resulting solution was 0.5 percent by weight periodic acid and 2 percent by weight glycolic acid. The baby oil was only partially oxidized. Since all concentrations and components were the same in the fifteenth and twenty-fourth examples, other than the substitution of periodic acid for sodium bromide, it is clear that periodic acid, albeit effective, is less preferable than sodium bromide. Analogously, in another embodiment, illustrated by a twenty-fifth example, sodium fluoride was substituted for the sodium bromide, this example otherwise having the same conditions as the twenty-fourth example. The results were similar to the twenty-fourth example.
EXAMPLES 26–27
An exemplary embodiment of a solution and process of the present invention is illustrated by a twenty-sixth example where, in the laboratory, an aqueous solution containing 1 percent by weight baby oil (specific gravity approximately 0.90) was first treated by adding hydrogen peroxide such that the resulting solution was 5 percent by weight hydrogen peroxide. A pre-mixed combination of a halogen compound, i.e. periodic acid with a carboxylic acid, i.e. glycolic acid, was then added such that the resulting solution was 0.5 percent by weight periodic acid and 2 percent by weight glycolic acid. The baby oil was only partially oxidized. Since all concentrations and components were the same in the thirteenth and twenty-sixth examples, other than the substitution of periodic acid for sodium bromide, it is clear that periodic acid, albeit effective, is less preferable than sodium bromide. Analogously, in another embodiment, illustrated by a twenty-seventh example, sodium fluoride was substituted for the sodium bromide, this example otherwise having the same conditions as the twenty-sixth example. The results were similar to the twenty-sixth example.
EXAMPLE 28
An exemplary embodiment of a solution and process of the present invention is illustrated by a twenty-eighth example where, in the laboratory, an aqueous solution containing 1 percent by weight light machine oil (specific gravity approximately 0.90) was first treated by adding sodium percarbonate such that the resulting solution was 10 percent by weight hydrogen peroxide. A pre-mixed combination of a halogen salt, i.e. sodium iodide with a carboxylic acid, i.e. glycolic acid, was then added such that the resulting solution was 0.5 percent by weight sodium iodide and 1 percent by weight glycolic acid. The light machine oil was fully and almost instantaneously oxidized after the pre-mixed sodium iodide and glycolic acid were added.
EXAMPLE 29
An exemplary embodiment of a solution and process of the present invention is illustrated by a twenty-ninth example where, in the laboratory, an aqueous solution containing 1 percent by weight light machine oil (specific gravity approximately 0.90) was first treated by adding sodium percarbonate such that the resulting solution was 5 percent by weight hydrogen peroxide. A pre-mixed combination of a halogen salt, i.e. sodium bromide with a carboxylic acid, i.e. oxalic acid, was then added such that the resulting solution was 0.5 percent by weight sodium bromide and 1 percent by weight oxalic acid. The light machine oil was only partially oxidized after the pre-mixed sodium bromide and oxalic acid were added. It is clear that oxalic acid, albeit effective, is less preferable than glycolic acid.
EXAMPLE 30
An exemplary embodiment of a solution and process of the present invention is illustrated by a thirtieth example where, in the laboratory, an aqueous solution containing 1 percent by weight light machine oil (specific gravity approximately 0.90) was first treated by adding sodium percarbonate such that the resulting solution was 10 percent by weight hydrogen peroxide. A pre-mixed combination of a halogen salt, i.e. sodium bromide with a carboxylic acid, i.e. benzoic acid, was then added such that the resulting solution was 0.5 percent by weight sodium bromide and 1 percent by weight benzoic acid. The light machine oil was slowly but fully oxidized after the pre-mixed sodium bromide and benzoic acid were added. It is clear that benzoic acid, although effective, is less preferable than glycolic acid.
EXAMPLE 31
An exemplary embodiment of a solution and process of the present invention is illustrated by a thirty-first example where, in the laboratory, an aqueous solution containing 1 percent by weight light machine oil (specific gravity approximately 0.90) was first treated by adding sodium percarbonate such that the resulting solution was 10 percent by weight hydrogen peroxide. A pre-mixed combination of a halogen salt, i.e. sodium bromide with a carboxylic acid, i.e. formic acid, was then added such that the resulting solution was 0.5 percent by weight sodium bromide and 1 percent by weight formic acid. The light machine oil was slowly but fully oxidized after the pre-mixed sodium bromide and formic acid were added. It is clear that formic acid, although effective, is less preferable than glycolic acid
EXAMPLE 32
An exemplary embodiment of a solution and process of the present invention is illustrated by a thirty-second example where, in the laboratory, an aqueous solution containing 1 percent by weight light machine oil (specific gravity approximately 0.90) was first treated by adding calcium peroxide such that the resulting solution was 10 percent by weight calcium peroxide. A pre-mixed combination of a halogen salt, i.e. sodium bromide with a carboxylic acid, i.e. glycolic acid, was then added such that the resulting solution was 0.5 percent by weight sodium bromide and 1 percent by weight glycolic acid. The light machine oil was fully oxidized after the pre-mixed sodium bromide and glycolic acid were added. Although completely oxidized, the rate of oxidation using calcium peroxide was less satisfactory than that achieved using sodium percarbonate.
EXAMPLE 33
An exemplary embodiment of a solution and process of the present invention is illustrated by a thirty-third example where, in the laboratory, an aqueous solution containing 1 percent by weight light machine oil (specific gravity approximately 0.90) was first treated by adding magnesium peroxide such that the resulting solution was 10 percent by weight magnesium peroxide. A pre-mixed combination of a halogen salt, i.e. sodium bromide with a carboxylic acid, i.e. glycolic acid, was then added such that the resulting solution was 0.5 percent by weight sodium bromide and 1 percent by weight glycolic acid. The light machine oil was fully and almost instantaneously oxidized after the pre-mixed sodium bromide and glycolic acid were added.
EXAMPLE 34
An exemplary embodiment of a solution and process of the present invention is illustrated by a thirty-fourth example where, in the laboratory, an aqueous solution containing 1 percent by weight light machine oil (specific gravity approximately 0.90) was first treated by adding sodium perborate such that the resulting solution was 10 percent by weight sodium perborate. A pre-mixed combination of a halogen salt, i.e. sodium bromide with a carboxylic acid, i.e. glycolic acid, was then added such that the resulting solution was 0.5 percent by weight sodium bromide and 1 percent by weight glycolic acid. The light machine oil was fully and almost instantaneously oxidized after the pre-mixed sodium bromide and glycolic acid were added.
EXAMPLES 35–41
The circumstances of the above fourteenth example, formed the basis for an additional seven laboratory tests, the thirty-fifth through forty-first, wherein the solution was reduced to 3 percent by weight hydrogen peroxide, and the pre-mixed combinations of the sodium bromide and glycolic acid included combinations wherein the resulting solution was as low as 0.00005 percent sodium bromide and 0.0001 percent glycolic acid. In such tests, the baby oil was fully and almost instantaneously oxidized following the introduction of the pre-mixed sodium bromide and glycolic acid, until, in the fortieth test, the sodium bromide concentration was reduced to 0.0001 percent by weight and the glycolic acid concentration was reduced to 0.0002 percent by weight. At such concentrations the oxidation, in a short period of time, was only partial, and in the forty-first test, a relatively fast partial oxidation, and a significantly delayed, but almost complete, oxidation was achieved when the sodium bromide concentration was further reduced to 0.00005 percent by weight and the glycolic acid concentration was further reduced to 0.0001 percent by weight. In both the fortieth and forty-first tests, the partial oxidation was satisfactory, albeit less satisfactory than a complete oxidation.
Accordingly, a satisfactory oxidation performance is indicated for a benchmark concentration of 1 percent by weight baby oil in water, using solutions of the present invention having the peroxygen compound added in a concentration ranging from 3 percent by weight to 30 percent by weight, the carboxylic acid added in a concentration ranging from 0.0001 percent by weight (1 ppm) to 10 percent by weight, and the halogen compound added in a concentration ranging from 0.00005 percent by weight (0.5 ppm) to 10 percent by weight. The foregoing upper ranges reflect the development of an undesirable foamy paste as the relative amount of water is reduced.
EXAMPLE 42
An exemplary embodiment of a solution and process of the present invention is illustrated by a forty-second example where, in the laboratory, an aqueous solution containing 1 percent by weight ammonia (specific gravity approximately 1.0) was first treated by adding sodium percarbonate such that the resulting solution was 10 percent by weight hydrogen peroxide. A pre-mixed combination of a halogen salt, i.e. sodium bromide with a carboxylic acid, i.e. glycolic acid, was then added such that the resulting solution was 0.5 percent by weight sodium bromide and 1 percent by weight glycolic acid. The ammonia was fully and almost instantaneously oxidized after the pre-mixed sodium bromide and glycolic acid were added.
EXAMPLES 43–47
The circumstances of the foregoing forty-second example, formed the basis for an additional five laboratory tests, the forty-third through forty-seventh, wherein the solution was reduced to as low as 1 percent by weight hydrogen peroxide, and the pre-mixed combinations of the sodium bromide and glycolic acid included combinations wherein the resulting solution was as low as 0.1 percent sodium bromide and 0.1 percent glycolic acid. In such tests, the ammonia was fully and almost instantaneously oxidized following the introduction of the pre-mixed sodium bromide and glycolic acid, until the hydrogen peroxide concentration was reduced to 1 percent by weight, sodium bromide concentration was reduced to 0.1 percent by weight and the glycolic acid concentration was reduced to 0.1 percent by weight. At such concentrations the oxidation was partial. The partial oxidation was satisfactory, albeit less satisfactory than a complete oxidation.
Accordingly, a satisfactory oxidation performance is indicated for a benchmark concentration of 1 percent by weight ammonia in water, using solutions of the present invention having the peroxygen compound added in a concentration ranging from 1 percent by weight to 30 percent by weight, the carboxylic acid added in a concentration ranging from 0.1 percent by weight to 10 percent by weight, and the halogen compound added in a concentration ranging from 0.1 percent by weight to 10 percent by weight. The upper ranges reflect the development of an undesirable foamy paste as the relative amount of water is reduced.
EXAMPLE 48
An exemplary embodiment of a solution and process of the present invention is illustrated by a forty-eighth example where, in the laboratory, light machine oil (specific gravity approximately 0.90) was introduced to an aqueous solution containing 10 percent by weight hydrogen peroxide, 0.5 percent by weight sodium bromide, and 1 percent by weight glycolic acid. The light machine oil was fully and almost instantaneously oxidized. From this example it is clear that a pre-mixed solution of a peroxygen compound with a carboxylic acid and a halogen compound is effective for oxidizing contaminants.
Prospectively, the pre-mixed solution of the exemplary embodiment of the forty-eighth example can be used to oxidize contaminants, such as hydrocarbon, on fresh water subsurface geologic formations. In such a case the subsurface formation is typically in fluid communication with the surface through a well bore which can be used as an injection route for the solution. The contaminated subsurface is exposed to the solution as the solution is injected through the well bore.
All the foregoing examples were conducted at approximately 1 atm, and without the addition of heat beyond ordinary room temperature or existing outdoor conditions. In such examples, pH ranged from 1–12, and the effectiveness of various solutions was not noticeably pH sensitive.
With respect to the above description then, it is to be realized that the optimum solutions and processes for a particular contaminated media or surface will include chemical, operational facility, and equipment implementations or changes, which will occur to those skilled in the art upon review of the present disclosure.
All equivalent relationships to those illustrated in the drawings and described in the specification are intended to be encompassed by the present invention.
The descriptions in this specification are for purposes of illustration only and are not to be construed in a limiting sense. The scope of the present invention is limited only by the language of the following claims. | My invention provides an oxidizing solution and process for the in situ oxidation of contaminants, including hydrocarbon, organic, bacterial, phosphonic acid, and other contaminants, the contaminants being found in various surfaces and media, including soil, sludge, and water. In a preferred embodiment, the solution includes a peroxygen compound, such as hydrogen peroxide, in solution with a pre-mixed solution of a carboxylic acid and a halogen salt, such as glycolic acid and sodium bromide, respectively. | 71,835 |
This is a divisional of U.S. application Ser. No. 08/258,549, filed Jun. 10, 1994, U.S. Pat. No. 6,022,543, which is a continuation of U.S. application Ser. No. 07/340,172, filed Feb. 21, 1989, now abandoned, which was the National Stage of International Application No. PCT/EP88/00551, filed June 22, 1988.
FIELD OF THE INVENTION
The invention relates to Hepatitis B surface antigen (“HBs antigen” or “HBsAG”) particles which are composed of polypeptides prepared by recombinant DNA processes, DNA sequences coding for these polypeptides and cell lines for the expression of the same. The present invention relates especially to new particles having increased immunogenicity.
BACKGROUND OF THE INVENTION
Expression in Host Cells
Advances in vaccine production techniques have made it possible to synthesize polypeptides corresponding to the HBs antigen in bacteria, yeast and mammalian cells. Transcription of eukaryotic genes in bacteria and yeast, however, adversely affects the efficaciousness of these polypeptides as antigens due to several drawbacks concerning the glycosilation and secretion of the polypeptides and composition of the particle formed therefrom.
For example, in the case of the Hepatitis B virus, the polypeptide antigens produced in vivo are heavily glycosilated (Gerlich, 1984: J. Virol.: 52 (2), 396). In prokaryotes, glycosilation is not an essential process so that polypeptides produced by genetically engineered bacteria are either not glycosilated or are incompletely glycosilated. In either case, polypeptides corresponding to HBsAg, when expressed in bacteria, do not raise antibodies which will see HBsAg sufficiently well for an effective vaccine. Although yeast as a eukaryotic host is capable of more complete glycosilation, polypeptides corresponding to HbsAg expressed in yeast share the same deficiency as in the case of bacterial expression. (Murray et al., 1979: Nature, 282, 575; Valenzuela et al., 1982: Nature, 298, 347; Miyariohara et al., 1983: PNAS, 80, 1).
As a further example, in bacteria the eukaryotic structural gene of the HBsAg is in most cases not efficiently transcribed. Furthermore the structure and function of the eukaryotic HBsAg gene product may be dependent on the additional post-translational processes of the linkage of disulfide bonds which can not be accomplished by the bacterial host.
Still further, the expressed polypeptide is rarely secreted from the bacterial host cells. They must be lysed to harvest the expressed polypeptide. During the purification process bacterial wall components may contaminate the polypeptide and cause serious allergic reactions or lead to anaphylactic shock in patients.
Finally, eukaryotic promoters usually do not work in bacteria and must be substituted by a bacterial promoter which can result in modification of the polypeptide expressed. (Offensperger et al., 1985: PNAS, 82, 7540; Valenzuela et al., 1980: ICN-UCLA Symp, Mol. Cell. Biol., 18 57).
FORMATION AND SECRETION OF PARTICLES
The natural forms of Hepatitis B virus (“HBV”) and HBV protein occur in three distinct morphologies:
the HBV-virion (Dane particle), which is thought to be the infectious material,
the filaments, and
the 20 or 22 nm particles (hereinafter “20 nm particle”) which consist only of a protein envelope.
The most interesting form for an efficient vaccine is the 20 nm particle because 1) the coding sequences are entirely known, 2) it is completely uninfectious, and 3) it causes some useful immunogenicity in a human organism.
The three known components of HBV particles differ in their relative amounts of the protein composition. There are three monomers called the major protein with 226 amino acids, the middle protein with 281 amino acids, and the large protein with 389 or 400 amino acids, depending on the subtype ayw and adw, respectively. The large protein is encoded by the complete sequence of the pre-S 1 -, pre-S 2 - and S-regions, whereas the middle protein is derived from only the pre-S 2 - and S-regions, and finally the major protein from only the S-region (Tiollais et al., 1985; Nature, 317, 489; Dubois et al., 1980: PNAS, 77, 4549; McAlzer et al., 1984: Nature, 307, 178).
The infectious virion of HBV (Dane particle) contains 40-80 times more of the high molecular monomers—the pre-S 1 and pre-S 2 peptides—compared to the 20 nm particle. It is now known that these pre-S polypeptides may be associated Faith some biological and clinical implications. The polyalbumin receptor on the pre-S polypeptides can bind polymerized albumins from humans and chimpanzees which are susceptible to HBV (Thung et al., 1983: Liver, 3, 290; Machida et al., 1984: Gastroenterology, 86, 910). This narrow host range and the known receptor for poly human serum albumin on human hepatocytes explain the hepatotropism of HBV: Dane particles are able to contact hepatocytes via poly human serum albumin taken up by hepatocytes from circulation. Based on this evidence the pre-S peptides should be helpful for an efficient vaccine against HBV because its antibody could be expected to block the significant site on Dane particles that are required for entering hepatocytes (Tiollais et al., 1985: Nature, 317, 489; Millich et al., 1985: Science, 228, 1195).
Literature data would also suggest a better protection against the infectious Dane-particle where the pre-S 1 epitope is present in much higher ratio than on the envelope particles.
The vaccine obtained from natural sources (e.g., donor blood), which causes a limited immunogenic protection, contains (almost) none of the pre-S proteins; this is due to two different reasons. First, the purification process is focused on the noninfectious 20 nm particles. These contain at most 1% pre-S 1 peptide compared to 15-20% in the Dane particle (Gerlich, 1984: J. Vir., 52 (2), 396: Tiollais et al., 1985: Nature, 317, 489; Gerlich, 1982: Virology, 123, 436). Second, the 20 nm particles are isolated from sera of anti-HBE positive carriers (Hevac B, HepaVac B) or are digested by proteases during the purification process. This proteolytic digestion has been shown to cut the pre-S-polypeptides leaving only the S monomers. As a result these vaccines contain none or very little pre-S polypeptides.
Therefore there is a demand for a vaccine in the form of HBs antigen particles which possess a high immunogenicity due to the composition of the particle, which undergo glycosilation in the cell and which are secreted continuously from the particle-producing cell.
REFERENCES AND PATENTS
EP-A-72 318 describes the expression of HBsAg in yeast cells, which have been transformed by a vector comprising a yeast replicon, a yeast promoter and a DNA sequence coding for the S peptide.
Laub et al., J. Virol., Vol. 48, No. 1, pp. 271-280, 1983, disclose the construction of a vector starting from simian virus 40 into which the HBsAq including the 163 codon precursor sequence was incorporated. Laub et al. report that CV-1 cells transformed with said vector yield a better expression when the vector contains only the coding sequence for the S protein as compared to the above vector which comprises additionally also the 163 codon precursor sequence.
Also Takeda Chemical Ind., Japanese Patent Application No. J5-8194-897-A describes the expression of the entire pre-S and S peptides. Reference is also made to the expression of the adw subtype.
Feitilson et al., Virology, Vol. 130, pp. 75-90, 1983, have described the partial expression of polypeptides within the pre-S coding sequence, including species with 24000, 28000, 32000, 43000 and 50000 dalton.
Further, DE-OS 34 39 400 describes the expression of an immunogenic polypeptide sequence of Hepatitis B virus. Said sequence represents a partial sequence of the pre-S 1 polypeptide, comprises 108 or 119 codons and starts with the first starting codon of HBsAg, and terminates 281 codons in front of the stop codon.
EP-A-154 902 discloses a Hepatitis B vaccine which contains a peptide with an amino acid chain of at least six consecutive amino acids within the pre-S chain coding region of the envelope of Hepatitis B virus. This vaccine is free of an amino acid sequence corresponding to the naturally occurring envelope proteins of Hepatitis B virus.
Also Kent et al. have described in Pept. Chem., Vol 22, pp. 16770, 1984, that a chemically synthesized peptide comprising the N-terminal 26 amino acids of the pre-S 2 region can serve as an antigen and may therefore be suitable as a synthetic vaccine.
OBJECTS OF THE INVENTION
None of the above discussed references consider the possibility that, by altering the composition of the monomers making up the 20 nm particles and approaching thereby the natural composition of the Dane particle, the antigenicity of the particle can be improved.
As discussed mentioned above, the immunogenicity of the peptide monomers of the virus envelope protein is very poor compared to assembled protein particles. The object of this invention is the development of protein particles which contain an amount of the pre-S polypeptide epitopes comparable to the natural composition of the surface structure of the infectious Dane particle.
It is a further object to utilize additional pre-S peptides containing important protective epitopes in the development of a better immune response, a longer protection and lower non-responder rate as compared to all the other products either already marketed or under development.
It is a further object to express HBsAg in mammalian cells. This requires overcoming known difficulties where expression of the desired peptide in a mammalian cell can result in:
different regulatory mechanisms for the three translational/(transcriptional) products
promoter-promoter inhibition
different strength of the start codons
not all peptides expressed.
SUMMARY OF THE INVENTION
The term “HBV S peptide” as used herein refers to the peptide encoded by the entire S region of the HBV genorne. The term “HBV pre-S 2 peptide” as used herein refers to the peptide encoded by the entire pre-S 2 and S regions of the HBV genome. The term “HBV pre-S 1 peptide” as used herein refers to the polypeptide encoded by the entire pre-S 1 , pre-S 2 and S regions of the HBV genome. The term “epitope” as used herein refers to a sequence of at least six consecutive amino acids encoded by the designated genome region (e.g., a “HBV pre-S 2 epitope” refers to a sequence of at least six amino acids encoded by the pre-S 2 region of the HBV genome). As used herein “antigenicity” means the ability to provoke an immune response (e.g., acting as a vaccine or an antigen), the ability to cause the production of antibodies (e.g. acting as an antigen) and/or the ability to interact with a cell surface receptor so as to enhance an immune response or production of antibodies (e.g., reacting with a T-cell surface receptor to enhance immune response).
The term “HBV” means any subtype of the virus, particularly adw, ayw, adr and ayr, described in the literature (P. Valenzuela, Nature Vol. 280, p. 815 (1979), Gerlich, EP-A-85 111 361, Neurath, EP-A-85 102 250). Examples of peptide sequences thereof, from which the epitopes of this invention can be derived, are shown in Figures XVI to XX.
In accordance with the present invention, recombinant DNA molecules are disclosed which comprise a first DNA sequence and a second DNA sequence. The first DNA sequence encodes for expression of an amino acid sequence a portion of which displays the antigenicity of an epitope selected from the group consisting of an HBV pre-S 1 epitope and an HBV pre-S 2 epitope. The second DNA sequence encodes for expression of a peptide which upon secretion will form particles which are at least 10 nm in diameter. These particles are believed to be the smallest particles which will effectively form a good vaccine. Preferably the peptide which upon secretion will form particles which are at least 10 nm in diameter is either HBV S peptide, HBV core antigen, polio surface antigen, Hepatitis A surface antigen, Hepatitis A core antigen, HIV surface antigen and HIV corehtigen. A substantial portion or all of the HBV S peptide is especially preferred as the peptide encoded by the second DNA sequence. In the recombinant DNA molecules encoding for the first and second DNA sequences must be (1) in the same reading frame, (2) encode for respective discrete regions of a single peptide, and (3) be operatively linked to an expression control sequence. Finally, these recombinant DNA molecules are free of DNA sequences encoding for the expression of the entire HBV pre-S 1 peptide or HBV pre-S 2 peptide.
Specific recombinant DNA molecules of the present invention are also disclosed wherein the first DNA sequence comprises a nucleotide sequence corresponding to the nucleotide sequence of (1) the HBV pre-S 1 and pre-S 2 regions from which the pre-S 2 start codon ATG has been deleted, (2) the HBV pre-S 1 and pre-S 2 regions and wherein the sequences flanking the pre-S 1 ATG have been changed from the natural sequence, (3) the HBV pre-S 1 and pre-S 2 regions and wherein the sequences flanking the pre-S 2 ATG have been changed from the natural sequence, (4) the HBV pre-S 1 and pre-S 2 regions and wherein the 5′ terminus of the pre-S 1 region has been deleted, (5) the HBV pre-S 1 and pre-S 2 regions and wherein the 5′ terminus of the pre-S 2 region has been deleted, (6) the HBV pre-S 1 region and wherein the 3′ terminus of the pre-S 1 region has been deleted, (7) the HBV pre-S 2 region and wherein the 3′ terminus of the pre-S 2 region has been deleted, (8) the HBV pre-S 1 and pre-S 2 regions from which the pre-S 2 ATG has been deleted and the second DNA sequence comprises a sequence corresponding to the nucleotide sequence of the HBV S region from which the S ATG has been deleted, and/or (a) an oligonucleotide described in Table I.
Host cells transfected with the recombinant DNA molecules of the present invention are also disclosed. As used herein, “transfected” or “transfection” refer to the addition of exogenous DNA to a host cell whether by transfection, transformation or other means. Host cells include any unicellular organism capable of transcribing and translating recombinant DNA molecules including without limitation mammalian cells, bacteria and yeast. Host cells of the present invention may also be cotransfected with a second recombinant DNA molecule comprising a DNA sequence encoding for expression of an amino acid sequence corresponding to a substantial portion or all of the amino acid sequence of the HBV S peptide.
Peptides are also disclosed comprising a first discrete region and a second discrete region. The first region displays the antigenicity of an epitope of an HBV pre-S 1 epitope or an HBV pre-S 2 epitope. The second region correspond to a substantial portion of a peptide which upon secretion will form particles which are at least 10 nm in diameter. Preferably the peptide which upon secretion will form particles which are at least 10 nm in diameter is either HBV S peptide, HBV core antigen, polio surface antigen, Hepatitis A surface antigen, Hepatitis A core antigen, HIV surface antigen and HIV core antigen. A substantial portion or all of the HBV S peptide is especially preferred. Preferably, the first region is located closer to the N-terminus of the peptide than the second region.
Immunogenic particles are also disclosed which comprise a plurality of first peptide monomers. Each of said first peptide monomers comprises a first discrete region and a second discrete region which can be the same as the first and second discrete regions of the peptides described above. Immunogenic particles are also disclosed which further comprise a plurality of second peptide monomers and wherein the first and second peptide monomers are bound together by interactive forces between the monomers. Each of said second peptide monomers comprising an amino acid sequence corresponding to a substantial portion of or all of the amino acid sequence of the HBV S peptide.
Immunogenic particles are also disclosed which contain substantially more than one percent, preferably more than five percent, of the pre-S 1 epitope. As used herein, a particle “contains one percent” of a designated epitope if peptide monomers having the designated epitope constitute one percent of all protein in the particle. Immunogenic particles which contain substantially more than ten percent, preferably more than fifteen percent, of the pre-S 2 epitope are also disclosed.
Pharmaceutical preparations and preparations useful for production of antibodies comprising the above-described immunogenic particles in sufficient concentration to elicit an immune response upon administration of said preparation and a suitable carrier are also disclosed. Suitable carriers are known to those skilled in the art and may include simple buffer solutions. other preparations useful for production of antibodies are disclosed comprising the above-described immunogenic particles in sufficient concentration to elicit an immune response upon administration of said preparation and a suitable carrier. Suitable carriers are known to those skilled in the art and may include simple buffer solutions.
A process for producing a transfected host call is disclosed which comprises providing host cells which have been made competent for uptake of DNA, exposing the host cells to a first preparation of DNA comprising one of the above-described recombinant DNA molecules, allowing under suitable conditions the host cells to take up DNA from the first preparation of DNA, and selecting for host cells which have taken up (exogenous DNA. The process may further comprise exposing the host cells to a second preparation of DNA comprising a DNA molecule encoding for a peptide including the amino acid sequence of the HBV S peptide and allowing under suitable conditions the host cells to take up DNA from the second preparation of DNA. The exposure and uptake of the second preparation of DNA can be done before or after exposure to and uptake of the first DNA preparation. Alternatively, the first DNA preparation can also include a DNA molecule encoding for a peptide including the amino acid sequence of the HBV S peptide.
A method for producing a peptide is also disclosed which comprises preparing an above-described recombinant DNA molecule, transfecting a host cell with the recombinant DNA molecule, culturing the host cell under conditions allowing expression and secretion of protein by the host cell, and collecting the peptide produced as a result of expression of DNA sequences within the recombinant DNA molecule. The peptide produced by such method can contain less than the entire amino acid encoded by the coding region of the recombinant DNA molecule. This may result from transcription and/or translation of only a portion of the coding region of the recombinant molecule or by deletions made in the peptide after translation.
A method of producing immunogenic particles is disclosed comprising preparing an above-described recombinant DNA molecule, transfecting a host cell with the recombinant DNA molecule, culturing the host cell under conditions allowing expression and secretion of protein by the host cell, and allowing under suitable conditions the aggregation of peptide monomers produced as a result of expression of exogenous DNA sequences within the host cell. A method of producing immunogenic particles is also disclosed which further comprises transfecting (cotransfection) the host cell with a DNA molecule encoding for a peptide including the amino acid sequence of the HBV S peptide. The cotransfection can occur before, after or simultaneous with the transfection of the above-described recombinant DNA molecule. Presence of peptides encoded by the cotransfected DNA molecule are necessary to obtain more than trace amounts of particles secreted from the host cell.
Methods of manufacturing a pharmaceutical preparation and a preparation useful for production of antibodies are disclosed comprising preparing an above-described recombinant DNA molecule, transfecting a host cell with the recombinant DNA molecule, culturing the host cell under conditions allowing expression and secretion of protein by the host cell, allowing under suitable conditions the aggregation of peptides produced as a result of expression of DNA sequences within the host cell to form immunogenic particles, and combining the immunogenic particles with a suitable carrier such that the immunogenic particles are present in sufficient concentration to cause production of antibodies upon administration of a preparation to an individual. Host cells used in these methods can also be cotransfected as previously described.
BRIEF DESCRIPTION OF THE FIGURES
FIGS. 1A-1C shows gene constructs encoding a polypeptide including the HBV pre-S1 region and a portion of the S region. The gene constructs also include the U2 promoter (FIG. 1 A), the MT promoter (FIG. 1B) or the H2K promoter (FIG. 1 C). The open boxes at the top of each figure signify inserts derived from the HBV genome, and the extent of deletions are indicated by the shaded segments thereof.
FIGS. 2A-2C shows gene constructs encoding a polypeptide including a portion of the HBV pre-S2 region and a portion of the S region. The gene constructs also include the U2 promoter (FIG. 2 A), the MT promoter (FIG. 2B) or the H2K promoter (FIG. 2 C). The open boxes at the top of each figure signify inserts derived from the HBV genome, and the extent of deletions are indicated by the shaded segments thereof.
FIGS. 3A-3C shows gene constructs encoding a polypeptide including a portion of the HBV pre-S1 region, a portion of the pre-S2 region, and a portion of the S region. The gene constructs also include the U2 promoter (FIG. 3 A), the MT promoter (FIG. 3B) or the H2K promoter (FIG. 3 C). The open boxes at the top of each figure signify inserts derived from the HBV genome, and the extent of deletions are indicated by the shaded segments thereof
FIGS. 4A-4C shows gene constructs encoding a polypeptide including at least a portion of the HBV pre-S1 region inserted within the S region at the XbaI site within S with a total deletion of the pre-S2 region. The gene constructs also include the U2 promoter (FIG. 4 A), the MT promoter (FIG. 4B) or the H2K promoter (FIG. 4 C). The open boxes at the top of each figure signify inserts derived from the HBV genome, and the extent of deletions are indicated by the shaded segments thereof.
FIGS. 5A-5C shows gene constructs encoding a polypeptide including at least a portion of the HBV pre-S2 region inserted within the S region at the XbaI site within S with a total deletion of the pre-S1 region. The gene constructs also include the U2 promoter (FIG. 5 A), the MT promoter (FIG. 5B) or the H2K promoter (FIG. 5 C). The open boxes at the top of each figure signify inserts derived from the HBV genome, and the extent of deletions are indicated by the shaded segments thereof
FIGS. 6A-6C shows gene constructs encoding a polypeptide including a portion of the HBV pre-S1 region and the S region with deletion of the S ATG. The gene constructs also include the U2 promoter (FIG. 6 A), the MT promoter (FIG. 6B) or the H2K promoter (FIG. 6 C). The open boxes at the top of each figure signify inserts derived from the HBV genome, and the extent of deletions are indicated by the shaded segments thereof.
FIGS. 7A-7C shows gene constructs encoding a polypeptide including a portion of the HBV pre-S2 region and the S region with deletion of the S ATG. The gene constructs also include the U2 promoter (FIG. 7 A), the MT promoter (FIG. 7B) or the H2K promoter (FIG. 7 C). The open boxes at the top of each figure signify inserts derived from the HBV genome, and the extent of deletions are indicated by the shaded segments thereof.
FIGS. 8A-8C shows gene constructs encoding a polypeptide including a portion of the HBV pre-S1 region, a portion of the pre-S2 region, and the S region with deletion of the S ATG. The gene constructs also include the U2 promoter (FIG. 8 A), the MT promoter (FIG. 8B) or the H2K promoter (FIG. 8 C). The open boxes at the top of each figure signify inserts derived from the HBV genome, and the extent of deletions are indicated by the shaded segments thereof.
FIGS. 9A-9B shows the nucleotide sequence of the pre-S1/pre-S2/S region of the HBV genome. Restriction sites (Bglll, MstII, and XbaI) and start codons for pre-S1 protein (“S1”), pre-S2 protein (“S2”), and S protein (“S”) are underlined.
FIGS. 10A-10B shows gene constructs encoding a polypeptide including at least a portion of the HBV pre-S2 region and the S region with deletion of the S ATG. The gene constructs also include the U2 promoter (FIG. 10 A), the MT promoter (FIG. 10B) or the H2K promoter (FIG. 10 C). The open boxes at the top of each figure signify inserts derived from the HBV genome, and the extent of deletions are indicated by the shaded segments thereof.
FIGS. 11 and 12 show the results obtained by caesium chloride sedimentation of immunogenic particles according to example 10 .
FIG. 13 shows a prior art construct shown in Table XI.
FIG. 14 shows the characterisation of particles derived from a construct according to a further embodiment of the present invention.
FIG. 15 shows the nucleotide sequence that encodes the HBV pre-S2 region and a portion of the S region, found in the gene construct of FIG. 10 B.
FIG. 16 shows the amino acid sequences of pre-S polypeptides from HBV subtypes ayw, adyw, adw2, adw, and adr, from which pre-S1 epitopes of the invention can be derived.
FIG. 17 shows the nucleotide and amino acid sequences of the pre-S1 region from HBV subtype adr.
FIG. 18 shows the nucleotide and amino acid sequences of the pre-S1 region from HBV subtype ayw.
FIG. 19 shows the nucleotide and amino acid sequences of the pre-S1 region from HBV subtype adw2.
FIG. 20 shows the nucleotide and amino acid sequences of the pre-S1 region from HBV subtype adw.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Preferred DNA constructs of the present invention are characterized by the presence of a selection marker selected from the group consisting of dhfr (dihydrofolate reductase), MT-neo (a neomycin resistance sequence coupled to a methallothionein and MT-ecogpt (a resistance-sequence coupled to a methallothionein promoter). The expression rate may be further enhanced by adding to the constructs a dhfr gene as an amplification gene.
HBV nucleotide sequences used in certain constructs of the present invention can be formed or isolated by any means including isolation and ligation of restriction fragments and synthetic oligonucleotides. Constructs specifically described herein were formed by the ligation of synthetic oligonucleotides to a 5′ XbaI-BqlII 3′ fragment from the S region of the HBV genome shown in Figure IX (hereinafter the “Xbal-BglII fragment”) which in derived from a BglII-BglrII HBV fragment including the entire pre-S 1 -pre-S 2 -S regions (the “BglI-Bg Fragment”). The pre-S 1 -pre-S 2 -S region of the HBV genome is shown in FIG. 9 . Oligonucleotides used in making such constructs are summarized in Table I.
TABLE I
Oligonucleotide Duplexes for Vector Construction
Restriction Sites and
Sequence (5′-3′)
Oligo. No.
Schematic Structure
Function
(sticky ends are underlined)
1
MstII-ATG-S1-XbaI
S1 (exchanged
TCAGG AAATGGAGAACATATCAGGA
flanking
TTCCTAGGACCCCTTCTCGTGTTACAG
sequence
GCGGGGTTTTTCTTGTTGACAAGAATC
ATG)
CTCACAATACCGCAGAGT
13
MstII-ATA-S1-XbaI
S1 (exchanged
TCAGG AAATAGAGAACATATCAGGA
flanking
TTCCTAGGACCCCTTCTCGTGTTACAGG
sequence
CGGGGTTTTTCTTGTTGACAAGAATCCT
ATA)
CACAATACCGCAGAGT
17
BglII-ATG-S2-EcoRI
S2 (exchanged
GATC TACCTGAACATGGAGTGG
flanking
sequence
ATG)
19
MstII-ATG(S)-S2-
S2 (20 amino
TCAGG CGCTGAACATGGAGAACATCTCC
XhoI
acids; with S
AGTTCAGGAACAGTAAACCCTGTTCTGA
ATG)
CTACTGCCTCTCCCTTATCGTCAATCTTC
23
BglII-ATG(S)-S1-
S1 (28 amino
GATC TTTAACATGGAGAACAATCCTCTG
XbaI
acids; with S
GGATTCTTTCCCGATCACCAGTTGGATCC
ATG)
AGCCTTCAGAGCAAACACCGCAAATCC
AGATTGGGACTTCAATCCCAGT
29
BglII-ATG(S)-S2-
S2 (26 amino
GATC TTTAACATGGAGAACCAGTGGAAT
XbaI
acids; with S
TCCACAACCTTCCACCAAACTCTGCAAG
ATG)
ATCCCAGAGTGAGAGGCCTGTATTTCCCT
GCTGGTGGCTCCAGT
33
XbaI-ATA(S)-StyI
S 5′ with ATA
CTAG ACCCTGCGCTGAACATAGAGAACA
TCACATCAGGATTCCTAGGACCCCTTCTC
GTGTTACAGGCGGGGTTTTTCTTGTTGACA
AGAATCCTCACAATACCGCAGAGC
35
XbaI-ATA(S)-HpaI-
S 5′ with ATA
CTAG ACCCTGTGGTTAACATAGAGAACA
StyI
TCACATCAGGATTCCTAGGACCCCTTCTC
GTGTTACAGGCGGGGTTTTTCTTGTTGACA
AGAATCCTCACAATACCGCAGAGC
37
BglII-S1-HpaI
S1
GATC TTTAACATGGAGAACAATCCTCTG
GGATTCTTTCCCGATCACCAGTTGGATCC
AGCCTTCAGAGCAAACACCGCAAATCC
AGATTGGGACTTCAATGTT
39
EcoRI-XbaI-Xhol-
S 5′ with ATA
AATT CTAGACTCGAGTCTGAACATAGAG
ATA(S)-StyI
AACATCACATCAGGATTCCTAGGACCCC
TTCTCGTGTTACAGGCGGGGTTTTTCTTGT
TGACAAGAATCCTCACAATACCGCAGA
GC
43
StyI-S2-XhoI
S 3′
CTAGG AACAGTAAACCCTGTTCTGACTA
CTGCCTCTCCCTTATCGTCAATCTTCTCTA
GGATTGGGGAC
45
BglII-ATG(S)-S1-
S1 (17 amino
GATC TTTAACATGGAGAACGATCACCAG
poly alanine-XbaI
acids; with S
TTGGATCCAGCCTCCAGAGCAAACACCG
ATG); poly
CAGCCGCCGCCGCCGCCGCCGCCGCCGCCG
alanine sequence
CCGCCGCCGCCGCCAAT
49
XbaI-S2-StyI
S 3′
CTAG ACACAGTAAACCCTGTTCTGACTA
CTGCCTCTCCCTTATCGTCAATCTTCTCGA
GGATTGGGGAC
55
BglII-S1-XbaI
S1 (28 amino
GATC TTTAACATGGAGACCAATCCTCTG
acids)
GGATTCTTTCCCGATCACCAGTTGGATCC
AGCCTTCAGAGCAAACACCGCAAATCC
AGATTGGGACTTCAAT
The oligonsotides in Table I were combined with the xbaI-BglII fragment to produce constructs with desired features. In certain constructs adapter oligonucleotide sequences (Table II) were used to create proper matching sticky ends on the oligonucleotides and other construct components.
TABLE II
Oligonucleotide Duplexes (Adapter Sequences)
Restriction Sites and
Oligo. No.
Schematic Structure
Sequence (5′-3′)
2
ApaI-BglII-HindIII
CTTAGATCTTTA
CCGGGAATCTAGAAATTCGA
4
MstII-XhoI
TCAGGAC
CCTCAGCT
7
EcoRI-HindIII-BglII
AATTCAAGCTTA
GTTCGAATCTAG
9
SalI-BglII-BamHI
TCGACAGATATG
GTCTAGACCTAC
15
EcoRI-BglII
AATTCCCCGGGA
GGGGCCCTCTAG
27
EcoRI-BglII-BnamHI-
AATTCAGATCTGGATCCGAGCTCA
HindIII
GTCTAGACCTAGGCTCGAGTTCGA
31
BamHI-HindIII
GATCCTTA
GAATTCGA
41
ApaI-BglII-XhoI
CAAAAGATCT T TTC
CCGGGT TT TCTAGAAAAGAGCT
47
XbaI-polyalanine-XhoI
CTAGAC(2OH GCC)GAC
TG(2OH CGG)CTGAGCT
53
EcoRI-BglII-XbaI-XhoI
AAT TCATCCAGATCTAATTCTC TAGATTAC
GTAGGTCTAGATTAAGAGATCTAATGAGCT
57
XhoI-XbaI
TCGAGGAGTCGACCTAGT
CCTCAGCTGGATCAGATC
61
BglII-EcoRI-BglII
GATCTAATTGAATTCAATTA
ATTAACTTAAGTTAATCTAG
63
EcoRI-SalI-EcoRI
AATTATGTCGACTA
TACAGCTGATTTAA
Other adaptor sequences may be used to combine desired oliqonucleotides from Table I with the XbaI-BglII fragment, other restriction fragments, oligonucleotides and other construct components. The necessary sequences of such other adapter sequences will be readily apparent to those skilled in the art from consideration of tables of restriction sites [e.g., that found at pages 121-128 of Methods in Enzymology , volume 152, “Guide to Molecular Cloning Techniques,” ad. Borger and Kimmel (Academic Press 1987) which is incorporated herein in its entirety by reference] and the sequences of the various nucleotides to be combined. Adapter sequences can also be used to introduce additional restriction sites into constructs of the present invention. It should be noted that adapter sequences must be selected or designed so that the proper reading frame is maintained throughout the HBV sequence.
Preferred gene constructs which were used to transfect host cells were prepared by recombinant DNA techniques in accordance with the present invention. Preferred embodiments of constructs with an enhanced expression rate are shown in Figures I-VIII and are schematically represented by the following:
pU2-structural gene
pU2-structural gene-dhfr
pU2-structural gene-dhfr-MT-neo
pU2-structural gene-dhfr-MT-egpt
pMT-structural gene-dhfr
pMt-structural gene-dhfr-MT-neo
pMT-structural gene-dhfr-MT-egpt
pH2K-structural gene-dhfr
pH2K-structural gene-MT-neo
pH2K-structural gene-MT-egpt
pH2K-structural gene-dhfr-MT-neo
pH2K-structural gene-dhfr-MT-egpt
Each of the constructs shown in Figures I-VIlI contain, in addition to a HBV sequence, a neomycin selection marker with the MT promoter, an ampicillin selection marker, a dhfr selection/amplification gene and a promoter for the HBV sequence. The promoter for the HBV sequence is preferably the U2 promoter, the MT promoter or the H2K promoter. Isolation of fragments containing the various promoters, the selection markers and amplification gene is described below. The HBV sequences in the constructs of FIG. 1-8 are schematically represented by a rectangular bar in each figure which indicates the oligonucleotides and/or adapter sequences from Tables I and II which were combined with the XbaI-BglII fragment. Shaded areas within the bar indicated generally regions of the entire pre-S 1 -pre-S 2 -S region which are not found in the specific construct. Oligonucleotides from Table I which can be used to construct each type of HBV sequence are indicated in the figures.
FIG. 10 depicts two additional constructs for expression of peptides including sequence from the pre-S2 region under the control of the MT promoter.
Constructs have also been made which include the entire BglII-BglII fragment from the HBV genome under the control of the US promoter. These constructs have produced peptides which include a deletion in the S region as indicated by Western blot analysis.
The above-cited promoters are specially preferable when their use is coupled with a modulation method using the dhfr gene and methotrexate to enhance the expression. This is achieved when in addition to the selection marker the dhfr minigene is also introduced into the plasmid sequence. It is essential that the dhfr gene is located on the same plasmid together with the structural gene to be expressed. An enhancement of the expression rate of the structural gene can then be obtained by adding methotrexate in the micromolar concentration range. Thereby a manyfold enhancement of the expression rate is achieved.
Suitable cells are e.g. VERO cells (monkey kidney cell line), 3T3-cells (murine fibroblast line), C127-cells (murine fibroblast line), L-cells and CHO—cells (Chinese hamster cells, which are either positive or negative in dehydrofolate reductase).
As a stop signal it is preferred to use a stop signal from a eukaryotic cell. Preferably the stop signal of the caseine DNA-sequence is used. As used throughout the following examples, “HBV protein” refers generically to any protein produced in accordance with the present invention which corresponds to HBsAg sequences.
EXAMPLE 1
Particle Purification Procedures
1. Fractionated Precipitation with Polyethylene Glycol (PEG)
The supernatant of HBV protein producing cultures was collected and split into portions of 2,400 ml. To each portion 144 g of PEG 6000 (Serva) were added and dissolved by stirring at room temperature for 20 minutes and was stirred for another 6 hours at 4° C. The precipitate was separated by centrifugation in 500 ml bottles an a GS 3 rotor at 9.000 rpm (15,000×g) for 30 minutes at 10° C. The supernatant was collected and 144 g of PEG 6000 were added and dissolved as described above. The solution was stirred at 4° C. for 3 hours. The precipitate from this solution was harvested as described above except that centrifugation was continued for 60 minutes.
2. Gel Chromatography
The material obtained after PEG precipitation was redissolved in 20 ml PBS and submitted to gel chromatography on A-5m (BioRad). Column dimensions were 25×1000 mm and 480 ml bed volume. In a typical fractionation run 1,000 ug of PEG precipitated HBV protein in 10 to 15 ml was loaded and eluted with PBS at a speed of 6 drops/min (18 ml/h) 3 ml fractions were collected. HBV protein eluted with the first peak. Collected fractions were submitted to a CsCl gradient.
3. Sedimentation in CsCl Gradient
About 30 fractions covering the first peak in column chromatography on A-5m and containing prepurified HBV protein were collected to approximately 100 ml. This solution was adjusted to a density of 1.30 g/cc with CsCl and subsequently transferred to a nitrocellulose tube fitting into a SW 27/28 rotor (Beckman). A gradient was set by underlaying 4 ml of a CsCl solution of 1.35 g/cc and by overlaying 4 ml of 1.25 g/cc followed by 4 ml of 1.20 g/cc density. This gradient had been run at 28,000 rpm for 50 hours at 10° C. Thereafter the gradient was fractionated and purified HBV protein floating in the 1.20 q/cc density layer was collected. The solution was desalted by three cycles of dialysis in bags against water.
EXAMPLE 2
Quantitative Determination of HBV Protein
1. With Radioimmunoassay
In the AUSRIA II-125 “sandwich” radioimmunoessay (commercially available from Abbot), beads coated with guinea pig antibody to Hepatitis B Surface Antigen (Anti-HBs) were incubated with serum or plasma or purified protein and appropriate controls. Any HBsAg present was bound to the solid phase antibody. After aspiration of the unbound material and washing of the bead, human 125T-Anti-HBs was allowed to react with the antibody-antigen complex on the bead. The beads were then washed to remove unbound 125 I-Anti-HBs.
)-Anti-HBs HBsAg
)-Anti-HBs . HBsAg 125I-Anti-HBs
)-Anti-HBs . HBsAg . 125-Anti-HBs
The radioactivity remaining on the beads was counted in a gamma scintillation counter.
2. With ELISA
In the Enzygnost HBsAg micro “sandwich” assay (commercially available from Behring), wells were coated with anti-HBs. Serum plasma or purified protein and appropriate controls were added to the wells and incubated. After washing, peroxidase-labelled antibodies to HBsAg were reacted with the remaining antigenic determinants. The unbound enzyme-linked antibodies are removed by washing and the enzyme activity on the solid phase is determined. The enzymatically catalyzed reaction of hydrogen peroxide and chromogen was stopped by adding diluted sulfuric acid. The colour intensity was proportional to the HBsAg concentration of the sample and was obtained by photometric comparison of the colour intensity of the unknown samples with the colour intensities of the accompanying negative and positive control sera.
EXAMPLE 3
Preparation of a Construct of the Present Invention Containing the Methallothionein Promoter
1) Isolation of the MI Promoter
The plasmid pBPV-342-12 (commercially available from ATCC) was digested with the endonucleases BglII and BamHI. Three DNA molecules were generated. The fragment of interest contains the methallothionein promoter and a pBR32Z sequence comprising 4.5 kb and is easily detectable from the other fragments (2.0 kb and 7.6 kb).
The reaction was performed in a total volume of 200 ul of reaction buffer at a final concentration of 0.5 ug/ul DNA including 100 units of each restriction enzyme. The completion of the digestion was checked after incubation at 37° C. for three hours by agarose gel electrophoresis at a 0.8% agarose gel. The reaction was stopped by adding 4 ul 0.5 M EDTA.
The 4.5 kb fragment was separated from the other fragments by preparative 1.2% agarose gel electrophoresis. The DNA was eluted from the agarose gel on DE-81 whatman filter paper from which the DNA was removed in a high salt buffer. The DNA was purified by a phenol/chloroform extraction and two ethanol precipitations.
2) Ligation of the 2.3 kb MBV BglII-BglII Fragment
A 2.3 kb BglII-BglII fragment containing the HBV pre-S 1 ,pre-S 2 and S coding regions was isolated from HBV-containing DNA. The 2-3 kb fragment was ligated together with the 4.5 kb fragment (obtained as described in C1) containing the methallothionein promoter.
2 ul of the 2.3 kb fragment were mixed with 3 ul of the 4.5 kb fragment and ligated together in a total volume of 10 ul ligation buffer, containing 2 unit T 4 -DNA ligase and 2 mM ATP at 14° C. overnight.
The ligation mixture was added to 150 ul competent bacterial cell suspension for DNA up-take. After the DNA up-date the bacterial cells were spread on LB agar plate containing 50 ug/ml ampicillin at volumes of 50 to 300 ul cell suspension per plate. The agar plates were incubated at 37° C. overnight. Single isolated bacterial colonies were screened for the presence of a plasmid containing the desired fragments.
3) Screening for Desired Plasmid Containing Bacterial Colonies.
Single colonies were picked with a toothpick and transferred to a LB-ampicillin media containing tube (5 ml). The tubes were incubated overnight at 37° C. by shaking rapidly. A mini-plasmid preparation of each grown bacterial suspension was made. The different resulting DNAs were proved by digestion with the restriction endonuclease EcoRI. Two molecules were expected, a 2.2 kb fragment and a 4.6 kb fragment. The digestion was analysed by agarose gel electrophoresis. Plasmid DNA was isolated from the bacterial cells.
4) Conversion of a Part of the HBV-gene Sequence.
The plasmid resulting from (3) above was digested with the endonucleases BglII and XbaI. Two molecules were expected. one 550 bp fragment and one 6.250 kb fragment which was isolated after agarose gel electrophoresis.
The 6.250 kb fragment was ligated together with oligomecleotide No.55 from Table I. The ligation mixture was added to 150 ul competent bacterial cell suspension for DNA up-take. Single isolated bacterial colonies were screened for the presence of the desired plasmid. The new plasmid was proved by a digestion with the endonucleases EcoRI and BglII. Two molecules were expected, one 1.9 kb and one 4.450 kb.
5) Insertion of a Neomycin Selection Marker.
The plasmid resulting from (4) above was linearized by digestion with the restriction enzyme EcoRI. The reaction was performed in a total volume of 50 ul and a final concentration of 1 ug/ul plasmid DNA. 50 units of ECoRI were added and the digestion was proved after incubation at 37° C. for three hours by agarose gel electrophoresis. The reaction was stopped by adding 1 ul of 0.5 M EDTA and the DNA was precipitated with a final concentration of 0.3 M sodium acetate and 3-4 volumes of ethanol at −80° C. for 30 minutes. The precipitated DNA was dissolved in 50 ul distilled water.
2 ul of the linearized plasmid were mixed with 3 ul of the DNA fragment containing the methallothionein promoter and the neomycin selection gene [isolated from the plasmid pMT-neo-E (available from ATCC) by digestion with the endonuclease EcoRI as a 4kb fragment], and ligated together. Single bacterial colonies were screened for the presence of the desired plasmid.
6) Additional of the dhfr Amplification Gene dhfr
The plasmid pdhfr3.2 (available from ATCC) was digested with the restriction endonuclease HindIII. Two molecules were generated, one of 3,000 bp containing the dhfr gene sequence and one of 3,400 bp. The 3,000 bp fragment was isolated and ligated into the plasmid resulting from (5) above which was previously opened by digestion with HindIII. The resulting plasmid is represented by FIG. 1 B.
EXAMPLE 4
1) Isolation of a Fragment Containing the U2 Promoter Sequence
The plasmid pUC-8-42 (available from Exogene ) was digested with the restriction endonucleases EcoRI and ApaI. Two DNA molecules were generated. The fragment of interest contains the U2-promoter comprising 340 bp and is easily detectable from the other fragment (3160 bp). The digestion was performed in a total volume of 200 ul of reaction buffer at a final concentration of 0.5 ug/ul DNA including 100 Units of each restriction enzyme. The completion of the digest was checked after incubation a 37° C. for three hours by agarose gel electrophoresis in a 0.7% agarose gel. The reaction was stopped by adding 4 ul 0.5 M EDTA. The 340 bp fragment was separated from the plasmid DNA by preparative 1.2% agarose gel electrophoresis. The DNA was eluted from the agarose gel on DE-81 Whatman filter paper from which the DNA was removed in a high salt buffer. The DNA was purified by a phenol/chloroform extraction and two ethanol precipitations.
2) Insertion of the Fragment Containing the Promoter Sequence into a Polylinker Plasmid
The plasmid pSP165 (commercially available from Promega Biotec) containing a polylinker sequence (containing the following restriction sites: EcoRI, SacI, SmaI, AvaI, BamHI, BglII, SalI, PstI, HindIII) was linearized with the restriction enzyme EcoRI. The reaction was performed in a total volume of 50 ul and a final concentration of 1 ug/ul plasmid DNA. 50 Units of EcoRI were added an the digestion was proved after incubation at 37° C. for three hours by agarose gel electrophores. The reaction was stopped by adding 1 ul of 0.5 M EDTA and the DNA was precipitated with a final concentration of 0.3 M sidium acetate and 3-4 volumes of ethanol at −80° C. for 30 minutes. The precipitated DNA was dissolved in 50 ul distilled water.
2 ul of plasmid DNA were mixed with 10 ul of the fragment DNA containing the V2 promoter sequence, and ligated together in a total volume of 25 ul of ligation buffer containing 2 units T4-DNA ligase and mM ATP at 14° C. overnight. Thereafter the DNA was purified by phenol/chloroform extractions followed by two ethanol precipitations and dissolved in 10 ul distilled water. The resulting sticky ends of EcoRI and ApaI had to be converted into blunt ends and ligated. The blunt ends were converted by a removing reaction with the Mung bean nuclease as follows: to 25 ul DNA (1 ug/ul concentration) reaction buffer, 20 units of enzyme and a final concentration of 1% glycerol to the reaction volume of 35 ul were added. After an incubation for 30 minutes at 30° C. the DNA was purified by phenol/chloroform extractions followed by two ethanol precipitations. The DNA was dissolved again in 5 ul distilled water. The resulting blunt ends were ligated together in 15 ul reaction volume containing 10× more T4 ligase then used above and 2 mM ATP at 14° C. overnight.
The ligation mixture was added to 150 ul competent bacterial cell suspension for DNA up-take. After the DNA up-take the bacterial cells were spread on LB agar plates containing 50 ug/ml ampicillin at volumes of 50 to 300 ul cell suspension per plate. The agar plates were incubated at 37° C. overnight. Single isolated bacterial colonies were screened for the presence of a plasmid containing the desired U2-promoter fragment.
3. Screening for Desired Plasmid Containing Bacterial Colonies
Single colonies were picked with a toothpick and transferred to a LB-ampicillin containing tube (5 ml). The tubes were incubated overnight at 37° C. by shaking rapidly. A mini plasmid preparation of each grown bacterial suspension was made. The different resulting plasnid was proved by digestion with both restriction endonucleases EcoRI and HindIII. Two molecules were found, a 400 bp fragment containing the U2 promoter sequence and the plasmid of 2,700 bp. The digestion was analysed by agarose gel electrophoresis. The resulting plasmid was isolated from the bacterial cells.
4) Insertion of the Neomycine Selection Marker
The plasmid pBPV-342-12 (commercially available from ATCC) was digested with the endonuclease EcoRI and BamHI. Two molecules were isolated, one containing the MT promoter together with the neomycin selection gene of 4,000 bp and the plasmid of 10,000 bp.
The plasmid resulting from (3) above was linearized with EcoRI and ligated together with the 4,000 bp fragment containing the MT-promoter together with the neomycin selection gene. The resulting sticky ends were also converted into blunt ends and ligated together as described above.
After bacterial transformation, colony selection and mini plasmid preparation, the resulting plasmids were analysed by a digestion with the restriction enzymes EcoRI and HindIII. Two DNA molecules were isolated, a 400 bp fragment and a 6,700 bp fragment.
5) Ligation of the BglII-BglII Fragment
The plasmid resulting from (4) above was linearized with BglII. The 2.3 kb-BglII-BglII fragment was ligated together with the linearized plasmid. Bacterial colonies were analysed to find the resulting plasmid. The plasmid-DNA was digested with EcoRI and two resulting fragments were obtained, a 700 bp fragment (containing the promoter and a part of the HBV-sequence) and a 8,700 bp fragment (containing the rest of the HBV-sequence, MT-neo and plasmid).
6) Alterations within the HBV-sequence
The plasmid resulting from (5) above was digested with the endonucleases BglII and MstII. Two molecules were generated, one of 300 bp containing part of the pre-S sequence and the other (9,100 bp) which was eluted as described above. This 9,100 bp fragment was ligated to another BglII/MstII 216 bp fragment (sequence
= AGATCT ACAGC ATG GGGCAGAATCTTTCCACCAGCAATCCTCTGGGATTCTTTCCCGACCA
Bg1II S1
CCAGTTGGATCCAGCCTTCAGAGCAAACACCGCAAATCCAGATTGGGACTTCAATCCCAA
CAAGGACACCTGGCCAGACGCCAACAAGGTAGGAGCTGGAGCATTCGGCCTGGGTTTCAC
CCCACCGCACGGAGGCCTTTTGGGGTGGAGC CCTCAGG )
MstII
coding for an altered pre-S 1 gene sequence.
The desired plasmid was digested with EcoRI and two resulting fragments were isolated, a 616 bp fragment and a 8,700 bp fragment.
EXAMPLE 5
Isolation of the H2K Promoter
The H2K promoter was isolated as an EcoRI/BglII fragment (2kb) from psp65H2 (available from Exogene).
Isolation of the egpt Selection Marker
The fragment containing the methallothionein promoter and the egpt-selection gene was isolated by digestion of the plasmid pMSG (available front Pharmacia) with the restriction enzyme EcoRI as a 3.6 kb fragment.
All other plasmid constructions were made in similar ways by combining fragments containing the necessary components and employing desired oligonucleotides and adapter sequences (where necessary).
EXAMPLE 6
Transfection of Mammalian Cells with Constructs of the Present Invention
In order to achieve secretion of substantial amounts of the HBV peptides encoded by constructs of the present invention, mammalian cells must be transfected with both the construct of the present invention and a construct which will express entire S protein. The cotransfection was performed in two steps (i.e., a separate transfection for each construct) or in a single step (i.e., one transfection using preparation of both constructs). Cotransfection was confirmed either by use of different selection markers on the two constructs or by detection of secretion of expression products of both constructs by immunoassay.
Alternatively, a sequence encoding the HBV peptide sequence of the present invention and a separate sequence encoding the entire S protein could be combined in a single construct.
EXAMPLE 7
General Procedures
General procedures useful in practicing the present invention may be found in (1) Methods of Enzymology , volume 152, “Guide to Molecular Cloning Techniques,” ed. Borger 3nd Kimmel (Academic Press 1987), and (2) Maniatis et al., “Molecular Cloning: A Laboratory Manual,” (Cold Spring Harber Laboratory 1982), both of which are incorporated herein in their antirety by reference. Specific techniques employed are described below.
1) Digestion with Endonucleases and Isolation of Fragments
The restriction endonucleases used were: BglII, BamHI, HindIII, EcoRI, XbaI, MstII, XhoI, Pf1MI, commercially available from Gibco/BRL with their respective restriction buffers (10=).
Unless otherwire indicated, restriction digests were performed and fragments were isolated as follows. Reactions typically contained 1-5 ug DNA.
distilled water was added to the DNA in an eppendorf tube to a final volume of 8 ul
1 ul of the appropriate 10×digestion buffer was added
1 ul (containing 5-10 U) restriction enzyme was added and mixed carefully
the reaction tube was incubated for 1 hour at 37° C.
digestion was stopped by adding 0.5 M EDTA (pH 8.0) to a final concentration of 10 mM
if the DNA was analysed directly on a gel, 1 ul of gel-loading dye III (Maniatis) was added, mixed and the sample was loaded into the slots of a 0.8% agarose gel.
The agarose gel normally contains 0.8% agarose 1×running buffer (TBE, Maniatis). Where a fragment (about 100-1000 bp) was isolated from an agarose gel the agarose was increased to 1.2 to 1.4%.
2) Competent Bacterial Cells
From a dense overnight culture, 1 ml of the bacterial cell suspension was added to 100 ml fresh growth medium (L-broth). The cells were grown at 37° C. to a density of OD 600 =0.7 which was reachad within 2 hours with vigorous shaking in a 500 ml Erlenmeyer flask. Growth was atopped by chilling the culture on ice for 10 minutes. From this culture, 3 ml were taken for harvesting the exponential bacterial cells at 3,000 rpm for 5 minutes. The cells were resuspended in 1.5 ml of 50 mM CaCl 2 in 10 mM Trio, pH 8.0, and incubated on ice for another 15 minutes. The cells were harvested once more by centrifugation at 3,000 rpm for 5 minutes and resuspended in 200 ul of 50 mM CaCl 2 in 10 mM Tris, pH 8.0, and used directly.
3) Transformation of Competent Bacterial Cells
The DNA to be transformed was suspended in 10 mM Tris, pH 7.5, 1 mM EDT 70 ul and added to the 200 ul bacterial cell suspension for DNA take-up. The mixture was incubated on ice for 30 minutes and then 1 ml L-broth was added. The mixture was incubated at 42° C. for 2 minutes and at 37° C. for 40 minutes. After the incubation, the cells were spread on agar plates containing 50 ug ampicillin/ml agar at volumes of 50-300 ul cell suspension per plate. The agar plates were incubated at 37° C. overnight. After this incubation period, single isolated bacterial colonies were formed.
4) Plasmid DNA Isolation
1 liter of plasmid-bearing cells was grown to 0.5 OD 600 in L-broth and amplified for 20 hours with 200 ug/ml chloramphenicol. The culture was then centrifuged at 4,000 rpm for 20 minutes in JA-10 rotor, 4° C. The pellet was resuspended in 18 ml cold 25% sucrose, 50 mM Tris, pH 8.0, transferred to a 250 ml Erlenmeyer flask and kept on ice. 6 ml 5 mg/ml lysozyme in 250 mM Tris, pH 8.0 was added and the mixture was left to stand 10-15 minutes. 6 ml 250 mm EDTA, pH 8.0, was added, mixed gently and incubated for 15 minutes on ice. 30 ml detergent (0.01% Triton X-100; 60 mM EDTA, pH 8.0; 50 mM Tris, pH 8.0) was added and the mixture was incubated for 30 minutes on ice. After incubation, the mixture was centrifuged at 25,000 rpm 90 minutes in SW28 rotor, 4° C.
Pronase was added to supernatant fluid to 250 ug/ml and incubated 30 minutes, 370° C. The solution was extracted with phenol once with ½ volume phenol equilibrated with 10 mM Tris, pH 8.0, 1 mM EDTA. The aqueous layer was removed. Sodium acetate was then added to a final concentration of 300 mM, followed by the addition of 3 volumes cold 100% ethanol and thorough mixing. The mixture was stored at −20° C. overnight.
The mixture was thawed and centrifuged. The pellet was resuspended in 6 ml 10 mM Tris, 10 mM EDTA, pH 8.0. 9.4 g CsCl and 0.65 ml of 6 mg/ml ethidium bromide were added and the volume was brought up to 10 ml with sterile double-distilled water. The 10 ml alignots were put into Beckman heat-sealable gradient tubes and centrifuged, 50,000 rpm, 48 hours in Ti70.1 Beckman rotor.
Plasmid bands were visualized with UV and removed with syringe and 18 gauge needle by piercing the side of the tube. Ethidium bromide was removed from the plasmid fractions by 3 successive extractions with equal volumes of isobutanol. Fractions were then (1) dialyzed against one 2-liter lot of 10 mM Tris, pH 7.4, 1 mM EDTA, pH 7.5, 5 mM NaCl for 2 hours or more at 4° C.; and (2) phenol extracted once with ⅓ volume phenol equilibrated as above. Sodium acetate was then added to a final concentration of 300 mM, followed by addition of two volumes of 100% ethanol. Precipitate formed at −20° C. overnight, or at −70° C. for 30 minutes.
5) Mini-Plasmid Preparation
1 ml of an overnight bacteria culture was put into an eppendorf tube and centrifugated for 20 minutes. The supernatant was removed. 100 ul of 50 mM glucose, 25 mM Tris (pH 8.0), 10 mM EDTA (pH 8.0) was added to the pellet, mixed by vortex and incubated for 5 minutes at room temperature. 200 ul of 0.2 N NaOH, 1% SDS was added, mixed by vortex and incubated for 5 minutes on ice. 150 ul 3 M Sodium acetate (pH 4.8) was added, mixed by vortex and incubated for 5 minutes on ice. After centrifugation for 5 minutes at 13,000 rpm the supernatant was decanted into a fresh appendorf tube. 3 volumes of 100% ethanol were supplemented, mixed well and incubated for 30 minutes at −80° C., then centrifuged for 10 minutes at 13,000 rpm. The ethanol was removed, the pellet washed with 70% ethanol, lyophilized and dissolved in 20 ul distilled water. 5 ul of this plasmid DNA solution were used directly for restriction analysis.
6) Nick Translation
Nick translation was performed according to Rigby et al., J. Mol. Biol., Vol. 113, pp. 237-251, 1977, which is incorporated herein by reference. The reaction mixture for 32 P-labeling of DNA contained 0.5 ug of a HBV fragment, in a total volume of 30 ul with 50 mM Tris, pH 7.8, 5 mM MgCl 2 , 10 mM mercaptoethanol, 0.1 mM dATP, 0.1 mM dGTP, 0.1 mM dTTP, 50 uCi 32 P-dCTP, 10 units DNA polymerase I, 3 ul of a 2×10 −5 fold dilution of 1 mg/ml DNase I and is incubated for 90 minutes at 15° C., yielding 3×10 6 to 12×10 6 total cpm, i.e. 1×10 7 to 5×10 7 cpm/ug DNA.
7) Southern Blot Analysis
To characterize the organization within the host cell genome of the vectors of this invention, chromosomal DNA from cell lines producing particles of this invention-were isolated and digested with the appropriate restriction enzyme(s) and analysed by the method of Southern (J. Mol. Biol., Vol. 98, pp. 503-517, 1975), which is incorporated herein by reference, using a 32 P-labeled DNA probe. Following digestion of the chromosomal DNA (20 ug) with the restriction enzyme BglII, the resulting fragments were separated by 0.7% agarose, gel electrophoresis. Thereafter, the DNA was denatured by exposing to 366 nm UV light for 10 minutes and by incubation in a solution of 0.5 M NaOH and 1 M NaCl for 45 minutes. The gels were neutralized by incubation in 0.5 M Tris, 1.5 M NaCl, pH 7.5 for 60 minutes. The DNA was transferred to a nitrocellulose filter by soaking in 3 M NaCl, 0.3 M Sodiumcitrate (20×SSC) for 20 hours through the gel by covering the top of the nitrocellulose filter with a staple of dry paper towals. The nitrocellulose filter was kept for 2 hours in a vacuum oven at 80° C. A radioactive DNA probe from the BglII fragment of the pHBV (2.3 kb) was prepared by nick translation.
For hybridization with the DNA probe, the nitrocellulose filter was sealed in a plastic bag containing 10 ml of prehybridization mixture: 50% formamide, 5×SSC, 50 mM Sodiumphosphate, pH 7.0, 5×Denhardt's solution, 250 ug/ml denatured salmon sperm DNA. The filter was incubated in this mixture for 4 hours at 45° C., after which the pre-hybridization mixture was replaced by the hybridization mixture: 50% formamide, 5×SSC, 20 ml Sodiumphosphate, pH 7.0, 1×Denhardt's solution, 100 ug/ml denatured salmon sperm DNA, 5×10 5 cmp/ml 32 P-probe. The filter, after incubating in the hybridization mix for 18 hours at 45° C., was washed three times, 5 minutes each, in 0.1×SSC, 0.1% SDS at 50° C. The filter was dried at 60° C. for 10 minutes and exposed to two X-ray films (XAR-5, KODAK) between two intensifying screens and kept at −80° C. The first X-ray film is developed after 3 days' exposure; the second film after 7 days' exposure.
8) Preparation of Mammalian Cells and DNA Precipitate for Transfection
The recipient cells (C127 or CHO-cells available from ATCC) were seeded in normal growth medium (DMEM+10% Fetal Calf Serum,Glycose and Glutamin) into petri-dishes (1-2×10 6 cells per dish, 10 cm) at day 1. The next day the medium was removed (4 hours before the DNA precipitate was added onto the cells), and the cells were washed twice with 1×PBS. Then 8 ml DMEM without FCS were added. 4 hours later the DNA precipitate (prepared as described below) was added to the cells. Again after 4 hours the madium was removed, 3 ml of Glycerol-Mix (50 ml 2×TBS buffer, 30 ml glycerol, 120 ml distilled water) were added. The Glycerol-Mix was immediately removed after an incubation at 37° C. for 3 minutes and the cells were washed with 1×PBS. The calls were cultivated overnight with 8 ml of DMEM with 10% FCS.
After 48 hours, the cells were recovered from the dish by treating with Trypain-EDTA-Solution (0.025% Trypsin+1 mM EDTA). Afterwards, to remove the Trypsin-EDTA the cells were washed with 1×PBS, suspended in DMEM with 10% FCS and distributed into 24 costar-well-plates (cells from one dish into four 24-well-plates). When the cells had grown wall, selection medium was added (concentration 0.5-1mg/ml of neomycin,or xanthine: 250 μg/ml, hypoxanthine: 15 μg/ml (or adenine: 25 μg/ml), thymidine: 10 μg/ml,aminopterine 2 μg/ml mycophenolic acid: 25 μg/ml for eco-gpt, for example). The medium was changed every week. The first growing cell colonies were seen after 2 weeks.
To 10 ug of plasmid DNA and 20 ug of carrier-DNA (salmon-sperm DNA, calf-thymus DNA) TE-buffer (10 mM Trix-HCl, 1 mM EDTA, pH 7.05) was added to a final volume of 440 ul and mixed together with 60 ul 2 M CaCl 2 . Then the same amount of 2×TBS (Hepes 50 mM, NaCl 280 mM, Na 2 HPO 4 1.5 mM, pH 7.05) was added and mixed well. The precipitation solution was incubated for 30 minutes at 37° C. and added directly to the cells which should be transfected.
EXAMPLE 8
Culturing of Transfected Cells to Secrete Protein
The selected cells are treated for further cultivation in normal growth medium as described in section 8.
EXAMPLE 9
F) Preparation of the Adjuvant of Purified Particles
To the desired concentration of antigen particles suspended in sterile saline, 1:10,000 volume Thimerosol, {fraction (1/10)} volume of filter-sterilized 0.2 M Al K(S04) 2 :12 H 2 O were added. The pH was adjusted to 5.0 with sterile 1 N NaOH and the suspension seas stirred at room temperature for 3 hours. The alum-precipitated antigen was recovered by centrifugation for 10 minutes at 2,000 rpm, resuspended in sterile normal saline containing 1:10,000 Thimerosol and aliquotad under sterile conditions.
EXAMPLE 10
Table III:
shows the ELISA data of the purified HBs
antigen particle produced from any HBV
sequence construct of the present invention
including the pre-S 1 region with total
deletion of pre-S 2 and deletions upstream
of the pre-S 2 ATG and the S region with
deletion of the S ATG and downstream the
S ATG through the XBaI site (e.g. the
construct of FIG. I-1) with the
anti-pre-S 1 monoclonal antibody MA 18/7.
The fractions 9-15 (FIG. XI) were pooled
after CsCl sedimentation.
Table IV:
shows the ELISA data of the purified HBS
antigen particle produced from any HBV
sequence construct of the present invention
including the pre-S 1 region with total
deletion of pre-S 2 and deletions upstream
of the pre-S 2 ATG and the S region with
deletion of the S ATG and downstream the
S ATG through the XBaI site
(e.g., the construct of FIG. 1A with the
anti-pre-S 2 monoclonal antibody MQ 19/10.
The fractions 9-15 (FIG. 11) were pooled
after CsCl sedimentation.
Table V:
shows the ELISA data of the purified HBs
antigen particle produced from an HBV
sequence construct of the present invention
including the pre-S 2 region with none of the
pre-S 1 region and deletions upstream of the
S ATG and downstream of the S ATG through
the XBaI site, and the S region with
deletion of the S ATG (e.g. the construct
of FIG. 2A) with the anti-pre-S 1 monoclonal
antibody MA 18/7. The fractions 9-15 (FIG. 12)
were pooled after CsCl sedimentation.
Table VI:
shows the ELISA data of the purified HBS
antigen particle produced from on HBV
sequence construct of the present invention
including the pre-S 2 region with none of the
pre-S 1 region and deletions upstream of the
S ATG and downstream of the S ATG through
the XBaI site, and the S region with
deletion of the S ATG (e.g. the construct
of FIG. 2A) with the anti-pre-S 2 monoclonal
antibody MQ 19/10. The fractions 9-15 (FIG. 12)
were pooled after CsCl sedimentation.
TABLE III
ELISA Measurement
CsCl-gradient
Monoclonal Antibody MA 18/7
Fraction No. 9-15 (pooled)
E 492 = 0.839
TABLE IV
ELISA Measurement
CsCl-gradient
Monoclonal Antibody MQ 19/10
Fraction No. 9-15 (pooled)
E 492 = 0.000
TABLE V
ELISA Measurement
CsCl-gradient
Monoclonal Antibody MA 18/7
Fraction No. 9-15 (pooled)
E 492 = 0.000
TABLE VI
ELISA Measurement
CsCl-gradient
Monoclonal Antibody MQ 19/10
Fraction No. 9-15 (pooled)
E 492 = 1.028
Table VII:
shows the ELISA data of the purified HBs
antigen particle produced from any HBV
sequence construct of the present invention
including the pre-S 1 region with total
deletion of pre-S 2 and deletions upstream
of the pre-S 2 ATG and the S region with
deletion of the S ATG (e.g., the construct
of FIG. 6B) with the anti-pre-S 1 monoclonal
antibody MA 18/7. The fractions 9-15 (FIG. 11)
were pooled after CsCl sedimentation.
Table VIII:
shows the ELISA data of the purified HBs
antigen particle produced from any HBV
sequence construct of the present invention
including the pre-S 1 region with deletions
upstream of the pre-S 2 ATG with deletion
of the S ATG (e g., the construct of FIG. 6B) with
the anti-pre-S 2 monoclonal antibody
MQ 19/10. The fractions 9-15 (FIG. 11) were
pooled after CsCl sedimentation.
Table IX:
shows the ELISA data of the purified HBs
antigen particle produced from an HBV
sequence construct of the present invention
including the pre-S 2 region with none of the
pre-S 1 region and deletions upstream of the
S ATG and the S region with deletion of the S ATG
(e.g., the construct of FIG. 7B) with the anti-pre-S 1
monoclonal antibody MA 18/7. The fractions 9-15
(FIG. XII) were pooled after CsCl sedimentation.
Table X:
shows the ELISA data of the purified HBs
antigen particle produced from an HBV
sequence construct of the present invention
including the pre-S 2 region with deletions
upstream of the S ATG with deletion of the S ATG
(e.g., the construct of FIG. 7B) with the anti-pre-S 2
monoclonal antibody MQ 19/10. The fractions 9-15 (FIG. 12)
were pooled after CsCl sedimentation.
TABLE VII
ELISA Measurement
CsCl-gradient
Monoclonal Antibody MA 18/7
Fraction No. 9-15 (pooled)
E 492 = 1.273
TABLE VIII
ELISA Measurement
CsCl-gradient
Monoclonal Antibody MQ 19/10
Fraction No. 9-15 (pooled)
E 492 = 0.000
TABLE IX
ELISA Measurement
CsCl-gradient
Monoclonal Antibody MA 18/7
Fraction No. 9-15 (pooled)
E 492 = 0.000
TABLE X
ELISA Measurement
CsCl-gradient
Monoclonal Antibody MQ 19/10
Fraction No. 9-15 (pooled)
E 492 = 0.985
Table XI
shows the ELISA data of purified HBs antigen
particles produced by construct
including the entire pre-S 1 - pre-S 2 - S
region under control of the LTR region of
rous sarcoma virus after stimulation with
stimulating substances (e.g. PMA) and the
additional cotransfection with S (FIG. 13).
TABLE XI
ELISA Measurement
CsCl-gradient
Monoclonal Antibody MA 18/7
Fraction No. 9-15 (pooled)
E 492 = 0.125
FIG. XIV
shows the characterisation of the
particles derived from gene constructs
according to table III (FIG. 1A) and
table V (FIG. 2A) cotransfected in
C127 after purification in the CsCl
gradient. The fraction collected had
a smaller volume.
Table XII
shows the serotyping of particles
according to FIG. 1A having the
S sequence done in the Pettenkofer
Institute.
TABLE XII
Results:
adw/ayw: positive
From the foregoing, it will be obvious to those skilled in the art that various modifications in the above-described compositions and methods can be made without departing from the spirit and scope of the invention. Accordingly, the invention may be embodied in other specific forms without departing from the spirit or essential characteristics thereof. Present embodiments, therefore, are to be considered in all respects as illustrative and not restrictive, the scope of the invention being indicated by the appended claims rather than by the foregoing description, and all changes which come within the meaning and range of equivalency of the claims are therefore intended to be embraced therein. | HBV surface antigen particles, prepared by recombinant DNA technology are described, said particles being composed of epitopes from the group of surface peptides and/or core peptide of non-A, non-B hepatitis virus, hepatitis A virus, or hepatitis virus B. Respective particles are especially characterized by a composition of different epitopes selected from pre-S and S peptides. There are also described DNA-sequences, plasmids, and cell lines coding for respective HBV surface antigen particles as well as a new vaccine containing the same. | 98,983 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority of provisional Application Ser. No. 60/686,666 filed Jun. 2, 2005, the entire content of which is incorporated herein by reference.
TECHNICAL FIELD
[0002] This invention relates generally to footwear liners, and more particularly to an absorbent footwear liner that substantially covers a footwear sole for absorbing and dissipating perspiration from a foot engaged therewith.
BACKGROUND AND SUMMARY OF THE INVENTION
[0003] There are over 250,000 sweat glands in a human foot. Unfortunately, shoes are not created with this in mind. Perspiration not only causes odor but also causes the surface of the foot to become moist. In fact the human foot has the capacity to produce at least ½ a cup of perspiration per day.
[0004] Typical footbeds of non-athletic shoes such as pumps, loafers, and sandals comprise a liner comprising a leather, plastic, or synthetic material which cannot absorb nor release foot produced perspiration. As a result, feet accumulating perspiration thereon slip on the footbeds causing the foot to shift inside the shoe and even slip completely out of the shoe in some cases. Further, persons with hyperhidrosis, commonly referred to as excessive sweating, have even more difficulties with typical footbeds such that simply keeping an open shoe on their feet is nearly impossible.
[0005] Heretofore shoe liners have been available for orthotic purposes, for overall cushioning, and as inserts for either the heel or ball of a foot to improve overall fit of the shoe. Existing shoe liners have not been designed to absorb moisture and prevent slippage due to perspiration. Further, existing shoe liners typically have adhesive tabs which do not secure the entire liner.
[0006] The present invention comprises an absorbent shoe liner which overcomes foregoing and other difficulties which have long since characterized the prior art. In accordance with the broader aspects of the invention, an absorbent shoe liner comprises an upper footbed layer which absorbs and dissipates perspiration and a lower layer comprising an adhesive area equal in size to the upper footbed layer for adhering the liner to substantially the entire surface of the footbed of a shoe.
[0007] In accordance with more specific aspects of the invention, an absorbent shoe liner comprises an upper layer comprising a fabric with moisture wicking capabilities and a lower layer comprising an adhesive material. Both the upper and lower layers extend across the entire footbed of a shoe covering the footbed from edge to edge and end to end. The fabric comprising the upper layer absorbs excess moisture from the foot thereby preventing the foot from slipping out of the shoe and further absorbing bacteria which prevents accumulation of odor inside the shoe. The adhesive lower layer keeps the shoe liner secure on the footbed of the shoe.
[0008] The upper layer may also include additional foam material substantially near where the ball or heel of the foot rests thereon for providing cushion for the foot. The foam material may be adhered either above or below the upper layer.
[0009] The shoe liner of the present invention is equally applicable to both open and close toed shoes for men, women, and children. The shoe liner can be fitted to nearly all shoe sizes by simply trimming the perimeter thereof. In addition to absorbing moisture and odor and preventing foot slippage, the shoe liner also provides a soft surface on which the foot rests contributing to the wearer's overall comfort. Further, the shoe liner may be also adhered to an orthotic that is placed inside a shoe, instead of directly onto the footbed of a shoe.
[0010] The shoe liner of the present invention may further include an additional layer comprising a gel material. The additional gel layer is placed beneath the lower adhesive layer. The gel layer adheres the shoe liner to a footbed of a shoe while providing additional cushioning.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] A more complete understanding of the present invention may be had by reference to the following Detailed Description when taken in connection with the accompanying Drawings, wherein:
[0012] FIG. 1A is an exploded perspective view of a shoe liner comprising a first embodiment of the present invention;
[0013] FIG. 1B is a perspective view of the adhesive layer of the embodiment shown in FIG. 1A having a different adhesive pattern;
[0014] FIG. 1C is a perspective view of the adhesive layer of the embodiment shown in FIG. 1A having yet another adhesive pattern;
[0015] FIG. 1D is a perspective view of the adhesive layer of the embodiment shown in FIG. 1A having yet another adhesive pattern;
[0016] FIG. 2 is an exploded perspective view of a shoe liner comprising a second embodiment of the present invention;
[0017] FIG. 3 is an exploded perspective view of a shoe liner comprising a third embodiment of the present invention; and
[0018] FIG. 4 is a an exploded perspective view of a shoe liner comprising the embodiment of FIG. 1 applied to an insertable shoe orthotic.
DETAILED DESCRIPTION
[0019] Referring now to the Drawings, and particularly to FIG. 1A , there is shown a footwear liner 10 comprising a first embodiment of the present invention. The footwear liner 10 comprises an upper layer 12 and a lower layer 14 adhered therebelow. The lower layer 14 comprises an adhesive material whereby the shoe liner covers and is adhered to an upper surface 16 of a footbed 18 .
[0020] The upper layer 12 comprises a fabric material capable of absorbing and dissipating moisture such as an athletic-wool felt comprising 70% wool and 30% rayon or other suitable materials known to those skilled in the art, including suede or synthetic suede; open and closed-cell foam materials; woven, nonwoven, or knit textiles; and manmade or natural textile blends, including microfibers.
[0021] The lower layer 14 comprises a double-sided adhesive film such as double-faced acrylic pressure sensitive adhesive tape with release liner sold by AdChem Corporation under the Product Name Adchem 8311M-76G-54 or other suitable adhesive materials known to those skilled in the art, including those applied by pressure-sensitive tape equipment, spray, slot die, sheet, roller coating, continuous pour, and embossed patterns, to maintain the upper layer 12 in adhesive engagement with a leather, plastic or synthetic material while leaving no residue once removed from the upper surface 16 of the footbed 18 . Both the upper layer 12 and lower layer 14 are formed such that the shoe liner 10 substantially covers the entire upper surface 16 of the footbed 18 and the entire shoe liner 10 is maintained in adhesive engagement therewith.
[0022] FIG. 1B illustrates an alternative lower layer 14 having an adhesive comprising a series of stripes extending longitudinally along substantially the entire layer 14 . This series of stripes could also extend transversely across substantially the entire layer 14 . FIG. 1C illustrates an alternative lower layer 14 having an adhesive comprising a series of circular applications positioned substantially across the entire length and width of layer 14 . FIG. 1D illustrates yet another alternative lower layer 14 having an adhesive comprising a strip extending about the entire perimeter of the upper layer 12 .
[0023] FIG. 2 illustrates the shoe liner 10 having an additional lower layer 20 comprising a gel material. The gel layer 20 comprises a gel material which adheres the shoe liner 10 to the footbed 18 while providing additional cushioning and comfort to a foot resting thereon. The gel layer 20 may be fabricated from a biodegradable synthetic material or other suitable materials known to those skilled in the art.
[0024] FIG. 3 illustrates the show liner 10 wherein the upper layer 12 comprises additional foam support 22 adhered to the upper layer 12 substantially near the location where the ball and the heal of the foot rest thereon.
[0025] FIG. 4 illustrates the shoe liner 10 adhered to the surface 24 of an orthotic 26 for insertion into a shoe. In FIG. 4 the shoe liner 10 is illustrated in accord with the embodiment of FIG. 1 , but the embodiments of FIGS. 2 and 3 can also be applied to the orthotic 26 .
[0026] The shoe liner is illustrated in conjunction with a right foot configuration but is equally applicable to a left foot configuration. Further, the shoe liner of the present invention is equally applicable to both open and close toed shoes for men, women, and children. The shoe liner is fitted to nearly all shoe sizes by simply trimming the perimeter thereof.
[0027] Although preferred embodiments of the invention have been illustrated in the accompanying Drawings and described in the foregoing Detailed Description, it will be understood that the invention is not limited to the embodiments disclosed, but is capable of numerous rearrangements, modifications, and substitutions of parts and elements without departing from the spirit of the invention. | An absorbent footwear liner comprising an upper absorbent layer and a lower layer comprising an adhesive equal in size to the upper layer for adhering the liner to substantially the entire surface of a footbed for absorbing and dissipating moisture thereon and preventing foot slippage on a shoe footbed due to perspiration. | 9,619 |
CROSS REFERENCE TO RELATED PATENT APPLICATION
[0001] The present patent application claims the right of priority under 35 U.S.C. §119 (a)-(d) of German Patent Application No. 10 2007 032 343.5, filed Jul. 11, 2007.
BACKGROUND OF THE INVENTION
[0002] The present invention relates to high-quality polyurethane (PU) elastomers and polyurethane urea elastomers which exhibit unique combinations of processing characteristics, oxidation resistance, mechanical and mechanical/dynamic properties in particularly demanding applications. These polyurethane elastomers and polyurethane urea elastomers are based on novel polycarbonate polyols.
[0003] Polyurethane elastomers were first sold commercially over 60 years ago by Bayer MaterialScience AG under the trade name Vulkollan®, based on 1,5-naphthalene diisocyanate (NDI, which is commercially available from Bayer MaterialScience AG), a long-chain polyester polyol and a short-chain alkanediol.
[0004] In addition to polyester polyols, polyether polyols, polycarbonate polyols and polyether ester polyols are also used as long-chain polyols. The choice of long-chain polyol is determined primarily by the requirements of the individual application. The concept of “customised properties” is also used in this connection. For example, polyether polyols are used if hydrolysis resistance and low-temperature properties are a priority. Polyester polyols have advantages over polyether polyols in terms of mechanical properties and UV stability. However, their low microbe resistance is a disadvantage. Polycarbonate polyols combine to some extent the advantages of polyether polyols and polyester polyols, but they are relatively expensive in comparison.
[0005] The advantages of polycarbonate polyols lie in particular in their UV stability, hydrolysis resistance and their mechanical properties.
[0006] The disadvantage of polyester polyols and polycarbonate polyols and their mixed types, polyester carbonate polyols, as compared with polyether polyols lies in their generally less advantageous low-temperature characteristics. This is due to structural factors and is based on the elevated polarity of carbonyl groups, which normally means that polyester polyols and polycarbonate polyols are partially crystalline, whereas polyether polyols, especially the propylene oxide-based types as the commercially largest group, are amorphous. For partially crystalline systems the relation between glass transition temperature (T g ) and melt temperature (T m ) is described by the known empirical rule established by Beaman and Bayer (M. D. Lechner, K. Gehrke and E. H. Nordmeier, Makromolekulare Chemie, Birkhäuser Verlag 1993, page 327)
[0000] T g =2/3 T m (I)
[0007] For example, if polycarbonate polyols have melt temperatures for the partially crystalline components of around 70° C. (343° K), the glass transition temperatures of the amorphous regions are in the order of magnitude of −43° C. (230° K). These values largely also apply if the polycarbonate polyols are present as soft segment polyols in segmented multi-block copolyurethanes, e.g. in the form of thermoplastic polyurethane elastomers (TPU) or polyurethane cast elastomers in integrated form. It is clear from this that it is desirable to have polycarbonate polyols which have a melting range as low as possible. On the one hand, this simplifies processing, and on the other, the working temperature range is extended down to lower temperatures as a consequence of the glass transition temperature, which is likewise reduced.
[0008] The upper limit of the working temperature range is determined by the thermal properties of the rigid segments (e.g. urethane, urea, isocyanurate groups, etc.), i.e. the structural elements present in the polyisocyanate building blocks.
[0009] The disadvantage of using 1,6-hexanediol as the diol component for polycarbonate polyols or polyadipate polyols, for example, as used in polyurethane chemistry, is the elevated viscosity with otherwise identical characteristic values (molecular weight and functionality).
[0010] There have been a number of attempts to modify the melting range of hexanediol polycarbonate polyol, which in industry is the most important polycarbonate polyol for polyurethane elastomers, in such a way as to cover the specific requirements of as many applications as possible. For example, in DE-A 3717060 part of the hexanediol is replaced by hexanediol ether units, for example, leading to a reduced crystalline proportion as compared with pure hexanediol polycarbonate polyol and a melting range shifted to lower temperatures. The disadvantage of this process, however, is that the incorporation of ether groupings has a negative influence on the oxidation and heat ageing resistance, as a result of which some important applications are not viable.
[0011] H. Tanaka and M. Kunimura (Polymer Engineering and Science, vol. 42, no. 6, page 1333 (2002)) indicate a way of eliminating at least the aforementioned disadvantage by using 1,6-hexanediol and 1,12-dodecanediol to produce copolycarbonate polyols which have markedly lower melt temperatures than their homopolycarbonate polyols. With the aid of the measurement technique they were using, they measured the melting point of hexanediol polycarbonate polyol at 47.4° C. and that of 1,12-dodecane polycarbonate polyol at 65.5° C., whereas a copolycarbonate polyol with a composition of 70 parts by weight of hexanediol to 30 parts by weight of 1,12-dodecanediol melts at 29.1° C.; this represents a lowering of the melting range by 18.3° C. and 36.3° C., respectively, as compared with the homopolymers. The values for the heat of fusion [J/g] behave in a similar manner, displaying a minimum when the polycarbonate polyol consists of 70 parts of hexanediol and 30 parts of 1,12-dodecanediol.
[0012] In spite of these in principle promising approaches, which incidentally were also used on thermoplastic polyurethane elastomers synthesised therefrom, it has so far not been possible to implement this method on an industrial scale, or at least not to any significant extent.
[0013] A substantial reason for this is that 1,12-dodecanediol in particular is so expensive that the resulting price of the polycarbonate polyol or copolycarbonate polyol and hence ultimately of the polyurethane elastomer is so high that the advantages that might arise from using 1,12-dodecanediol in whole or in part are outweighed.
[0014] This means that any technical advantages would be achieved at too high a cost.
[0015] Therefore, an object of the present application was to provide polyurethanes which do not have the aforementioned disadvantages.
SUMMARY OF THE INVENTION
[0016] The invention relates to polycarbonate polyols having an OH value of 50 to 80 mg KOH/g and an average functionality of 1.9 to 2.2. These polycarbonate polyols are the reaction product of
(1) a mixture comprising
A) one or more α,ω-alkanediols having 4 to 8 carbon atoms, B) technical dodecanediol which comprises (1) 30 to 50 wt. % of 1,12-dodecanediol, (2) 5 to 20 wt. % of diols having fewer than 10 carbon atoms and (3) no diols having more than 12 carbon atoms, and wherein the technical dodecanediol is present in an amount of from 15 wt. % to 85 wt. %, based on the total weight of the mixture of A) and B), and C) 0 to 10 wt. %, based on the total weight of the mixture of A), B) and C), of one or more alkanols having 4 to 10 carbon atoms and a hydroxyl functionalities of 1 to 3;
with (2) a carbonyl component from the group consisting of diaryl carbonates, dialkyl carbonates and carbonyl chloride.
[0024] A process for the preparation of these novel polycarbonate polyols is also provided.
[0025] The present invention also relates to NCO prepolymers prepared from these novel polycarbonate polyols with a polyisocyanate component, and to a process for the preparation of these NCO prepolymers.
[0026] In addition, this invention relates to polyurethane elastomers and/or polyurethane urea elastomers comprising the reaction product of the NCO prepolymers prepared from the polycarbonate polyols and one or more chain extenders. A process for the preparation of these elastomers is also provided herein.
DETAILED DESCRIPTION OF THE INVENTION
[0027] The molecular weight of the polycarbonate polyols of the present invention is in the range of from about 1200 to about 2500 Da. The viscosity of these polycarbonate polyols, measured at 75° C., is between about 900 and about 2600 mPas, and these have an average functionality in the range of from about 1.9 to about 2.2. This is achieved by optionally adding monools or polyols to the mixture used to prepare the polycarbonate polyols. Examples of suitable polyols and monools in this connection include but are not limited to 1,1,1-trimethylol propane and 1-octanol, respectively. Functionalities below 2 can also be achieved by not completely reacting the dialkyl carbonates and/or diaryl carbonates used so that alkyl carbonate and/or aryl carbonate end groups are formed.
[0028] The reaction of (1) the mixture of components A), B) and optionally C), with (2) the carbonyl component takes place by methods known to the person skilled in the art. Carbonyl chloride (i.e. phosgene), dialkyl carbonates and/or diaryl carbonates can be used as (2) the carbonyl component. Dimethyl carbonate and/or diphenyl carbonate are preferred carbonyl components.
[0029] In accordance with the present invention, the polycarbonate polyols can then be processed further, preferably via a prepolymer stage, to form polyurethane (PU) materials. These polyurethane materials can be prepared by reacting the polycarbonate polyols of the invention, optionally with the added use of short-chain organic compounds having hydroxyl end groups and/or amino end groups and/or water, with polyisocyanates, preferably diisocyanates.
[0030] The invention also provides NCO prepolymers having an NCO group content of 3 to 15 wt. %. These NCO prepolymers are obtained by reacting polycarbonate polyols of the invention, and a polyisocyanate selected from the group consisting of 1,5-naphthalene diisocyanate, 2,4′-diphenylmethane diisocyanate (2,4′-MDI), 4,4′-diphenylmethane diisocyanate (4,4′-MDI), mixtures of 2,4′-diphenylmethane diisocyanate and 4,4′-diphenylmethane diisocyanate, carbodiimide-/uretonimine-modified diphenylmethane diisocyanate derivatives, polynuclear homologues of the diphenylmethane series, diisocyanatotoluenes, hexamethylene diisocyanate, isophorone diisocyanate, with the isocyanate component being present in a molar excess. More specifically, it is preferred that the polyisocyanate and the polycarbonate polyols are present in amounts such that the molar ratio of NCO to OH groups is from 2:1 to 10:1.
[0031] The present invention also provides polyurethane elastomers and/or polyurethane urea elastomers which are obtained by reacting NCO prepolymers as described herein, with an isocyanate-reactive blend of (i) one or more aliphatic diols having primary hydroxyl groups and number-average molecular weights of 62 to 202, optionally, in amounts of 0-10 wt. %, based on the weight of the aliphatic diols, of compounds selected from the group consisting of short-chain polyols with functionalities >2 to 4, higher-molecular-weight polyols with a functionality of 2 and polycarbonate polyols according to the invention, or (ii) one or more aromatic diamine-type chain extenders selected from the group consisting of 4,4′-methylene-bis-(2-chloroaniline) (MBOCA), 3,3′,5,5′-tetraisopropyl-4,4′-diamino-diphenylmethane, 3,5-dimethyl-3′,5′-diisopropyl-4,4′-diaminophenylmethane, 3,5-diethyl-2,4-toluene diamine, 3,5-diethyl-2,6-toluene diamine (DETDA), 4,4′-methylene-bis-(3-chloro-2,6-diethylaniline), 3,5-dimethylthio-2,4-toluene diamine, 3,5-dimethylthio-2,6-toluene diamine and 3,5-diamino-4-chlorobenzoic acid isobutyl ester, optionally, in the presence of water, and/or further auxiliary substances and additives.
[0032] Suitable aliphatic diols to be used herein include butanediol, hexanediol, cyclohexanediol, 2,2′-thiodiethanol or mixtures thereof. These diols are preferred.
[0033] If water is used as a chain extender and/or as a blowing agent, the polyurethane elastomers preferably have densities of 0.3 to 0.9 g/cm 3 .
[0034] The polyurethane and polyurethane urea elastomers are preferably produced by the casting method, wherein there are substantially two different processes. The first is the NCO prepolymer method, in which long-chain polyol (i.e. the polycarbonate polyol) and polyisocyanate in stoichiometric excess are reacted to form a prepolymer having NCO groups, and then subjecting this prepolymer to chain extension with a short-chain organic compound having hydroxyl end groups or amino end groups, and/or water. Secondly, PU cast elastomers can also be produced by the one-shot method, in which long-chain polyol and short-chain organic compounds are mixed with hydroxyl end groups or amino end groups, and/or water, and then reacted with a polyisocyanate.
[0035] In addition to polyurethane cast elastomers, polyurethane elastomers suitable for thermoplastic processing can also be produced from the polycarbonate polyols of the invention by methods known to the person skilled in the art.
[0036] In addition to the components described above as suitable for the present invention, the conventional catalysts and auxiliary agents can also be used in the production of the polyurethane or polyurethane urea elastomers.
[0037] Examples of suitable catalysts are trialkylamines, diazabicyclooctane, tin dioctoate, dibutyl tin dilaurate, N-alkyl morpholine, lead octoate, zinc octoate, calcium octoate, magnesium octoate, the corresponding naphthenates, p-nitrophenolate, etc.
[0038] Examples of suitable stabilizers are Brønsted acids and Lewis acids including, for example, hydrochloric acid, benzoyl chloride, organomineral acids, for example, dibutyl phosphate, also adipic acid, malic acid, succinic acid, racemic acid or citric acid.
[0039] Examples of UV stabilizers and hydrolysis stabilizers are, for example, 2,6-dibutyl-4-methylphenol and carbodiimides.
[0040] Incorporable dyes which can likewise be used are those which have Zerewitinoff-active hydrogen atoms that can react with NCO groups.
[0041] Other auxiliary substances and additives include emulsifiers, foam stabilizers, cell regulators and fillers. An overview can be found in G. Oertel, Polyurethane Handbook, 2 nd edition, Carl Hanser Verlag, Munich, 1994, chapter 3.4.
[0042] The use of the polyurethane elastomers according to the invention lies in the area of technical components, and is thus, extremely wide-ranging. It includes, for example, roller coatings, electrical encapsulation, pipeline pigs, knives, wheels, rollers, screens, etc.
[0043] The following examples further illustrate details for the process of this invention. The invention, which is set forth in the foregoing disclosure, is not to be limited either in spirit or scope by these examples. Those skilled in the art will readily understand that known variations of the conditions of the following procedures can be used. Unless otherwise noted, all temperatures are degrees Celsius and all percentages are percentages by weight.
EXAMPLES
Composition of the Raw Materials Used in the Examples
[0000]
T12DD: Technical dodecanediol commercially available from Invista which comprised a mixture of (1) 30 to 50 wt. % of 1,12-dodecanediol, (2) 5 to 20 wt. % of one or more diols having few than 10 carbon atoms and (3) no diols having more than 12 carbon atoms
DPC: diphenyl carbonate
Hexanediol: 1,6-Hexanediol commercially available from Aldrich
4,4′-MDI: 4,4′-diphenylmethane diisocyanate
1,5-NDI: 1,5-naphthalene diisocyanate
Magnesium hydroxide carbonate: as pentahydrate commercially available from Aldrich
Dibutyl phosphate: dibutyl phosphate commercially available from Aldrich
Crosslinker RC 1604: a crosslinker commercially available from Rheinchemie
Butanediol: 1,4-Butanediol from Aldrich
Baytec® VPPU 0385: Ether group-containing polycarbonate polyol from Bayer MaterialScience AG with a hydroxyl value of 56 mg KOH/g and a functionality of 2
TMP: 1,1,1-Trimethylolpropane from Aldrich
Crosslinker 10GE32: Crosslinker from Bayer MaterialScience AG
[0056] The viscometer used to determine the viscosity of materials in the examples was a MCR 51 from Anton Paar.
[0057] A Lambda 25 UV/Vis spectrometer from Perkin Elmer was used for the photometric determination of aromatic end groups (e.g. phenoxy and phenyl carbonate) and of free phenol in polycarbonate polyols.
A) Production of Polycarbonate Polyols
Example A3
According to the Invention
[0058] 2946 g (15.34 mol) of T12DD, 1264 g (10.71 mol) of hexanediol (i.e. 70 wt. % of T12DD based on the combined weight of T12DD and hexanediol) and 4952 g (23.14 mol) of DPC and 160 mg of magnesium hydroxide carbonate were heated to 180° C. for 90 minutes in a distillation apparatus under nitrogen whilst stirring. The mixture was then cooled to 110° C., a vacuum (15 mbar) was applied and phenol was removed by distillation. When phenol distillation slowed down, the bottom temperature was increased in small increments over 10 hours to reach 200° C., the overhead temperature not being permitted to rise above 80° C. Distillation was carried out for approx. 1 hour at 200° C. and 15 mbar, and then for about an additional 1 hour at 200° C. and under a pressure of below 1 mbar. In this phase, phenol residues were driven out of the column with a hot air blower. After cooling to around 80° C., a sample was taken. The OH value, the end groups (by photometry) and the viscosity were determined. The mixture was then neutralised at 80° C. by stirring in 960 mg of dibutyl phosphate.
[0000] OH value: 60 mg KOH/g
Viscosity: 1180 mPas (75° C.)
End groups: Phenol: 0.02 wt. %, phenoxy and phenyl carbonate: not detectable
[0059] Examples A1, A2 and A4 were carried out in the same way as Example A3. The relevant data for each Example can be found in Table 1.
[0000] TABLE 1 Polycarbonate polyols Example A.1. (C) A.2. A.3. A.4. (C) T12DD content [wt. %] 0 30 70 10 OH value [mg KOH/g] 56.4 54.9 60.0 58.9 Viscosity [75° C.] [mPas] 2850 2180 1180 790 (C) = Comparison
B) Production of MDI prepolymers:
Example B3
According to the Invention
[0060] 1850 g (7.4 mol) of 4,4′-MDI were introduced into a 6 liter three-necked flask with heating mantle, stirrer and internal thermometer under a nitrogen blanket at 50° C. whilst stirring. Then, 3001 g of a polycarbonate polyol from Example A3 which was preheated to 80° C. were added over approx. 10 minutes whilst stirring. Stirring was then continued under nitrogen at 80° C. The reaction was completed after 2 hours. The NCO group content was 10.0 wt. % and the viscosity was 2050 mPas (at 70° C.).
[0061] The NCO prepolymer was stored in a glass flask at room temperature and remained liquid and resistant to sedimentation for a period of over 3 months.
[0062] Examples B1, B2 and B4 were performed in the same way as Example B3, except that instead of polycarbonatediol A3, polycarbonate diols A1, A2 and A4 were used in these Examples, respectively. The relevant data can be found in Table 2.
[0000]
TABLE 2
NCO prepolymers based on polycarbonate polyols A1 to A4 with
NCO contents of 10 wt. %
Example
B1 (C)
B2
B3
B4 (C)
Polycarbonatediol
A1 (C)
A2
A3
A4 (C)
Viscosity (at 70° C.)
[mPas]
4220
3180
2050
1447
Resistant to crystallisation (at
No
Yes
Yes
No
room temperature)
Resistant to sedimentation
No*)
No
Yes
No*)
(after 3 months and at room
temperature)
*)These samples solidify completely when left to stand at room temperature
(C) = Comparison
[0063] Table 2 shows that prepolymer B3 which was produced from polycarbonate polyol A3 in accordance with the present invention, has particularly favorable properties. In particular, Example B3 has a viscosity below 2500 mPas (70° C.) and exhibits good resistance to crystallisation and sedimentation at room temperature. The prepolymer B2 is still perfectly useable but has a higher viscosity than prepolymer B3. In the case of prepolymer B1 (comparison) and prepolymer B4 (comparison) produced from polycarbonate polyol A1 (comparison) and polycarbonate polyol A4 (comparison), a sediment quickly forms at room temperature, and both NCO prepolymers solidify completely when stored at room temperature.
C) Production of Cast Elastomers:
[0064] 1) Chain Extension with 1,4-butanediol:
[0065] 100 parts of a prepolymer (from Example B) preheated to 70° C. and degassed were stirred for 30 seconds with 10.15 parts of 1,4-butanediol. The reacting melt was poured into metal molds heated to 115° C. and annealed at 110° C. for 24 hours. After storing at room temperature for 21 days the mechanical data was determined (see Table 3). In the formulations in Table 3, all of the amounts shown are parts by weight.
[0000] 2) Chain Extension with Crosslinker RC 1604:
[0066] 100 parts of a prepolymer (from Example B) preheated to 70° C. and degassed were stirred for 30 seconds with 26.5 parts of crosslinker RC 1604 (crosslinker temperature: 105° C.). The reacting melt was poured into metal molds heated to 115° C. and annealed at 110° C. for 24 hours. After storing at room temperature for 21 days the mechanical data was determined (see Table 3). In the formulations in Table 3, all of the amounts shown are parts by weight.
[0000]
TABLE 3
Production and properties of polyurethane and polyurethane urea elastomers by reacting the MDI prepolymers with
butanediol or crosslinker 1604
Example
C1-1 (C)
C2-1 (C)
C1-2
C2-2
C1-3
C2-3
C1-4 (C)
C2-4 (C)
Formulation:
Prepolymer
B1 (C)
B1 (C)
B2
B2
B3
B3
B4 (C)
B4 (C)
MDI prepolymer
[parts]
100
100
100
100
100
100
100
100
NCO content of prepolymer
[%]
10.01
10.01
10
10
10.0
10
10.02
10.02
Prepolymer viscosity (70° C.)
[mPas]
4220
4220
3180
3180
2050
2050
1447
1447
Crosslinker 1604
[parts]
—
26.5
—
26.5
—
26.5
—
26.5
1,4-Butanediol
[parts]
10.15
—
10.15
—
10.15
—
10.15
—
Processing:
Prepolymer temperature
[° C.]
70
70
70
70
70
70
70
70
Crosslinker temperature
[° C.]
23
105
23
105
23
105
23
105
Casting time
[s]
125
28
130
48
120
40
135
43
Retraction time
[min]
7
3
6
3
5
3
7
3
Table temperature
[° C.]
116
116
116
116
116
116
116
116
Mold temperature
[° C.]
110
110
110
110
110
110
110
110
Release time
[min]
24
24
24
24
24
24
24
24
Mechanical properties:
DIN 53505
Shore A
97
100
97
100
97
100
98
100
DIN 53505
Shore D
49
71
49
71
48
69
50
70
DIN 53504
Tensile modulus 100%
[MPa]
15.56
31.31
15.51
29.87
12.52
26.72
12.23
24.74
DIN 53504
Tensile modulus 300%
[MPa]
35.15
—
26.97
—
—
—
—
—
DIN 53504
Yield stress
[MPa]
37.91
40.67
27.63
37.58
14.76
32.89
12.86
29.56
DIN 53504
Ultimate elongation
[%]
364
186
351
171
205
205
201
212
DIN 53515
Graves
[kN/m]
123
170
97
159
77
156
65
141
Impact resilience
[%]
43
56
48
57
51
57
49
57
DIN 53516
Abrasion (DIN)
[mm 3 ]
23
44
23
52
—
—
—
—
DIN 53420
Density
[g/mm 3 ]
1.200
1.210
1.177
1.185
—
—
—
—
DIN 53517
Compression set 22° C.
[%]
18.3
59.6
18.3
58.9
21.9
65.1
29.2
63.4
DIN 53517
Compression set 70° C.
[%]
33.0
82.9
38.9
86.0
43.3
84.5
47.8
85.4
D) Production of Cast Elastomers Based on 1,5-Naphthalene Diisocyanate:
[0067] 93.3 parts of a polycarbonate polyol (from Example A3) preheated to 125° C. were stirred with differing amounts of 1,5-naphthalene diisocyanate (1,5-NDI), a vacuum of approx. 15 mbar was applied until constancy of temperature was reached. Differing amounts of chain extenders were then stirred in for 30 seconds. The reacting melt was poured into metal molds heated to 115° C. and annealed at 110° C. for 24 hours. After storing at room temperature for 21 days the mechanical data was determined (see Table 4B). In the formulations in Table 4A, all of the amounts shown are parts by weight.
E) Production of Cast Elastomers (not According to the Invention)
[0068] Baytec® VPPU 0385 is a commercial product based on 1,6-hexanediol and diphenyl carbonate.
[0069] The polycarbonate Baytec® VPPU 0385 was reacted with 1,5-NDI to form an NCO prepolymer. This prepolymer was then chain extended to obtain the NDI cast elastomer, in which the chain extension was performed with 1,4-butanediol. Preparation of the cast elastomer was as described in Example D). 100 parts by weight of polycarbonate polyol, 18 parts by weight of 1,5-NDI and 2 parts by weight of 1,4-butanediol were used.
[0000]
TABLE 4A
Production and properties of cast elastomers based on polyol A3 and NDI
Formulation:
D1
D2
D3
D4
D5
D6
D7
D8
D9
D10
Polyol A3
[parts]
93.3
93.3
93.3
93.3
93.3
93.3
93.3
93.3
93.3
93.3
1,5-NDI
[parts]
18
25
21
27
30
18
18
18
18
18
1,4-Butanediol
[parts]
2
5
3.4
5.8
—
2
2.3
2
2.3
2.3
TMP
[%]
—
—
—
—
—
10
20
30
40
60
Crosslinker 10GE32
[parts]
—
—
—
—
9.5
—
—
—
—
—
Processing:
Polyol temperature
[° C.]
122
125
126
130
133
122
122
122
122
122
Reaction time
[min]
10
9
7
8
7
10
10
9
11
10
Temperature
[° C.]
132.8
128.5
126.5
127.9
127.1
129.4
129.1
129.4
130
128.7
maximum
Casting time
[s]
105
35
60
25
165
105
105
110
180
190
Setting time
[min]
16
7
7
5
9
17
19
23
25
60
Table temperature
[° C.]
116
116
116
116
116
116
116
116
116
116
Mold temperature
[° C.]
110
110
110
110
110
110
110
110
110
110
Release time
[min]
—
—
—
—
—
—
—
—
—
—
Post-cure temperature
[° C.]
110
110
110
110
110
110
110
110
110
110
Post-cure time
[h]
24
24
24
24
24
24
24
24
24
24
Prep viscosity (120° C.)
[mPas]
4865
1625
2615
1310
1040
—
—
—
—
—
[0000]
TABLE 4B
Production and properties of cast elastomers based on polyol A3 and NDI
Formulation:
D1
D2
D3
D4
D5
D6
D7
D8
D9
D10
Mechanical properties:
DIN 53505
Shore A
94
97
96
97
98
93
92
92
91
85
DIN 53505
Shore D
38
44
41
47
49
36
35
35
33
28
DIN 53504
Tensile modulus
[MPa]
8.70
13.62
10.85
13.97
14.68
8.13
7.82
7.56
7.06
5.52
100%
DIN 53504
Tensile modulus
[MPa]
16.09
19.03
15.84
19.09
19.38
15.27
15.20
15.58
16.70
16.63
300%
DIN 53504
Yield stress
[MPa]
26.99
23.58
23.92
21.38
23.03
26.83
26.02
27.37
26.66
23.86
DIN 53504
Ultimate
[%]
459
468
509
388
422
451
417
414
376
336
elongation
DIN 53515
Graves
[kN/m]
62
80
21
86
106
53
47
41
31
75
Impact resilience
[%]
62
62
62
62
57
60
59
58
56
50
DIN 53516
Abrasion (DIN)
[mm 3 ]
27
30
29
37
30
27
29
29
35
34
DIN 53517
Compression set
[%]
18.3
18.4
19.7
22.3
20.8
18.9
18.1
18.0
16.5
15.2
22° C.
DIN 53517
Compression set
[%]
33.6
33.5
34.3
36.8
35.8
35.2
34.0
34.6
33.0
30.0
70° C.
DIN 53517
Compression set
[%]
51.2
48.3
46.8
50.4
48.5
50.9
48.4
48.7
48.8
40.6
100° C.
DIN 53517
Compression set
[%]
83.7
77.6
72.5
76.2
73.6
93.7
91.8
83.9
84.9
82.0
120° C.
F) Hydrolysis and Hot-Air Ageing of NDI Cast Systems
[0070] It was able to be shown that the systems according to the invention have excellent properties in terms of their behavior with regard to hydrolysis and hot-air ageing, and are superior to conventional systems.
[0000]
TABLE 5
Hydrolysis characteristics and hot-air ageing (as determined by
DIN 53508) of the NDI cast elastomer according to the invention of
Example D1)
[days]
0
7
14
21
42
56
63
Storage in water at
100° C.
Shore A
94
91
90
90
91
92
92
Tensile modulus
[MPa]
8.70
6.10
6.03
5.26
6.22
6.17
6.29
100%
Tensile modulus
[MPa]
11.71
8.19
7.72
7.15
7.27
7.45
7.22
200%
Tensile modulus
[MPa]
16.09
10.10
9.13
8.72
7.60
8.07
7.61
300%
Yield stress
[MPa]
26.99
16.83
12.53
11.06
7.51
8.17
7.54
Ultimate elongation
[%]
459
653
615
515
330
350
317
Storage in air at
150° C.
Shore A
94
96
91
89
89
90
87
Tensile modulus
[MPa]
8.70
6.63
6.08
5.69
5.57
5.75
5.69
100%
Tensile modulus
[MPa]
11.71
8.30
7.75
7.56
7.39
7.43
7.45
200%
Tensile modulus
[MPa]
16.09
9.74
9.33
9.33
9.17
8.97
8.85
300%
Yield stress
[MPa]
26.99
17.50
16.90
15.99
14.77
13.29
13.42
Ultimate elongation
[%]
459
684
709
622
567
566
599
[0071] Table 5 shows that the NDI cast elastomer DI also withstands extreme loads. The sharpest drop in mechanical data occurs right at the start of loading, in other words between 0 and 7 days. This behavior is typical of such tests, however. From this point onwards, the system according to the invention changes only marginally and displays virtually constant values even in a hot-air ageing test at 150° C. over 9 weeks at tensile modulus values of 100%, 200% and 300%. By contrast, a comparable, conventional system exhibits a greater drop in mechanical data after just 14 days at only 130° C. (see Table 6). The same applies with regard to storage in water.
[0000]
TABLE 6
Hydrolysis characteristics and hot-air ageing (as determined by
DIN 53508) of an NDI cast elastomer not according to the invention -
Example E)
[days]
Storage in water at 80° C.
0
3
14
28
Shore A
89
88
87
87
Tensile modulus 100%
[MPa]
5.4
5.8
4.9
4.9
Tensile modulus 300%
[MPa]
9.5
10.2
8.4
8.1
Yield stress
[MPa]
42.4
35.6
30.3
26.0
Ultimate elongation
[%]
638
603
679
740
[days]
Storage in air at 130° C.
0
3
14
Shore A
89
87
85
Tensile modulus 100%
[MPa]
5.4
5.5
5.2
Tensile modulus 300%
[MPa]
9.5
8.6
8.0
Yield stress
[MPa]
42.4
29.2
22.7
Ultimate elongation
[%]
638
748
723
[0072] Although the invention has been described in detail in the foregoing for the purpose of illustration, it is to be understood that such detail is solely for that purpose and that variations can be made therein by those skilled in the art without departing from the spirit and scope of the invention except as it may be limited by the claims. | The present invention relates to high-quality polyurethane and polyurethane urea elastomers which exhibit unique combinations of processing characteristics, oxidation resistance, mechanical and mechanical/dynamic properties in particularly demanding applications. These polyurethane elastomers and polyurethane urea elastomers are based on novel polycarbonate polyols. | 57,917 |
BACKGROUND OF THE INVENTION
This invention relates to carriers for pickup trucks and more particularly to a carrier which is removably attached to the side walls of the open bed of a pickup truck and which supports loads above the open bed.
The carrying capacity of a pickup truck is limited not only by the size of its open bed but by the height of the side walls and tail gate which define the bed. For example, if a pickup truck is used to carry particulate material, such as sand and gravel, the height of the side walls and tail gate will govern the quantity of particulate material that the truck will carry.
I have invented a load carrier for a truck which is attached to the upper edge of the side walls of a pickup truck and which support loads above the open box. It does not matter whether the side walls and tail gate are high or low. Thus, the capacity of the truck is no longer limited by the height of its side walls and tail gate.
My load carrier can be used in conjunction with a conventional tonneau cover for a pickup truck. Such covers are usually attached by snap fasteners to rails located on the upper horizontal margins of the side walls of the truck. According to one embodiment, a bar is received in a slot in each rail and slides along the length of the rail. The bar can be positioned where it is most convenient and bolted or screwed in place to prevent it from moving. A bracket is attached to each bar and to the bracket is attached a stringer which supports a load.
According to another embodiment of the load carrier, a clamp is provided for connecting a bracket to each rail and side wall of the truck. Like the first embodiment, the bracket connects the stringer to the truck. The clamp can be connected anywhere along the length of the side wall so that the position of the stringer can be adjusted to where it is most convenient.
Loads such as skis, bicycles, sheets of plywood, lengths of lumber and so on can be tied to the stringer so that they are above the upper margins of the side walls and tonneau cover if there is one.
SUMMARY OF THE INVENTION
Briefly, the load carrier of my invention includes a pair of rails which are affixed to the upper margin of each side wall of a pickup truck. Each rail has a longitudinally extending slot along which a bar slides. A bracket is connected to each bar and a stringer is connected to the brackets in the two rails. The stringer extends transversely across the open bed for supporting a load.
The second embodiment of the load carrier has a pair of rails each adapted to rest on the upper margin of each side wall of the truck. A clamp connects a bracket to each rail and each side wall of the truck. A stringer is connected to the brackets and extends transversely across the open bed.
DESCRIPTION OF THE DRAWINGS
The load carrier of the invention is described with reference to the accompanying drawings in which:
FIG. 1 is a perspective view of a pair of load carriers in conjunction with the open bed of a pickup truck and a tonneau cover for the bed;
FIGS. 2 and 3 are partial sections of a stringer to which a load is connected;
FIG. 4 is an enlarged perspective view of the components of the load carrier together with a portion of the side wall of the truck;
FIG. 5 is an elevation of the components illustrated in FIG. 4 ;
FIG. 6 is an perspective view of the components of a second embodiment of the load carrier;
FIG. 7 is an elevation of the carrier illustrated in FIG. 6 .
Like reference characters refer to like parts throughout the description of the drawings.
DESCRIPTION OF THE PREFERRED EMBODIMENT
With reference to FIG. 1 an open bed, generally 10 , of a pickup truck has a pair of side walls 12 , 14 and a tail gate 16 . A rail 18 extends along the upper horizontal margin of side wall 12 and a like rail (not illustrated) extends along the length of the upper margin the other side wall 14 . A number of grommets 20 are spaced along the length of the rail for receipt of dome fasteners attached to tonneau cover 22 . Two spaced load carriers 24 , 26 are connected to the rails and extend across the open bed 10 .
With reference to FIGS. 4 and 5 , rail 18 has lower and upper flanges 30 , 32 and a vertical web 34 which interconnects the two flanges. The rail is seated on pad 35 . An upper lip 36 extends downward from an edge of the upper flange 32 and a lower lip 38 extends upwardly from the edge of the lower flange. A number of apertures are spaced along the length of the upper flange. One of those apertures is identified as 39 in FIG. 5 .
The lips, web and the portion of the upper and lower flanges which extend therebetween define a slot 40 which extends the length of the rail. A bar 42 , rectangular in section, is received in the slot and is free to slide therein. Lips 36 , 38 confine the bar in the slot. Apertures 46 are formed in the upper wall of the bar. The latter apertures open into threaded bores which extend downwardly into the bar.
A bracket 48 has a horizontal wall 50 , a vertical wall 52 and an intermediate wall 53 which extends therebetween. Apertures 54 are formed in the horizontal wall. The spacing between the apertures 54 is the same as that between apertures 39 in the upper flange and between the apertures 46 in the bar. The bracket can be connected to the upper flange and to the bar by means of connecting means such as screws 55 which pass through the apertures in the horizontal wall of the bracket, through the apertures in the upper flange and into the threaded bores in the bar. Each screw will accordingly pass through apertures which register or correspond with one another. The apertures which are in register or correspond in position with one another are those which offer a passageway for a screw.
The bracket can be positioned where it is most convenient. Once in that position, the bar can be moved until it is beneath the bracket and its apertures are in register with those in the bracket and upper flange. Screws can then be passed through those apertures to connect the bracket to the rail.
A stringer 60 has an end which is connected to the vertical wall 52 of the bracket by means of screws which pass through apertures in the wall and into threaded bores in the stringer.
The length of stringer 60 is adjustable. With reference to FIGS. 2 and 3 , the stringer is made up of a rod 62 of square cross-section and a sleeve 64 having an elongated opening 66 of the same cross-section as the rod but slightly larger so that the rod may slide freely in the opening. A handle 68 is pivotally attached to the sleeve and has an inner end 70 which moves into and out of contact with the rod as the handle pivots. When the inner end is out of contact with the rod as illustrated in FIG. 2 , the rod may freely slide in the sleeve so that the length of the stringer can be adjusted. When the inner end contacts the rod, as illustrated in FIG. 3 , the bar is fixed in position and the length of the stringer is no longer adjustable.
With reference again to FIGS. 4 and 5 , on the side of the rail opposite the slot, a track 72 is formed. A slider 74 is free to slide along the track. A socket 76 of a snap fastener is connected to the slider. The head or rounded portion of the fastener is attached to the outer edge of tonneau cover 22 for removable attachment of the cover to the rail.
As illustrated in FIG. 1 , two or more stringers can be attached to the truck. Each end of the stringer is attached to a rail by a bracket. A load can be connected to the stringers by ropes, spring clips and the like. Once connected, the load will be above the open bed and will occupy no space in it.
With reference to FIGS. 6 and 7 , rail 80 has the same construction as rail 18 and rests on pad 81 which in turn rests on the upper horizontal margin 82 of the side wall of the track. The rail is attached the side walls of a pickup truck in the manner illustrated in FIG. 1 . Bracket 83 has a first horizontal wall 84 and a first vertical wall 86 . An intermediate wall 88 , offset from the angle of the two walls 84 , 86 extends downwardly from the rear edge of wall 84 and terminates at the lower edge of wall 86 . A second vertical wall 90 extends downwardly from the front edge of wall 84 and terminates at a second horizontal wall 92 .
A stringer 94 is attached by screws or other means to the first vertical wall 86 . Holes are provided in the stringer and like holes are provided in the vertical wall for this purpose. The stringer serves the same function as stringer 60 of the previous Figures.
Wall 84 of the bracket rests on the upper flange 100 of rail 80 . Wall 92 is seated on a pad 102 which rests on margin 82 of the side wall of the truck. Wall 84 is not attached to the rail nor is wall 92 attached to the side wall of the truck.
A clamp, generally 110 , has jaws 112 , 114 which contact wall 92 and the underside 82 a of the margin of the side wall of the truck. The jaws are interconnected by means of a threaded stud 116 having a head 118 which when rotated in one direction causes the jaws to separate from one another and when rotated in the opposite direction causes the jaws to approach each other. The clamp is of conventional construction.
In operation, the bracket is clamped to the rail and side wall of the truck in the manner illustrated in FIG. 7 . No screws, bolts or other connectors are needed for this purpose apart from the clamp. The position of the bracket can be positioned where the stringers will be most conveniently located. Its position can be anywhere along the length of the side walls.
The load carrier of FIGS. 6 and 7 is simple of construction. It is made up of components which in most cases are of conventional construction and widely available. For example, the clamps which are used to attach the carrier to the truck may be of a variety of different constructions. There is no requirement for clamps to be of a particular shape or size.
It will be understood of course that modifications can be made in the load carrier illustrated and described herein without departing from the scope and purview of my invention as defined in the following claims. | A load carrier has a pair of rails each being affixed to one of the two side walls of the open bed of a pickup truck. Each rail has a longitudinally extending slot along which a bar slides. A bracket is connected to each bar. The two ends of a stringer are connected to the two brackets so that stringer extends transversely across the open bed for supporting a load. Instead of bars, clamps are used to connect the brackets to the rails. | 10,492 |
RELATED APPLICATIONS
[0001] This application is a divisional application from co-pending application Ser. No. 12/156,915, which in turn claims priority to and benefit of U.S. Provisional Application No. 61/124,632 filed Apr. 19, 2008, the disclosure of which is incorporated herein for all purposes.
FIELD OF THE INVENTION
[0002] The present invention is directed to a multifunctional organo-silicone compound and the use of that compound in personal care and other applications. These compounds by virtue of their unique structure provide outstanding microemulsions and provide outstanding skin feel.
BACKGROUND OF THE INVENTION
[0003] Organofunctional silicone compounds are one of two types, internal and terminal depending upon the location of the silicone group.
[0004] The so-called terminal group has the organic functional groups at the alpha and omega terminus of the molecule. Typical of this class of compounds is the class of compounds currently called bis-dimethicone conforming to the following structure:
[0000]
[0000] In the case where R is —(CH 2 ) 15− CH 3 the compound is bis cetyl dimethicone,
[0005] The other type of compound is one in which the organofunctionality is located on non-terminal ends of the molecule. This type of compound is called a “comb” compound since the organofunctionality lies in the molecule much like the teeth of a comb. These compounds are shown in the following structure:
[0000]
[0000] In the case where R is —(CH 2 ) 15− CH 3 the compound is simply cetyl dimethicone,
[0006] These two classes of compounds have been known for many years. Typical patents showing these compounds and their derivatives are seen in the following patents:
[0007] There are limitations on the properties of the silicone compounds of these classes and the products are often used in different applications. The functionality of these materials is determined by the way in which they orientate in solvent. Specifically, in what conformation the lowest energy is achieved. Since oil and silicone are not soluble in each other the internal oil soluble groups rotate around the Si—O—Si bond and associate with each other in essentially spherical globules.
[0000]
[0008] The result is a sphere with silicone on the perimeter and oil soluble groups in the interior.
[0009] Now consider the terminal substituted compound. Since the organofunctional groups are fixed at the end they cannot simple rotate to associate. They form what we refer to as a sandwich type association that has the lowest energy.
[0000]
[0010] The molecular association results in a conformation that forms resembles a sandwich in which the bread is silicone rich and the “meat” is oily (i.e. alkyl groups).
[0011] Unlike either of these, we have surprisingly found that when a molecule has both terminal and comb groups present it forms different associations we refer to as star associations in which smaller aggregates form. If one considers these materials as tennis balls, the core is silicone and the yellow fuzzy coating is the oil phase. These small compact units have unexpected properties both in terms of tactile feel on the skin and the ability to make micro emulsions in water or oil, making them very valuable for use in personal care applications.
THE INVENTION
Object of the Invention
[0012] The object present invention a series of silicone star polymers and their use in personal care applications. Other objects will become clear by reading the specification.
DETAILED DESCRIPTION OF THE INVENTION
[0013] The compounds of the present invention conform to the following structure:
[0000]
[0000] wherein:
a is an integer ranging from 0 to 200;
b is an integer ranging from 1 to 20;
R is selected from the group consisting of
[0000] —(CH 2 ) n —CH 3 ; —(CH 2 ) 3 —O—(CH 2 CH 2 O) x —(CH 2 CH(CH 3 )—O) y H
[0014] and mixtures thereof;
[0000] n is an integer ranging from 7 to 42;
x is an integer ranging from 0 to 20;
y is an integer ranging from 0 to 20.
[0015] The compounds of the present invention are prepared by the reaction of a silanic hydrogen containing silicone polymer conforming to the following structure:
[0000]
[0000] wherein:
[0016] a is an integer ranging from 0 to 200;
[0017] b is an integer ranging from 1 to 20;
[0000] and an alpha olefinic containing polymer selected from the group consisting of:
[0000] CH 2 ═CH—(CH 2 ) n-2 —CH 3 ;
[0000] CH 2 ═CH—CH 2 —O—(CH 2 CH 2 O) x —(CH 2 CH(CH 3 )—O) y H
[0018] and mixtures thereof;
[0000] wherein;
n is an integer ranging from 7 to 42;
x is an integer ranging from 0 to 20;
y is an integer ranging from 0 to 20.
Preferred Embodiment
[0019] In a preferred embodiment R is —(CH 2 ) n —CH 3 .
[0020] In another preferred embodiment R is
[0000] —(CH 2 ) 3 —O—(CH 2 CH 2 O) x —(CH 2 CH(CH 3 )—O) y H.
[0021] In another preferred embodiment R is a mixture of —(CH 2 ) n —CH 3 and
[0000] —(CH 2 ) 3 —O—(CH 2 CH 2 O) x —(CH 2 CH(CH 3 )—O) y H.
[0022] In another preferred embodiment n is 15.
[0023] In another preferred embodiment n is 17.
[0024] In another preferred embodiment x ranges from 1 to 20.
[0025] In another preferred embodiment n ranges from 5 to 15.
[0026] In another preferred embodiment a is zero.
[0027] In still another preferred embodiment a=b.
[0028] In still another embodiment a is 0, and b is 1.
EXAMPLES
Silanic Hydrogen Compounds
[0029] Silanic hydrogen compounds conform to the following structure:
[0000]
[0000] wherein:
[0030] a is an integer ranging from 0 to 200;
[0031] b is an integer ranging from 1 to 20.
[0032] They are commercially available from Siltech LLC of Dacula, Ga. The specific values reported below for the molecule were determined by Si-29 nmr.
[0000]
Example
a
b
1
0
1
2
10
5
3
25
7
4
50
10
5
100
15
6
200
20
[0033] Olefinic Compounds
[0034] Alpha olefins are commercially available form a variety of sources including Chevron. They conform to the following structure:
[0000] CH 2 ═CH—(CH 2 ) n-2 —CH 3 ;
[0000]
Example
n
7
9
8
11
9
23
10
20
11
33
12
42
[0035] Allyl Alcohol Alkoxylates
[0036] Allyl alcohol alkoxylates are commercially available from several sources including Dow Chemical, Ethox Chemical, Siltech Corporation and KAO Chemical.
[0000] They conform to the following structure:
[0000] CH 2 ═CH—CH 2 —O—(CH 2 CH 2 O) x —(CH 2 CH(CH 3 )—O) y H
[0000]
Example
x
y
13
8
0
14
18
18
15
4
3
16
2
2
17
20
20
Products of the Present Invention
[0037] Alkyl Products General Procedure
[0038] The specified number of grams of alpha olefin (Examples 7-12) are added to a vessel having agitation and cooling. If the alpha olefin is solid at room temperature is added as chunks. Next the specified number of grams of silanic hydrogen (examples 1-6) is added. The batch is then heated until the alpha olefin is liquid, or 80 C whichever is lower. Next 20 ppm Karnstedt catalyst (based upon the weight of all materials to be added) is added. Cooling is added to control the exotherm. It is not uncommon for the temperature to rise from 80 C to 120 C. Hold at 120 C for 4 hours, checking the Silanic hydrogen content until it becomes vanishing small.
[0000]
Silanic Hydrogen
Alpha Olefin
Example
Example
Grams
Example
Grams
18
1
90
7
217
19
2
168
8
248
20
3
233
9
404
21
4
370
10
417
22
5
497
11
654
23
6
733
12
818
[0039] Allyl Alcohol Alkoxylate Products General Procedure
[0040] The specified number of grams of allyl alcohol alkoxylates (Examples 13-17) are added to a vessel having agitation and cooling. Next the specified number of grams of silanic hydrogen (examples 1-6) is added, following by the specified number of grams of anhydrous isopropanol. The batch is then heated until the alpha olefin is liquid, or 80 C whichever is lower. Next 20 ppm Karnstedt catalyst (based upon the weight of all materials to be added) is added. Cooling is added to control the exotherm. It is not uncommon for the temperature to rise from 80° C. to 90° C. Hold at 120 C for 4 hours, checking the Silanic hydrogen content until it becomes vanishing small. Distill off isopropanol using vacuum.
[0000]
Silanic Hydrogen
Allyl alcohol alkoxylate
Isopropanol
Example
Example
Grams
Example
Grams
Grams
24
1
90
13
532
200
25
2
168
14
2484
1000
26
3
233
15
533
200
27
4
370
16
341
300
28
5
497
17
2752
600
29
6
733
18
535
400
[0041] Mixed Alpha Olefin/Allyl Alcohol Alkoxylate Products
[0042] General Procedure
[0043] The specified number of grams of silanic hydrogen compound (Example 1-6) is added to a vessel with mixing, cooling, and two dropping funnels. The specified number of grams of isopropanol is then added. 20 ppm Karnstedt catalyst (based upon the weight of all materials to be added) is added. The reaction mass is heated to 80 C and the specified number of grams of the specified allyl alcohol alkoxylates (Examples 13-17) is added to the vessel from one dropping funnel while simultaneously the specified number of grams of alpha olefin is added from the other funnel. Cooling is added to control the exotherm. The two dropping funnels are adjusted so they both empty in one hour. Hold at 120 C for 4 hours, checking the Silanic hydrogen content until it becomes vanishing small. Distill off isopropanol using vacuum.
[0000]
Silanic Hydrogen
Alpha Olefin
Allyl alkoxylate
Isopropanol
Example
Example
Grams
Example
Grams
Example
Grams
Grams
24
1
180
7
217
13
532
200
25
2
336
8
248
14
2484
1000
26
3
466
9
404
15
533
200
27
4
740
10
417
16
341
300
28
5
994
11
654
17
2752
600
29
6
1466
12
818
18
535
400
APPLICATIONS EXAMPLES
Example Appearance
[0000]
18 Clear liquid with an outstanding dry skin feel.
19 Clear liquid with some cushion and outstanding feel
20 Intermediate hardness solid. Easily spread outstanding lotion additive.
21 Intermediate hardness.
22 Hard wax but yields well under pressure
23 Hard solid white wax with exceptional skin drag. Useful in stick products.
24 Water soluble with an outstanding slip and conditioning.
25 Water soluble material with outstanding wet comb when applied to hair.
26 Water soluble product. Provides outstanding feel in antiperspirant applications.
27 Micro emulsion. Outstanding lubricant in water.
28 Micro emulsion.
29 Water soluble solid white wax with exceptional emolliency
[0056] Examples 30-35 are emulsifiers suitable for making water in oil and oil in water emulsions.
[0057] The outstanding skin feel, hair lubrication and emulsification observed in evaluating the compounds of the present invention make them well suited for personal care applications.
[0058] While the illustrative embodiments of the invention have been described with particularity, it will be understood that various other modifications will be apparent to and can be readily made by those skilled in the art without departing from the spirit and scope of the invention. Accordingly, it is not intended that the scope of the claims appended hereto be limited to the examples and descriptions set forth hereinabove but rather that the claims be construed as encompassing all the features of patentable novelty which reside in the present invention, including all features which would be treated as | The present invention is directed to a multifunctional organo-silicone compound and the use of that compound in personal care and other applications. These compounds by virtue of their unique structure provide outstanding micro emulsions and provide outstanding skin feel. | 21,601 |
[1] 1. This application claims the benefit of Japanese Application No. 10-066200 which is hereby incorporated by reference.
BACKGROUND OF THE INVENTION
[2] 2. 1. Field of the Invention
[3] 3. The present invention relates to a projection display apparatus having a polarized beam splitter for receiving a light from a light valve and analyzing a modulated light. More specifically, the present invention relates to an improvement on the polarized beam splitter.
[4] 4. 2. Description of the Related Art
[5] 5. In Published Japanese Patent Registration No. 259930, disclosed is a color projection display apparatus for separating a light from a light source into respective color lights of R, G and B by a color-separation optical system, making incident each of the color lights on a polarized beam splitter to be polarized and separated, making incident one of lights obtained by polarizing and separating a color light on a reflection light valve arranged for each color light to be modulated, making incident emitted reflected lights including the modulated lights on the polarized beam splitter, analyzing the same and thereby extracting the modulated lights, composing such analyzed modulated lights with one another by a composing optical system and then projecting the composed light by a projection optical system.
[6] 6. In FIG. 7, shown is a structure of the projection display apparatus disclosed in the Published Japanese Patent Registration No. 2599309.
[7] 7. Specifically, a light emitted from a light source 71 is made incident on a dichroic mirror 72 arranged as a “color-separation optical system” on an optical axis. Then, the light is subjected to a color-separation into a B light to be transmitted and R and G lights to be reflected according to a dichroic characteristic of the mirror 72 . The transmitted B light is made incident on a polarized beam splitter 74 B for the B light as a “polarization and separation optical system”. An S polarized light of the B light reflected by a polarizing and separating section of the polarized beam splitter 74 B is made incident on a reflection light valve 75 B.
[8] 8. On the other hand, a mixed light of the reflected R and G lights is made incident on a dichroic mirror 73 arranged as a “color-separation optical system” on the optical axis in parallel with the dichroic mirror 72 . Then, the mixed light is subjected to a color-separation into a G light to be reflected and an R light to be transmitted according to a dichroic characteristic of the mirror 73 .
[9] 9. The G light obtained by the color-separation is made incident on a polarized beam splitter 74 G as a “polarization and separation optical system”. An S polarized light reflected by a polarizing and separating section of the polarized beam splitter 74 G is made incident on a light valve 75 G for the G light. Likewise, the R light is made incident on a polarized beam splitter 74 R as a “polarization and separation optical system”. Then, an S polarized light reflected by a polarizing and separating section of the polarized beam splitter 74 R is made incident on a light valve 75 R for the R light.
[10] 10. The S polarized lights respectively made incident on the light valves 75 B, 75 G and 75 R are modulated by signals applied to the same, reflected and emitted as lights including modulated and unmodulated lights. These lights are then made incident on the polarized beam splitters 74 B, 74 G and 74 R for the respective colors, and subjected to an analysis by the polarizing and separating sections of the polarized beam splitters 74 B, 74 G and 74 R. Only the modulated lights are extracted as P polarized lights transmitted through the polarized beam splitters 74 B, 74 G and 74 R, and the analyzed lights are color-composed by a dichroic mirror 76 and a mirror 77 arranged as a “composing optical system”. Then, a result of the color composing is projected to a projection lens 77 as a “projection optical system”.
[11] 11. In the projection display apparatus disclosed in the foregoing Published Patent Gazette, as described above, the dichroic mirrors 76 and 77 are used as the composing optical system. Another apparatus has also been disclosed, where a cross dichroic prism is used as “composing optical system”.
[12] 12. The inventors of the present invention are confronted with a problem inherent in the foregoing conventional projection display apparatus, which is constructed in a manner that the reflection light valves 75 B, 75 G and 75 R are arranged for the respective colors, modulated lights among lights reflected by the light valves 75 B, 75 G and 75 R are analyzed by the polarized beam splitters 74 B, 74 G and 74 R arranged for the respected colors and then the analyzed lights are color-composed. Specifically, for an image projected on a screen by the projection optical system (projection lens 78 ), it was impossible to make registration adjustment (pixel positioning) coincident among the colors. Consequently, pixel deviation occurred.
[13] 13. Usually, with reference to the pixel positioning, relative to projected images from one of the light valves 75 B, 75 G and 75 R for specified color lights, pixel deviation of specified positions of the other light valves 75 B, 75 G and 75 R for the other colors must be limited to ½ pixel or lower, preferably within ⅓ pixel on full surfaces of the projected images.
[14] 14. A level of pixel deviation which is not a problem at all for the conventional light valves 75 B, 75 G and 75 R, each of these having a pixel size of about 40 μm, becomes a severe problem for a light valve having a very small pixel size of about 10 μm.
[15] 15. Further, as a projected image is increased in size to be displayed on a large screen, the foregoing problem of pixel deviation will become severer.
[16] 16. The inventors found as a result of earnest studies that the problem of pixel deviation is not a problem to be created after execution of a vibration test or an environmental test such as a temperature cycle for the projection display apparatus. Rather, this is a basic problem which was created at the time of assembling the constituting members of the projection display apparatus already. The inventors found a characteristic of the problem is that although an original shape of the display section of the light valve is rectangular, the display section is deformed to be a parallelogram, and consequently, pixel deviation occurs in a projected light from the light valve for a specified color light.
[17] 17. Furthermore, the inventors investigated projected images by replacing, among the constituting members of the projection display apparatus, the members for the respective light colors. When an experiment was made by replacing the polarized beam splitter with another for the other color light and arranging the same, a projected image of another color light was also projected in a parallelogram of the same size. Therefore, it was discovered that the projection of the image in the parallelogram rather than in the original rectangular shape can be attributed to the polarized beam splitter.
SUMMARY OF THE INVENTION
[18] 18. It is an object of the present invention to provide a projection display apparatus capable of reducing distortion of a projected light.
[19] 19. It is another object of the invention to provide a projection display apparatus for enabling registration of pixels of a plurality of light valves.
[20] 20. The present invention provides a projection display apparatus which comprises: a modulator including two-dimensionally arrayed pixel units for modulating an incident light and emitting the modulated light; a analyzer for analyzing the emitted light from the modulator; and a projection optical system for projecting the analyzed light from the analyzer. The analyzer includes a polarized beam splitter having a pair of prisms and an adhesive layer held between the pair of prisms. A difference in thickness between thin and thick portions of the adhesive layer is set equal to a predetermined value or lower based on a pixel pitch of the modulator.
[21] 21. According to the projection apparatus constructed in the foregoing manner, since a difference in thickness between the thin and thick portions of the adhesive layer is set equal to a specified value or lower based on the pixel pitch of the modulator, an occurrence of pixel deviation after passing through the polarized beam splitter can be prevented corresponding to an accuracy of the pixel pitch, and thus distortion of a projected image can be easily eliminated. Moreover, in the case of the projection display apparatus using the plurality of light valves, accurate pixel registration can be made for each light valve.
[22] 22. In accordance with a preferred aspect of the present invention, if a refractive index of the pair of prisms is n 1 , a refractive index of the adhesive layer is n 2 , a difference in thickness between the thin and thick portions of the adhesive layer is D and a pixel pitch is P, a value of ΔX being determined by the following expression
Δ X = D ( n 1 2 · n 2 2 - 0.5 · n 1 2 - 1 2 )
[23] 23. and satisfies a following relationship:
ΔX<(½)P
[24] 24. With the projection display apparatus constructed in the foregoing manner, an occurrence of pixel deviation after passing through the polarized beam splitter can be prevented more effectively.
[25] 25. In accordance with a first aspect of the present invention, provided is a projection display apparatus which comprises: a light valve for modulating an incident light and emitting the modulated light; a polarized beam splitter for receiving a light emitted from the light valve and analyzing a modulated light as a light to be transmitted; and a projection optical system for projecting an analyzed light which has been transmitted through and emitted from the polarized beam splitter, wherein the polarized beam splitter has a structure where an adhesive layer exhibiting a refractive index n 2 is held between two glass prisms, each of which exhibits a refractive index n 1 , and if a difference in thickness between thin and thick portions of the adhesive layer is D and a pixel pitch of the light valve is P, a value of ΔX satisfies a relationship of ΔX<(½)P, the value of ΔX being determined by the following expression:
Δ X = D ( n 1 2 · n 2 2 - 0.5 · n 1 2 - 1 2 )
[26] 26. In accordance with a second aspect of the present invention, provided is a projection display apparatus which comprises: a light source; a color-separation optical system for color-separating a light emitted from the light source into R, G and B lights; polarization and separation optical systems arranged for respective color lights obtained by the color-separation of the color-separation optical system, each polarization and separation optical system performing a polarization and separation for each color light; light valves for the respective color lights, each of which makes incident one of polarized lights obtained by the polarization and separation of the polarization and separation optical systems thereonto, modulates each color light, reflects and emits the modulated light; analyzing optical systems for the respective color lights, each of which makes incident each color light emitted from the light valve and analyzes the modulated light; a composing optical system for color-composing lights analyzed by the analyzing optical systems; and a projection optical system for projecting a light obtained by composing of the composing optical system, wherein the polarization and separation optical systems and the analyzing optical systems are polarized beam splitters arranged for the respective color lights, a polarized light reflected by each of the polarized beam splitters is made incident on the light valve, and among lights emitted from the light valves, a polarized light to be transmitted is used, and wherein each of the polarized beam splitters has a structure where an adhesive layer exhibiting a refractive index n 2 is held between two glass prisms, each of which has a refractive index n 1 , and if a difference in thickness between thin and thick portions of the adhesive layer is D and a pixel pitch of the light valve is P, a value of ΔX satisfies a relationship of ΔX<(½)P, the value of ΔX being determined by the following expression:
Δ X = D ( n 1 2 · n 2 2 - 0.5 · n 1 2 - 1 2 )
[27] 27. In accordance with a third aspect of the present invention, provided is a projection display apparatus which comprises: a light source; a polarization and separation optical system for polarizing and separating a light emitted from the light source; a color-separation optical system for color-separating one polarized light obtained by polarization and separation of the polarization and separation optical system in the foregoing polarization and separation optical system into R, G and B lights; light valves arranged for respective color lights, each of which makes incident each color light obtained by separation of the color-separation optical system, modulates the same based on a color signal and then emits the modulated light; a composing optical system for color-composing color lights emitted from the light valves; an analyzing optical system for extracting only a modulated light from a composed light obtained by the composing optical system; and a projection lens for projecting a light analyzed by the analyzing optical system, wherein the polarization and separation optical system and the analyzing optical system are polarized beam splitters arranged for respective color lights, a polarized light reflected by each of the polarized beam splitters is made incident on the light valve, and among lights emitted from the light valve, a polarized light to be transmitted is used as a analyzed light, and wherein each of the polarized beam splitters has a structure where an adhesive layer having a refractive index n 2 is held between two glass prisms, each of which has a refractive index n 1 , and if a difference in thickness between thin and thick portions of the adhesive layer is D and a pixel pitch of the light valve is P, a value of ΔX satisfies a relationship of ΔX<(½)P, the value of ΔX being determined by the following expression:
Δ X = D ( n 1 2 · n 2 2 - 0.5 · n 1 2 - 1 2 )
BRIEF DESCRIPTION OF THE DRAWINGS
[28] 28. For a more complete understanding of the present invention and the advantages thereof, reference is now made to the following description taken in conjunction with the accompanying drawings.
[29] 29.FIG. 1 is a view illustrating a structure of a projection display apparatus of a first embodiment of the present invention.
[30] 30.FIG. 2 is a view illustrating an occurrence of distortion when an image from a light valve is transmitted through a polarized beam splitter of the present invention.
[31] 31.FIG. 3 is a view illustrating a state of a light beam passed through an adhesive layer of the polarized beam splitter.
[32] 32.FIG. 4 is a view illustrating a structure of a projection display apparatus of a second embodiment.
[33] 33.FIG. 5 is a view illustrating a structure of a projection display apparatus of a third embodiment.
[34] 34.FIG. 6 is a view illustrating a projection display apparatus of a fourth embodiment.
[35] 35.FIG. 7 is a view showing a projection display apparatus of a conventional example.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
First Embodiment
[36] 36.FIG. 1 is a view for explaining a structure of a projection display apparatus of a first embodiment. In this projection display apparatus, lights emitted from a light source 3 are roughly parallel light beams and random-polarized, passed through a polarization converter 2 and then converted into S polarized lights.
[37] 37. The parallel light beams made incident on the polarization converter 2 are first made incident on a first lens plate 22 having a plurality of lens elements 22 a arrayed in a matrix form (e.g., 4×5), and then each of the parallel light beams is divided into a number corresponding to the number of lens elements 22 a based on apertures decided by an outer shape of each of the lens elements 22 a. The outer shapes of the lens elements 22 a of the first lens plate 22 are identical to one another, and similar to shapes of light valves 41 R, 41 G and 41 B (described later) which are objects to be illuminated.
[38] 38. In a focal position of each lens element 22 a of the first lens plate 22 , arranged is a second lens plate 23 which includes lens elements 23 a arrayed in positions corresponding to those of the lens elements 22 a. Because of the foregoing arrangements of the first and second lens plates 22 and 23 , the parallel light beams made incident on the respective lens elements 22 a of the first lens plate 22 are converged on a center part of the lens elements 23 a of the second lens plate 23 . Then, a luminescent point is formed on the lens elements 23 a.
[39] 39. A light emitted from the luminescent point of the lens element 23 a of the second lens plate 23 is made incident on a polarized beam splitter prism array 24 which is arranged in the vicinity of a light exit surface of the second lens plate 23 . This polarized beam splitter prism array 24 includes polarized beam splitters 24 a and 24 b, each of which has a width equal to ½of a width of the lens element 23 a of the second lens plate 23 . In this embodiment, one polarized beam splitter 24 a is arranged in a place facing a center side of each of the lens elements 23 a, and the other polarized beam splitter 24 b is arranged in a place facing a boundary side of each of the lens elements 23 a. Accordingly, the light emitted from the luminescent point on the lens element 23 a is polarized and separated into P and S polarized lights: the P polarized light being made incident on the polarized beam splitter 24 a and passed through a polarizing and separating section of the same; and the S polarized light being reflected on the polarizing and separating section, made incident on the adjacent polarized beam splitter 24 b, reflected on a polarizing and separating section of the same and then emitted. The P polarized light passed through the polarized beam splitter 24 a is then converted into an S polarized light by a ½ wavelength phase plate 25 arranged in a light exit surface of the polarized beam splitter 24 a. As a result, all the lights from the light source 3 are converted into S polarized lights by being passed through the polarization converter 2 .
[40] 40. Each light from the light source converted into an S polarized light by the polarization converter 2 is then made incident on a cross dichroic mirror 94 which includes a dichroic mirror 94 a having a B light reflection characteristic and a dichroic mirror 94 b having R and G light reflection characteristics, Lhe dichroic mirrors 94 a and 94 b being arranged in X-shape. Here, the light is color-separated into a B light component which advances in a direction perpendicular to an incident optical axis, and a mixed light between G and R light components which advance in a direction opposite the direction of the B light.
[41] 41. The B light obtained as a result of the foregoing color-separation by the cross dichroic mirror 94 advances to enter a bending mirror 95 , further advances after changing an optical axis by right angle and then enters a polarized beam splitter 1 B for the B light. The mixed light of the G and R lights obtained by the color-separation advances after changing an optical axis by right angle by a bending mirror 96 , and then enters a G light reflection dichroic mirror 98 arranged on the optical axis. The mixed light is then color-separated into an R light component which is directly transmitted, and a G light component which is reflected and advances after changing an optical axis by right angle. The R and G lights obtained as a result of the color-separation by the dichroic mirror 98 are respectively made incident on polarized beam splitters 1 R and 1 G.
[42] 42. The cross dichroic mirror 94 , the bending mirrors 95 and 96 and the G light reflection dichroic mirror 98 constitute a color-separation optical system.
[43] 43. Polarizing and separating sections of the polarized beam splitters 1 B, 1 G and 1 R are arranged to reflect incident S polarized lights of respective colors. Accordingly, incident B, G and R lights are respectively reflected by the polarizing and separating sections 1 B a, 1 G a and 1 R a of the polarized beam splitters 1 B, 1 G and 1 R, and then emitted from the polarized beam splitters 1 B, 1 G and 1 R. In the vicinity of the light exit surfaces thereof, arranged are reflection light valves 45 B, 45 G and 45 R for respective color lights. The S polarized lights of respective colors made incident on the light valves 45 B, 45 G and 45 R are reflected and emitted as mixed lights of modulated light (P polarized light) and unmodulated light (S polarized light).
[44] 44. The modulated and unmodulated lights from the light valves 45 B, 45 G and 45 R are respectively made incident on the polarized beam splitters 1 B, 1 G and 1 R again. The polarized beam splitters 1 B, 1 G and 1 R analyze lights transmitted through the polarizing and separating sections 1 B a, 1 G a and 1 R a as modulated lights (P polarized lights). The analyzed lights of respective colors are made incident from different incident surfaces on a cross dichroic prism 99 of a color composing optical system. Then, the colors composition is completed by a B light reflection dichroic layer 99 B and an R light reflection dichroic layer 99 R which are arranged in an X-shape inside the cross dichroic prism 99 . As a result, a composed light of the B, G and R lights is emitted from a light exit surface of the cross dichroic prism 99 . The composed light emitted from the cross dichroic prism 99 is then made incident on a projection lens 6 , and then projected as a full-color image on a not-shown screen.
[45] 45. Referring to FIG. 2, a method to prevent a projected image from being a parallelogram in the projection display apparatus of FIG. 1 will be described.
[46] 46. In the projection display apparatus shown in FIG. 1, the polarized beam splitters 1 B, 1 G and 1 R are respectively arranged for B, G and R lights. In FIG. 2, however, the polarized beam splitter 1 B is described as a representative of the polarized beam splitters. For easy description of directions, X, Y and Z axes orthogonal to one another are defined as shown. Further, since the projection lens 6 of the projection display apparatus is set telecentric with respect to the light valve 45 B side, principal rays 1 3 to 1 6 are parallel between the light valve and the polarized beam splitter 1 B.
[47] 47. Deformation of the projected image to be a parallelogram can be understood when the polarized beam splitter 1 B is constituted as follows. Specifically, as shown in FIG. 2, a polarized beam splitter 1 is manufactured in such manner that right-angled isosceles triangle optical prisms 1 a and 1 b having refractive indexes n 1 are prepared, and a polarizing and separating film 1 d (or 1 e ) is formed on a bottom surface facing one right angle (apex angle) thereof, followed by adhering or cementing the optical prisms 1 a and 1 b to each other using adhesive. In this case, it is difficult to set a thickness of an adhesive layer 1 c to be uniform on the full surface. Thus, the adhesive layer 1 c is, as shown in the drawing, formed to be wedge-shaped having more thickness toward a Y-direction. The polarizing and separating surface is a plane parallel to a ( 101 ) plane if defined by using the foregoing coordinate.
[48] 48. Next, five light rays 1 1 to 1 5 (referred to as 1 1 , 1 2 , 1 3 , 1 4 and 1 5 , hereinafter) reflected and emitted from four corners and an approximately central part of a display surface of the reflection light valve 45 B will be defined. The light rays 1 1 to 1 5 are vertically incident onto an upper plane lf (parallel to XY plane) of the polarized beam splitter 1 B and respectively transmitting through the upper plane if, the light rays 1 1 to 1 5 are directly moved ahead, then emitted from the prism 1 a and made incident on the adhesive layer 1 c having a refractive index n 2 in accordance with Snell's law (law of refraction). The light rays 1 1 and 1 2 are passed through thin places of the adhesive layer 1 c. Thus, these light rays 1 1 and 1 2 advance with little deviation and become light rays and 1 1 ′ and 1 2 ′. The light rays 1 3 and 1 4 are likewise made incident vertically to the upper plane 1 f of the polarized beam splitter 1 and directly moved ahead. The light rays 1 3 and 1 4 advance through the prism 1 a to enter the adhesive layer 1 c. But this light incident portion of the adhesive layer 1 c has a largest thickness and thus causes a positional shift of ΔX in an X-direction. Specified shifting occurs with the light rays 1 3 and 1 4 , and light rays 1 3 ′ and 1 4 ′ parallel to the light rays 1 3 and 1 4 are emitted. The light ray 1 5 emitted from the approximately central part of the light valve 45 B is likewise made incident from the upper plane 1 f of the polarized beam splitter 1 , and moved ahead through the prism 1 a. As an incident portion of the adhesive layer 1 c for the light ray 1 5 has a thickness of ½ of that of the incident portion for the light rays 1 3 and 1 4 , the light ray 1 5 is shifted in the X-direction by an amount of (ΔX·½) to enter the prism 1 b. A shifted light ray advances in parallel with the light ray 1 5 , and then exists as a light ray 1 5 ′.
[49] 49.FIG. 2 is a qualitative view illustrating deviation and emission of a light ray emitted from a display section of the light valve 45 B in parallel with a -Z direction when the light ray is transmitted through the polarized beam splitter 1 B. In FIG. 2, a dotted line indicates a position corresponding to the display section of the light valve 45 B (position of a light ray when the ray is not passing through the polarized beam splitter 1 B). A solid line indicates a position of the light ray after having passed through the polarized beam splitter 1 B. Accordingly, it can be understood qualitatively that no changes occur in a length in the Y-direction, but the light ray having passed through the thickest portion of the adhesive layer 1 c is deformed to be a parallelogram, which is a result of ΔX deviation made in the X-direction in proportion to the thickness of the adhesive layer 1 c.
[50] 50. Therefore, it can be understood that since the adhesive layer 1 c is formed to be wedge-shaped without having uniform thickness as shown in FIG. 2, a projected image is distorted to be a parallelogram.
[51] 51. Referring to FIG. 3, illustrated is a state of a light ray made incident on the prisms 1 a and 1 b and the adhesive layer 1 c of the polarized beam splitter 1 B when viewed from the Y-direction of FIG. 2.
[52] 52. It is now assumed that a light ray has been made incident from an object (prism 1 a ) having a refractive index n 1 on a position A of an object (adhesive layer 1 c ) having a thickness d 1 and a refractive index n 2 (usually n 1 >n 2 ) by an incident angle θ 1 .
[53] 53. In accordance with Snell's law, the following relationship is established with a refractive angle θ 2 :
n 1 ×sin(θ 1 )= n 2 ×sin(θ 2 ) . . . (1)
[54] 54. The light ray having advanced through the adhesive layer 1 c with the refractive angle θ 2 is emitted from the adhesive layer 1 c in a position B, refracted with the angle θ 1 , and then emitted into the prism 1 b.
[55] 55. A length AB from the position A to the position B is expressed as follows:
AB=d 1 /cos(θ 2 ) . . . (2)
[56] 56. An amount of deviation ΔX 1 of the light ray is expressed as follows:
ΔX 1= AB ×sin(θ 2 −θ 1 ) . . . (3)
[57] 57. For the light rays 1 1 to 1 5 of FIG. 2, the foregoing θ 1 may be set to 45°.
[58] 58. By setting θ 1 to 45° in the foregoing expressions (1) to (3), the amount of deviation ΔX 1 can be changed as follows:
Δ X1 = d 1 ( n 1 2 · n 2 2 - 0.5 · n 1 2 - 1 2 ) ( 4 )
[59] 59. For the light rays 1 3 and 1 4 of the polarized beam splitter 1 B shown in FIG. 2, if a thickest portion of the wedge shape of the adhesive layer 1 c is D, a maximum deviation amount ΔX in this case is expressed as follows:
Δ X = D ( n 1 2 · n 2 2 - 0.5 · n 1 2 - 1 2 ) ( 5 )
[60] 60. If a pixel pitch of the light valve 45 B is p in the X-direction, the foregoing deviation amount ΔX should be set to be (½)×p or less, preferably to be (⅓)×p or less. With these values of the deviation amount, no problems will occur in a projected image.
[61] 61. In the projection display apparatus of the embodiment, the polarized beam splitter 1 B is manufactured with a precision for satisfying the expression (5). In this case, although a projected image is slightly distorted to be a parallelogram, the distortion is about ½ pixel at the maximum. Accordingly, a precision necessary for image processing can be nearly achieved.
[62] 62. The embodiment has been described by using the adhesive layer 1 c which is changed in thickness in the Y-direction. But the present invention is not limited to this For example, the invention can be applied to an adhesive layer which is changed in thickness in the X-direction.
[63] 63. It was described above with reference to FIG. 2 that almost no wedge or gap exist in the adhesive layer lc for the light rays 1 1 and 1 2 . In most actual cases, however, a portion of the adhesive layer 1 c to be adhered has a limited thickness, and portions of the adhesive layer 1 c for the light rays 1 3 and 1 4 are thicker.
[64] 64. In such a case, it is only necessary to argue a difference in thickness between the thickest and thinnest portions of the adhesive layer 1 c. This is because the light rays 1 1 to 1 5 take shapes where all the solid lines indicating the amounts of deviation in FIG. 2 have been moved in parallel by amounts equal to the foregoing minimum thickness in the X-direction, and the parallel movements can be adjusted by registration adjustment of the light valve 45 B.
[65] 65. Only the polarized beam splitter 1 B has been described. The same thing can be said for the other polarized beam splitters 1 G and 1 R. In other words, if each of these splitters is manufactured with a precision for satisfying the foregoing expression (5), distortion of a projected image will be only ½ pixel at the maximum, and thus an image which nearly satisfies a precision for image processing will be obtained.
[66] 66. The projected display apparatus has a structure where a light from the light source is color-separated into B, G and R lights by the color-separation optical system, and the polarized beam splitters 1 B, 1 G and 1 R are arranged for the respective color lights. Polarization and separation are performed by the polarized beam splitters 1 B, 1 G and 1 R, and lights emitted from the respective color light valves 45 B, 45 G and 45 R are also analyzed by the splitters 1 B, 1 G and 1 R. Especially, the lights made incident from the light valves 45 B, 45 G and 45 R on the polarized beam splitters 1 B, 1 G and 1 R are analyzed as polarized lights to be transmitted. The analyzed lights of respective colors are color-composed, and then projected by the projection lens 6 .
[67] 67. In this case, as described above, since the lights emitted from the light valves 45 B, 45 G and 45 R for the respective color lights are analyzed as polarized lights to be transmitted by the polarized beam splitters 1 B, 1 G and 1 R for the respective color lights, registration can be enabled among the light valves 45 B, 45 G and 45 R for the respective color lights, and also distortion of a projected image can be reduced.
[68] 68. Next, the specific embodiments of the present invention will be described.
FIRST EXAMPLE
[69] 69. If a refractive index n 1 of each of the prisms 1 a and 1 b as the constituting elements of the polarized beam splitters 1 B, 1 G and 1 R is 1.84 and a refractive index n 2 of the adhesive layer 1 c is 1.42, then the following is established:
ΔX=0.91D
[70] 70. Accordingly, (½)P>ΔX(=0.91D) should be set. More preferably, (⅓)p>ΔX(=0.91D) should be set.
[71] 71. If a pixel pitch p of each of the light valves 45 B, 45 G and 45 R is 40 μm, a difference between a maximum thickness and a minimum thickness of the wedge shape of the adhesive layer 1 c should be limited to about 22 μm or lower (preferably, 15 μm).
[72] 72. If a pixel pitch p of each of the light valves 45 B, 45 G and 45 R is a small pixel pitch of 10 μm, then ¼ of the foregoing value is necessary for the thickness difference of the wedge shape of the adhesive layer 1 c. Accordingly, the difference should be set equal to 5.5 μm or lower (preferably, 4 μ m or lower).
SECOND EXAMPLE
[73] 73. If a refractive index n 1 of each of the prisms 1 a and 1 b as the constituting elements of the polarized beam splitters 1 B, 1 G and 1 R is 1.84 as in the case of the foregoing embodiment and a refractive index n 2 of the adhesive layer 1 c is 1.57 larger than that of the foregoing embodiments, then the following is established:
ΔX=0.34D
[74] 74. Accordingly, (½)p>ΔX(=0.34D) is set. More preferably, (⅓)P>ΔX(=0.34D) is set.
[75] 75. If a pitch of each of the light valves 45 B, 45 G and 45 R is 40 μm, then a difference between a maximum thickness and a minimum thickness of the wedge shape of the adhesive layer 1 c must be limited to about 59 μm or lower (preferably, 39 μm or lower).
[76] 76. If a pixel p of each of the light valves 45 B, 45 G and 45 R is a small pixel pitch of 10 μm, then ¼ of the foregoing value is necessary for the thickness difference of the wedge shape of the adhesive layer 1 c. Accordingly, the difference must be set equal to 15 μm or lower (preferably, 10 μm or lower). But this value is larger compared with that in the first embodiment.
Second Embodiment
[77] 77. A projection display apparatus of a second embodiment functions as follows:
[78] 78. First, lights from a light source are polarized and separated by a polarized beam splitter; one polarized light is made incident on, for example Phillips color-separation prism to be color-separated into R, G and B lights; these R, G and B lights are made incident on reflection light valves arranged for the respective color lights to be modulated; the lights thereby emitted are made incident on the light exit surface of the prism again for color composing; the lights are made incident on the polarized beam splitter; only the modulated lights are analyzed; and then the analyzed lights are projected by a projection lens. In the system for using the analyzed lights in the polarized beam splitter as lights to be transmitted, the number of polarized beam splitters to be used is one. Accordingly, image deviation of each light valve never occurs in the polarized beam splitter, and a problem of a distorted projected image can be solved.
[79] 79. Referring to FIG. 4, illustrated is a structure of the projection display apparatus of the second embodiment. Lights emitted from a light source 3 are roughly parallel light beams and randomly polarized. These lights are passed through the same polarization converter 2 as that of the first embodiment so as to be converted into S polarized lights.
[80] 80. The lights converted into S polarized lights by the polarization converter 2 are first made incident on a polarized beam splitter 101 . A polarizing and separating section 101 P of the polarized beam splitter 101 is arranged in an S direction for reflecting the S polarized lights. Thus, the S polarized lights made incident on the polarized beam splitter 101 are reflected by the polarizing and separating section 101 P and then emitted. The lights are then made incident on Phillips prism 7 which constitutes a color-separation composing optical system.
[81] 81. Phillips prism 7 is composed of first, second and third prisms 71 , 72 and 73 . A gap is provided between the first and second prisms 71 and 72 . A B light reflection dichroic film 70 B is formed on a surface constituting the first prism 71 , and an R light reflection dichroic film 70 R is formed on a joint surface between the second and third prisms 72 and 73 .
[82] 82. A B light component included among white S polarized lights made incident on the first prism 71 of Phillips prism 7 is reflected by the dichroic film 70 B to advance through the first prism 71 . The B light is subjected to a total reflection by an incident surface thereof while advancing through the first prism 71 , and advances to exit from the first prism 71 . Then, a light valve 41 B for B light arranged in the vicinity of a light exit surface of the first prism 71 is illuminated by the S polarized light. A mixed light component of an R light and a G light which advance after being transmitted through the first prism 71 is made incident on the second prism 72 to advance. Then, the mixed light is divided into an R light component and a G light component: the R light being reflected by the R light reflection dichroic film 70 R provided in the joint surface between the second and third prisms 72 and 73 to advance, and the G light being directly transmitted to advance into the third prism 73 . The former R light advances through the second prism 72 , further advances after being totally reflected by a surface which forms the gap with the first prism 71 and exits. Then, an light valve 41 R for R light is illuminated. The latter G light directly advances through the third prism 73 to exit from the same. Then, a light valve 41 G for G light is illuminated.
[83] 83. The lights of respective colors made incident on the light valves 41 R, 41 G and 41 B for the respective colors are subjected to modulation by color signals inputted thereto. These lights are then reflected/emitted as mixed lights of modulated P polarized lights and unmodualted S polarized lights.
[84] 84. The lights emitted from the light valves 41 R, 41 G and 41 B for the respective lights are moved ahead in opposite directions on the same optical axis as an incident optical axis to enter Phillips prism 7 again. Then, a composed light is emitted from the incident surface of the first prism 71 .
[85] 85. The color-composed light emitted from Phillips prism 7 is made incident on the polarized beam splitter 101 . Only the modulated light included in this composed light is analyzed as a light to be transmitted by a polarizing and separating section 101 P of the polarized beam splitter 101 . The unmodulated light is discarded as a reflected light. The analyzed light is made incident on the projection lens 6 . Then, a full-color image is projected on a not-shown screen.
[86] 86. The polarized beam splitter 101 now in use serves both as a polarization and separation optical system and a light analyzing optical system. This splitter 101 is manufactured with a precision for satisfying the expression (5) of the first embodiment. As a result, although a projected image is slightly distorted to be a parallelogram, its distortion is only about ½of one pixel at the maximum, and thus the image can nearly satisfy a precision necessary for image processing.
Third Embodiment
[87] 87.FIG. 5 is a view for explaining a structure of a projection display apparatus of a third embodiment. In the apparatus of the third embodiment, rather than analyzing a modulated light from a composed light by using one polarized beam splitter, polarized beam splitters for light analyzing are provided for respective color lights.
[88] 88. Lights emitted from a light source 3 are roughly parallel light beams and random polarized. These lights are passed through the same polarization converter 2 as that of the second embodiment so as to be converted into S polarized lights.
[89] 89. The lights converted into S polarized lights by the polarization converter 2 are made incident on a dichroic mirror 81 arranged on an optical axis for transmitting a B light and reflecting G and R lights, and then color-separated into a transmitted B light and a composed light of reflected G and R lights. The latter composed light of the G and R lights advances in a direction orthogonal to the B light to enter a dichroic mirror 82 having a G light reflection property, which is arranged on the optical axis in parallel with the dichroic mirror 81 . Then, the composed light is reflected and color-separated into a G light which advances in an orthogonal direction and an R light which is transmitted to advance straight. As can be understood from the foregoing descriptions, the dichroic mirrors 81 and 82 constitute a color-separation optical system for color-separating a light from the light source into R, G and B lights.
[90] 90. The B, G and R lights obtained by color-separation are made incident on polarized beam splitters 201 B, 201 G and 201 R arranged for the respective color lights. Polarizing and separating sections of the polarized beam splitters 201 B, 201 G and 201 R are arranged in an S direction so as to reflect incident S polarized lights. Incident S polarized lights of the respective colors are respectively reflected by the polarizing and separating sections and then emitted from the polarized beam splitters 201 B, 201 G and 201 R.
[91] 91. The S polarized lights of the respective colors emitted from the polarized beam splitters 201 B, 201 G and 201 R are then made incident on reflection light valves 45 B, 45 G and 45 R arranged in the vicinity of light exit surfaces. The S polarized lights made incident on the light valves 45 B, 45 G and 45 R are subjected to modulation by color signals inputted thereto. Modulated lights by the light valves 45 B, 45 G and 45 R become P polarized lights. These P polarized lights are reflected and emitted together with S polarized light as unmodulated lights, and then made incident from the light exit surfaces in opposite directions on the polarized beam splitters 201 B, 201 G and 201 R again. The modulated P lights included in the lights made incident on the polarized beam splitters 201 B, 201 G and 201 R are transmitted through the respective polarizing and separating sections and analyzed, and then transmitted through the polarized beam splitters and emitted. The B light included in the modulated P polarized lights emitted from the polarized beam splitters 201 B, 201 G and 201 R is made incident on a B light reflection dichroic mirror 86 arranged on an optical axis, reflected by the same and then moved ahead after changing the optical axis to be vertical. The G light is made incident on a G light reflection dichroic mirror 87 arranged on an optical axis in parallel with the dichroic mirror 86 , reflected by the same and then moved ahead by changing the optical axis to be vertical. The G light is then made incident on the dichroic mirror 86 , transmitted and then composed with the B light. The R light is made incident on the dichroic mirrors 87 and 86 , transmitted through these elements to advance, and then color-composed with the G and B lights. As can be understood from the foregoing, the dichroic mirrors 86 and 87 constitute a color composing optical system.
[92] 92. A composed light formed by the color composing optical system which includes the dichroic mirrors 86 and 87 is made incident on a projection lens 6 , and a full-color image is projected on a not-shown screen.
[93] 93. Each of the polarized beam splitters 201 B, 201 G and 201 R serves both as a polarization and separation optical system and a light analyzing optical system, and is manufactured with a precision for satisfying the expression (5) described above with reference to the first embodiment. Therefore, although a projected image is slightly distorted to be a parallelogram, the distortion is only about ½ of one pixel at the maximum, and thus the image can nearly satisfy a precision necessary for image processing.
Fourth Embodiment
[94] 94.FIG. 6 is a view for explaining a structure of a projection display apparatus of a fourth embodiment. This projection display apparatus comprises: a light source 3 composed of a lamp and a concave mirror; a polarization converter 2 for converting a light from the light source 3 into an S polarized light, which is the same as that of the first embodiment; a polarized beam splitter 301 having a polarizing and separating section 301 P; a light valve 40 as a reflection type light modulator arranged on an optical axis in the vicinity of a light exit surface of the polarized beam splitter 301 ; and a projection lens 6 for projecting a modulated light transmitted through the polarized beam splitter 301 and analyzed on a screen (not shown).
[95] 95. In the projection display apparatus, lights emitted from the light source 3 are parallel light beams and random polarized, and passed through the same polarization converter 2 as that of the second embodiment so as to be converted into S polarized lights.
[96] 96. The S polarized lights formed by the polarization converter 2 are made incident on the polarized beam splitter 301 . But since the polarizing and separating section 301 P of the polarized beam splitter 301 is arranged so as to reflect an S-polarized lights and transmit a P-polarized lights, the S polarized lights are reflected by the polarizing and separating section 301 P, moved ahead after changing an advancing direction to be vertical, and then emitted from the polarized beam splitter 301 . The S polarized lights emitted from the polarized beam splitter 301 and made incident on the light valve 40 are, in a specified region selected by a color signal to the light valve 40 , subjected to modulation, and then converted into P polarized lights where a vibrating direction has been changed by 90°. In an unselected region, i.e., in a region not selected by the color signal, the incident S polarized lights are directly reflected/emitted. Specifically, a light emitted from the light valve 40 is a mixed light of a modulated P polarized light and an unmodulated S polarized light. This emitted light is made incident on the polarized beam splitter 301 again, and then polarized and separated by the polarizing and separating section 301 P into a modulated P polarized light to be transmitted and an unmodulated S polarized light to be reflected and discarded, in other words analyzed as such. The modulated P polarized light transmitted through the polarized beam splitter 301 and analyzed is made incident on the projection lens 6 , and then projected on the screen.
[97] 97. The polarized beam splitter 301 used in the fourth embodiment serves both as a polarization and separation optical system and a light analyzing optical system. This splitter 301 is manufactured with a precision for satisfying the expression (5) described above with reference to the first embodiment. Therefore, although a projected image is slightly distorted to be a parallelogram, the distortion is only about ½of one pixel at the maximum, and thus the image can nearly satisfy a precision necessary for image processing.
[98] 98. Although the preferred embodiments of the present invention have been described in detail, it should be understood that various changes, substitutions and alternations can be made therein without departing from spirit and scope of the inventions as defined by the appended claims. | A projection display apparatus comprises a modulator, an analyzer, and projecting optical system. The modulator includes two-dimensionally arrayed pixel units and it modulates an incident light and emits the modulated light. The analyzer analyzes the emitted light from the modulator. The projection optical system projects the analyzed light from the analyzer. The analyzer includes a polarized beam splitter having a pair of prisms and an adhesive layer held between the pair of prisms. The difference in thickness between thin and thick portions of the adhesive layer is set equal to a predetermined value or less, based on a pixel pitch of the modulator. | 50,939 |
CROSS REFERENCE TO RELATED APPLICATION
The present application claims priority and is related to commonly assigned co-pending U.S. patent application Ser. No. 09/935,540, AT&T Reference No. BS 00185, entitled, “On-Demand Blocking Service” by Mark Kirkpatrick, filed on Aug. 23, 2001, which is incorporated herein by reference for all that it teaches and discloses.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention broadly relates to telecommunication services, and, more particularly, to a telephone service where a called party can block phone calls from a specific caller by simply instructing the telephone service provider's network for the same.
2. Description of the Related Art
Telephones and telephone communication are so prevalent in modern society that they may be justifiably considered an integral part of human existence. Telephones are useful not only to carry out personal communication, but also to transact business. Telephones give their operators access to the world. However, because of the ease with which a telephone call may be placed, there may be times when the called party (hereafter, the “callee”) prefers to block unwanted phone calls from a calling party (hereafter, the “caller”). For example, a callee may not wish to receive any more phone calls from a telemarketer who interrupted the callee's dinner conversation with callee's friends. As another example, a callee may want to place a block on harassing phone calls from an unknown caller prior to reporting the incident to the police.
Telephone service providers (or telephone companies) provide many calling services designed to protect a callee from unwanted or undesired phone calls and also to help the callee identify the calls that the callee considers important. For example, the caller ID service lets the callee see the name and phone number of the caller trying to reach the callee-all before the callee answers the phone. The display unit for the caller ID service may also display the date and time of the incoming call. Thus, the callee can decide beforehand whether or not to take the call. In the call waiting ID service, the callee can view the incoming caller's name and phone number while the callee is on phone with another caller. The callee does not need to hang up on the current caller to receive the incoming call. In the anonymous call blocking service, the callee may request the telephone service provider to block calls from callers who prevent their names and phone numbers from being displayed on the callee's caller ID device. When activated, the anonymous call blocking service plays a message to the blocked callers instructing them to hang-up, remove their blocking, and call again.
It is noted that the anonymous call blocking service may block all the anonymous phone calls regardless of the identity of the caller. Thus, a callee subscribing to such a service may not be able to receive phone calls from those desired callers (e.g., friends, relatives, etc.) who happen to have call blocks placed on their phone lines. Furthermore, the anonymous call blocking service may discourage certain callers to perform the removal of call blocking and initiate another phone call to the callee. In such a situation, it may be desirable that the callee be able to receive the phone call first, and, thereafter, place a block on all the future phone calls if the caller of the received phone call is found to be undesirable or unwanted.
Of course, the callee always has an option to directly contact a telemarketer and request the telemarketer to remove the callee's phone number from the telemarketer's call list. However, such requesting may be burdensome to the callee, and, even after the request, the telemarketer may still fail, for whatever reason, to comply with the callee's request. To remedy such a situation, there is a subscription-based call-blocking service available to telemarketers. The service allows a telemarketer to provide a list of “do-not-call” telephone, modem, and fax numbers to the service, which, in turn, blocks all the phone calls placed from the subscriber telemarketer's establishment to any of the phone numbers appearing in the “do not call” list. However, a telemarketer may not avail of such a service and may frequently end up calling the callee who had earlier requested the telemarketer not to call the callee. This may be quite annoying and disturbing to the callee.
In a privacy protection service offered on a subscription basis by Ameritech of Chicago, USA, all calls showing up as “blocked”, “private”, “out of area”, “unavailable”, or “unknown” on a caller ID display of the service subscriber (i.e., the callee) are first identified by the service. Thereafter, the service answers such calls without ringing the subscriber's (i.e., callee's) phone—i.e., the subscriber remains unaware of such phone calls until they are allowed to go through by the service. The service asks the caller to give his or her name, which is then displayed to the subscriber callee. The callee can thereafter select whether to answer the call or to reject the call with or without appropriate voice message. Although such an arrangement offers privacy protection against unscrupulous callers or telemarketers, the manner of call blocking may be analogized with the anonymous call blocking service described hereinbefore where the service blocks calls from all callers (regardless of the identity of the caller) who prevent their names and phone numbers from being displayed on the callee's caller ID device. Thus, in such a privacy protection service, some desirable callers may also face call blocking along with some undesirable ones. The subscriber (i.e., the callee) does not have control over which caller is to be blocked and which caller is to be allowed to contact the subscriber. furthermore, if a caller is unable to clearly identify himself/herself to the service because of, for example, the caller's age, physical condition, or the place and atmosphere surrounding the calling area, etc., that caller may not get a chance to speak with 20 the subscriber even if the caller is not one of the unwanted callers.
It is therefore desirable to allow the callee to control the call blocking process and to selectively block those callers who are found to be unwanted or undesirable. It is thus desirable to offer a telephone service that allows the service subscriber (i.e., the callee) to respond to a phone call first, and, then, instruct the service to place a block on future phone calls if the caller is found to be undesirable or unwanted.
SUMMARY OF THE INVENTION
In a telecommunication system configured to provide a connection between a caller and a callee via a telephone network, wherein the telephone network is configured to connect the caller and the callee, the present invention includes a method for allowing the callee to prevent the caller from establishing the connection with the callee. The method includes receiving an instruction from the callee to prevent the caller from establishing the connection with the callee and identifying a first telephone number associated with the caller. The method also includes preventing one or more phone calls from the first telephone number from being forwarded to a second telephone number associated with the callee.
The present invention has the advantage that it allows a callee to control the call blocking process and to selectively block those callers who are found to be unwanted or undesirable The present invention also has the advantage that it allows a service subscriber {i.e., the callee) to respond to a phone call first, and, then, instruct the service to place a block on future phone calls if the caller is found to be undesirable or unwanted.
BRIEF DESCRIPTION OF THE DRAWINGS
Further advantages of the present invention may be better understood by referring to the following description taken in conjunction with the accompanying drawings, in which:
FIG. 1 shows an exemplary system configuration to implement the on-demand call blocking service according to an embodiment of the present invention; and
FIG. 2 illustrates a flowchart for the on-demand call blocking service according to an embodiment of the present invention.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
FIG. 1 shows an exemplary system configuration to implement the on-demand call blocking service (the “blocking service”) according to an embodiment of the present invention. In the embodiment illustrated in FIG. 1 , a calling party (the “caller”) 10 is shown to be in communication with the called party (the “callee”) 12 via an AIN (Advanced Intelligent Network) platform 14 . The callee 12 utilizes the call blocking service—either on a subscription basis or on a per-usage basis—as described in more detail herein below. It is noted that the caller and the callee are represented by corresponding telephone terminals in FIG. 1 for ease of depiction. In actuality, the caller and the callee may be humans operating the telephones 10 and 12 respectively. Furthermore, the terms “called party” or “callee”, as used herein, includes the actual person the caller wishes to be connected to or any other person at the called telephone number picking up or answering the caller's phone. It is further noted that the terms “callee” and “subscriber” are used interchangeably herein below.
It is observed that the caller 10 or the callee 12 may not be directly connected to the AIN 14 , but, instead, through a local PSTN (Public Switched Telephone Network) or ISDN (Integrated Services Digital Network) as illustrated by the dotted clouds 16 and 18 respectively. A local PSTN/ISDN (e.g., the PSTN/ISDN 18 ) may be operated by a Competitive Local Exchange Carrier (CLEC). In one embodiment, the same PSTN/ISDN (e.g., PSTN/ISDN 16 ) may be qualified to handle calls for both the caller 10 and the callee 12 . A telephone company (telco) or CLEC central office switch may form part of the initial PSTN/ISDN platform that a call encounters first prior to being routed to the AIN platform 14 . The AIN 14 may include a more advanced and sophisticated switching and call processing mechanism as discussed herein below in more detail. Thus, in the discussion given herein, it is implicitly assumed that regular PSTNs may not be capable of performing AIN functionality. However, that may not hold true in every circumstance and, hence, in one embodiment, the PSTN/ISDN 16 and/or 18 may include the AN functionality represented by block 14 in FIG. 1 and discussed herein below.
An Advanced Intelligent Network (AIN) is a vendor- and platform-independent telecommunications network that is designed with distributed network intelligence in databases called Service Control Points (SCPs) (e.g., the SCP 22 in FIG. 1 ). By separating call processing intelligence from the switch, advanced intelligent networks promise reduced service provider dependence on switch-generic features. New services can be created on distributed platforms across the network much faster and at substantial cost savings. Service creation may also be distributed in workstations called Service Creation Environments (SCEs) (e.g., the SCE 28 in FIG. 1 ). The SCP 22 and SCE 28 are described later herein below.
In both wireline and wireless networks, the AIN architecture separates call processing intelligence and feature functionality from network switches, placing that intelligence and functionality in platforms spread across the network. The call processing intelligence is sometimes referred to as service logic An AIN infrastructure typically involves service logic on network platforms, an out-of-band signaling system (e.g., the signaling system#7, or SS7), and AIN-capable software in the network switch. With this infrastructure in place, service providers, end users and third parties may be able to create and modify services independently of switch vendors. Some of the advantages of the AIN architecture (for wireline or wireless networks) include: reduced service provider dependence on switch generic availability for features and services; cost savings by having multiple applications reside on one platform and sharing resources; rapid creation and deployment of services; allows service providers to create differentiating services; facilitation of mobility management functions; reduced fraud; and in case of wireless intelligent networks (WIN), facilitation of interoperability with wireline networks.
The voice-associated functions may stay closely coupled to the AIN switch (e.g., the SSP 20 ), but SCPs may be used to deploy data-related services (such as Short Message Service, Unified Messaging, or Debit cards) and may be placed anywhere that a SS7 data connection can be maintained. The AIN provides advanced services which cannot be easily implemented in the switch or cannot be best offered from a central point in the network. To achieve this, the digital switch (e.g., the switch in the telco central office) is enhanced so that it becomes an AIN service switching point (SSP) 20 , thus enabling it to notify the service control point (SCP) 22 when processing the call/connection requires an AIN interaction.
Additional AIN functional architecture is illustrated in FIG. 1 . The AIN platform 14 may also include a Service Data Point (SDP) 24 and an Intelligent Peripheral (IP) 26 . The existing software which controls the switch (i.e., the SSP 20 ) and communicates with a user terminal (here, the caller telephone unit 10 and the callee telephone unit 12 ) is the call control function (CCF) 30 . The service switching function (SSF) 32 is added to provide the interface to enable call processing to interact with the AIN control platform represented by the SCP 22 . The flexibility of the AN arises from the SCP 22 which comprises a service control function (SCF) 34 and a service data function (SDF) 38 . The SCF 34 runs services via service logic programs (SLPs) 36 . The SDF 38 may run on the SDP 24 and provide service information such as the caller block status information. Service-independent building blocks (SIBS) are used to construct AIN services in SLPs. The SLPs communicate with the underlying SSPs via NAP (intelligent network application part) operations.
The software for the on-demand call blocking service of the present invention may be created on the SCE 28 and then loaded onto the SCP 22 as part of the SLPs 36 running on the SCP 22 . Alternatively, upon creation, the software may first be stored on one or more data storage media (e.g., compact discs (CDs), floppy diskettes, magnetic tape cartridges, digital versatile disks (DVDs), etc.). Thereafter, the storage media may be transported to the SCP 22 to load the blocking service software thereon. A service (e.g., the blocking service of the present invention) is a software application on the AIN platform 14 that provides a defined set of functions that interact with the AIN platform 14 (and, hence, with the users of the AIN 14 ) and a set of service data. The software developer may define the functionality of the blocking service along with the type and scope of data used by the service. The blocking service of the present invention primarily creates and maintains (or stores) at least one caller block table 42 in the SDP 24 as shown in FIG. 1 .
The software for the on-demand call blocking service may be switch-independent. However, in one embodiment, the software that implements the functionality of the call blocking service is created for a Nortel switching platform. The software for the connection service is executed in a UNIX environment and is written in C++ and Java programming languages.
The specialized resource function (SRF) 40 (in the IP 26 ) can be temporarily connected to the callee/subscriber 12 to play announcements and collect digits from the callee. An IVR (Interactive Voice Response) system 44 may be implemented in the IP 26 through the SRF 40 so that the callee/subscriber 12 can interact with the call blocking service and can input data or call processing selections via a telephone handset in response to voice prompts received from the IVR system 44 . The entire process may be generally explained as follows: When the callee dials a special sequence (comprising a combination of numerals, letters, and symbols) to access the call blocking service, the special sequence is first received by the SSP 15 . The SSF 32 in the SSP 20 recognizes the special access sequence as different from regular telephone numbers and forwards the access sequence to the SCP 22 for further processing. The SCP 22 (via the SCF 34 ) identifies the service requested (i.e., the call blocking service) from part of the access sequence dialed by the callee 12 and returns information about how to handle the call to the SSP 20 . Initially, when a customized voice announcement is to be played 20 to greet the subscriber and to offer the call blocking service options to the subscriber, the SCF 34 may instruct the SRF 40 in the IP 26 to relay the customized voice announcement (using the 1VR system 44 ) to the customer 12 via the CCF 30 acting as an interface between the IP 26 and the callee telephone unit 12 . Any digits entered by the callee 12 when prompted by the call blocking service after the initial greeting are collected by the SRF 40 (through the CCF 30 ) and sent to the SCF 34 for further processing by the SCP 22 . The SCP 22 may then instruct the SDF 38 to access the caller block table 42 , if needed, to place or remove a block on a caller's telephone number as specified by the callee.
FIG. 2 illustrates a flowchart for the on-demand call blocking service according to an 30 embodiment of the present invention. For the sake of simplicity, the discussion herein below refers to the call blocking service software as performing various operations described—i.e., without repetitively identifying individual AIN network entities responsible to implement each feature/operation of the call blocking service. However, it is understood that the blocking service software does not function in a vacuum; rather, various call processing functions are carried out by the software (in the SLP 36 ) in conjunction with and with the help from several network entities (e.g., the SCP 22 , the IP 26 , the SDP 24 , etc.) in the AM platform 14 as discussed herein before.
As noted hereinbefore, the callee 12 first answers the phone call from the caller 10 , and, thereafter, decides whether to block the caller 10 . If the callee 12 decides to place a block on all phone calls from the caller 10 , the callee 12 dials a specific sequence that comprises a combination of numerals (digits), letters, and/or symbols (e.g., “*”, “#”). For example, one such sequence is “*75B”. The access sequence may be predefined by the commercial provider of the call blocking service so as to enable the SCP 22 to identify that the callee/subscriber 12 wishes to invoke the call blocking service. As shown in FIG. 2 , at block 48 , the call blocking service first receives a call from the callee/subscriber 12 that contains the special access sequence (e.g., *75B or *88) to activate the blocking service. Upon receiving an indication (i.e., the access sequence) from the callee/subscriber 12 that the callee 12 wishes to activate the call blocking service, the call blocking service (with the help of the IVR system 44 , for example) voice prompts the callee 12 (at block 50 ) requesting the callee 12 to enter either the digit “1” to place a call block or the digit “2” to perform administrative tasks. The callee/subscriber 12 may enter the desired digit using the numeric keypad on the callee's telephone unit 12 . In one embodiment, the call blocking software is configured to detect digits sent in the DTMF (Dual Tone Multi Frequency) format from subscriber telephones. The software for the call blocking service waits for the response from the callee 12 (block 52 ) unless a timeout occurs (block 54 ). If the callee 12 does not enter the callee's selection (i.e., digit “1” or “2”) prior to the expiration of a predetermined time period (i.e., the timeout period), the blocking service may play a voice announcement (e.g., “Thanks for calling the call blocking service from XYZ. Good Bye.”) to the callee 12 and terminate the call thereafter (block 56 ). The callee 12 may, of course, dial into the blocking service again (using the same service access sequence) to place a call block or to perform administrative tasks.
The timeout period at block 54 may be predetermined by the service provider or by the developer of the call blocking service software. In an alternative embodiment, the service provider may offer one more chance to the callee 12 prior to disconnecting the line. Here, the service may prompt the callee 12 once again (block 50 ) and repeat the procedure given by blocks 52 and 54 prior to finally disconnecting the caller at block 56 .
Once the call blocking service receives an input from the subscriber 12 (e.g., the digits “1” or “2”), the blocking service takes over further call processing. If the collected digit is a “1” (block 58 ), the blocking service (at block 60 ) places a block on future calls originating from the most recent telephone number that the callee 12 last received a call from immediately prior to accessing the blocking service (at block 48 ). In one embodiment, the call blocking service software places the to-be-blocked telephone number in the caller block table 42 and marks that number as blocked. For example, the service may place a “1” against that telephone number to indicate to the SCP 22 that all calls from that telephone number to the callee 12 are blocked. On the other hand, the service may place a “0” against a previously blocked telephone number to indicate to the SCP 22 that a block on the corresponding telephone number has been removed by the callee 12 (as discussed later herein below) and, hence, any phone calls placed from that telephone number to the callee's telephone number be allowed to go through.
In one embodiment, the call blocking service may depend on the existing reverse caller-ID or reverse white pages look-up technology (e.g., the technology behind the “*69” service presently offered by some telephone service providers) to identify and obtain the telephone number to be blocked. The AIN network 14 may retrieve the telephone number to be blocked using the existing reverse caller-ID technology and supply that telephone number to the call blocking service software to be stored in the caller block table 42 . It is noted that the AIN network 14 may be capable of obtaining the most recent caller's telephone number even if the caller has “blocked” the caller's telephone number. However, if the caller uses a PBX (Private Branch Exchange) or similar switching facility, the AIN network 14 may not be able to identify the actual telephone number used by the caller to place the call. In that event, the call blocking service according to the present invention may place a block on all telephone calls originating from that PBX or switching facility.
In one embodiment, after the callee 12 first enters the digit “1” (at block 58 ), the call blocking service may play a canned message to the callee/subscriber 12 prompting the callee 12 to enter mother “1” to record a message in callee's voice for the blocked party (block 62 ), or to enter the digit “2” to select one of the pre-recorded messages supplied by the service provider (block 66 ), or to simply hang up (block 70 ). If the callee enters a “1” (at block 62 ), then the service further prompts the callee to record a voice message of predetermined duration (e.g., a maximum of 60 seconds). The blocking service will then answer all future calls from the blocked caller with the callee's voice message (block 64 ). If the callee 12 enters a “2” instead (at block 66 ), the blocking service may play a set of pre-recorded messages in sequence to allow the callee to select one of them (at block 68 ). The service may voice prompt the callee after each playback whether the callee wishes to select that voice message or to continue listening to other remaining messages. Alternatively, the service may assign a different number to each message and, after finishing playing back all the pre-recorded messages, prompt the callee to enter the number (using the keypad on the callee's telephone 12 ) for the message the callee wishes to select. Thus, the service not only places a block on the phone calls from the caller specified by the callee, but also plays a callee-selected voice message to the blocked caller whenever that caller attempts to call the callee. The callee may hang up after selecting the voice message, or without selecting one. If the callee hangs up (at block 70 ) without selecting/recording a voice message, the blocking service may not play any message to the blocked caller. In other words, the service may simply disconnect the caller's calls without any voice message.
After placing the subscriber-requested call block and after the callee/subscriber 12 selects/records the playback message, if any, the service may play a voice announcement (e.g., “Thanks for using the call blocking service from XYZ. The call block you requested has been placed. Good Bye.”) to the callee 12 before the callee hangs up. Thereafter, the blocking service will terminate the call (block 56 ). If the callee hangs up without recording/selecting a voice message, the service may not play any such voice announcement in that case.
If the callee 12 inputs the number “2” instead (at block 72 ), the blocking service software recognizes the input as a request by the callee 12 to perform administrative tasks. The blocking service then voice prompts the callee 12 to perform one or more pre-designated administrated tasks (block 74 ). Some exemplary administrative tasks include: (1) The callee 12 instructs the service to remove a block placed caller on a specific telephone number. Here, the callee 12 supplies the telephone number to the blocking service software and then instructs the software to remove the block for that telephone number. The software may then access the telephone number in the caller block table 42 and enter a “0” against that telephone number; The callee 12 may also instruct the blocking service to send a voice message to the caller whose telephone number has been unblocked. The callee may either record a voice message of a predefined maximum duration (e.g., 60 seconds) or select one from a set of pre-recorded messages in a manner similar to discussed hereinbefore with reference to blocks 62 - 68 ; and The callee 12 may continue the block on a specific telephone number, but, may choose to record/select a new voice message for that telephone number or revise an earlier-recorded message. The service will then play the most recent voice message every time a call is received from the blocked telephone number. In one embodiment, the service provider may allow the callee/subscriber 12 to unsubscribe the call blocking service using the administrative function selection at block 72 .
In an alternative embodiment, the call blocking software may allow the callee/subscriber 12 to specify one or more telephone numbers (using the DTMF keypad on the callee's telephone) that the callee wishes to be blocked in addition to the telephone number of the most recent caller. Such an option may be provided either as part of the administrative function choice (starting at block 72 ) or as part of the routine call block choice at block 58 . For example, if the additional call blocking option is provided as part of the routine call block choice at block 58 , the call blocking software may prompt the callee/subscriber 12 to enter additional telephone numbers, if any, that the callee wishes to place blocks on. Such a prompting may occur after a block is placed on the most recent caller (at block 60 ) and prior to the callee hanging up at block 70 . In response to the prompting, the callee can enter one or more telephone numbers to be blocked and the call blocking software may store those telephone numbers in the caller block table 42 along with a “1” placed against each such telephone number. Thus, with such an option available to the callee/subscriber 12 , the callee/subscriber does not need to wait to receive a call from a caller before placing a call block against that caller.
As noted hereinbefore, the service provider may specify a fixed value for the timeout interval at block 54 . However, in one embodiment, the service provider may modify the call blocking software to allow selected callee/subscribers 12 to flexibly alter the value of the timeout period. For example, when a callee is an elderly or a disabled person, it may be desirable to offer the callee more time to respond to the service prompts. In that case, the service provider may either modify the timeout interval when the callee signs up for the call blocking service or allow the callee to modify the timeout interval using the administrative function selection at block 72 . A timeout interval selection option may then be offered as part of the administrative tasks selection at block 74 . Similarly, the service provider may also allow the callee to specify other parameters for the call blocking service (e.g., duration of callee's voice message at block 64 ) based on the callee's physical or mental condition, age, etc. The callee/subscriber can also change or modify values entered earlier and reenter new values for one or more parameters. The callee/subscriber 12 may enter various values using the DTMF keypad on the callee's telephone.
The service provider may require the callee/subscriber 12 to provide certain subscriber-specific information when the subscriber first subscribes to the call blocking service. The subscriber-specific information may include, for example, the subscriber's name, subscriber's billing address, the duration for which the subscriber wishes to activate and maintain the call blocking service, and any other data (e.g., extended timeout period at block 54 ) that the subscriber wishes to communicate to the service provider. The subscriber-specific information may also include the subscriber's phone number for which the subscriber wishes to have the call blocking service. The call blocking service software can then store the callee's telephone number (for example, in the SDP 24 ) and associate that number with the callee. Thus, any time the callee/subscriber (or someone else using the callee's telephone) dials the special access sequence (e.g., *88) to activate the call blocking service, the service software validates the subscriber's identity by comparing the telephone number (obtained using, for example, the reverse caller-ID technology) from which the access sequence is received with the subscriber telephone numbers stored in the AIN network 14 . If a match is found, the call blocking software allows the service requester to access various features offered by the call blocking service. In one embodiment, the call blocking service software may allow the subscriber 12 to transmit various subscriber-specific information over the Internet to the service provider's computer. The subscriber 12 may be required to access over the Internet a webpage maintained by the service provider to enter the subscriber-specific information.
It is noted that all of the call blocking service features discussed hereinbefore (including, for example, the submission of subscriber-specific information) can be implemented in a wireless environment (e.g., in a cellular telephone network). Thus, a cellular phone subscriber may also be offered the call blocking service according to the present invention. Furthermore, as noted hereinbefore, the call blocking service may be offered, for example, on a subscription basis (e.g., monthly or yearly subscription with unlimited access during the subscription period) or the subscriber may be charged on a per-access basis.
The foregoing describes an intelligent telephone service that allows subscribers to control the call blocking process and to selectively block telephone calls to their telephone numbers from those callers who are found to be unwanted or undesirable. The call blocking service may be implemented on an AIN platform through the call blocking service software running on the AIN platform. With a special access code, the subscriber can access the blocking service using the subscriber's telephone and instruct the service to place a block on telephone calls from one or more callers. Upon receiving the special access code and validating the subscriber's subscription status, the service automatically prompts the subscriber whether the subscriber wishes to place a block on the future phone calls from the most recent caller. In addition to authorizing the block, the subscriber can record a voice message or select a pre-recorded voice message for the blocked caller. The service will play the recorded/selected voice message to the caller whenever a phone call to the subscriber's telephone number is received from that blocked caller. The service also allows the subscriber to perform various administrative tasks such as for example, subscriber account management, removal of one or more call blocks placed earlier, etc., using the subscriber's telephone. Thus, the service allows the service subscriber to respond to a phone call first, and, then, instruct the service to place a block on future phone calls if the caller is found to be undesirable or unwanted.
While several embodiments of the invention have been described, it should be apparent, however, that various modifications, alterations and adaptations to those embodiments may occur to persons skilled in the art with the attainment of some or all of the advantages of the present invention. It is therefore intended to cover all such modifications, alterations and adaptations without departing from the scope and spirit of the present invention as defined by the appended claims. | In a telecommunication system configured to provide a connection between a caller and a callee via a telephone network, wherein the telephone network is configured to connect the caller and the callee, a method for allowing the callee to prevent the caller from establishing the connection with the callee. The method includes receiving an instruction from the callee to prevent the caller from establishing the connection with the callee and identifying a first telephone number associated with the caller. The method also includes preventing one or more phone calls from the first telephone number from being forwarded to a second telephone number associated with the callee. | 34,923 |
CROSS REFERENCES TO RELATED APPLICATIONS
[0001] This application claims the benefit of priority under 35 U.S.C. §120 to U.S. application Ser. No. 08/727,837, filed Sep. 27, 1996 (now U.S. Pat. No. 5,771,218), Ser. No. 08/917,865, filed Aug. 27, 1997, (now U.S. Pat. No. 6,128,134), Ser. No. 08/943,274, filed Oct. 3, 1997 (now U.S. Pat. No. 6,096,155), Ser. No. 09/018,891, filed Feb. 5, 1998 (now U.S. Pat. No. 5,912,872), Ser. No. 09/503,249, filed Feb. 14, 2000 (now U.S. Pat. No. 6,610,166), Ser. No. 09/637,364, filed Aug. 15, 2000 (now U.S. Pat. No. 6,522,618), and pending Ser. No. 10/647,262, filed Aug. 26, 2003, which are hereby incorporated by reference in their entirety for all purposes.
FIELD OF THE INVENTION
[0002] The present invention is directed to integrating multiple optical elements on a wafer level. In particular, the present invention is directed to efficient creation of integrated multiple elements.
BACKGROUND OF THE INVENTION
[0003] As the demand for smaller optical components to be used in a wider variety of applications increases, the ability to efficiently produce such optical elements also increases. In forming such integrated multiple optical elements at a mass production level, the need for accurate alignment increases. Further, such alignment is critical when integrating more than one optical element.
[0004] Integrated multiple optical elements are multiple optical elements stacked together along the z-axis, i.e., the direction of the light propagation. Thus, light traveling along the z-axis passes through the multiple elements sequentially. These elements are integrated such that further alignment of the elements with themselves is not needed, leaving only the integrated element to be aligned with a desired system, typically containing active elements.
[0005] Many optical systems require multiple optical elements. Such required multiple optical elements include multiple refractive elements, multiple diffractive elements and refractive/diffractive hybrid elements. Many of these multiple element systems were formed in the past by bonding individual elements together or bonding them individually to an alignment structure.
[0006] In bulk or macroscopic optics to be mounted in a machined alignment structure formed using a mechanical machining tools, the typical alignment precision that can be achieved is approximately 25-50 microns. To achieve a greater level of 15-25 microns, active alignment is required. Active alignment typically involves turning on a light source, e.g., a laser, and sequentially placing each optic down with uncured ultra-violet (UV) adhesive. Then each part is moved, usually with a translation stage, until the appropriate response from the laser is achieved. Then the part is held in place and the epoxy is cured with UV light, thereby mounting the element. This is done sequentially for each element in the system.
[0007] Alignment accuracies of less than 15 microns for individual elements can be achieved using active alignment, but such accuracies greatly increase the amount of time spent moving the element. This increase is further compounded when more than one optical element is to be aligned. Thus, such alignment accuracy is often impractical even using active alignment.
[0008] In many newer applications of optics, as in the optical head configuration set forth in U.S. Pat. Nos. 5,771,218 and 6,522,618, which are hereby incorporated by reference, and the integrated beam shaper application noted above, there is a need to make optical systems composed of several micro-optical components and in which the tolerances needed are much tighter than can be achieved with conventional approaches. In addition to requiring tight tolerances, elements of lower cost are also demanded. The alignment tolerance needed may be 1 micron to 5 microns, which is very expensive to achieve with conventional methods. Unfortunately, these active alignment requirements are complex, time consuming, and relatively expensive. Further, the level of size reduction in the vertical direction of an optical head is limited. In addition, the relatively large size of the elements of an optical head which can be manipulated is determined by the need for active alignment.
[0009] To achieve greater alignment tolerances, passive alignment techniques have been used as set forth in U.S. Pat. No. 5,683,469 to Feldman entitled “Microelectronic Module Having Optical and Electrical Interconnects”. One such passive alignment technique is to place metal pads on the optics and on the laser and place solder between them and use self-alignment properties to achieve the alignment. When solder reflows, surface tension therein causes the parts to self-align. However, passive alignment has not been employed for wafer-to-wafer alignment. In particular, the high density of solder bumps required and the thickness and mass of the wafer make such alignment impractical.
[0010] Another problem in integrating multiple optical elements formed on separate wafers at a wafer level arises due to the dicing process for forming the individual integrated elements. The dicing process is messy due to the use of a dicing slurry. When single wafers are diced, the surfaces thereof may be cleaned to remove the dicing slurry. However, when the wafers are bonded together, the slurry enters the gap between the wafers. Removing the slurry from the gap formed between the wafers is quite difficult.
[0011] Integrated elements are also sometimes made by injection molding. With injection molding, plastic elements can be made having two molded elements located on opposite sides of a substrate. Multiple plastic elements can be made simultaneously with a multi-cavity injection molding tool.
[0012] Glass elements are also sometimes made by molding, as in U.S. Pat. No. 4,883,528 to Carpenter entitled “Apparatus for Molding Glass Optical Elements”. In this case, just as with plastic injection molding, multiple integrated elements are formed by molding two elements on opposite sides of a substrate. Glass molding however has disadvantages of being expensive to make tooling and limited in size that can be used.
[0013] To make optics inexpensive, replication techniques are typically used. In addition to plastic injection molding and glass molding discussed above, individual elements may also be embossed. An example of such embossing may be found in U.S. Pat. No. 5,597,613 to Galarneau entitled “Scale-up Process for Replicating Large Area Diffractive Optical Elements”. Replicated optics have not been used previously together with solder self-alignment techniques. For each replication method, many individual elements are generated as inexpensively as possible.
[0014] Such replication processes have not been used on a wafer level with subsequent dicing. This is primarily due to the stresses imposed on the embossed layer during dicing. When using embossing on a wafer level, unique problems, such as keeping the polymer which has been embossed sufficiently attached to the substrate, e.g., such that the alignment, especially critical on the small scale or when integrating more than one element, is not upset.
[0015] Further, these replication processes are not compatible with the wafer level photolithographic processes. In particular, replication processes do not attain the required alignment accuracies for photolithographic processing. Even if embossing was compatible with lithographic processing, it would be too expensive to pattern lithographically on one element at a time. Further, the chemical processing portion of lithographic processing would attack the embossing material.
[0016] Other problems in embossing onto plastic, as is conventionally done, and lithographic processing arise. In particular, the plastic is also attacked by the chemicals used in lithographic processing. Plastic also is too susceptible to warping due to thermal effects, which is detrimental to the alignment required during lithographic processing.
SUMMARY OF THE INVENTION
[0017] Therefore, it is a feature of an embodiment to provide an integrated optical system that substantially overcomes one or more of the problems due to the limitations and disadvantages of the related art.
[0018] It is a feature of an embodiment to integrate optics on the wafer level.
[0019] It is another feature of an embodiment to integrate optics with an optoelectronic device.
[0020] It is yet another feature of an embodiment to integrate optics with an optoelectronic device forming a system having a reduced thickness.
[0021] At least one of the above and other features and advantages may be realized by providing an integrated optical imaging system, including a first substrate having first and second opposing surfaces, a second substrate having third and fourth opposing surfaces, a spacer between a substantially planar portion of the third surface of the second substrate and a substantially planar portion of the second surface of the first substrate, at least two of the spacer, the first substrate and the second substrate sealing an interior space between the third surface of the second substrate and the second surface of the first substrate, and an optical imaging system having n surfaces, where n is greater than or equal to two, at least two of the n surfaces of the optical imaging system are on respective ones of the first, second, third and fourth surfaces.
[0022] The optical imaging system may be on at least two of the first, second, third and fourth surfaces. The spacer may be bonding material between the first and second substrates. The spacer may be opaque.
[0023] The integrated optical imaging system may include a detector in optical communication with the optical imaging system. The detector may be within the interior space. The detector may be an array of detectors. The optical imaging system may include an array of lenses, each lens associated with a corresponding detector. The array of lenses may be within the interior space. Each lens may focus an image on the corresponding detector.
[0024] The integrated optical imaging system may include a third substrate associated with the detector. The detector may be mounted on the third substrate. The first through third substrates may be secured together, e.g., on a wafer level. The first and second substrates may be secured on a wafer level via the spacer. The integrated optical imaging system may include a second spacer between the third substrate and the second substrate, the second spacer, the third substrate and the second substrate forming a second interior space in which the detector is enclosed.
[0025] The first and second substrates may be secured on a wafer level via the spacer. The optical imaging system may include a refractive element. The refractive element may be a replica. The optical imaging system may include first and second optical elements in a same optical path and on different ones of the first through fourth surfaces, the first optical element being a replica and the second optical element being a lithograph.
[0026] At least one of the above and other features and advantages may be realized by providing a method of making an integrated optical imaging system, including providing a first substrate having first and second opposing surfaces, providing a second substrate having third and fourth opposing surfaces, providing a spacer between a substantially planar portion of the third surface of the second substrate and a substantially planar portion of the second surface of the first substrate, at least two of the spacer, the first substrate and the second substrate sealing an interior space between the third surface of the second substrate and the second surface of the first substrate, and providing an optical imaging system having n surfaces, where n is greater than or equal to two, at least two of the n surfaces of the optical imaging system are on respective ones of the first, second, third and fourth surfaces.
BRIEF DESCRIPTION OF THE DRAWINGS
[0027] The above and other features and advantages of embodiments will become readily apparent to those of skill in the art by describing in detail embodiments thereof with reference to the attached drawings, in which:
[0028] FIG. 1 illustrates a first embodiment for bonding together two wafers;
[0029] FIG. 2 illustrates a second embodiment for bonding together two wafers;
[0030] FIG. 3A illustrates a perspective view of wafers to be bonded;
[0031] FIG. 3B illustrates a top view of an individual die on a wafer to be bonded;
[0032] FIGS. 4A-4B illustrate specific examples of bonding two substrates together;
[0033] FIG. 5 is a flow chart of the bonding process of an embodiment;
[0034] FIG. 6A illustrates embossing an embossable material onto a support substrate using a master element;
[0035] FIG. 6B illustrates embossing an embossable material on a support substrate using a master element;
[0036] FIG. 7 illustrates a wafer on which optical elements have been formed on both sides;
[0037] FIG. 8 illustrates a cross-sectional view of a substrate having a hybrid element consisting of a microlens with a diffractive element integrated directly thereon;
[0038] FIG. 9A illustrates a schematic view of a configuration of an integrated optical apparatus in accordance with an embodiment;
[0039] FIG. 9B illustrates a schematic view of another configuration of an integrated optical apparatus in accordance with an embodiment;
[0040] FIG. 9C illustrates a schematic view of an integrated optical apparatus according to an embodiment;
[0041] FIG. 10 illustrates a fragmentary side perspective view of an integrated optical apparatus according to an embodiment;
[0042] FIG. 11A illustrates a side elevational view of an integrated optical apparatus according to an embodiment;
[0043] FIG. 11B illustrates side elevational view of the integrated optical apparatus as shown in FIG. 11A rotated ninety degrees;
[0044] FIG. 12A illustrates a plan view of the component side of a first transparent substrate of an integrated optical apparatus according to an embodiment;
[0045] FIG. 12B illustrates a plan view of a holographic optical element of a first transparent substrate of an integrated optical apparatus according to an embodiment;
[0046] FIG. 12C illustrates a plan view of a refractive lens surface of a second transparent substrate of an integrated optical apparatus according to an embodiment;
[0047] FIG. 13 illustrates a cross sectional view of an integrated optical apparatus of an embodiment having a diffractive element in the transmit path and separate diffractive elements in the return path;
[0048] FIG. 14 illustrates a cross sectional view of an integrated optical head of an embodiment having a diffractive element and a refractive element on a single substrate in the transmit path and no optical elements in the return path;
[0049] FIG. 15 illustrates a cross sectional view of an integrated optical head of an embodiment having a diffractive element and a refractive element on two substrates in the transmit path and no optical elements in the return path;
[0050] FIG. 16 illustrates a perspective view showing an article including two wafers according to an embodiment; and
[0051] FIGS. 17A-17D illustrate vertical fragmentary sectional views of example alignment features according to an embodiment.
DETAILED DESCRIPTION OF EMBODIMENTS
[0052] In the drawings, the thickness of layers and regions may be exaggerated for clarity. It will also be understood that when a layer is referred to as being “on” another layer or substrate, it may be directly on the other layer or substrate, or intervening layers may also be present. Further, it will be understood that when a layer is referred to as being “under” another layer, it may be directly under, or one or more intervening layers may also be present. In addition, it will also be understood that when a layer is referred to as being “between” two layers, it may be the only layer between the two layers, or one or more intervening layers may also be present. Like numbers refer to like elements throughout. As used herein, the term “wafer” is to mean any substrate on which a plurality of components are formed on a planar surface which are to be separated through the planar surface prior to final use.
[0053] As can be seen in FIG. 1 , a first substrate wafer 10 and a second substrate wafer 12 are to be bonded together in order to provide integrated multiple optical elements. A wafer may be a disc, typically 4, 6, 8, or 12 inches in diameter and typically having a thickness between 400 microns and 6 mm.
[0054] These wafers have an array of respective optical elements formed thereon on either one or both surfaces thereof. The individual optical elements may be either diffractive, refractive or a hybrid thereof. Dashed lines 8 indicate where the dicing is to occur on the wafers to provide the individual integrated elements.
[0055] A bonding material 14 is placed at strategic locations on either substrate in order to facilitate the attachment thereof. By surrounding the optical elements which are to form the final integrated die, the adhesive 14 forms a seal between the wafers at these critical junctions. During dicing, the seal prevents dicing slurry from entering between the elements, which would result in contamination thereof. Since the elements remain bonded together, it is nearly impossible to remove any dicing slurry trapped therebetween. The dicing slurry presents even more problems when diffractive elements are being bonded, since the structures of diffractive elements tend to trap the slurry.
[0056] Preferably, an adhesive or solder can be used as the bonding material 14 . Solder is preferable in many applications because it is smoother than adhesives and allows easier movement prior to bonding. Adhesives have the advantages of being less expensive for a number of applications, they can be bonded with or without heating, they do not suffer with oxidation, and they can be transparent.
[0057] When using a fluid adhesive as the bonding material, the viscosity of the fluid adhesive is important. The adhesive cannot be too thin, or else it beads, providing indeterminant adhesion, allowing the dicing slurry to get in between the elements on the wafers, thereby contaminating the elements. The adhesive cannot be too thick, or the restoring force is too great and sufficient intimate contact between the substrates 10 and 12 to be bonded is not achieved. The fluid adhesive preferably has a viscosity between 1,000 and 10,000 centipoise. Satisfactory epoxies include Norland 68 and Masterbond UV 15-7.
[0058] When a fluid adhesive is employed, it must be provided in a controlled manner, such as ejected from a nozzle controlled in accordance with the desired coordinates to receive the fluid adhesive. After alignment of the wafers, the entire assembly is cured, thereby hardening the fluid adhesive and completing the bonding.
[0059] When solder is used, an electroplating or sputtering process may be employed. For example, a masking material may be put over the substrate wherever the substrate is not to have solder. Then the entire wafer is placed into a bath or sputtering chamber. Then solder is placed over the entire wafer and the masking material is pulled off, leaving solder where there was no masking material. Once the wafers are appropriately aligned, the solder is then heated up to reflow. The solder is cooled and allowed to re-harden, thereby completing the bond.
[0060] When using the bonding material used alone as shown in FIG. 1 is a fluid adhesive, a more viscous adhesive is needed in order to ensure that the bonding material remains where it is deposited. Even using a viscous adhesive, the adhesive still typically spreads over a relatively large area, resulting in a need for a larger dead space between elements to be integrated to accommodate this spread without having the adhesive interfere with the elements themselves.
[0061] It is also difficult to control the height of the adhesive when the adhesive is used alone. This results in the amount of adhesive being overcompensated and the height of the adhesive, and hence the separation between the wafers, often being greater than desired. The difficulty controlling the height of the adhesive also results in air being trapped within the space containing the optical elements. This arises from the uncertainty as to the height and the timing of when a vacuum is pulled on the wafer pair. This air is undesirable, as it may expand upon heating and disrupt the bond of the elements.
[0062] Therefore, an advantageous alternative is shown in FIG. 2 , in which only an individual integrated optical element of the wafer is shown. Stand offs 16 for each element to be integrated are etched or replicated into the bottom substrate wafer 12 at the same time the array of optical elements are made for the substrate wafer 12 , and typically will be of the same material as the substrate wafer. These stand offs 16 preferably include a trench formed between two surfaces in which the adhesive 14 is to be placed. These trenches then provide precise spacing between the substrates to be bonded and provide more of a bonding surface to which the adhesive 14 can adhere. This increased surface area also reduces beading problems.
[0063] When solder is used as the bonding material 14 , solid stand-offs are preferably used to provide the desired separation between the wafers. The solder is then deposited in a thin, e.g., 4-5 micron, layer on top of the stand-offs. While the solder could be used alone as shown in FIG. 1 , it is more feasible and economical to use the solder in conjunction with stand-offs.
[0064] The use of the stand-offs allows a more uniform and predictable height to be obtained, resulting in less air being trapped between the bonded elements. A vacuum may now be pulled just before or at contact between the bonding material and the other substrate, due to the reduction in variability of the separation.
[0065] The substrate not containing the stand-offs may have notches formed thereon to receive the stand-offs 16 therein. These notches can be formed at the same time any optical elements on that surface are formed. In such a configuration, the stand-offs 16 and the corresponding notches will serve as alignment features, facilitating alignment of the wafers to one another.
[0066] FIG. 3A shows the two substrates 10 and 12 prior to being bonded and diced. The individual optical elements 19 to be integrated may consist of one or more optical elements. Further, the optical elements on the wafers may be identical, or may differ from one another. Prior to joining the wafers 10 , 12 , the bonding material 14 is placed on at least one of the wafers in the manner described above. Advantageously, both substrates 10 and 12 include fiducial marks 18 somewhere thereon, most likely at an outer edge thereof, to ensure alignment of the wafers so that all the individual elements thereon are aligned simultaneously. Alternatively, the fiducial marks 18 may be used to create mechanical alignment features 18 ′ on the wafers 11 , 12 . One or both of the fiducial marks 18 and the alignment features 18 ′ may be used to align the wafers.
[0067] FIG. 3B shows a top view of a substrate 12 to be bonded including the location of the surrounding bonding material 14 for a particular element 19 . As can be seen from this top view, the bonding material 14 is to completely surround the individual optical element, indicated at 19 .
[0068] For either embodiment shown in FIG. 1 or 2 , the bonding material provided either directly or using stand-offs completely seals each element to be individually utilized. Thus, when dicing a wafer in order to perform the individual elements, dicing slurry used in the dicing process is prevented from contaminating the optical elements. Thus, in addition to providing a structural component to maintain alignment and rigidity during dicing, the bonding material seal also makes the dicing a much cleaner process for the resultant integrated dies.
[0069] A specific example of integrated multiple optical elements is shown in FIG. 4A . A refractive 20 is formed on a surface of the first substrate 12 . A diffractive 22 is formed on a surface of the other substrate 10 . A diffractive 28 may also be formed on a bottom surface of either substrate. The stand offs 16 forming the trenches for receiving the adhesive 14 are formed at the same time as a refractive lens.
[0070] Another specific example of integrated multiple optical elements is shown in FIG. 4B . An active element 25 , e.g., a laser, is provided on the first substrate 12 . The first substrate 12 may be etched to provide a reflective surface 27 , 17 therein. The second substrate 11 , which has been separated to form dies with diffractive elements 22 thereon, may be mounted to the first substrate 12 via the adhesive 12 . Stand-offs 29 may be provided to insure alignment between the reflective surface 27 , 17 , the active element 25 and the diffractive element 22
[0071] When the lens 20 on the wafer 12 is directly opposite the other wafer, the vertex of the lens 20 may also be used to provide the appropriate spacing between the substrates 10 and 12 . If further spacing is required, the stand offs 16 may be made higher to achieve this appropriate spacing.
[0072] In addition to using the fiducial marks 18 shown in FIG. 3A for alignment of the substrates 10 , 12 , the fiducial marks 18 may also be used to provide metalized pads 24 on opposite sides of the substrates rather than their bonding surfaces in order to facilitate alignment and insertion of the integrated multiple optical element into its intended end use. Such metal pads are particularly useful for mating the integrated multiple optical elements with an active or electrical element, such as in a laser for use in an optical head, a laser pointer, a detector, etc. Further, for blocking light, metal 26 may be placed on the same surface as the diffractive 22 itself using the fiducial marks 18 .
[0073] It is to be understood that any of the optical designs of embodiments may be realized by vertically stacking of n/2 substrates may provide up to n parallel surfaces on which optical elements may be created. Further, even with optical elements formed on the surface, substantially planar regions may remain on the surfaces, facilitating securing thereof with adjacent surfaces.
[0074] FIG. 5 shows a flow chart of the general process of bonding together two wafers in accordance with the present invention. In step 30 , a substrate wafer is positioned relative to the bonding material to be distributed. In step 32 , the bonding material is applied to the wafer in a pattern to provide sealing around the optical elements, either directly or with the stand-offs 16 . In step 34 , the second substrate wafer is aligned with the first substrate wafer. Just before contact is achieved, a vacuum is pulled to remove air from between the substrates. In step 36 , the wafers are brought into contact. In step 38 , the alignment of the two wafers is confirmed. In step 40 , the adhesive is cured or the solder is reflowed and then allowed to harden. Once firmly bonded, in step 42 , the bonded wafers are diced into the individual elements.
[0075] The elements to be bonded together are preferably created by direct photolithographic techniques, as set forth, for example, in U.S. Pat. No. 5,161,059 to Swanson, which is hereby incorporated by reference, for the diffractive optical elements, or in creating the spherical refractive elements by melting a photoresist as taught in O. Wada, “Ion-Beam Etching of InP and its Application to the Fabrication of High Radiance InGAsP/InP Light Emitting Diodes,” General Electric Chemical Society, Solid State Science and Technology, Vol. 131, No. 10, October 1984, pages 2373-2380, or making refractive elements of any shape employing photolithographic techniques used for making diffractive optical elements when the masks used therein are gray scale masks such as high energy beam sensitive (HEBS) or absorptive gray scale masks, disclosed in provisional application Ser. No. 60/041,042, filed on Apr. 11, 1997, which is hereby incorporated by reference.
[0076] Alternatively, these photolithographic techniques may be used to make a master element 48 in glass which in turn may then be used to stamp out the desired element on a wafer level in a layer of embossable material 50 onto a substrate 52 as shown in FIG. 6B . The layer 50 is preferably a polymer, while the substrate 52 may be glass, e.g., fused silica, or plastic, preferably polycarbonate or acrylic. The polymer is preferably a UV curable acrylate photopolymer having good release from a master and good adherence to a substrate such that it does not crack after cure or release from the substrate during dicing. Suitable polymers include PHILIPS type 40029 Resin or GAFGARD 233. Dashed lines 58 indicate the dicing lines for forming an individual integrated element from the wafer.
[0077] In the embodiment shown in FIG. 6A , the layer of embossable material 50 is provided on the master element 48 . A layer of adhesion promoter 54 is preferably provided on the substrate 52 and/or a layer of a release agent is provided on the master element 48 in between the master element and the embossing material. The use of an adhesion promoter and/or release agent is of particular importance when the master and the substrate are of the same material or when the master naturally has a higher affinity for adhesion to the embossable material.
[0078] The type of adhesion promoter used is a function of the photopolymer to be used as the embossable material, the master material and the substrate material. A suitable adhesion promoter for use with a glass substrate is HMDS (hexamethyl disilizane). This adhesion promoter encourages better bonding of the embossable material onto the substrate 52 , which is especially critical when embossing on the wafer level, since the embossed wafer is to undergo dicing as discussed below.
[0079] The provision of the embossable layer 50 on the master 48 and of the adhesion promoting layer 54 on the substrate 52 advantageously provides smooth surfaces which are to be brought into contact for the embossing, making the elimination of air bubbles easier as noted below. The provision of the embossable layer on the master 48 also provides a convenient mechanism for maintaining alignment of contacted, aligned wafer which have not been bonded, as discussed below.
[0080] If either the substrate or the master is made of plastic, it is preferable to place the polymer on the other non-plastic component, since plastic absorbs strongly in the UV region used for activating the polymer. Thus, if the UV radiation is required to pass through plastic, a higher intensity beam will be required for the desired effect, which is clearly less efficient.
[0081] The use of embossing on the wafer level is of particular interest when further features are to be provided on the wafer using lithographic processes, i.e., material is selecting added to or removed from the wafer. Such further features may include anti-reflective coatings or other features, e.g. metalization pads for aligning the die diced from the substrate 52 in a system, on the embossed layer. Any such features may also be lithographically provided on an opposite surface 56 of the substrate 52 .
[0082] Typically an anti-reflective coating would be applied over the entire surface, rather than selectively. However, when using both an anti-reflective coating and metal pads, the metal would not adhere as well where the coating is present and having the coating covering the metal is unsatisfactory. Further, if the wafer is to be bonded to another wafer, the bonding material would not adhere to the surface of having such an anti-reflective coating, thereby requiring the selective positioning of the coating.
[0083] For achieving the alignment needed for performing lithographic processing in conjunction with the embossing, fiducial marks as shown in FIG. 3 may be provided on both the substrate 52 and the master 48 . When performing lithographic processing, the alignment tolerances required thereby make glass more attractive for the substrate than plastic. Glass has a lower coefficient of thermal expansion and glass is flatter than plastic, i.e., it bows and warps less than plastic. These features are especially critical when forming elements on a wafer level.
[0084] When placing the master on the substrate, the wafer cannot be brought straight down into contact. This is because air bubbles which adversely affect the embossed product would be present, with no way of removing them.
[0085] Therefore, in bringing the master into contact with the substrate, the master initially contacts just on one edge of the substrate and then is rotated to bring the wafer down into contact with the substrate. This inclined contact allows the air bubbles present in the embossable material to be pushed out of the side. Since the master is transparent, the air bubbles can be visually observed, as can the successful elimination thereof. As noted above, it is the presence of these air bubbles which make it advantageous for the surfaces to be brought into contact be smooth, since the diffractive formed on the surface of the master 48 could trap air bubbles even during such inclined contact.
[0086] The degree of the inclination needed for removing the air bubbles depends on the size and depth of the features being replicated. The inclination should be large enough so that the largest features are not touching the other wafer across the entire wafer on initial contact.
[0087] Alternatively, if the replica wafer is flexible, the replica wafer may be bowed to form a slightly convex surface. The master is then brought down in contact with the replica wafer in the center and then the replica wafer is released to complete contact over the entire surface, thereby eliminating the air bubbles. Again, the amount of bow required is just enough such that the largest features are not touching the other wafer across the entire wafer on initial contact.
[0088] When using the fiducial marks themselves to align the master element 48 to the glass substrate 52 in accordance with the present invention, a conventional mask aligner may be used in a modified fashion. Typically in a mask aligner, a mask is brought into contact with a plate and then a vacuum seals the mask and plate into alignment. However, a vacuum cannot be created when a liquid, such as a polymer, embossable material is on top of a wafer. Therefore, the above inclined contact is used. Once contact is established, the wafers are aligned to one another in a conventional fashion using the fiducial marks before being cured.
[0089] Further, the intensity required to cure the polymer is very high, e.g., 3-5 W/cm 2 , and needs to be applied all at once for a short duration, e.g., less than 30 seconds. If enough energy and intensity are not applied at this time, hardening of the polymer can never be achieved. This is due to the fact that the photoinitiators in the polymer may be consumed by such incomplete exposure without full polymerization. However, it is not easy to provide such a high intensity source with the mask aligner. This is due both to the size and the temperature of the high energy light source required. The heat from the high energy source will cause the mask aligner frame to warp as it is exposed to thermal variations. While the mask aligner could be thermally compensated or could be adapted to operate at high temperatures, the following solution is more economical and provides satisfactory results.
[0090] In addition to the inclined contact needed for placing the master in full contact with the substrate in the mask aligner, once such full contact is achieved, rather than curing the entire surface, a delivery system, such as an optical fiber, supplies the radiation from a UV source to the master-substrate in contact in the mask aligner. The delivery system only supplies UV radiation to individual spots on the polymer.
[0091] The delivery system is small enough to fit in the mask aligner and does not dissipate sufficient heat to require redesign of the mask aligner. When using an optical fiber, these spots are approximately 2 mm. Alternatively, a UV laser which is small and well contained, i.e., does not impose significant thermal effects on the system, may be used.
[0092] The delivery system provides the radiation preferably to spots in the periphery of the wafer in a symmetric fashion. For a 4 inch wafer, only about 6-12 spots are needed. If additional spots are desired for increased stability, a few spots could be placed towards the center of the wafer. These spots are preferably placed in the periphery and a minimal number of these spots is preferably used since an area where a tack spot is located does not achieve as uniform polymerization as the areas which have not been subjected to the spot radiation.
[0093] These tack spots tack the master in place with the substrate. The illumination used for curing the tack spots is only applied locally and there are few enough of these tack spots such that the area receiving the illumination is small enough to significantly affect the rest of the embossable material. Once alignment has been achieved and the master tacked into place, the substrate-master pair is removed from the aligner and then cured under the high intensity UV source over the entire surface for full polymerization. The tack spots prevent shifting of the alignment achieved in the mask aligner, while allowing the substrate-master pair to be removed from the mask aligner to thereby use the high energy light source external to the mask aligner for curing the polymer.
[0094] Alternatively, the fiducial marks may be used to form mechanical alignment features on the perimeter of the surfaces to be contacted. The mechanical alignment features may provide alignment along any axis, and there may be more than one such mechanical alignment feature. For example, the stand-offs in FIG. 4 are for aligning the wafers along the y axis, while the metal pads provide alignment of the wafer pair to additional elements along the x and z axes. The alignment features are preferably formed by the embossing itself.
[0095] The embossing and the lithographic processing on the opposite surface may be performed in either order. If the embossing is performed first, it is advantageous to leave the master covering the embossed layer until the subsequent processing on the opposite surface is complete. The master will then act as a seal for the embossed structure, protecting the polymer from solvents used during lithographic processing and keeping the features accurate throughout heating during lithographic processing.
[0096] If the lithographic processing is performed first, then more precise alignment is required during embossing to provide sufficient alignment to the photolithographic features than is required during normal embossing. Thus, embossing equipment is not set up to perform such alignment. Then, the above alignment techniques are required during embossing.
[0097] Once all desired processing has been completed, the wafer is diced to form the individual elements. Such dicing places mechanical stresses on the embossed wafer. Therefore, full polymerization and sufficient adhesion of the embossed portion to the substrate is of particular importance so that the embossed portion does not delaminate during dicing. Therefore, care must be taken in selecting the particular polymer, an adhesion promoter, and the substrate, and how these elements interact. Preferably, in order to avoid delamination of the embossed layer during dicing, the adhesion of the polymer to the substrate should be approximately 100 grams of shear strength on a finished die.
[0098] When both wafers to be bonded together as shown in FIGS. 1-4 have been embossed with a UV cured polymer, the typical preferred use of a UV epoxy for such bonding may no longer be the preferred option. This is because the UV cured polymer will still highly absorb in the UV region, rendering the available UV light to cure the epoxy extremely low, i.e., in order to provide sufficient UV light to the epoxy to be cured, the intensity of the UV light needed is very high. Therefore, the use of thermally cured resin to bond such wafers is sometimes preferred.
[0099] Alternatively, polymer on the portions not constituting the elements themselves may be removed, and then the UV epoxy could be employed in these cleared areas which no longer contain the UV polymer to directly bond the glass substrate wafer having the UV polymer with another wafer. A preferably way to remove the polymer includes provides a pattern of metal on the master. This metal blocks light, thereby preventing curing of the polymer in the pattern. When a liquid polymer is used, this uncured polymer may then be washed away. Other materials, such as the UV epoxy for wafer-to-wafer bonding or metal for active element attachment or light blocking, may now be placed where the polymer has been removed.
[0100] In addition to the bonding of the two substrates shown in FIGS. 1-4 , the alignment marks may be used to produce optical elements on the other side of the substrate itself, at shown in FIG. 7 . The creation may also occur by any of the methods noted above for creating optical elements. The double sided element 70 in FIG. 7 has a diffractive element 72 on a first surface 70 a thereof and a refractive element 74 on a second surface 70 b thereof, but any desired element may be provided thereon. Again, metal pads 76 may be provided through lithographic processing on the hybrid element.
[0101] A further configuration of an integrated multiple optical elements is shown in FIG. 8 , in which a diffractive element 82 is formed directly on a refractive element 84 . The refractive element may be made by any of the above noted photolithographic techniques. In the specific example shown in FIG. 8 , the refractive element is formed by placing a circular layer of photoresist 86 on a surface of optical material using a mask. The photoresist is then partially flowed using controlled heat so that the photoresist assumes a partially spherical shape 87 . Thereafter, the surface is etched and a refractive element 84 having substantially the same shape as the photoresist 87 is formed by the variable etch rate of the continually varying thickness of the photoresist 87 . The microlens 84 is then further processed to form the diffractive element 82 thereon. The diffractive element may be formed by lithographic processing or embossing.
[0102] The wafers being aligned and bonded or embossed may contain arrays of the same elements or may contain different elements. Further, when alignment requirements permit, the wafers may be plastic rather than glass. The integrated elements which are preferred to be manufactured on the wafer level in accordance with the present invention are on the order of 100 microns to as large as several millimeters, and require alignment accuracies to ±1-2 microns, which can be achieved using the fiducial marks and/or alignment features of the present invention.
[0103] When the optical elements are provided on opposite surfaces of a substrate, rather than bonded facing one another, tolerable alignment accuracies are ±10 microns. This is due to the fact that when light is transmitted through the thickness of the glass, slight amounts of tilt can be corrected or incorporated.
[0104] As an alternative to the fiducial marks used for passive alignment, the fiducial marks may be used to create mechanical alignment features, such as corresponding groves joined by a sphere, metalization pads joined by a solder ball, and a bench with a corresponding recess. Only a few of these alignment features is needed to align an entire wafer.
[0105] All of the elements of the present invention are advantageously provided with metalized pads for ease of incorporation, including alignment, into a system, typically including active elements. The metalized pads may efficiently be provided lithographically on the wafer level.
[0106] An example of active elements, i.e., optoelectronic elements, to be incorporated with the optical elements made in accordance with any of the above embodiments is illustrated below with reference to an optical head.
[0107] FIG. 9A illustrates an optical design schematic of an integrated assembly including a light source 110 , a transmit diffractive optical element (DOE) 106 , a transmit refractive lens 112 , a return refractive lens 108 and a detector 117 . These elements are integrated onto transparent substrates. Light output by the light source 110 is split into a plurality of light beams by the DOE 106 . These beams are delivered to a target surface 114 via the transmit refractive lens 112 . In FIG. 9A , two beams 102 , 104 are shown as an example, although any number may be used. These beams are reflected by the target surface to the detector 17 via the return refractive lens 8 . The detector may include more than one detector, one for each beam, or a single detector with unique areas designated for each beam.
[0108] When the light source is a laser, it is preferably the semiconductor laser chip itself, i.e., not a laser inside a can as typically provided for a macroscopic system. Since the dimensions of the integrated system are much smaller than those for a conventional macroscopic system, the light source must be fairly close to the DOE 106 , so that the beam will not be too large thereon and all of the beam will be received by the DOE 106 . Thus, part of the integrated approach of the present invention preferably includes providing the laser chip or die itself adjacent to a transparent substrate.
[0109] In forming an integrated optical apparatus, the first design was to attempt to simply scale down a macroscopic design. In other words, a single lens was placed in the return path, as shown in FIG. 9A . In a macroscopic configuration, this lens in the return path provides both separation to the beams as well as focusing thereof in order to properly deliver them to the detector.
[0110] In the transmit path from the light source to the detector, the light from the light source 110 is delivered to the DOE on the top surface of the substrate 111 at a distance from the light source 110 . This distance is used to advantage to provide an adequately wide beam at the DOE. The beams formed by the DOE are focused on surface 114 located at a distance from the lens 112 . This distance is chosen to achieve adequate spot size modulation depth and depth of focus at the media surface.
[0111] In the return path from the target 114 to the detector 117 , the 110 refractive lens 118 is located at a distance d 2 from the target and the detector 117 is located a distance d 1 from the refractive lens 118 . The distances d 1 , d 2 are dictated by the substrates 111 , 121 on which these elements are mounted. The ratio of the distances d 1 /d 2 determines the amount of demagnification of the image reflected from the media that occurs in a lens. In using a single lens in the return path, this demagnification affects not only spot size but spot spacing. Assuming, for example, a spot size of 0.020 mm on the target 114 , a demagnification of ¼ gives a spot size of 0.005 mm which because of aberration is spread to an area 0.025 mm. When a single lens in the return path is used, as shown in FIG. 9A , the spacing of the spots is demagnified to 0.025 mm and significant crosstalk noise results. This can be seen by the overlapping beams in the plane of the detector 117 in FIG. 9A . The overlapping of the beams also occurs at the return refractive lens 118 . In order for the refractive lens to image the beams at a point at which they are sufficiently separated such that the beams will be distinguishable on the detector 117 , the return refractive lens 118 would have to be placed closer to the target 114 . However, such positioning would destroy the desired integrated nature of the optical apparatus.
[0112] In this configuration, in order for the return refractive lens 118 to properly focus the beams, the angles of the beams 102 , 104 need to be as small as possible and as similar as possible, so that these beams may both impinge upon a central portion of the return refractive lens 118 . In the relative scale of FIG. 9A , using the distances from the top surface of the top substrates to the target, the angle of beam 102 is 5.6 degrees and the angle of beam 104 is 6.9 degrees. However, the beams 102 , 104 also need to be sufficiently separated on the detector 117 . These two design constraints cannot be met using the single refractive lens 118 for receiving all of the beams in the return path while providing an integrated optical apparatus.
[0113] FIG. 9B is an alternative configuration created by recognizing that by providing larger angles to the light beams and providing greater difference between the angles of the light beams, the need for an optical element in the return path so could be eliminated. In other words, the separation between the light beams 102 , 104 in FIG. 9B is sufficient such that the beams remain separate and distinguishable on the detector 117 without requiring an optical element in the return path to provide this separation. In FIG. 9B , the angle of beam 102 is 8 degrees and the angle of beam 104 is 11 degrees.
[0114] In FIG. 9B , the distance between the top surfaces of the top substrates and the target 114 is the same as it was in FIG. 9A . This clearly results in the beams being further separated on the target 114 . For many applications, this increased separation is not a problem, but for those for which a particular separation is desired, the integrated optical head can be positioned closer to the target 114 .
[0115] While the configuration shown in FIG. 9B is advantageous for integrated apparatuses, for many applications, the complete elimination of optical elements in the return path results in an unacceptable level of noise. A solution, an example of which is shown in FIG. 9C is to include separate optical elements for each beam in the return path. The ability to use more than one optical element in the return path can be realized due to the increased separation between the beams. The feasibility of such a solution, requiring more than one optical element for each beam, is facilitated by the passive alignment discussed in detail below.
[0116] FIG. 9C is an optical design schematic of an assembly according to the invention for use in, for example, detecting an optical track on a storage media. A light source 110 directs coherent light, with a dispersion angle of fifteen degrees, upward through an object distance d 1 through a diffractive element (DOE) not shown and to a refractive lens 112 . The DOE divides the light into a number of beams, only three of which are shown as a plurality of rays in FIG. 9C . The beams are focused on surface 114 located at an image distance from the lens 112 . The spot size and spacing of the light on the image surface 114 determines the tracking accuracy and therefore the amount of information that can be stored on the media. The size to which the spot can be reduced is in the instant design, approximately 0.020 mm. In the design of FIG. 9C , the refractive lens 112 must have a significant curvature in order to focus the light to 0.020 mm spots on the media. The spots of light are spaced approximately 0.100 mm from each other on the media to limit crosstalk noise. As would be readily understood by those skilled in the art the optical head can be positioned by the illustrated positioning means 129 .
[0117] Preferably, all optical elements needed to create the more than one beam, direct the beams onto the target and direct the beams from the target to the detector are on the substrate and/or any structure bonded thereto, thereby providing an integrated optical apparatus. Preferably, any optical elements in both the return path and the transmit path are less than 500 microns in diameter, more preferably, less than 300 microns in diameter. The actual size of the elements will be dictated by the overall size of the device with which the integrated optical apparatus is to be used, with a lower practical limit being on the order of a wavelength.
[0118] If a design were attempted using a single lens as taught in the prior art where the elements are not integrated, the lens curvature required to focus the laser light to 0.020 mm spots in this compact architecture would control the dimensions of the single lens. Thus the use of a single lens as taught in the prior art for reducing the size of optical heads, is a limiting factor in size reduction of the entire optical head assembly. This factor is one of the reasons that multiple lenses are employed in the instant invention instead of a single lens. The use of multiple lenses is enabled by having the separation between the beams be sufficient so that each beam is incident only on one of the lenses in the return path.
[0119] The ratio of the distances d 1 /d 2 determines the amount of demagnification of the image reflected from the media that occurs in a lens. In a single lens design, this demagnification affects not only spot size but spot spacing. A demagnification of ¼ gives a spot size of 0.005 mm which because of aberration is spread to an area 0.025 mm. If a single lens design had been used, the spacing of the spots would also have been demagnified to 0.025 mm and significant crosstalk noise would result. By using individual lenses, spaced approximately 0.200 mm, the detectors can be spaced at about 0.220 mm and thereby eliminate crosstalk noise using the 0.025 mm light spots.
[0120] Thus, by providing increased separation to the beams in the transmit path, separate optical elements for each beam's return path may be used, thus allowing proper focusing of the beams on the detector. Further, such separate elements are more readily integrated into a compact system. In an integrated system, it is advantageous to place the grating on the media as close to the light source as possible, but separation between the beams needs to be maintained. If the distance is too small, in order to maintain the separation, a bigger angular deflection is required. Then the beams are more spread out and the system will become too large in the x-y direction (with z being in the plane of the paper). This spread also increases the aberrations. Therefore, the angles need to be as small as possible, while maintaining separation even over the small distance from the light source and to the detector.
[0121] FIG. 10 is a side view of a magnetic floppy disk head 105 with an optical tracking assembly according to a preferred embodiment of the invention. Head 105 is mounted, in arm 103 by known means not shown, for the extension across the various tracks of media 114 . Head 105 is electrically connected to read and write circuits and tracing control circuits by a flexible printed circuit 107 . A recess 9 of approximately two millimeters by one point six millimeters and four and a half or five millimeters deep is provided in head 105 in which the optical assembly comprising substrate 111 is mounted and connected to flexible printed circuit 107 . It will be appreciated that the same assembly techniques and methods of the invention may be used to assemble optical disk read heads, as well as magnetic disk heads with optical tracking.
[0122] Referring now to FIG. 11 , a first transparent substrate 111 comprising fused silica or other optical material has component mounting metalized pads or contact pads placed on its bottom surface 113 , such as using substrate fiducial marks or indicia and accurately aligned photolithographic masks and metal deposition steps known in the art of microelectronic circuit manufacture. In this preferred embodiment, surface 113 of substrate 111 is approximately 1.6 mm by 2 mm and the substrate 111 is approximately 0.8 mm thick. A laser chip 115 is mounted to the surface 113 by means of some of the mentioned metalized pads. As shown in FIG. 11 , laser 115 is an edge emitting laser with the laser light directed upwards through means of a precision mirror 133 as shown in FIG. 12 . It will by understood that the edge emitting laser 115 can be replaced with a vertical cavity surface emitting laser and thereby obviate the need for the precision mirror in order to direct the laser beam normal to the substrate surface.
[0123] An optical detector chip 117 is also mounted to the component surface of substrate 111 by means of the metalized pads. A hologram surface 119 on the opposite side of substrate 111 carries the diffractive optical elements shown in detail in FIG. 14 . The diffractive optical element phase profiles are designed using the computer calculations and manufactured using techniques taught by Swanson et al. in U.S. Pat. No. 5,161,059, the entire disclosure of which is incorporated herein by reference.
[0124] The optical elements are created photolithographically using the same fiducial marks or indicia used to place the metalized pads. Alternately second fiducial marks that have been aligned with the first marks may be used to align the masks that are also used to create the optical elements. In this way, when the light source, mirror and detector are mounted on their metalized pads, the optical paths among the devices and through the optical elements are in optical alignment as shown more clearly in FIGS. 11A and 11B . The precision mirror, if needed for redirecting light from an edge emitting laser, is considered to be a device for the purposes of this description only because of the way it is mounted using metalized pads and solder as a silicon chip would be mounted. The hologram surface 119 also has the attachment areas 123 that attach the first transparent substrate 111 with a second transparent substrate 121 .
[0125] The second substrate 121 carries the refractive optics in a surface 125 that provides the second lens of lens pairs or doublets. Light from laser 115 is shaped and split by a diffractive optical element in hologram surface 119 into five separate beams of light that are directed through substrate and travel approximately 2.4 mm to the media. Only the chief ray of each beam is shown in FIG. 11A for clarity of the description. One beam is used for intensity feedback to control the electrical power to laser 115 . The other four beams are used for media position or tracking detection. The beams of coherent light are reflected from media 114 and return through second substrate 121 and first substrate 111 to be detected by detector 117 . Since the elements are all in their designed optical alignment by virtue of the placement of the metalization pads, there is no need to energize the laser and move the elements relative to each other to bring them into optical alignment. In other words, passive alignment is used rather than the active alignment requiring operation of the laser as in the prior art. It will be recognized that although the beams preferably pass first through the diffractive optical element in surface 119 , the order of the optical elements in the light path could be changed or the elements could be combined into one more complex element without departing from the scope of the invention.
[0126] FIG. 11B is another side view of the assembly of FIG. 11A . As shown in FIG. 11B , the light emitted by edge emitting laser 115 comes out substantially parallel to the plane of component surface 113 and must be directed normal to the component surface by the 45 degree surface of mirror 133 . The light can then pass through substrate 111 , a diffractive optical element in surface 119 , a refractive lens 161 in surface 125 , substrate 121 and be reflected from media 114 as shown in FIGS. 9A-9C and 11 A.
[0127] FIG. 12A is a plan top view of the component surface 113 looking down through transparent substrate 111 . Electrical contact metalizations 139 , 141 , 143 and 145 provide electrical connections to detecting photo-diodes in detector 117 . Centered under detector 117 is a metalized area 153 having three apertures through which light reflected from media 114 is received. Solder ball alignment areas 147 on each side of area 53 serve both as electrical contacts and as alignment mechanisms in this embodiment. The areas 149 are also solder balls or pads which serve to align and connect the laser 115 to the first substrate and provide current to laser 115 . Areas 151 on the other hand only provide mechanical alignment and mechanical attachment of mirror 133 to first transparent substrate 111 .
[0128] The hologram surface 119 appears in FIG. 12B in plan view, again looking down onto substrate 111 . Hologram surface 119 has metalized area 155 which acts as a mask to reduce stray light but allow three beams created by diffractive optics from the light from laser to be directed to media 114 from which they are reflected to reach detector 117 through the five apertures shown in metalized areas 159 . Surrounding metalized area 155 is a diffraction grating 157 that scatters stray light from laser 115 so that it does not adversely affect detector 117 .
[0129] FIG. 12C shows the refractive lens surface 125 , again in plan view looking down, this time through substrate 121 . Lens 161 in combination with the diffractive optical elements in mask 155 shape and focus the laser light into three spots of approximately 20 mm diameter and spaced at approximately 100 microns onto media 14 . Lenses 163 and 165 focus the light reflected from media 114 through mask 159 to detector 117 for position control and/or reading. Lens 167 focuses reflected light to the photo-diode of detector 117 that provides an intensity level signal to the power control circuits which control the electrical power provided to laser 15 . Surrounding both surface 119 and surface 125 is an attachment area shown generally as area 171 in FIGS. 12B and 12C . Area 171 contains spacing stand off benches and is the area in which an adhesive is placed in order to join substrate 121 . The standoff benches passively define a proper or desired vertical spacing or alignment. Preferably the adhesive is ultraviolet light cured adhesive that can be laid down without concern for time to harden. The adhesive is placed in areas 171 and then after the substrates 111 and 121 are aligned, the assembly is flooded with ultra-violet light to catalyze the adhesive. In an alternate embodiment, the adhesive is replaced with photolithographically placed metalization pads and the two substrates are joined using solder ball technology.
[0130] FIG. 12B also shows three diffractive optical elements 173 , 175 with mask 155 . These three elements 135 provide the five beams of light to be reflected from the media, the three main rays of which are shown in FIG. 11A . Element 175 provides the power control beam that is reflected from the media and is received at aperture 179 in mask 159 as shown in FIG. 12B . Elements 173 and 177 each provide two beams that interfere at the media surface to create a dark band with two light bands on either side of the dark bands. The light bands are reflected back down to the pairs of apertures 181 , 183 and 185 , 187 shown in FIG. 12C to provide the varying light intensity that is used to detect an optical track on the media. The apertures 173 , 175 and 177 containing diffractive elements are each approximately 100 microns long and 20 microns wide.
[0131] FIG. 13 illustrates an alternative to providing separate refractive elements in each return path. In FIG. 13 , each refractive element in the return path has been replaced with a diffractive element 39 . The refractive element in the transmit path has also been replaced with a diffractive element 137 for splitting radiation output by the radiation source 115 , and delivered to the diffractive element 137 via the precision mirror 133 . The diffractive element 137 provides separation to the beams delivered to the grating on the surface 114 . The use of diffractive elements in the return path is typically not as advantageous as refractive elements. The diffractive elements are more wavelength dependent and less efficient for larger angles.
[0132] Also in FIG. 13 , as well as FIGS. 14-15 , the active elements are mounted on a support substrate 131 , preferably a silicon substrate. This support substrate 131 also serves as a heat sink for the active elements mounted thereon. Attachment areas 123 separate the substrate 131 from the substrate 111 on which the diffractive elements 137 , 139 are mounted. The active elements may be mounted support substrate 131 using passive alignment in a similar manner as discussed above regarding the mounting of these elements on the transparent substrate 111 . The attachment areas 123 can be provided by etching a recess into the support substrate 131 in which the laser 115 , the detector 117 , and the optional mirror 133 may be provided. In other words, the unetched portions of the substrate 131 serve as attachment areas 123 . The substrates 111 , 131 may then be bonded with solder material 127 . Further, an angled sidewall of the substrate adjacent the recess therein can serve as the mirror 133 . Alternately, the attachment areas 123 may include spacer block separate from the substrate 131 , as shown in FIGS. 14 and 15 . The mirror 133 can be a separate element from the spacer blocks, as shown in FIG. 14 or can itself serve as a spacer block, as shown in FIG. 15 .
[0133] As shown in FIG. 14 , another embodiment of the present invention is directed to employing no optical elements in the return path. The diffractive element 137 in the transmit path is designed to provide sufficient spread to the radiation such that the beams incident on the detector 117 are still distinguishable. This is facilitated by the provision of a refractive element 119 on an opposite surface of the substrate 111 from the diffractive element.
[0134] FIG. 15 illustrates yet another embodiment in which no optical elements are used in the transmit path. In FIG. 15 , the refractive element 119 is mounted opposite the diffractive element 137 on a further substrate 121 .
[0135] Alternatively, a single surface hybrid element as illustrated in FIG. 8 may be used in the transmit path, for example, in place of the two surface hybrid element shown in FIG. 14 .
[0136] In the structures of all of the figures discussed throughout having more than one substrate, all of the substrates may be passively aligned and attached using patterns formed photolithographically as discussed below. While the following discussion references the transparent substrates 111 , 121 , the support substrate 131 may also be aligned in an analogous fashion. When aligning the support substrate containing active elements, the integrated optical apparatuses shown in FIGS. 13-15 may be formed by passively aligning a support wafer having a plurality of active elements thereon with a transparent wafer having a corresponding plurality of optical elements. This support-transparent wafer pair may then be diced apart. Alternatively, the support wafer can be diced and individual laser/detector assemblies aligned and attached to the transparent wafer such as by flip-chip attachment. By first forming individual active assemblies, the lasers can be tested separately.
[0137] FIG. 16 shows the two transparent substrates 111 and 121 prior to their being assembled into optical assemblies and diced. Because each element has been accurately placed on each substrate using photolithography, the entire wafers can be aligned and joined prior to being diced into chips without the need to energize any of the laser devices on the substrate 111 . FIG. 16 shows the substrates inverted from the way they are shown in FIGS. 10 , 11 A and 11 B in order to show the lasers, mirrors and detectors in place on top of each die. Of course, if the support substrate 131 being aligned with one or both of the transparent substrates, to form the configurations shown in FIGS. 13-15 , these active elements are not on the top of the wafer 111 .
[0138] Prior to putting the wafers together, the adhesive material, e.g., ultra-violet curable solder, is placed in the area 171 of each die on at least one of the wafers. After the adhesive is placed, the two wafers are placed one above the other and aligned. In one embodiment of the invention, a known photolithographic mask aligning tool is used with vernier fiduciary marks 193 and 195 to monitor the relative displacement of the two substrates until they are in alignment with each other. The substrate 111 can then be lowered onto substrate 121 , the alignment—rechecked, and the adhesive catalyzed by ultraviolet light.
[0139] In another embodiment, the two wafers are passively aligned using mechanical mating elements 191 . Three forms of mechanical mating elements, in addition to the spacer block previously discussed, are contemplated and shown in FIGS. 17A , 17 B and 17 C. One, shown in FIG. 17A , takes the form of V-shaped grooves 197 etched into matching faces of the substrates 111 and 121 . These grooves 197 are then aligned with sphere 199 to index the two wafers into alignment. Note that only a few grooves and spheres are needed to align all of the dies while they are still together as a wafer. Another embodiment of the alignment means, shown in FIG. 17B , comprises photolithographically placed metalization pads 201 which are then connected by reflowing a solder ball 203 . Alternatively, the metalization pads 201 may be solder, without the need for the solder ball 203 . In a still further embodiment of FIG. 17C , a bench 205 is raised by etching the surrounding surface and the bench 205 is indexed into a recess 207 , also created by photolithographically placed etchant, preferably reactive ion etchant.
[0140] In the adhesive area 171 of each die, means may be needed to accurately space the two substrates from each other. Spacing is accomplished in one embodiment by means of a bench 209 shown in FIG. 17D . Three or more benches 209 may be located in the area 171 around each die in an adhesive with high compressive. In another embodiment, the solder bumps or balls and metalizations are used in area 203 accomplishing both attachment and alignment as shown in FIG. 17B . Alternately, when an adhesive with high compressive strength is chosen, only three or more such benches are needed for spacing the entire wafers and after the adhesive has set, the joined wafers can be diced without substrate spacing.
[0141] Having described the invention in terms of preferred embodiments thereof, it will be recognized by those skilled in the art of optical system design that various further changes in the structure and detail of the implementations described can be made without departing from the spirit and scope of the invention. By way of example, the diffractive optical elements may be placed on the same surface of a substrate on which the electronic components are accurately placed with these diffractive optical elements using photolithography. Likewise refractive optical elements may be placed using photolithography in alignment on the other surface of the same substrate thereby allowing an entire optical assembly to be fabricated using but one substrate without the need for actively energizing a light source in the assembly to accomplish alignment.
[0142] The invention being thus described, it would be obvious that the same may be varied in many ways. Such variations are not regarded as a departure from the spirit and scope of the invention, and such modifications as would be obvious to one skilled in the art are intended to be included within the scope of the following claims. | An integrated optical imaging system includes a first substrate having first and second opposing surfaces, a second substrate having third and fourth opposing surfaces, a spacer between a substantially planar portion of the third surface of the second substrate and a substantially planar portion of the second surface of the first substrate, at least two of the spacer, the first substrate and the second substrate sealing an interior space between the third surface of the second substrate and the second surface of the first substrate, and an optical imaging system having n surfaces, where n is greater than or equal to two, at least two of the n surfaces of the optical imaging system are on respective ones of the first, second, third and fourth surfaces. | 74,922 |
TECHNICAL FIELD
[0001] The present invention relates to a server and a method for providing content to users.
BACKGROUND OF THE DISCLOSURE
[0002] A variety of content distribution systems have been developed in the past. One such content distribution systems is a “content delivery network or “CDN”. CDNs have been utilized by content providers on behalf of third parties. Specifically, CDNs have been used for storing, caching, or transmission of content such as web pages, streaming media and applications.
[0003] FIG. 1 is a schematic diagram illustrating a server (network) system 1 as the perspective view of the Pyramid comprising a Main server 2 , a Root server 3 , a Midgress server 4 , an Edge server 5 and terminals 61 to 68 .
[0004] The main server 2 is a controller and/or operator of this server system 1 . It explicates that main server 2 will control the operation of the system from “Top to Bottom” by transmitting the instruction, content such as media content through server system 1 . The Root server 3 is the top level server of a cache server. For example, the Root server 3 is installed in continental areas i.e. North America, South East Asia, and Europe etc., as Regional servers. The Routings of data (content) are performed based on a routing table and a DNS configuration on the network.
[0005] The Midgress server 4 is the middle level server of the cache server. For example, Midgress server 4 is installed in country areas i.e. USA, Japan, Taiwan, Thailand and etc., as Country servers. The Edge server 5 is the low level server of the cache server. Moreover, The Edge server 5 is the nearest server which user can receive and/or transmit the data (content) to the server system 1 . For example, the Edge server 5 is installed in city areas, i.e. San Diego, Tokyo, Taipei, and Bangkok etc., as local servers. Terminals 61 to 68 comprise a desktop PC, a notebook PC, a mobile phone, a tablet, a smartphone and the like. Users or customers are able to communicate and/or receive and/or transmit data (content) with the server system 1 using these terminals. Terminals 61 to 68 are installed applications and are registered as system accounts and/or members of the server system 1 .
[0006] The procedure of operation system can be explicated as following: First, the Main server 2 transmits an instruction or content to the Root server 3 , then, the Root server 3 forwards the instruction or content to the Midgress server 4 . Afterwards, the Midgress server 4 transmits the instruction or content to the Edge server 5 , and at the end of process, the Edge server 5 transmits the content to the terminals 61 to 68 . In other words, the Edge server 5 is the most appropriate server in terms of location, for example the nearest access server, to the terminals 61 to 68 .
[0007] FIG. 2 is a schematic diagram illustrating a basic data flow in the server system 1 of FIG. 1 . To show how the server system 1 operates according to the ideas of “Top to Bottom” through Multi-layer structure of a cache server. As shown in this figure, the Cache server 8 may include the Root server 3 , the Midgress servers 41 to 42 , and the Edge servers 51 to 54 . In this way, “Data (Content) is transmitted to terminal users 1 - 8 via the Multi-layer structure of cache server 8 ”. For example, the Root server 3 receives data (content) from an storage origin 7 , then, the Root server 3 forwards the received data (content) to the Midgress servers 41 to 42 . Afterwards, the Midgress servers 41 to 42 transmit the forwarded data (content) to the Edge servers 51 to 54 . At the end of this process, terminals 61 and 62 may receive data (Content) from the Edge server 51 . Terminals 63 and 64 may receive data (Content) from the Edge server 52 . Terminals 65 and 66 may receive data (Content) from the Edge server 53 . And, terminals 67 and 68 may receive data (Content) from the Edge server 54 . This could also explain that each of the terminals 61 - 68 may receive data (content) from their nearest edge server.
[0008] It should be noted that the definition of the term “request” used in the present specification is “a request to confirm whether there is any message in the Main server 2 ”. In a case where, there is a text message, the Main server 2 directly provides the text message to a terminal. On the other hand, if there is a request for content, the Main server 2 provides the terminal with a URL of the Storage origin 7 in which the content is stored. Thereby, the terminal accesses the Storage origin 7 thorough the CDN using the provided URL and gets the requested content stored therein.
[0009] FIG. 3 is a schematic diagram illustrating a prior art data flow diagram in the server system of FIG. 1 , when a user requests data from the server system 1 . In a case where the data is a text message, user No. 1 sends a request to the Main server 2 through the terminal 61 . That is, user No. 1 confirms whether there is any message for the terminal 61 in the Main server 2 . If there is any message, the Main server 2 will directly provide the message(s) to the terminal 61 based on the request (confirmation) of user No. 1 . On the other hand, if the requested data is content(s) such as media content, the requested content which has been stored in the Storage origin 7 is provided to the terminal 61 via the cache server 8 when the Main server 2 receives the request from terminal 61 . If the user No. 1 sends a request for content to the main server 2 through the terminal 61 , the Main server 2 allows the Storage origin 7 to transmit the requested content to the terminal 61 via the Cache server (Multi-layers) 8 . This may also be explained as follows: the Root server 3 receives the content from the Storage origin 7 . Then, the Root server 3 forwards the content to the Midgress server 41 . Afterwards, the Midgress server 41 transmits the content to the Edge server 51 . At the end of process, the content is provided to the terminal 61 by the Edge server 51 . During the process, cache of content is stored (cached) in each cache server, in which the content has been passed through.
[0010] When another user, i.e. No. 2 , requests the same content thorough the terminal 62 , the user No. 2 may receive the requested content from the Edge server No. 1 51 . However, when another user, such as for example the user No. 8 , requests the same content through the terminal 68 , the route is longer, therefore the transmission takes longer time. For example, first, the terminal 68 accesses the Edge server 54 (No. 4 ). However, the edge server 54 (No. 4 ) fails to receive the content. Next, the edge server 54 (No. 4 ) will access the Midgress server 42 (No. 2 ).
[0011] In addition, when a user of any messenger service may access a group of cache servers for the first time to get a requested content, the user has to access the Storage origin 7 to receive the content. This is mainly due to the fact that the cache of content is not stored in the cache servers in the route of the user's request (continued to fail, that is, “cache miss”), and thus, it causes time delay to get the requested content.
SUMMARY OF THE INVENTION
[0012] Therefore, an object of the present invention is to provide a server and a method for providing content to users immediately with less cache miss.
[0013] In accordance with one aspect of the present invention, a method for providing content to a user includes the steps of receiving information from a terminal of the user and transmitting a cache of content related to the user to a cache server related to the terminal based on the information such that the terminal receive the cache content from the cache server upon the request of the user.
[0014] In accordance with a second aspect of the present invention, a server is provided for delivering content. The server includes information registration part for storing information received from a terminal of a user; and a transmission part that sends content related to the user to a cache server related to the terminal of the user.
[0015] In accordance with a third aspect of the present invention, a method for providing content to a user includes the steps of sending content associated with a user terminal to a cache server from a main server; storing the content in a content database of the cache server; and sending the content to the user terminal from the cache server based on a user request.
BRIEF DESCRIPTION OF DRAWINGS
[0016] FIG. 1 is a schematic diagram illustrating a server (network) system.
[0017] FIG. 2 is a schematic diagram illustrating a basic data flow in the server system of FIG. 1 .
[0018] FIG. 3 is a schematic diagram illustrating a prior art data flow diagram in the server system of FIG. 1 .
[0019] FIG. 4 is a schematic diagram illustrating an embodiment of data flow in the server system of FIG. 1 .
[0020] FIG. 5 is a schematic diagram illustrating another embodiment of data flow in the server system of FIG. 1 .
[0021] FIG. 6 is a schematic diagram illustrating yet another embodiment of data flow in the server system of FIG. 1 ;
[0022] FIG. 7 is a schematic diagram illustrating yet another embodiment of data flow in the server system of FIG. 1 .
[0023] FIG. 8 is a flowchart illustrating operation steps of a main server.
[0024] FIG. 9 is a flowchart illustrating operation steps of the main server after the flow of FIG. 8 .
[0025] FIG. 10 is a flowchart illustrating operation steps of a cache server;
[0026] FIG. 11 is a block diagram illustrating a configuration of a main server.
[0027] FIG. 12 is a block diagram illustrating a configuration of a cache server.
DETAILED DESCRIPTION OF THE INVENTION
[0028] The present invention describes in the detail below with the reference to the drawings. As those skilled in the art will recognize, the foregoing description merely refers examples of the invention for overview purposes. It is not limiting and the description may be realized in a variety of systems and methods.
[0029] FIG. 4 is a schematic diagram illustrating one embodiment of data flow diagram in the server system of FIG. 1 , when an end user sends a request for content to the server system 1 . The user terminal 61 also sends specific information to the Main server 2 with confirmation of message from the end user at the same time. The specific information may include identity information of the cache server in a network communicating to the terminal such as an IP address etc. The Main server 2 then receives the specific information from the user terminal 61 , and will recognize the cache server, which is related to the user terminal 61 .
[0030] Therefore, when the Storage origin 7 receives the content which will be sent to the user terminal 61 from another user or service provider, the Storage origin 7 transmits the content to the cache server related to the user terminal 61 . Additionally, the Storage origin 7 transmits a content URL, which is linked to the Storage origin 7 , to the Main server 2 before the user terminal 61 sends a request for message and/or content. For example, when the user terminal 61 sends a request for new message(s), the Main server 2 transmits the content URL to the user terminal 61 and the user terminal 61 will access the Storage origin 7 using the content URL. Finally, the content will be transmitted from the Storage origin 7 to the Root server 3 , Midgress server 41 (No. 1 ), and Edge server 51 (No. 1 ) sequentially, and will be stored in each of the Root server 3 , the Midgress server 41 (No. 1 ), and the Edge server 51 (No. 1 ) respectively. In this embodiment, the Edge server 51 (No. 1 ) is the nearest server which is located in direct contact with the user terminal 61 of the end user No. 1 . Therefore, the user terminal 61 may receive immediately the requested content from the Edge server 51 (No. 1 ) without complicated routing upon receiving the user request from the end user No. 1 , with a first attempt to download.
[0031] Similarly, each of the user terminals 62 to 68 may send information, such as for example IP address of each the Edge servers 51 to 54 with which they are in direct contact, to the Main server 2 with any request of message or content. It should be noted that the Main server 2 recognizes the cache server (Edge server) related to the user terminals 62 to 68 , respectively.
[0032] Therefore, when the Storage origin 7 receives content which will be sent to the user terminals 62 to 68 from another user or service provider, the Storage origin 7 will transmit the content to the cache servers related to the user terminals 62 to 68 , respectively. Additionally, the Storage origin 7 transmits the content URL which is linked to the Storage origin 7 to the Main server 2 before any of the user terminals 62 to 68 sends a request for message and/or content, respectively. For example, when the user terminals 62 to 68 sends a request for new message(s), the Main server 2 transmits the content URL to the user terminals 62 to 68 and the user terminals 62 to 68 may access the Storage origin 7 using the content URL.
[0033] Finally, when the Storage origin 7 receives content which will be sent to, for example, the user terminal 62 , the content will be transmitted from the Storage origin 7 to the Root server 3 , the Midgress server 41 (No. 1 ), and the Edge server 51 (No. 1 ) sequentially, and will be stored in each of the Root server 3 , the Midgress server 41 (No. 1 ), and the Edge server 51 (No. 1 ) respectively. In this embodiment, the Edge server 51 (No. 1 ) is the nearest server which is in direct contact with the user terminal 62 , end user No. 2 related to the content. Therefore, the user terminal 62 may receive the content from the Edge server 51 (No. 1 ) immediately without complicated routing upon receiving the request for content from the end user No. 2 , with a first attempt to download.
[0034] In the same manner, when the Storage origin 7 receives content which will be sent to the user terminal 63 related to the end user No. 3 or the user terminal 64 related to the end user No. 4 , the content will be transmitted from the Storage origin 7 to the Root server 3 , the Midgress server 41 (No. 1 ), and the Edge server 52 (No. 2 ) sequentially, and will be stored in each of the Root server 3 , the Midgress server 41 (No. 1 ), and the Edge server 52 (No. 2 ) respectively. In this embodiment, the Edge server 52 (No. 2 ) is the nearest server which is in direct contact with both of the user terminals 63 and 64 from the end users No. 3 and No. 4 related to the content. Therefore, the user terminals 63 and 64 may receive the content from the Edge server 52 (No. 2 ) immediately without complicated routing upon receiving the request for content from the end users No. 3 and No. 4 , respectively, with a first attempt to download.
[0035] Furthermore, when the Storage origin 7 receives content which will be sent to the user terminal 65 related to the end user No. 5 or the user terminal 66 related to the end user No. 6 , the content will be transmitted from the Storage origin 7 to the Root server 3 , the Midgress server 42 (No. 2 ), the Edge server 53 (No. 3 ) sequentially, and will be stored in each of the Root server 3 , the Midgress server 42 (No. 2 ), and the Edge server 53 (No. 3 ) respectively. In this embodiment, the Edge server 53 (No. 3 ) is the nearest server which is in direct contact with both of the user terminals 65 and 66 from the end users No. 5 and No. 6 related to the content. Therefore, the user terminals 65 and 66 may receive the content from the Edge server 53 (No. 3 ) immediately without complicated routing upon receiving the request for content from the end users No. 5 and No. 6 , respectively, with a first attempt to download.
[0036] In addition, when the Storage origin 7 receives content which will be sent to the user terminal 67 related to the end user No. 7 or the user terminal 68 related to the end user No. 8 , the content will be transmitted from the Storage origin 7 to the Root server 3 , the Midgress server 42 (No. 2 ), the Edge server 54 (No. 4 ) sequentially, and will be stored in each of the Root server 3 , the Midgress server 42 (No. 2 ), and the Edge server 54 (No. 4 ) respectively. In this embodiment, the Edge server 54 (No. 4 ) is the nearest server which is in direct contact with both of the user terminals 67 and 68 from the end users No. 7 and No. 8 related to the content. Therefore, the user terminals 67 and 68 may receive the content from the Edge server 54 (No. 4 ) immediately without complicated routing upon receiving the request for content from the end users No. 7 and No. 8 , respectively, with a first attempt to download.
[0037] In another embodiment, the Main server 2 may receive location information of end users 1 - 8 from the user terminals 61 - 68 , and determine the cache server which is most suitable for the specific user terminals. That is, the Main server 2 may determine IP address of an adequate edge server based on the location information of the end user.
[0038] In yet another embodiment, the information may include routes to the network and/or patterns of use. In this embodiment, the Main server 2 determines the cache server 8 related to the user terminal based on the received information from the user terminal. By way of examples, the routes to the network may include a WiFi network and a cellular network, e.g., 3G line. In a case where the end user changes the WiFi network and/or to the 3G line, the Main server 2 may determine the cache server related to the user terminal based on the information about the routes to the network. In this way, the user terminal can transmit the information of edge server with a request for the content or message to the Main server 2 only when the change occurs, such as for example when the end user moves to another location, and therefore, the network is changed, etc.
[0039] Patterns of use may include different user terminals such as, for example, personal computers (PCs), smartphones, or any other communication devices that may be used during day or night. For example, user terminals at office are used during the day, and other terminals at home are used during the night. In this embodiment, the Main server 2 may determine the cache server related to the user terminal based on information related to the patterns of use. The reception frequency of the information is not limited in particular. For example, the Main server 2 may receive the information from the user terminal periodically. However, in consideration of loads of the server, it is preferable to receive the information when a change of the information occurs.
[0040] FIG. 5 is a schematic diagram illustrating another embodiment of data flow in the server system of FIG. 1 , when an end user requests content from the server system 1 . In this embodiment, a case is explained there the Storage origin 7 receives content which would be sent to the end users No. 1 and No. 8 . For example: the user terminals 61 and 68 send information such as, for example, the IP address of each of the Edge servers with which they are in direct contact with respect to Main server 2 . The Main server 2 , then, recognizes the cache server (Edge server) related to the user terminal 61 and the user terminal 68 based on the received information, respectively.
[0041] Therefore, when the Storage origin 7 receives content which would be sent to the user terminals 61 and 68 from another user or service provider, the Storage origin 7 transmits the content to the cache server related to the user terminal 61 and the user terminal 68 , respectively. And, the Storage origin 7 transmits content URL which is linked to the Storage origin 7 to Main server 2 before the terminal 61 and terminal 68 send a request for message and/or content respectively. For example, when terminal 61 and terminal 68 request new message(s), Main server 2 transmits the content URL to the user terminal 61 and the user terminal 68 . Then, the user terminals 61 and 68 access the Storage origin 7 through the content URL.
[0042] Finally, the content is transmitted from the storage origin 7 to the Root server 3 , the Midgress server 41 (No. 1 ), and the Edge server 51 (No. 1 ) sequentially, and will be stored in each of the Root server 3 , the Midgress server 41 (No. 1 ), and the Edge server 51 (No. 1 ) respectively. In this embodiment, the Edge server 51 (No. 1 ) is the nearest edge server or in direct contact with the user terminal 61 . Furthermore, the content is transmitted from the storage origin 7 to the Root server 3 , the Midgress server 42 (No. 2 ), and the Edge server 54 (No. 4 ) sequentially, and stored in each of the Root server 3 , the Midgress server 42 (No. 2 ), and the Edge server 54 (No. 4 ) respectively. In this embodiment, the Edge server 54 (No. 4 ) is the nearest edge server or is in direct contact with the user terminal 68 . Therefore, the user terminal 61 can receive the content from the Edge server 51 (No. 1 ) immediately without complicated routing upon receiving the request from the user No. 1 with the first attempt for download. And, the user terminal 68 can receive the content from the Edge server 54 (No. 4 ) and immediately without complicated routing upon receiving the request from the user No. 8 , with the first attempt for download.
[0043] FIG. 6 is a schematic diagram illustrating another embodiment of data flow in the server system of FIG. 1 , when an end user requests content from the Main server 2 . In this embodiment, the Storage origin 7 receives content which would be sent to the end user No. 1 , end user No. 3 , end user No. 5 , and the end user No. 7 . For example, it is assumed that in this embodiment, the end users No. 1 , No. 3 , No. 5 and No. 7 belong to the same SNS group, or enroll in the same account for the corporate advertising. By way of example, the user terminals 61 , 63 , 65 and 67 send information such as the IP address of each of Edge servers with which they are in direct contact to the Main server 2 . The Main server 2 , then, recognizes the cache server (Edge server) related to the user terminals 61 , 63 , 65 , and 67 based on the information, respectively.
[0044] Therefore, when the Storage origin 7 receives content which would be sent to user terminal 61 , 63 , 65 , and 67 from another end user or service provider, the Storage origin 7 transmits the content to the cache server related to user terminals 61 , 63 , 65 , and 67 , respectively. And, the Storage origin 7 transmits content URL which is linked to the Storage origin 7 to the Main server 2 before the user terminals 61 , 63 , 65 , and 67 request message and/or content respectively. For example, when the user terminals 61 , 63 , 65 , and 67 request a new message(s), the Main server 2 transmits the content URL to the user terminal 61 , 63 , 65 , and 67 . And the user terminals 61 , 63 , 65 , and 67 access the Storage origin 7 through the content URL.
[0045] Finally, the content is transmitted from the Storage origin 7 to the Root server 3 , the Midgress server 41 (No. 1 ), and the Edge server 51 (No. 1 ) sequentially, and will be stored in each of the Root server 3 , the Midgress server 41 (No. 1 ), and the Edge server 51 (No. 1 ) respectively. In this embodiment, the Edge server 51 (No. 1 ) is the nearest edge server or the one with direct contact with the user terminal 61 . And, the content is transmitted from the storage origin 7 to the Root server 3 , the Midgress server 41 (No. 1 ), and the Edge server 52 (No. 2 ) sequentially, and will be stored in each of the Root server 3 , the Midgress server 41 (No. 1 ), and the Edge server 52 (No. 2 ). In this embodiment, the Edge server 52 (No. 2 ) is the nearest edge server or the one in direct contact with the user terminal 63 . In addition, the content is transmitted from the Storage origin 7 to the Root server 3 , the Midgress server 42 (No. 2 ), and the Edge server 53 (No. 3 ) sequentially, and will be stored in each of the Root server 3 , the Midgress server 42 (No. 2 ), and the Edge server 53 (No. 3 ). In this embodiment, Edge server 53 (No. 3 ) is the nearest edge server or the one in direct contact with the user terminal 65 . Furthermore, the content is transmitted from the Storage origin 7 to the Root server 3 , the Midgress server 42 (No. 2 ), and the Edge server 54 (No. 4 ) sequentially, and will be stored in each of the Root server 3 , the Midgress server 42 (No. 2 ), and the Edge server 54 (No. 4 ). In this embodiment, the Edge server 54 (No. 4 ) is the nearest edge server or the one in direct contact with the user terminal 67 .
[0046] Therefore, the user terminal 61 can receive the content from the Edge server 51 (No. 1 ) immediately without complicated routing upon receiving the request of end user No. 1 , with the first attempt for download. Thus, the terminal 63 can receive the content from the Edge server 52 (No. 2 ) immediately without complicated routing upon receiving the request from the end user No. 3 , with the first attempt for download. Terminal 65 can receive the content from the Edge server 53 (No. 3 ) immediately without complicated routing upon receiving the request from the end user No. 5 , with the first attempt for download. And, terminal 67 can receive the content from the Edge server 54 (No. 4 ) and immediately without complicated routing upon receiving the request from the end user No. 7 , with the first attempt for download.
[0047] FIG. 7 is a schematic diagram illustrating yet another embodiment of data flow in the server system of FIG. 1 , where there are multiple users who receive the same content, and the content may be stored a in common Midgress server. In this embodiment, the Storage origin 7 receives content related to the end users No. 1 and No. 3 . For example, the user terminals 61 and 63 send information such as IP address of each of the Edge servers with which they are in direct contact to the Main server 2 . The Main server 2 recognizes the cache server (Edge server) related to the user terminals 61 and 63 based on the received information, respectively. Therefore, when the Storage origin 7 receives the content related to the user terminals 61 and 63 from another end user or service provider, the Main server 2 transmits the content to the cache server related to the user terminals 61 and 63 .
[0048] For example, the content is transmitted from the Storage origin 7 to the Root server 3 , the Midgress server 41 (No. 1 ), sequentially, and will be stored in the Root server 3 , and the Midgress server 41 (No. 1 ). In this embodiment, the Midgress server 41 (No. 1 ) is the common midgress server of user terminals 61 and 63 from the end users No. 1 and No. 3 related to the content. Therefore, the user terminals 61 and 63 can receive the content from the Midgress server 41 (No. 1 ) immediately without complicated routing upon receiving the request from the end user No. 1 and No. 3 . If the number of users receiving the content is large, it is possible to store the content in the midgress server as explained in the present embodiment, and not stored in each of the edge servers related to each user terminals. In this embodiment, the Main server 2 decides the most appropriate midgress server related to user terminals 61 and 63 based on the received information, and the content is subsequently stored in the midgress server.
[0049] FIG. 11 is a block diagram illustrating a configuration of an embodiment of the Main server 2 . And, FIG. 8 and FIG. 9 are a flowchart illustrating operation steps of the Main server 2 . In this embodiment, as shown in FIG. 11 , the Main server 2 may include a Registration Information part 201 , a Determination Part 204 , a Transmission part 206 , a user information database 203 , a cache server information database 205 , and a content database 215 . As shown in FIG. 8 , an end user installs an application for the content delivery system through a user terminal at the first step (S 200 ). If the end user successfully installs the application into the user terminal 6 , the user registration is implemented (S 201 ) and a user account is created. The user registration is implemented by the Registration Information part 201 , and then, the information of registered user is stored in the user information database 203 of FIG. 11 .
[0050] Next, the Main server 2 receives the information from the user terminal (S 202 ). If the information is related to identity information of the cache server in a network in communication with the user terminal, such as for example an IP address, the Main server 2 stores the information of the related cache server in the cache server information database 205 of FIG. 11 (S 204 ). In such a case, the operation of step S 203 is unnecessary. On the other hand, if the information is related to routes to the network or patterns of use, etc., the Main server 2 will determine the cache server related to each user terminal based on the received information (S 203 ). This determination step is implemented by determination part 204 of the Main server 2 . Thereafter, the Main server 2 stores the information of the related cache server in the cache server information database 205 (S 205 ). At the end of step, the Main server 2 will register the determined cache server which is related to the user terminal.
[0051] FIG. 9 is a flowchart illustrating operation steps of Main server 2 after the flow diagram of FIG. 8 . At first, the Main server 2 receives a content from a service provider or other users (S 210 ) and the content is then stored in the content database 215 (Storage origin 7 ) of the Main server 2 . Thereafter, the Main server 2 searches user the information database 203 and the cache server database 205 (S 211 ). Then, the Main server 2 determines the cache server which receives the content (S 212 ). These steps are implemented by determination part 204 of the Main server 2 . Accordingly, the Main server 2 transmits the related content to the determined cache server 8 (S 213 ). And subsequently, the content is stored in the content database 804 of the cache server 8 .
[0052] FIG. 12 is a block diagram illustrating a configuration of a cache server. And, FIG. 10 is a flowchart illustrating operation steps of the cache server. In this embodiment, as shown in FIG. 12 , the cache server 8 may include a Registration Information part 800 , a Determination Part 802 , Transmission part 802 , user information database 801 , and a content database 804 . As shown in FIG. 10 , the cache server 8 receives a request from the end user of user terminal 6 (S 800 ). Then, the determination part 802 of the cache server 8 performs a search within the information database 801 (S 801 ), and selects the content which will be sent to the end user from the content database 804 (S 802 ). Thereafter, the transmission part 803 of cache server 8 sends the selected content, stored in content database 804 , to the user terminal 6 of the related end user (S 803 ). | A server and method for transmitting content to an end user are provided. The server receives information from a user terminal and transmits the content related to the user terminal to a cache server based, at least in part, on information received from the user terminal. Accordingly, the user terminal receives the content from the nearest cache server upon the request of the end user. The method according to the embodiments of the present invention is capable of providing content immediately to end users with low cache miss rate. | 32,853 |
This is a continuation of application Ser. No. 817,681, filed July 21, 1977.
FIELD OF THE INVENTION
This invention relates to high radiance light emitting devices for light emitting devices for optical communications, and methods for manufacturing them. More particularly, it relates to light emitting devices which have a structure permitting a highly efficient coupling with an optical fiber, and methods for manufacturing them.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a vertical sectional view of a prior-art light emitting device,
FIG. 2 is a vertical sectional view of an embodiment of the light emitting device of this invention,
FIG. 3 is a vertical sectional view of another embodiment of the light emitting device of this invention,
FIG. 4 is a view for explaining the operation of the radiation region confinement according to the light emitting device of this invention,
FIGS. 5a-5e are process diagrams showing an embodiment of a manufacturing method for the light emitting device of this invention,
FIGS. 6a and 6b are views showing components necessary for assembling the light emitting device of this invention as a light emitting diode product, and the structure of the assembled and finished product, respectively, and
FIG. 7 is a view showing still another embodiment of the light emitting device of this invention.
DESCRIPTION OF THE PRIOR ART
A known light emitting device as a light emitting diode for optical communication is described in `Material of the Society for Researchers in Light Quantum Electronics, OQE 75-71` published by the Institute of Electrical Communication in 1975 in Japan. More specifically, as illustrated in FIG. 1, on a semiconductor substrate 11 having a bandgap wider than that of a radiation region, an epitaxial layer 12 of the opposite conductivity type to that of the substrate 11 is grown. Thereafter, a glass film layer for current confinement 13 is provided in such a manner that a hole is located at the central part of the layer 12. Further, ohmic contacts 14 and 15 are provided on the bottom of the substrate and on the glass film layer 13, respectively. A p-n junction 16 is formed by the substrate 11 and the epitaxial layer 12. In this case, radiated light produced in the p-n junction 16 is introduced into an optical fiber (not shown) from a window for light extraction 17 as indicated by arrow L.
Another prior-art device is disclosed in Japanese Patent Application Public-disclosure No. 159688/1975. It includes a semiconductor substrate which is made of a material having a first bandgap, and an epitaxial layer which is made of a semiconductor material having a second bandgap wider than the first one. The substrate and the epitaxial layer have the same conductivity type. A p-n junction is formed by diffusing Zn from the outside surface of the epitaxial layer so as to get into the semiconductor substrate beyond the epitaxial layer.
Of these prior-art devices, the first is disadvantageous in that the area, determined by the glass film layer, for current confinement and the region from which light radiates do not correspond in size, the radiation region being larger due to the "current spreading phenomenon." Since the p-n junction 16 gets to a cloven side surface 18, it touches the external air and causes the nonradiative recombination due to a surface recombination current, so that the external efficiency is low. Further, the semiconductor substrate 11 exhibiting the wider bandgap has a low carrier concentration in the order of 10 18 cm -3 for a reason in the preparation of a crystal and its ohmic contact resistivity with the electrode layers 14, 15 is comparatively high, so that the energy efficiency in the case of the coupling with the optical fiber is lowered.
In the second prior-art device, the surface recombination current is suppressed by the localized p-n junction owing to the Zn diffusion. In general, however, a diffused junction is inferior to a grown junction by LPE in the perfectness of a crystal of a radiation region. Consequently, the external efficiency of this device is low. Another disadvantage is that the life of this device is shorter than that of the device with the grown junction.
SUMMARY OF THE INVENTION
This invention has for its objects to provide a light emitting device having a structure for eliminating the phenomenon in which the area of a radiation region becomes larger than the area to be determined by a glass film for current confinement, and to provide a method of manufacturing such device.
The subject matters of this invention reside in a light emitting device comprising a III-V compound semiconductor substrate whose bandgap is wider than that of a radiation region and which has a certain conductivity type, a layer of a second III-V compound semiconductor which is deposited on the upper surface of the III-V compound semiconductor substrate and which has the opposite conductivity type to that of the substrate, a current control layer which is deposited on the upper surface of the layer of the second III-V compound semiconductor and which has a hole for current flow, said current control layer being a layer of high carrier concentration or low resistivity as has the same conductivity type as that of the III-V compound semiconductor substrate, an ohmic contact which is provided on the upper surfaces of the layer of high carrier concentration or low resistivity and the layer of the second III-V compound semiconductor, and an ohmic contact which is provided on the bottom side of the III-V compound semiconductor substrate; and in a method wherein such light emitting device is manufactured by the liquid or vapor phase epitaxial growth and wherein the layer of high carrier concentration or low resistivity is formed by the diffusion process.
In this invention, the junction for radiation is not a diffused junction but it is formed by the liquid or vapor phase epitaxial growth, and besides, the regional confinement for the junction is done by the reverse-bias effect of the p-n junction. Further, the ohmic contact region of the III-V compound semiconductor having the wider bandgap is put into a sufficiently high carrier concentration so as to lower its contact resistivity with the ohmic contact. The portion of a window for radiation extraction is doped with no impurity and is left at a low carrier concentration, thereby to reduce the internal absorption of light. Thus, a light emitting device which exhibits excellent characteristics especially as a light emitting diode for communications employing an optical fiber can be obtained.
Hereunder, embodiments of this invention will be described.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Embodiment 1
FIG. 2 shows an embodiment of the light emitting device according to this invention. In the figure, numeral 21 designates a crystal layer for light transmission which is formed of a p-conductivity type layer having a bandgap wider than that of a radiation region. Numerals 22 and 23 designate n-type and n + -type crystal layers, respectively, which are successively and continuously grown on the crystal layer 21. Numerals 24 and 25 indicate selective diffusion layers of Zn which are formed in the p-type crystal layer 21 and in the n-type crystal layer 22 and n + -type crystal layer 23, respectively. The Zn diffused layer 24 exhibits a low contact resistivity to an electrode layer 26. The Zn diffused layer 25 exhibits a low contact resistivity to an electrode layer 27, and acts on a p-n junction 29, to be described below, so as to confine the p-n junction current. The ohmic contact electrode layers for the p-type and n-type, 26 and 27 are made of a metal. Shown at 28 is a window for extracting radiation indicated by arrow L, and an optical fiber (not shown) is attached to this portion. The p-n junction 29 is formed by the liquid phase epitaxial growth. By controlling the diffusion depth of the Zn diffused layer 25 in the n-type crystal layer 22 and the n + -type crystal layer 23, the radiation region can be formed into a size corresponding to the size of the extracting window 28.
In this manner, according to this invention, the Zn layer 25 is diffused in the n-type crystal layer 22 and the n + -type crystal layer 23, and the diffusion depth is controlled, whereby the radiation region is confined to a small area of the p-n junction 29 as explained later, making it possible to attain light emission of very high radiance. The surface of the electrode layer for the n-type ohmic contact, 27 is so formed as to become flat without any unevenness over the n + -type crystal layer 23 and the Zn diffused layer 25 in order that the electrode layer may efficiently radiate heat in close contact with a heat sink (not shown).
In the light emitting device of embodiment, the electrode 26 may be disposed on the bottom of the p-type crystal layer 21 directly without providing the Zn diffused layer 24, as shown in FIG. 3.
It will now be explained that, with the structure according to this invention as described above, the current flow region is confined to a specific part only, the radiation being done from the small area of the p-n junction. FIG. 4 shows current paths in the case of applying a voltage to the light emitting device shown in FIG. 2. There can be considered three cases where electrons starting from the electrode layer for the n-type ohmic contact, 27 travel along arrows of broken lines A, B and C. Here, when the electrons flow over a long distance in the n-type crystal layer 22 as indicated by the arrow B, the resistance is much higher than in the case where they flow along the arrow A. Therefore, the number of the electrons flowing as indicated by the arrow B is almost zero. Since the p-n junction D between the n-type crystal layer 22 and the p-type Zn diffused layer 25 is reverse-biased, current flow is restricted to passage through only a small portion E in the p-n junction 29 as shown in FIG. 4 when the light emitting device is forward biased, so that light of high radiance is emitted from the portion E as indicated by arrow of solid line L.
The n + crystal layer 23 provided on the n-type crystal layer 22, as shown in FIG. 2 and FIG. 3, can be omitted with an n-type crystal layer then being substituted for the n + crystal layer.
As apparent from the above description, the light emitting device of this invention simultaneously solves the problems of the prior arts, i.e., the current spreading phenomenon of the radiation region, the lowering of the external efficiency ascribable to the surface recombination current, and the disadvantages of short life, low reliability, etc.
EMBODIMENT 2
An example of the manufacturing process of the light emitting device of this invention will now be described with reference to FIGS. 5a-5e.
As shown in FIG. 5a, on a III-V compound semiconductor substrate doped with an impurity bestowing a predetermined conductivity type, for example, an n-type or p-type (1 0 0) GaAs substrate 30 whose carrier concentration is in the order of 10 17 cm -3 , Ga 1-x Al x As 31 (0<x≦1) which is about 200 μm thick is grown by the liquid phase epitaxial growth so that, by way of example, the value x may continuously decrease from 0.4 to 0.1 upwards from the substrate surface. Subsequently, the grown layer is polished until the AlAs composition of its upper surface becomes above 15% (above x=0.15), and it is put into the mirror surface state. According to a Capacitance-Voltage measurement, the carrier concentration of the crystal layer 31 was 5×10 17 cm -3 . At the next step, using the crystal layer 31 as a substrate and by a sliding method employing a graphite jig, a first layer 32 (p-type Ga 1-x Al x As layer, 0<x≦1), a second layer 33 (n-type Ga 1-x Al x As layer, 0<x≦1) and a third layer 34 (n + -type Ga 1-x Al x As layer, 0<x≦1) are successively and continuously crystal-grown from a Ga solution (in which GaAs or Al is used as a solute, and Zn or Si being a p-type bestowing impurity or Te being an n-type bestowing impurity is used as a dopant).
At this time, the thicknesses of the first layer 32, the second layer 33 and the third layer 34 were, for example, about 30 μm, 2 μm and 1 μm, respectively. The carrier concentrations of the respective layers are controlled by the quantities of addition of the dopants Zn, Si and Te, and were, for example, 2-3×10 18 cm -3 , 1×10 18 cm -3 and 5×10 18 cm 31 3.
Subsequently, as shown in FIG. 5b, parts of the substrate 30 and the crystal layer 31 are polished and removed so that the total thickness may become 150 μm, and the exposed surface of the crystal layer 31 is finished into a mirror surface. Thereafter, an Al 2 O 3 film 35 and a PSG (Phospho-Silicate-Glass) film 36 which are 1000 A and 2000 A thick respectively are deposited on each of the front and rear surfaces of the resultant structure. Next, the outer peripheral parts of the films 35 and 36 are removed (when the device of FIG. 3 is to be produced, the films 35 and 36 are deposited entirely on the bottom surface), to form a diffusion mask of a diameter of 40 μm on the side of the third layer 34 and a diffusion mask of a diameter of 150 μm on the side of the crystal layer 31.
Thereafter, the resultant structure is vacuum-sealed into a quartz ampoule together with a ZnAs 2 source, and Zn diffused layers 37 and 38 being about 2.5 μm thick as shown in FIG. 5c are formed by a heat treatment at 650° C. for 120 minutes (when the device of FIG. 3 is to be fabricated, the glass layer except the light extracting portion at the bottom of the substrate is removed in advance). At this time, the spacing between the diffusion surface A of the Zn diffused layer 37 and the first layer 32, that is, the thickness of the second layer 33 at this part is about 0.5 μm.
Subsequently, as shown in FIG. 5d, using the films 35 and 36 as an evaporation mask, AuZn or AuSbZn to become an ohmic contact electrode layer on the p-side, 39 is evaporated to a thickness of about 2 μm.
Further, as shown in FIG. 5e, that part of the ohmic contact electrode layer 39 which corresponds to a light extracting window 42 and the films 35 and 36 which have been employed as the diffusion mask are removed by the photo-lithograph respectively. At this time, the diffusion mask (films 35 and 36) on the n-side or on the upper side of the illustration is covered with apiezon in advance. After completion of the photo-lithographic treatment, the apiezon is removed with trichloro-ethylene, and the films 35 and 36 having been employed as the diffusion mask on the n-side (upper side) are successively removed. Subsequently, AuGe-Ni-Au 40 is evaporated on the upper surface of the resultant structure as an n-type ohmic contact electrode layer to a thickness of about 1 μm. Further, Au 41 being about 9 μm thick is deposited on the electrode layer 40 by the electrolytic plating.
Thereafter, the resultant structure in the state of a wafer is cut by scribing into the state of a chip of about 600 μm×600 μm. Then, a light emitting diode chip (hereinafter, abbreviated to "LED chip") as the light emitting device of this invention is obtained.
In a concrete example of the above embodiment, a GaAs substrate is used as the starting substrate, and the grown substance is obtained by growing a layer of a crystal mixed with the substrate material, the crystal being a crystal of another III-V element than used in forming the substrate, whereby the layer is a mixture of the III-V compound and the another III-V element, having a bandgap wider than that of the substrate. The step of providing the n + -type mixed crystal layer need not be carried out in some device structures to be fabricated.
FIG. 6a and FIG. 6b are sectional views respectively showing components which are required for assembling a light emitting diode by the use of the LED chip described above, and the light emitting diode finished. In these figures, numeral 61 designates a stem having an insulating part 61a, numeral 62 a submount, numeral 63 the LED chip according to this invention, numeral 64 a fiber connector, and numeral 65 an optical fiber.
The sequence of assemblage is as stated below. First, the submount 62 and the LED chip 63 are bonded into an integral form. Subsequently, the submount 62 and the LED chip 63 in the integral form are bonded onto the lower surface of the fiber connector 64. The resultant structure is bonded into the stem 61 through a layer 66 of a low fusing metal such as indium, and the stem 61 and the fiber connector 64 are hermetically fixed with an epoxy resin 67. Thereafter, the optical fiber 65 is caused to pass through the fiber connector 64. The optical fiber 65 has its lower end face brought into close contact with the light extracting window of the LED chip 63, and is fixed to the fiber connector 64 with an epoxy resin 68.
After such assemblage, measurements were executed. As the result, characteristics to be mentioned below were obtained. The optical fiber 65 had a numerical aperture of 0.16, a core diameter of 85 μm, and a length of 50 cm. When a d.c. current of 100 mA was conducted, the optical fiber output was 350 μW on the average, the center wavelength of light emission was 8300 A, and the spectral half-width was 270 A. As the chip light output in the state in which the fiber was not attached, a considerably large value of 4-7 mW was obtained. The thermal resistance was as low as 30-50 deg./W.
In this case, the thermal resistance was low as mentioned above, and the heat radiation was favorably done, so that the saturation of the light output versus the increase of the bias current was little. When the bias current was 100 mA 0-p and modulation depth was 40%, the modulation distortion of the light output was low to the extent of -50 dB. The Current-Voltage characteristics were also inspected. As the result, there was no leakage current, and such good characteristics as a forward voltage of 1.65 V (I F =100 mA, d. c.) and a breakdown voltage of about 10 V were exhibited.
Further, the radiation region was measured. As the result, the radiation diameter was as extremely small as about 45 μm, and it was verified that the radiation region hardly spread from the area confined by the selective Zn diffusion layer 25 in FIG. 2. In this manner, according to this invention, the light emission of extraordinarily high radiance can be obtained from the very small area.
EMBODIMENT 3
FIG. 7 shows the sectional structure of a light emitting device according to another embodiment of this invention. A light extracting window 51 is formed in such a way that a portion corresponding to the light extracting window 28 in FIG. 2 is removed by the mask etching with an etchant of H 2 SO 4 -H 2 O 2 -H 2 O. In case of this structure, a p + region 47 in a p-type portion need not be formed by the selective diffusion, but it may be formed in such a way that after diffusion over the entire area of a wafer surface, the removal by the mask etching is carried out into a depth slightly greater than the diffusion depth, i.e., the mask-etched portion becoming slightly deeper than the diffused layer 47. The other steps of manufacture may be executed similarly to those illustrated in FIGS. 5a-5e.
An advantage in this case is that, by suitably selecting the diameter of the light extracting window 51 to be etched and removed, the coupling of the device with an optical fiber is done in a very good condition, so the troublesome operation of mask registration can be omitted. Needless to say, there is added the advantage that, by such deep etching and removal, the light output is enhanced to the amount of the component of light absorption by the removed portion.
In FIG. 7, numeral 43 indicates a p-conductivity type layer, numeral 44 an n-conductivity type layer, numeral 45 an n + -conductivity type layer, numerals 46 and 47 Zn diffused layers formed simultaneously, numeral 48 a p-n junction, numeral 49 an electrode layer for n-type ohmic contact, and numeral 50 an electrode layer for p-type ohmic contact.
Although, in the foregoing embodiments, only the case of employing Ga 1-x Al x As (0<x≦1) as the semiconductor material has been stated, it is needless to say that similar effects are achieved with mixed crystals of other III-V compound semiconductors such as GaAs 1-x P x (0<x≦1), In x Ga 1-x As (0<x≦1), GaAs 1-x Sb x (0≦x<1) and Ga 1-x In x P (0≦x<1) or with hetero-junctions employing III-V compound semiconductor materials different from each other. The process of crystal growth is not restricted to the liquid phase growth, but a similar method of manufacture is applied and similar effects are achieved even by the vapor phase growth.
Further, although the above description has been made, for the brevity of explanation, of the embodiments of this invention in the case of fabricating the individual light emitting devices, this invention can of course be performed likewise to the foregoing cases even in case of fabricating a function element in which a large number of light emitting diodes are integrated on a single semiconductor substrate.
As set forth above, according to this invention, the radiation region of a p-n junction is confined to a very small area thereby to attain light emission of high radiance and high efficiency, a diffused layer of high carrier concentration is provided at a portion of contact with an electrode layer thereby to lower the contact resistivity, a portion of a light passage is left at a low carrier concentration thereby to reduce the absorption of light, and the coupling with an optical fiber can be easily conducted, so that the device of this invention is greatly effective as a light emitting device. | In a prior-art injection type light emitting device which is constructed so that a predetermined range of a p-n junction formed by a semiconductor substrate and an epitaxial layer provided thereon may radiate, a radiation region in the p-n junction becomes larger in area than the region into which current is introduced, on account of the current spreading phenomenon. The construction of a light emitting device free from the phenomenon and a method for manufacturing the light emitting device are disclosed. | 22,131 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] This invention is related in general to data communications systems. In particular, the invention consists of an adaptive system for transmitting messages depending on dynamic system resources and system requirements.
[0003] 2. Description of the Prior Art
[0004] Complex systems such as digital data storage systems traditionally include system resources such as processors, communication buses, and data storage devices. Typical data storage devices include hard-disk drives, magneto-optical drives, and magnetic tape cartridges. These system resources are dynamically allocated to specific tasks as the system is utilized. If a system resource fails or is taken off-line for maintenance, the system resources available for allocation are decreased. To address the problem of failed system resources, a notification is typically sent to a central location. This notification is used to generate corrective action, i.e., repair or replacement of the defective part. These notifications may either be sent when a system resource becomes unavailable or may be scheduled for later transmission.
[0005] In U.S. Pat. No. 5,892,898, Fujii et al. disclose an event management system for identifying and logging event information. The event management system includes an application for reporting an event message in response to an occurrence of a particular event. It would be advantageous, however, to transmit an event message at a deferred period of time. In particular, it would be advantageous to defer transmission until a notification window is open.
[0006] In U.S. Pat. No. 5,809,491, Kayalioglu et al. disclose a system for generating an exception report for a particular problem based on call traffic. The system maintains a count of occurrences for the problem. If the count exceeds a threshold, the system generates an exception report. It would be advantageous to have a similar system directed to hardware resources. For example, it would be advantageous to maintain a count of the number of failed hardware devices, such as hard-disk drives. It would be advantageous if this count of failed hardware devices was utilized to determine if an error notification should be deferred or transmitted as soon as possible.
[0007] It would also be advantageous to have a system of tracking the historical usage of system resources and utilizing the historical information to predict future system resource requirements. This prediction could be used to aid in the decision of deferring or transmitting a notification. Additionally, it would be advantageous to track current system resources and evaluate whether deferred notifications should be changed to instant notifications based on the current or near future system needs.
SUMMARY OF THE INVENTION
[0008] The invention disclosed herein utilizes a system resource monitoring algorithm to track the number of specific types of unavailable system resources. If the number of unavailable system resources exceeds a pre-established threshold, a notification is immediately transmitted. Otherwise, the notification is stored for deferred transmission. A predictive algorithm may utilize historical system resource requirements to dynamically adjust the threshold. If the threshold is lowered below the level of available system resources, previously deferred notifications may be changed to immediate notifications.
[0009] Various other purposes and advantages of the invention will become clear from its description in the specification that follows and from the novel features particularly pointed out in the appended claims. Therefore, to the accomplishment of the objectives described above, this invention comprises 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 description disclose just a few of the various ways in which the invention may be practiced.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] FIG. 1 is a block diagram illustrating an adaptive message delivery system including a system resource monitoring device, a predictive device, a threshold establishment device, and a notification queue.
[0011] FIG. 2 is a block diagram illustrating the adaptive message delivery system of FIG. 1 and a system under test.
[0012] FIG. 3 is a flow chart illustrating the process of establishing and adapting a notification threshold.
[0013] FIG. 4 illustrates the process of FIG. 3 and is expanded to include a predictive algorithm.
[0014] FIG. 5 is a flow chart illustrating the process of FIG. 4 with the added step of removing a deferred notification.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0015] This invention is based on the idea of monitoring system resources and sending notifications when these system resources become unavailable. The invention disclosed herein may be implemented as a method, apparatus or article of manufacture using standard programming or engineering techniques to produce software, firmware, hardware, or any combination thereof. The term “article of manufacture” as used herein refers to code or logic implemented in hardware or computer readable media such as optical storage devices, and volatile or non-volatile memory devices. Such hardware may include, but is not limited to, field programmable gate arrays (“FPGAs”), application-specific integrated circuits (“ASICs”), complex programmable logic devices (“CPLDs”), programmable logic arrays (“PLAs”), microprocessors, or other similar processing devices.
[0016] Referring to figures, wherein like parts are designated with the same reference numerals and symbols, FIG. 1 is a block diagram of an adaptive message delivery system 10 including a system resource monitoring device 12 , a predictive device 14 , a threshold establishment device 16 , and a notification queue 18 . In a simple embodiment of the invention, the system resource monitoring device keeps track of the number of specific types of available system resources. For example, turning to FIG. 2 , the adaptive message delivery system 10 is shown with a system under test 100 . In this embodiment of the invention, the system under test 100 is a data storage system including multiple processors 102 and data storage devices 104 . The system resource monitoring device 12 determines when either a processor 102 or a data storage device 104 becomes unavailable for use by the data storage system 100 . These devices may become unavailable as a result of mechanical failure, corrupted control software, interference with communication channels, improper power-on, or removal for preventive maintenance or replacement.
[0017] Notice 106 of a device unavailability is passed to the threshold establishment device 16 where a resource number 20 representative of available system resources is adjusted. This resource number 20 is compared against a threshold 22 . If the resource number 20 is equal to or exceeds the threshold 22 , a deferred notification 24 is placed in the notification queue 18 for deferred delivery. Deferred delivery would normally occur during a pre-determined period of time referred to as a notification window. If, however, the resource number 20 is less than the threshold 22 , an instant notification 26 is transmitted as soon as possible. In this embodiment of the invention, the instant notification is transmitted to a centralized reporting facility 28 .
[0018] The threshold 22 may be a fixed number or may be adjusted to account for variations in system resource usage. One method of adjusting the threshold 22 is to utilize a predictive device 14 to anticipate future system resource needs. This can be accomplished by maintaining a resource usage history 30 based on prior system resource utilization. This resource usage history may be maintained as a look-up-table or other data structure in a memory device, such as a random access memory (“RAM”) or a non-volatile memory such as a disk file. If a pattern of system resource utilization is detected, the predictive device 14 may vary the threshold 22 in anticipation of heavy, normal, and light periods of system resource utilization. In this manner, a deferred notification 24 of a failure of a data storage device 104 may be placed in the notification queue 18 during periods of light resource utilization. A failure of an additionally data storage device 104 may result in an instant notification 26 notification being transmitted if the resource number 20 associated with data storage devices 104 is lower than the associated threshold 22 . However, if the predictive device anticipates normal or heavy system resource utilization in the near future, the threshold 22 may be lowered, resulting in both the first failure and second failure producing instant notifications.
[0019] Another aspect of the invention is that changes to the threshold 22 by the predictive device 14 may result in a deferred notification 24 being removed from the notification queue 18 and being transmitted as an instant notification 30 . For example, a deferred notification 24 may be placed in the notification queue 18 during a period when the threshold 22 for data storage devices is low. Subsequently, the predictive device 14 determines that a normal or high period of usage is approaching and adjusts the threshold 22 upward, indicating a need for a higher number of data storage devices 104 . If the resource number 20 is lower than the threshold 22 , the deferred notification 24 is removed from the notification queue 18 and transmitted to the centralized reporting facility.
[0020] FIG. 3 is a flow chart illustrating an adaptive message delivery algorithm 198 . In step 200 , a threshold 22 is established for each specific type of system resource, i.e., processor 102 or data storage device 104 . In step 202 , a resource number 20 indicative of the number of a type of system resources that are currently available is established. In step 204 , the resource number 20 is compared to the threshold 22 . If the resource number 20 is less than the threshold, an instant notification 26 is transmitted to a centralized reporting facility 28 in step 206 . Else, a deferred notification 24 is placed in the notification queue 18 in step 208 .
[0021] FIG. 4 illustrates the process of FIG. 3 expanded to include a predictive algorithm. In step 190 , a resource usage history 30 is maintained in a memory device such as a random access memory or a non-volatile memory such as a disk file. In step 192 , the predictive device 14 analyzes the resource usage history 30 to ascertain resource usage patterns. The predictive device 14 may include a hardware device 14 a or a computing device 14 b implementing a software construct (analysis software) 14 c to analyze the resource usage history 30 . Once resource usage patterns have been ascertained, the predictive device 14 adjusts the threshold 22 to accommodate anticipated system resource usage in step 194 . FIG. 5 is a flow chart illustrating the process of FIG. 4 with the added step of removing a deferred notification 24 from the notification queue 18 and transmitting an instant notification 26 in step 206 , in response to the threshold 22 being adjusted (step 194 ).
[0022] Those skilled in the art of making data communication systems may develop other embodiments of the present invention. For example, an adaptive message delivery system 10 may be used to monitor more than one system under test 100 . Or, instant notifications 26 may be transmitted to more than one location. However, the terms and expressions which have been employed in the foregoing specification are used therein as terms of description and not of limitation, and there is no intention in the use of such terms and expressions of excluding equivalents of the features shown and described or portions thereof, it being recognized that the scope of the invention is defined and limited only by the claims which follow. | A device monitors a system's available resources and produces either a deferred notification or an instant notification based on a comparison with an established threshold. The threshold may be adjusted if current or anticipated system resource utilization changes. Changes to the threshold may result in deferred notifications being removed from a queue and an instant notification being transmitted to a reporting facility. | 12,604 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention relates to methods of polymerizing rosin.
2. Brief Description of the Prior Art
The term "polymerized rosin" refers to the resinous mixture obtained when rosin is treated under various conditions with strong inorganic acids, organic acids or acidic clays. The mixture comprises non-dimerizable resin acids such as dehydroabietic acid, resin acids containing some unsaturation which do not react and a number of different types of polymerized resin acids including dimerized resin acids. The mixture also contains a minor amount of esters, resin acid anhydrides and non-saponifiable substances. Polymerized rosin may be refined, usually by distillation, to remove some portion of the monomeric resin acids and other substances to produce a mixture containing a higher concentration of polymerized resin acids. This refined mixture always has a higher softening point than unrefined polymerized rosin and it is referred to as "dimerized rosin" in many textbooks.
Much prior art exists that bears upon the conversion of rosin to a more polymeric substance. Among the literature descriptions of prior art methods, U.S. Pat. Nos. 2,136,525; 2,108,982; 2,307,641; and 2,328,681 are examples; also the U.S. Pat. Nos. 2,515,218; 2,251,806; 2,532,120; and 4,105,462.
Previous methods described for polymerizing rosin have relied on the use of strong inorganic acids, such as sulfuric acid as the catalysts. In these procedures, the rosin is dissolved in an inert solvent during the polymerization reaction. A serious disadvantage of these methods is the formation of an acidic sludge that requires separation from the polymerized product.
Alternate methods have been described in which the catalysts are sulfonated organic polymers (U.S. Pat. No. 4,414,146), or a halogenated methanesulfonic acid (U.S. Pat. No. 4,339,377). The reaction is generally carried out in an inert organic solvent. Thus, the prior art for the polymerization of rosin includes both a catalyst and a solvent.
The present invention is an improvement over the prior art in that the polymerization is effected by formic acid which acts as both a solvent and a catalyst. This is unexpected in that two prior patents U.S. Pat. Nos. 2,375,618 and 2,492,146 teach against the operability of formic acid to function as such a catalyst. In fact, U.S. Pat. No. 2,375,618 specifically states that "heating rosin with an aliphatic carboxylic acid alone does not result in the preparation of a material of increased softening point". The polymerized rosin is recovered by a simple distillation of the solvent, formic acid. Furthermore, the latter can be effectively reused for subsequent cycles of polymerization. An additional advantage is that formic acid is an inexpensive and stable reagent.
The product formed by the formic acid procedure consists of 27-45% dimerized rosins, a yield comparable to those obtained by other methods. The dimerized rosins residue, left after distillation of the formic acid, can be directly esterified without prior purification of the dimer. The oxidation stability and physical properties of the dimerized rosin compare favorably with commercially available products, such as Sylvatac 95, produced by the Sylvachem Division of SCM Corporation.
SUMMARY OF THE INVENTION
The invention comprises the polymerization of rosin in the presence of a catalytic proportion of formic acid.
DETAILED DESCRIPTION OF THE INVENTION
The method of the invention is based on the discovery that formic acid is an effective catalyst for promoting the polymerization of rosin. Rosins which may be advantageously polymerized by the method of the invention are represented by tall oil rosin, wood rosin and gum rosin.
The method of the invention may be carried out by simply mixing the rosin with a catalytic proportion of formic acid and heating the mixture to a temperature within the range of from about 10° C. to about reflux temperature. Preferably the mixture is heated to a temperature of from about 90° to about 150° C. Advantageously, the mixture is agitated by stirring during the period of heating.
Advantageously, the proportion of rosin to formic acid is 1:1 to 3:1 by weight.
Progress of the desired polymerization may be followed by employment of conventional analytical techniques. In general, polymerization is complete within about 1 to 12 hours at the preferred temperatures.
Upon completion of the polymerization, the desired product may be separated from the reaction mixture by distillation to remove residual formic acid.
Formic acid is a well known reagent as is the method of its preparation. In the method of the invention, it is employed in a substantially anhydrous form, i.e., for example 97% formic acid. In such a form, a catalytic proportion comprises from about 0.5 to about 20 weight percent of the reaction mixture, preferably 1 to 5 weight percent in the presence of a solvent of high dielectric constant.
In a preferred embodiment process of the invention, additional formic acid is present in the reaction mixture as solvent for the reactant rosin. Under these circumstances, the formic acid present in the reaction mixture may comprise 20 to 50 weight percent of the reaction mixture. Other solvents may also be employed, particularly polar solvents and solvents having a high dielectric constant, preferably greater than 40.
Representative of these solvents are toluene, xylene, and the like; halogenated hydrocarbons such as carbon tetrachloride, ethylene dichloride and the like; oxygenated solvents such as sulfolane, acetic acid and the like.
In another embodiment process of the invention, the solvent and catalyst formic acid is recovered and re-used in further polymerization of rosin.
Those skilled in the art will appreciate that many modifications may be made to the above-described embodiments of the invention without departing from the spirit and the scope of the invention. For example, the process of the invention may also employ as co-catalysts, any of the known rosin polymerization catalysts such as inorganic mineral acids and strong organic acids. Particularly preferred as co-catalysts are perchloric acid, p-toluenesulfonic acid, trifluoromethanesulfonic acid and methanedisulfonic acid, solid acid catalysts such as acid clays, such as filtrol-13 and the like, strongly acidic macroreticular resins, such as Amberlyst 15 and the like.
The following examples describe the process of making and using the invention and the best mode contemplated by the inventor of carrying out the invention but are not to be considered as limiting.
EXAMPLE 1
After the addition of 100 g of 97% formic acid and 100 g of rosin (Unitol NCY; Union Camp Corp., Wayne, N.J.) to a suitable size reflux vessel, the mixture was heated to reflux temperature (105° C.). Samples of the resulting reaction mixture were withdrawn after 1, 2 and 3 hours for analytical purposes. The monomer and dimer contents of the samples at each time point were determined by gel permeation chromatography (GPC). The final product, obtained after distillation of the formic acid, was analyzed in a similar manner.
The formic acid recovered from the first cycle was used as a polymerization solvent and catalyst with a fresh batch of rosin. This procedure was repeated a third time. As in a first cycle, samples were also analyzed for the extent of dimerization during the second and third cycles.
The analytical results summarized in Table 1 below indicate that each cycle yielded approximately 27% of the dimerized rosin.
TABLE 1______________________________________FORMIC ACID DIMERIZATION OF ROSINHCO.sub.2 H/Rosin 50/50 W/.sub.W SOFTEN- % HCO.sub.2 H ING % RECOVERED TIME POINT DIMER BY DISTILLA-HCO.sub.2 H USE HRS. °C. GPC TION______________________________________Initial 1st 1,0 -- 22 94Cycle 2,0 -- 25 3,0 -- 27Stripped -- 88 29 95Sample 1,0 -- 172nd Cycle 2,0 -- 21 3,0 -- 24Stripped -- 88 27 95Sample 1,0 -- 203rd Cycle 2,0 -- 21 3,0 -- 24Stripped -- 88 27Sample______________________________________
EXAMPLE 2
One hundred grams of rosin (Unitol NCY, supra.) was added to one hundred grams of 97% formic acid in a suitable vessel. The mixture was heated to a temperature of circa 100° C. for a period of about 3 hours. At the end of this time the reaction mixture was allowed to cool to room temperature and poured into an excess (V/V) of water. The insoluble dimerized rosin was taken up in ether. The ether solution was washed, dried over anhydrous sodium sulfate and stripped of ether to yield a product containing 25.9 percent dimerized rosin (GPC).
EXAMPLE 3
The procedure of Example 1, supra., was repeated except that 50 grams of the formic acid was replaced with an equal proportion of toluene. The product showed a dimer content of 14.3 percent.
EXAMPLE 4
The procedure of Example 2, supra., was repeated except that when the temperature of the reaction mixture first reached 100° C., 1 weight percent of 70% perchloric acid was added to the reaction mixture and when the reaction mixture was poured into an excess of water, sodium carbonate was added to neutralize the perchloric acid. The product showed a dimer content of 43.8 percent.
EXAMPLE 5
The procedure of Example 1, supra., was repeated except that when the temperature of the reaction mixture first reached 100° C., 0.5 weight percent of para-toluenesulfonic acid monohydrate was added to the reaction mixture. After workup the product showed a dimer content of 37.8 percent.
EXAMPLE 6
The procedure of Example 1, supra., was repeated except that 0.5 weight percent of methanedisulfonic acid was added to the reaction mixture. Upon workup the product showed a dimer content of 39.4 percent.
EXAMPLE 7
The procedure of Example 1, supra., was repeated except that 0.5 weight percent of a macroreticular sulfonic acid resin such as Amberlyst 15 was added to the reaction mixture. The macroreticular resin was filtered off after the reaction mixture was allowed to cool to room temperature. Upon workup the product showed a dimer content of 29.6 percent.
EXAMPLE 8
The procedure of Example 1, supra., was repeated except that 0.5 weight percent of trifluoromethanesulfonic acid was added to the reaction mixture. Upon workup the product showed a dimer content of 39.7 percent.
EXAMPLE 9
The procedure of Example 2, supra., was repeated except that 98 grams of the formic acid was replaced by sulfolane. The product showed a dimer content of 19.8 percent and a softening point of 85° C. | Formic acid is disclosed as a catalyst for polymerizing rosin. The discovery is the basis of a method for polymerizing rosin by heating the rosin in the presence of a catalytic proportion of formic acid. The catalyst is easily separated from the polymerized rosin for reuse. | 11,099 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] This patent application contains improvements by the same inventor on co-pending utility patent application Ser. No. 14/087401 filed on Nov. 22, 2014. The present invention relates to the field of compounds which include but are not limited to tooth whitening compounds, dental bonding and filling compounds used to fill a tooth after a cavity has been drilled out of the tooth, and adhesives used to bond two objects together, and in particular to apparatus which dispenses tooth whitening compounds used to whiten teeth, apparatus used to dispense dental bonding compounds, and apparatus used to dispense adhesives
[0003] 2. Description of the Prior Art
[0004] One significant problem with prior art apparatus used to retain and dispense tooth whitening compounds is that they are reused over and over, resulting in the possible transmission of diseases from one dental patient to another.
[0005] The following 26 patents and published patent applications are the closest prior art references which were uncovered in the search. A complete set of copies of these patents and patent applications are enclosed herewith for your review.
[0006] 1. U.S. Pat. No. 5,611,687 issued to Eugene C. Wagner on Mar. 18, 1997 for “Oral Hygiene Delivery System” (hereafter the “Wagner Patent”);
[0007] 2. U.S. Pat. No. 6,176,632 issued to Hidehei Kageyama et al. on Jan. 23, 2001 for “Liquid Container” (hereafter the “'632 Kageyama Patent”);
[0008] 3. U.S. Pat. No. 6,227,739 issued to Hidehei Kageyama on May 8, 2001 for “Liquid Container” (hereafter the “'739 Kageyama Patent”);
[0009] 4. United States Published Patent Application No. 2005/0063766 to Sou Y, Chen et al. on Mar. 24, 2005 for “Applicator Pen” (hereafter the “Chen Published Patent Application”);
[0010] 5. U.S. Pat. No. 6,918,515 issued to Yoshio Noguchi on Jul. 19, 2005 for “Liquid Container” (hereafter the “Noguchi Patent”);
[0011] 6. United States Published Patent Application No. 2006/0275225 to Michael Prencipe et al. on Dec. 7, 2006 for “Applicator and Method For Applying A Tooth Whitening Composition” (hereafter the “Prencipe Published Patent Application”);
[0012] 7. U.S. Pat. No. 7,201,527 issued to Richard Christopher Thorpe et al. on Apr. 10, 2007 for “Twist Up Pen Type Dispenser With Brush Applicator” (hereafter the “Thorpe Patent”);
[0013] 8. United States Published Patent Application No. 2007/0086830 to Hidehei Kageyama on Apr. 19, 2007 for “Liquid Container” (hereafter the “Kageyama Published Patent Application”);
[0014] 9. United States Published Patent Application No. 2008/0274066 to Robert Eric Montgomery on Nov. 6, 2008 for “Compositions, Methods, Devices, And Kits for Maintaining or Enhancing Tooth Whitening” (hereafter the “Montgomery Published Patent Application”).
[0015] 10. U.S. Pat. No. 7,794,166 issued to Jun Zhang on Sep. 14, 2010 for “Press-Type Cosmetic Container with Anti-Press Means” (hereafter the “Zhang Patent”);
[0016] 11. United States Published Patent Application No. 2011/0129288 to Junya Uehara on Jun. 2, 2011 for “Liquid Applicator” (hereafter the “Uehara Published Patent Application”);
[0017] 12. U.S. Pat. No. 7,980,778 issued to Tetsuaki Akaishi et al. on Jul. 19, 2011 for “Liquid Applicator” (hereafter the Akaishi Patent”);
[0018] 13. U.S. Pat. No. 8,328,449 issued to James C. Wightman et al. on Dec. 11, 2012 for “Click Pen Applicator Device And Method of Using Same” (hereafter the “Wightman Patent”);
[0019] 14. Japanese Patent No. JP096151123A issued to Shiraishi Katsuhiko et al. on Jun. 10, 1997 for “Tooth Coating Liquid” (hereafter the “Katsuhiko Japanese Patent”);
[0020] 15. Japanese Patent No. JP2007130437A issued to Kageyama Shuhei on May 31, 2007 for “Liquid Container” (hereafter the “Shuhei Japanese Patent”).
[0021] 16. U.S. Pat. No. 4,121,739 issued to William David Devaney et al. on Oct. 24, 1978 for “Dispenser With Unitary Plunger And Seal Construction” (hereafter the “Devaney Patent”);
[0022] 17. U.S. Pat. No. 5,104,005 issued to Franz K. Schneider, Jr. et al. on Apr. 14, 1992 for “Dual Component Mechanically Operated Caulking Gun” (hereafter the “Schneider Patent”);
[0023] 18. U.S. Pat. No. 5,310,091 issued to Walter B. Dunning et al. on May 10, 1994 for “Dual Product Dispenser” (hereafter the “Dunning Patent”);
[0024] 19. U.S. Pat. No. 5,333,760 issued to Christen Simmen on Aug. 2, 1994 for “Dispensing And Mixing Apparatus” (hereafter the “Simmen Patent”);
[0025] 20. U.S. Pat. No. 5,535,922 issued to Bernard J. Maziarz on Jul. 16, 1996 for “Caulking Gun Dispensing Module For Multi-Component Cartridge” (hereafter the “Maziarz Patent”);
[0026] 21. U.S. Pat. No. 6,116,900 issued to Calvin D. Ostler on Sep. 12, 2000 for “Binary Energizer And Peroxide Delivery System For Dental Bleaching” (hereafter the “Ostler Patent”);
[0027] 22. U.S. Pat. No. 6,283,660 issued to Patrick J. Furlong et al. on Sep. 4, 2001 for “Pen Dispensing And Cartridge System” (hereafter the “Furlong Patent”);
[0028] 23. United States Published Patent Application No. 2009/0095777 to Frank Francavilla on Apr. 16, 2009 for “Dispensing Pen” (hereafter the “Francavilla Published Patent Application”);
[0029] 24. U.S. Pat. No. 7,748,980 issued to Paul Mulhauser et al. on Jul. 6, 2010 for “Dispenser for Dental Compositions” (hereafter the “Mulhauser Patent”);
[0030] 25. U.S. Pat. No. 7,882,983 issued to Dean K. Reidt et al. on Feb. 8, 2011 for “Capsule for Two-Component Materials” (hereafter the “Reidt Patent”);
[0031] 26. U.S. Pat. No. 8,096,449 issued to Wilheilm A. Keller on Jan. 17, 2012 for “Dispensing Appliance for a Multiple Cartridge” (hereafter the “Keller Patent”).
[0032] The Wagner Patent Discloses:
“A delivery system for a liquid oral hygiene preparation suitable for tooth whitening, tooth cleansing and the treatment of. The delivery system includes an elongate barrel shaped body. A supply of the hygiene preparation saturates a fibrous wadding carried in a hollow chamber of the body. At an end of the body, an applicator formed of felt or synthetic fibers is seated. The applicator includes a broad tip and a stem wick which is received in the wadding and draws the preparation to the tip by capillary action. The preparation is applied to tooth surfaces, oral lesions, and the like by pressing the tip against the surface to receive the preparation and, where appropriate, wiping the tip along the surface. In an alternate embodiment, ball applicator is provided and the hygienic preparation may be carried in the chamber without the wadding.”
[0034] The '632 Kageyama Discloses:
“A liquid container such that the liquid received in it will not easily spring out from its tip even if it is wrongly operated, comprises a tank portion for receiving a liquid, a knock bar stretching axially movably within the tank portion which is designed to have on its axial tip portion a pump shelf portion whose diameter have been enlarged, an induction bar fixed into the tip of the knock bar, a brush provided on the tip side of the induction bar, and a spring for always energizing the above knock bar and induction bar rearward. On the internal periphery surface of the above tank portion, a plurality of ribs are formed which stretch axially and on top of which the above pump shelf portion can slide, the internal periphery surface ahead of the ribs is at the same level as and continuous with the top face of the ribs and designed as a diameter-reducing portion where the pump shelf portion can slide. The pump shelf portion slidably touches the ribs when it is not biased.”
[0036] The '739 Kageyama Patent is Related to the Previously Discussed Patent and Discloses:
“A liquid container includes a body having a tank portion housing liquid, and a liquid supply port at a front side thereof, a piston moving forward inside the tank portion, a piston rod being integrally connected to the piston and extending rearward, the piston rod having an external thread formed in a periphery thereof, an operation cylinder being attached to a rear part of the body in a relatively rotatable fashion, a piston rod guide being adapted to be rotated integrally with the operating cylinder, the piston rod guide having an internal thread hole which is engaged with the external thread of the piston rod, and a ratchet cylinder being fixed in the rear inside the body, the ratchet cylinder having a bore through which the piston rod is pierced in a relatively unrotatable fashion. The operation cylinder is formed with serrated gear teeth at a front end thereof, and the ratchet cylinder is formed with a ratchet gear tooth which is brought into engagement with the serrated gear teeth and adopted to be selectively protruded or retracted in an axial direction, at a rear end thereof.”
[0038] The Chen Published Patent Application Disloses:
“ FIG. 1 is a cross-sectional view of an applicator pen 100 according to a first embodiment. The applicator pen 100 is formed of a number of different sub-assemblies that are then combined in an engaging manner to form the applicator pen 100 . More specifically, the applicator pen 100 includes a body 110 and an applicator assembly 200 that serves to restrict and disperse an applicator material 112 that is stored within the body 110 . The applicator pen 100 also includes a drive mechanism 300 for advancing the applicator material 112 within the body 110 such that it is introduced into and dispersed through the applicator assembly 200 to the consumer. The drive mechanism 300 is coupled to a button assembly 400 that permits the consumer to simply advance the applicator material 112 an incremental amount within the body 110 upon manipulation of the button assembly 400 , e.g., a press and release action of the button assembly 400 . While the applicator material 112 can be any number of different types of materials, it will be appreciated that one exemplary use of the applicator 100 is as a cosmetic applicator and therefore, in this particular use, the applicator material 112 is in the form of a cosmetic product. For example, the applicator material 112 can in the form of conventional make-up, such as an eye shadow or liner, lipstick, other facial products, etc. The applicator material 112 is typically a viscous material, such as a liquid, gel or other material that has some flow properties.”
[0041] The focus of this patent application is primarily a cosmetic applicator for eyeshadow, a liner, etc. and not for teeth whitening.
[0042] The Noguchi Patent Discloses:
“In a liquid container, the dimension of inside diameter of a liquid supply portion is not subject to any restriction, and also a liquid leakage suppressing mechanism that is not subject to any restriction by the viscosity of stored liquid is provided. A liquid container includes a body having a tank for storing a liquid; a supply mechanism which is connected to the tip end portion of the body and has a brush for supplying the liquid; and a drive mechanism for pushing out the liquid L in the tank T to the supply mechanism. A valve which is normally closed and can be opened only when the drive mechanism is operated is provided between the tank and the supply mechanism.”
[0044] The Prencipe Published Patent Application Discloses:
“The dispenser 10 is shown as a complete unit in FIGS. 1 and 2 . The dispenser is comprised of three sections. These are an applicator section 12 , a whitening product storage section 14 and a dispenser drive section 16 . The applicator section is comprised of an overcap 18 , an applicator surface 30 , an applicator surface holder 32 , an applicator mounting unit 36 and a delivery channel 34 . The whitening product in product chamber 40 is delivered to the applicator surface through delivery channel 34 . A tubular wall 20 forms the product chamber 40 . Piston 42 forms the upper wall of product chamber 40 . The dispenser drive section 16 is comprised of the mechanism to advance piston 42 downward in whitening product chamber 40 . This dispenser drive section is shown in more detail in FIG. 5 . Rotating unit 22 will rotate while tubular wall 20 of the whitening product chamber is stationary. FIG. 7 shows an applicator tip with a fibrillated surface The applicator tip is comprised of channel 60 having a cross-section 65 which receives the peroxide containing tooth whitening composition from storage chamber 40 . Fibrillated surface 62 is the application surface to apply the composition to the teeth. The peroxide tooth whitening composition flows through opening 64 of the channel 60 . Applicator surface holder 66 holds channel 60 and is in turn held in place by applicator mounting unit 68 . FIG. 8 is an exploded view of the applicator tip of FIG. 7 . Additionally shown in this view is a chamber 70 on the applicator surface holder channel 72 of the applicator mounting unit 68 . Flange 74 holds the applicator surface holder 66 in applicator mounting unit 68 .”
[0048] The Dwyer Published Patent Application Discloses:
“A method for manufacturing a cosmetic product applicator assembly includes selecting a disposable handle having a desired design from a number of handles of various designs. Each of the handles includes an elongated, decorative housing with a first end having an opening, a hollow chamber extending from the opening into the housing, and a flattened portion for displaying a word, phrase, symbol or design. A cosmetic product applicator having a first terminal end from which the cosmetic product is dispensed and a second terminal end opposite the first terminal end is inserted into the handle. The hollow chamber is adapted to receive and engage the second terminal end of the applicator in a non-rotatable manner.”
[0050] The Thorpe Patent Discloses:
“As shown in FIGS. 2 and 5 , the twist up pen type dispenser with brush applicator 1 comprises a body 2 , preferably substantially in the shape of a cylinder, having a top 3 , a bottom 4 , an outer surface 5 and an inner surface 6 which defines an annular space 7 . As shown in FIGS. 4 and 5 , material 8 may be within the annular space 7 , which functions as a reservoir for the material 8 within the twist up pen type dispenser with brush applicator 1 . The material 8 may be a dentifrice, such as tooth gel, tooth paste, mouthwash, mouth rinse, tooth whitener and combinations thereof, cosmetics, such as mascara and eyeliner, hair colorants such as darkeners, like darkeners for facial hair such as moustaches, dyes or similar materials, or skin treatment compositions, combinations thereof, and the like.”
[0052] The Kageyama Published Patent Application Discloses:
“To provide a liquid container which includes a liquid supply member that is exchangeably mounted thereto and prevents liquids in liquid supply members from being mixed each other after exchanging the liquid supply members. The liquid container is provided which includes a container body with a tank section to hold a liquid, an applicator coupled to the front end of the container body, a piston which is advanced through the tank section, and a piston advancing mechanism which has a pushing member and causes the piston to be advanced through the tank section in response to the operation of the pushing member. The applicator is removably coupled to the container body, and the piston advancing mechanism causes the piston to be moved only forward.”
[0054] The Montgomery Published Patent Application Discloses:
“The first and/or second tooth whitening compositions are preferably disposed in a delivery device 10 (e.g., FIGS. 2-4, 9, and 10 ), such as a dispensing tube, pencil, pen or liquid stick having an applicator 12 , such as a felt tip 14 ( FIG. 3 ), brush 16 ( FIG. 4 ), roller ball, or non-woven pad. In one embodiment, the delivery device 10 includes more than one applicator 12 that may be removably engaged with the device 10 . In an embodiment wherein the device 10 is a pen or a pencil, the applicator 12 may be retractable and/or housed in a cap 18 . The tooth whitening compositions of the present invention may be housed directly within a reservoir 20 in the device 10 or may be supplied in a removable cartridge (not shown) within the reservoir 20 that may be replaced or refilled. The delivery device 10 may dispense the tooth whitening composition through a transfer channel 21 through capillary action, such as in a flow through pen, or through an actuator 22 , such as mechanical piston with a click mechanism, twist button and ratchet mechanism, or pushbutton mechanism, or through a vacuum method of ejection, or through other such mechanical means for transferring the composition from the device to an oral cavity surface in need of treatment. The actuator 22 may be present on first end 24 of the device 10 and the applicator on a second end 26 of the device 10 or the actuator 22 may be present on a side wall 28 of the device. In one embodiment, the delivery device 10 includes a felt tip 14 or brush 16 applicator 12 wherein the inventive composition is dispensed to the applicator 12 through actuation of the actuator 22 , such as by a clicking or twisting mechanism. Kotobuke Pencil, Japan, is one manufacturer of such types of delivery devices 10 (see, e.g., U.S. Pat. No. 6,176,632).
[0056] The Zhang Patent Discloses:
“The present invention is related to a press-type cosmetic container with an anti-press means. That is, a cosmetic container adopts the way of pressing to output the material therein. More particularly, the press cover of the cosmetic container is stopped by a block to prevent discharging or leaking the material in the cosmetic container.”
[0058] Claim 1 of the Patent Reads as Follows:
“A press-type cosmetic container with an anti-press means comprising: a tube member having a sleeve at the one end thereof, the outer edge of the sleeve being disposed a collar base; a rotating tube member being disposed a female ringing slot at the inner edge of the one end thereof, the rotating tube member being female-connected to the outer edge of the sleeve and the collar base of the tube member being slid on the female ringing slot so as to make the rotating tube member be turned around on the sleeve, wherein two axial extending ribs are disposed at the inner wall of the another end of the rotating tube member, a block is disposed between the two ribs, and a resisting member is disposed beside the two ribs; a press cover having two wedging member being extended outwardly and disposed on the two side edges thereof respectively, the one end of the press cover located at the wedging member being embedded at the inner edge of the free end of the rotating tube member, and the one wedging member being disposed beyond the two ribs; herein the block stops pressing the press cover in order to stop outputting material in the cosmetic container and then achieve the function of preventing improper pressing, and the rotating tube member is then turned around, the two wedging members are moved to locations beside the resisting member so as to output the material.”
[0060] The Uehara Published Patent Application Discloses:
“The present invention is a liquid applicator which, in its assembled state an applying part, joint, and front barrel are fixed to a barrel body front end portion, the step of an indented/projected engaging portion on the inner peripheral side of the applying part rear end portion is abutted from behind against and engaged with the step of an indented/projected engaging portion on the outer peripheral side of the forward part of the joint. At the same time, an indented/projected engaging portion on the outer peripheral side of the applying part rear end portion is abutted against and engaged with an indented/projected engaging portion on the inner peripheral side of the front barrel's forward part, and an indented/projected engaging portion on the inner peripheral side of the front barrel rearward part is engaged with an indented/projected engaging portion on the outer peripheral side in the rearward part of joint, whereby applying part, joint and front barrel are formed so as to fix the applying part to barrel body by means of the joint and the front barrel.”
[0062] The Akaishi Patent Discloses:
“A liquid applicator includes a liquid pressing mechanism 6 for pressurizing an application liquid 4 inside a main body 2 so as to supply the application liquid to an applying member 10 at the front end by the pressing of liquid pressing mechanism 6 , wherein the applying member 10 is made of an elastic material, has a valve structure 8 which is formed with a communication path 24 for communication between the inside and outside of main body 2 and can close the communication path 24 by elasticity in the normal condition and open the communication path 24 by elastic deformation of the communication path when the application liquid is pressurized by liquid pressing mechanism 6 , and, an ejection opening 24 a of communication path 24 of valve structure 8 is arranged to front onto the applying portion 10 a of the applying member 10 .”
[0064] The Wrightman Patent Discloses:
“A click pen applicator device that provides predetermined dosing of the formulation for precise application, and rapidly primes the formulation using the dosing click mechanism to prepare the applicator for use.”
[0066] Claim 1 of the Patent Reads as Follows:
“A device for dispensing a formulation comprising: a centerband having a proximal end and a distal end and defining a storage section having the formulation disposed within; an applicator section situated at the distal end of the centerband; and a multistage actuator section situated at the proximal end of the centerband for rapid priming with a click dispensing mechanism with a piston seat having two sets of external threads on a shaft with an unthreaded length therebetween.”
[0068] The Katsuhiko Japanese Patent Discloses:
“PROBLEM TO BE SOLVED: To obtain a coating liquid capable of coloring tooth or tooth crowns to white or any other color by using an acrylic resin prepared by neutralizing an acrylic ester-methacrylic eater-based copolymer with a specific compound. SOLUTION: This tooth coating liquid contusions ethanol and an acrylic resin prepared by neutralizing an acrylic ester-methacrylic ester-based copolymer with 2-amino-2-methyl-1,3-propanediol or 2-amino-2-methyl-1-propanol, and may also contain a color pigment or extender pigment, and furthermore, ceramic(s) and/or a vinyl acetate resin. It is preferable that this coating liquid comprises 10-94.8 wt. % or more of ethanol, 0.1-30 wt. % of a pigment, 0.1-20 wt. % of the above acrylic resin, and 5-30 wt. % of ceramic(s) and/or butyl acetate resin. The pigment is pref. titanium dioxide (optimally, 100 nm primary particle diameter on average).”
[0070] The Shuhei Japanese Patent Discloses:
“PROBLEM TO BE SOLVED: To provide a liquid container which includes a liquid supply member that is exchangeably mounted thereto and prevents liquids in liquid supply members from being mixed each other before and after exchanging the liquid supply members. SOLUTION: The liquid container includes a container body 12 with a tank section T to hold a liquid, an applicator 20 coupled to the front end of the container body 12 , a piston 22 which is advanced through the tank section T, and a piston pressing mechanism 23 which has a knocking member 32 and causes the piston 22 to be pressed through the tank section T in response to the operation of the knocking member 32 . The applicator 20 is removably coupled to the container body 12 , and the piston pressing mechanism 23 causes the piston 22 to be moved only forward.”
[0072] The Devaney Patent Discloses:
“A dispenser for precisely metering viscous fluids from a cartridge. The dispenser includes a cartridge body and a plunger having a piston head at its extremity. The plunger is unitarily configured from a plastic material, including seal rings in the piston head. Each piston head including two such seal rings axially spaced from one another and configured to include sharp peripheral edges permitting resilient wedging contact within the bore of the cartridge.”
[0074] The Schneider Patent Discloses:
“A dual component caulking gun which utilizes a gun body to which there is affixed a dual component cartridge assembly designed to carry dual component cartridges. A ball screw is journaled within the gun body for rotary motion but locked against axial motion and extends in a direction opposite the component cartridge assembly. A pair of ram rods are journaled through the gun body and terminate at the first end in ejector rams and at their opposite end in a transfer bar that is interconnected to the ball screw by means of a ball screw nut.”
[0076] The Dunning Patent Discloses
“A dispenser for simultaneously dispensing and mixing a pair of fluid products such as chemically reactive resins, from a pair of axial adjacent front and rear chambers. A piston is mounted within each of the chambers and is moveable with respect to the hollow interior of the respective chamber for dispensing the fluid product therefrom. Telescopic movement of the rear chamber within the front chamber moves the pistons synchronously through the chambers to provide for controlled discharge of the products through a front discharge nozzle. A fixed hollow delivery tube extends through the interior of the front chamber and telescopically receives therein a post which is mounted on a rear wall of the rear chamber. The rear chamber has a relatively tight sliding fit within the front chamber so that a partial vacuum is formed within an annular space which forms between the two pistons as they move apart upon discharge of the two products to produce a “suck back” effect on product remaining in the discharge nozzle.”
[0078] The Simmen Patent Discloses:
“A dispensing and mixing apparatus for simultaneously dispensing from a cartridge into a static mixing element components which harden when mixed. The components exit the cartridge into the mixing element without intermixing as the components leave the cartridge. The initial intermixing of the components takes place within the mixing element. The cartridge is reusable since the components do not become mixed and harden as they come out of the cartridge. The chambers in the cartridge are of semi-cylindrical configuration and have rounded corners. Ribs can be provided on the cartridge for stiffening the cartridge from deforming under extrusion.”
[0080] The Maziarz Patent Discloses:
“The invention provides a dispensing module for dispensing multi-part adhesive from a multi-component cartridge utilizing a standard caulking gun. The dispensing module comprises a piston actuator and a module housing which when assembled with a standard multi-component cartridge and inserted into a standard caulking gun allows the components from the multi-component cartridge to be dispensed.”
[0082] The Ostler Patent Discloses:
“A dental bleach storage, mixing and delivery device and related method are disclosed. The device includes a barrel with at least two chambers. The chambers store components that when mixed can form a dental bleach or whitener. A plunger is provided that can be reciprocated within the barrel to force such components from their chambers. A mixing tip is provided for the end of the barrel. The components may be forced through the mixing tip which thoroughly mixes them together. The resulting bleach or whitener is applied to a patient's teeth where oxygen ions released from the bleach or whitener and will whiten the patient's teeth.”
[0084] The Furlong Patent is a pen dispensing cartridge system which issued in 2001 and is still in full force and effect. The patent discloses:
“The present invention features a pen used, for example, to dispense nail polish for finger nail application. The design is for a unit of use, meaning that the preferred pen uses cartridges, i.e., units. In a preferred embodiment, each cartridge is filled with polish and has a brush head. After the cartridge is used, the user simply disposes of the old cartridge and replaces it with a new cartridge for the next application.”
[0086] The Francavilla Discloses:
“The present invention is related to a dispensing device. The dispensing device includes a container; a dispensing opening located at one end of the container; a plunger located inside the container; a pushbutton associated with the plunger; and a drive mechanism configured to drive the plunger linearly inside the container from a first position towards the dispensing opening when the pushbutton is pressed and to hold the plunger at a second position, wherein the second position is closer to the dispensing opening than the first position.”
[0088] The Reidt Patent Discloses:
“Capsule ( 10 ) for two or more components of a material which are to be mixed together, comprising a cartridge ( 11 ) comprising an outlet ( 12 ), a first component chamber ( 13 ) for containing a first component, and a second component chamber ( 14 ) for containing a second component, the two chambers ( 13 , 14 ) opening into the outlet ( 12 ); and a piston ( 15 ) which at least with its front end sits in the cartridge ( 11 ), lies with its rear end outside the component chambers ( 13 , 14 ) and, when it is pushed forwards, presses the two components out of their component chambers ( 13 , 14 ).”
[0090] The Mulhauser Patent discloses a dispenser for dental compositions.
[0091] Claim 1 of this Patent Reads as Follows:
“An apparatus for dispensing dental compositions, the apparatus comprising: a) a body comprising a top shell portion, a bottom shell portion, and a chamber received therein; b) a replaceable cartridge having at least two lumens with at least two pistons, the cartridge operable to dispense a component of a dental compound contained within the lumens, and wherein the cartridge is further operable to be at least partially inserted into the chamber; c) an inner mechanical system disposed in the body, the inner mechanical system comprising a rack system, said rack system having at least two racks operable to be urged forward to engage a piston in each lumen of the cartridge; d) a button system in contact with the body, the button system operable to be depressed in a direction substantially forward and in line with the rack system by a user such that the button system engages the inner mechanical system when depressed, such that the rack is advanced a predetermined distance such that a metered amount of the components of the dental compound is dispensed from the at least two lumens; and e) wherein the inner mechanical system further comprises a plurality of teeth disposed on the rack system, and a drive spring and a pawl spring disposed on the body, the drive spring and the pawl spring being operable to interface with at least one of a plurality of teeth on the rack system and at least one surface of the button system such that depression of the button system by a user initiates drive spring to advance the rack system a predetermined distance proportional to the distance between a first selected tooth located on the rack and a second selected tooth located on the rack and initiates the pawl spring to disengage from a third selected tooth on the rack and engage a fourth selected tooth on the rack located at a distance substantially equal to the distance between the first tooth and the second tooth, and release of the button causes the drive spring to disengage from said first selected tooth and engage the second selected tooth on the rack.”
[0093] The Keller Patent discloses a dispensing appliance for a multiple cartridge. The broadest claim is claim 1 which reads as follows:
“A dispensing appliance for a multiple cartridge or syringe, comprising: a housing configured to receive the multiple cartridge or syringe, and wherein the housing has a housing thread and a rotatable portion that has a complementary thread, wherein the housing thread and the rotatable portion cooperate in such a manner that by a mutual rotation of the housing thread and the rotatable portion, the rotatable portion is continuously displaceable relative to the housing in a dispensing direction, wherein the housing is configured to receive the multiple cartridge or syringe having at least two adjacent and parallel storage containers, wherein a thrust force of the rotatable portion is transmitted to a multiple ram with a single thrust plate, and wherein the multiple ram slides in the at least two adjacent and parallel storage containers of the multiple cartridge or syringe and the thrust plate is non-rotatably guided inside the housing.”
[0095] There is a significant need for an improved apparatus to dispense compounds including but not limited to tooth whitening compounds where the tooth whitening compounds are dispensed from a new and unused retainers. There is also a significant need for an improved apparatus to dispense dental bonding compounds from new and unused retainers and adhesive compounds from new and unused retainers.
SUMMARY OF THE INVENTION
[0096] The present invention involves the field of numerous types of compounds which by way of example includes tooth whitening compounds and in particular, to specific apparatus which are used to retain tooth whitening compounds and then dispense them either into a dental tray where the tray is placed over the patient's teeth for a period of time or the tooth whitening compound is directly applied to the patient's teeth by the dentist or the dental assistant. More broadly described, the present invention includes compounds and applicators used to dispense the compounds including tooth whitening compounds, dental bonding and filling compounds, adhesives such as glue, finely ground powder, jells, creams, paints, cosmetics, lipstick, non-medicated cosmetics, medicated cosmetics, construction material compounds, and virtually any substance that has a sufficient viscosity to be pushed through a dispensing cartridge in a dispensing pen and either out of the cartridge, from the cartridge into an applicator, or from the cartridge into a mixing chamber and then out of the mixing chamber primarily into an applicator, which are hereafter jointly referred to in this patent application as “compounds”.
[0097] The cartridges have either a single interior chamber or two interior chambers where the dual or two chambers are separated by a dividing wall. For a compound that does not require mixing, a single compound in a single interior chamber cartridge is used. Where two compounds are divided and only mixed immediately before use, the dual interior chamber cartridge is used.
[0098] Although the summary discussed below relates to tooth whitening compounds in detail, it is understood that the present invention includes all products defined above as compounds and is not limited to tooth whitening compounds.
[0099] The present invention involves a dispensing pen which removably retains a single use capsule containing tooth whitening compound and removably retains disposable tooth whitening applicators. One of the major problems with prior art tooth whitening applicators is that the applicator itself is reused over and over again through syringes which contain the tooth whitening compound and even though they are sterilized, run the risk of transmitting disease from one patient to another. Therefore, there is a significant need for an improved tooth whitening apparatus where the capsule containing the tooth whitening compound or compounds is disposable and replaceable with a new clean capsule with a fresh supply of tooth whitening compound or compounds and the applicator heads which are used to apply the compounds to teeth or to a dental tray are also disposable and replaced with new applicators so that the patient receives a completely new and sterile system for the purpose of applying tooth whitening compounds. The only portion of the apparatus which is reused is the retaining pen which is used to removably retain the tooth whitening compound and to removably retain the tooth whitening applicators.
[0100] The variations of the embodiments of the present invention involve two variations on the interior of the single use capsule. The variations of the embodiments of the present invention also involve the location of the single use capsule.
[0101] In one embodiment of the present invention, the interior chamber of the unidose single use cartridge or capsule contains tooth whitening compound in a sealed condition with a cap that has an openings which is sealed by a frangible opening which seals the capsule until it is ready for use and a screw on cap which contains at a remote end a piercing object to pierce the frangible seal so that the tooth whitening compound can be dispensed from the capsule. In one variation, the capsule or cartridge has a single interior chamber so that the tooth whitening compound does not require any mixing before the tooth whitening compound is dispensed from the capsule or cartridge (capsule and cartridges are used and referred to interchangeably). For this variation, the rear of the interior chamber of the capsule or cartridge contains a single plunger having a pair of spaced apart sidewalls forming a seal against the interior sidewall of the cartridge. The rear of the plunger also includes a single pocket which receives a pushing piston from the retaining pen, the pushing piston is moves in a forward direction within the pen by an improved ratchet mechanism of the present invention. The pushing piston engages and pushed the single pocket in the rear of the single plunger to push the compound out of the cartridge through an opening in a front nozzle of the capsule after a seal on the nozzle is opened. In one sub-variations of this embodiment, the cartridge is retained within an interior chamber of the pen withe the nozzle extending through a front opening in the pen. In another sub-variation, the pen has a threaded exterior sidewall with male threads adjacent the front of the pen and the cartridge has mating interior female threads by which the cartridge is threaded onto the front of the pen and extends from the front of the pen and is exterior to the pen. The is still a similar sealing configuration on the rear of the cartridge which the single piston pushing against the single pocket in the sealing plunger which now extends out of the pen into the exterior cartridge. The same new and novel ratch mechanism pushes the piston in increments to push the plunger which pushes the whitening compound out of the opening in the nozzle.
[0102] In an alternative embodiment of the present invention, the interior chamber of the unidose single use cartridge or capsule also contains tooth whitening compound in a sealed condition with a cap that has an openings which is sealed by a frangible opening which seals the capsule until it is ready for use and a screw on cap which contains at a remote end a piercing object to pierce the frangible seal so that the tooth whitening compound can be dispensed from the capsule. In the alternative variation, the capsule or cartridge has an interior longitudinal dividing wall with separate tooth whitening compounds in each chamber bounded by an interior surface of the cartridge and the dividing wall. The divided interior chamber retains two separate compounds which are separated from each other while in the cartridge by the a dividing wall. The interior rear of the cartridge has a different plunger having opposing interior faces to push a compound in a respective portion of the interior of the cartridge forward and out of the cartridge, and a pair of opposed angular sidewalls ending in rear wall sidewalls forming a seal against the interior sidewall of the cartridge. Each rear end of the plunger has a pocket to receive a respective pushing piston from a dual piston mechanism in the retaining pen. The interior chamber is divided into two equal chambers which contain different compounds which cannot come in contact with each other because the dividing wall extends for the entire diameter and length of the interior chamber of the cartridge. For dual compounds where less is need of one of the two compounds, the dividing wall is thicker on one side to reduce the volume of compound in the smaller chamber, the design of the plunger is modified to accommodate the revised sidewall. For the operating mechanism for the dual chamber cartridge, the mechanism includes a pair of pistons which are respectively used to engage a respective pocket of the two-pocket plunger used with the dual chamber cartridge and a ratchet mechanism to incrementally move each pushing piston in a forward direction within the pen by an improved ratchet mechanism of the present invention. The pushing pistons respectively engage and push a respective one of the two pockets in the rear of the dual plunger to push the compounds out of the cartridge through an opening in a front nozzle of the capsule after a seal on the nozzle is opened. After the compounds are pushed out of the cartridge, they are mixed in ax a mixing chamber before being dispensed. In one sub-variation of this embodiment, the cartridge is retained within an interior chamber of the pen withe the nozzle extends through a front opening in the pen. In another sub-variation, the pen has a threaded exterior sidewall with male threads adjacent the front of the pen and the cartridge has mating interior female threads by which the cartridge is threaded onto the front of the pen and extends from the front of the pen and is exterior to the pen. The is still a similar sealing configuration on the rear of the cartridge which the dual pistons respectively pushing against a respective one of the two pockets in the sealing plunger which now extends out of the pen into the exterior cartridge. The same new and novel ratch mechanism pushes the pistons in increments to push the plunger which pushes the whitening compound out of the opening in the nozzle into the mixing chamber.
[0103] The additional significant improvement is the new sand novel ratchet mechanism which mechanically pushes the single piston or dual pistons in increments to push a plunger in increments to dispense a desired amount of compound.
[0104] After the compound, wether single or mixed dual is dispensed, it extends to an applicator. With respect to alternative embodiments of the applicators, one embodiment is a straight applicator which is generally frustum shaped having a narrow dispensing tip and a threaded end which is threaded onto either the threaded end of the mixing tip or a threaded end of the cartridge and through which the tooth whitening compound flows and can be placed either into a dental tray or onto a patient's teeth.
[0105] In an alternative embodiment of the applicator, the applicator is horn-shaped or bent so that the tooth whitening can be directly applied to locations in the patient's mouth where teeth are near the back of the mouth, either upper or lower teeth and usually on the exterior but if necessary, also on the top or interior of the tooth.
[0106] In an alternative embodiment of the applicator, the applicator has an opening with a brush so that the tooth whitening compound extends through the applicator opening and then the brush is used to apply the tooth whitening compound onto the patient's tooth.
[0107] It is a primary object of the present invention to provide a reusable capsule and reusable applicator so that tooth whitening compounds which are contained in the capsule are used only once and the applicators used to apply the tooth whitening compound are also used only once and then discarded and replaced with a separate tooth whitening compound retaining capsule or cartridge and also replaced with separate applicator heads.
[0108] It is a further object of the present invention to provide a single use cartridge or capsule which contains a single compound which does not need to be mixed with any other compound and can simply be dispensed once the sealed capsule or cartridge is opened to dispense the tooth whitening compound onto teeth or onto a dental tray where it can be used.
[0109] It is a further object of the present invention to provide a single use capsule which has a dividing wall so that the capsule contains two separate compounds which are separated from each other and which may either have equal amounts of compounds on either side of the dividing wall or different amounts of compound where one compound is less than the other compound depending upon the formulation required for that tooth whitening application and then the compounds are mixed when they enter a chamber for mixing purposes.
[0110] It is the primary object of the present invention to provide a non-reusable container and non-reusable applicator head so that a fresh container containing fresh tooth whitening compounds, fresh dental bonding and filling compounds and adhesive compounds and fresh new applicators are used every time a new compound is dispensed so that a compound is not reused from one patient to another or from one adhesive bonding application to another, thereby providing safety and health to subsequent patients and products.
[0111] Further novel features and other objects of the present invention will become apparent from the following detailed description, discussion and the appended claims, taken in conjunction with the drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0112] Referring particularly to the drawings for the purpose of illustration only and not limitation, there is illustrated:
[0113] FIG. 1 is a cross-sectional view of the dispensing pen which retains a single use cartridge within the dispensing pen and further discloses the new and novel mechanical ratchet mechanism of the present invention;
[0114] FIG. 2 is a top left perspective view of the dispensing pen with the dispensing pen illustrated in a transparent exterior to enable illustration of a portion of the opera+ting mechanism of the new and novel mechanical ratchet mechanism;
[0115] FIG. 3 is a top left enlarged perspective view of a section of the dispensing pen with the enlarged section of the dispensing pen illustrated in a transparent exterior to enable illustration of an enlarged portion of the operating mechanism of the new and novel mechanical ratchet mechanism;
[0116] FIG. 4 is a top right enlarged perspective view of a section of the dispensing pen with the enlarged section of the dispensing pen illustrated in a transparent exterior to enable illustration of an enlarged portion of the operating mechanism of the new and novel mechanical ratchet mechanism;
[0117] FIG. 5 is a top right perspective view of the dispensing pen with the dispensing pen illustrated in a transparent exterior to tenable illustration of a portion of the opera+ting mechanism of the new and novel mechanical ratchet mechanism;
[0118] FIG. 6 is a top perspective view of the unidose single use cartridge which contains a compound as defined above including compound selected from the group consisting of a tooth whitening compound, a dental bonding and filling compound, and an adhesive compound in a sealed condition with the cap threadedly retained onto the single use cartridge, and which cartridge is disposed of and replaced with a new single use cartridge for subsequent application of a compound;
[0119] FIG. 7 is an exploded view showing the same capsule illustrated in FIG. 6 but with the sealing cap removed, the single use capsule or cartridge (the term capsule or cartridge are used interchangeably) having an exterior surface which is generally cylindrical in shape and a rear surface which is generally flat with an opening, a front surface which is generally frustum shaped extending from the body of the cylinder to a nozzle having a cylindrical surface extending from the frustum and extending to a dispensing nozzle tip having threads on the exterior surface and a frangible seal on the front end of the tip, also illustrating the threaded cap which is cylindrical and a front end with an interior chamber having a piercing tooth;
[0120] FIG. 8 is a bottom perspective view of the unidose single use cartridge with an anti-rotation slit in the bottom of exterior surface of the exterior wall of the tooth whitening retaining cartridge, the slit does not extend so deep that it goes into the interior chamber of the cartridge, the purpose of the anti-rotation slit is to be inserted into a mating member in the dispensing pen to prevent the cartridge from rotating once it is placed into the pen.
[0121] FIG. 9 is a side cross-sectional view of a first embodiment of the unidose single use cartridge illustrating a single interior chamber which retains one compound, and a rear plunger having an interior face to push the compound in the interior of the cartridge forward and out of the cartridge, and an angular sidewall ending in a rear wall forming a seal against the interior sidewall, the rear end of the plunger having a pocket to receive a single pushing piston;
[0122] FIG. 10 is an exploded view illustrating the front of the multi-sectional shaft and a single piston and a dual piston;
[0123] FIG. 11 is a top cutaway view of a second embodiment of the unidose single use cartridge having a divided interior chamber which retains two separate compounds which are separated from each other while in the cartridge by a dividing wall, and a rear plunger having opposing interior faces to push a compound in a respective portion of the interior of the cartridge forward and out of the cartridge, and a pair of opposed angular sidewalls ending in rear wall sidewalls forming a seal against the interior sidewall of the cartridge, each rear end of the plunger having a pocket to receive a respective pushing piston from the dispensing pen;
[0124] FIG. 12 is an exploded view illustrating a top right perspective view of the unidose dispensing pen with a single piston affixed to the new and novel ratchet operating mechanism illustrated in FIG. 1 within the dispensing pen, and a single chamber cartridge before it is inserted into a chamber adjacent the front of and within the dispensing pen and also illustrating a cartridge anti-rotation member within the chamber;
[0125] FIG. 13 is a top right side perspective view of the dispensing pen of the present invention as illustrated in FIG. 12 , with the cartridge within the dispensing pen having the new and novel ratchet mechanism of the present invention as illustrated in FIGS. 1-5 , with the single use cartridge retained within the interior chamber of the dispensing pen with the front portion of the top removed and the threaded nozzle protruding through the front opening of the dispensing pen;
[0126] FIG. 14 is a longitudinal cross-sectional view of the mixing nozzle of the present invention used with a cartridge having a divided interior housing two separate compounds;
[0127] FIG. 14A is perspective view of the entire mixing nozzle including the two halves as illustrated in FIG. 14 sonic welded together at their respective mating surfaces at a location illustrated along a seam line to form an entire mixing tip;
[0128] FIG. 15 is a perspective view of a straight dispensing nozzle used with a single chamber cartridge or used with a mixing tip and a dual chamber cartridge;
[0129] FIG. 16 is a cross-sectional view of the straight dispensing nozzle illustrated in FIG. 15 ;
[0130] FIG. 17 is a perspective view of a bent horn tip dispensing nozzle used with a single chamber cartridge or used with a mixing tip dual chamber cartridge;
[0131] FIG. 18 is a cross-sectional view of the bent horn tip dispensing nozzle used with a single chamber cartridge or use with a mixing top dual chamber cartridge;
[0132] FIG. 19 is a cross-sectional view of an applicator brush;
[0133] FIG. 20 is a cross-sectional view of the dispensing pen which retains the new and novel mechanical ratchet mechanism of the present invention, with a single use cartridge threaded onto the front of the cartridge, the single use cartridge being either a single chamber cartridge as previously described with a single pushing piston or a dual chamber cartridge with a dual piston as previously described, the applicators and mixing chamber, as required respectively threaded onto the threaded nozzle in the front of the cartridge;
[0134] FIG. 21 is a side cross-sectional view of a first embodiment of the unidose single use cartridge illustrating a single interior chamber which retains one compound, and a rear plunger having an interior face to push the compound in the interior of the cartridge forward and out of the cartridge, and an angular sidewall ending in a rear wall forming a seal against the interior sidewall, the rear end of the plunger having a pocket to receive a single pushing piston, where the single chamber cartridge is retained on the front of the dispensing pen;
[0135] FIG. 22 is a top cutaway view of a second embodiment of the unidose single use cartridge having a divided interior chamber which retains two separate compounds which are separated from each other while in the cartridge by a dividing wall, and a rear plunger having opposing interior faces to push a compound in a respective portion of the interior of the cartridge forward and out of the cartridge, and a pair of opposed angular sidewalls ending in rear wall sidewalls forming a seal against the interior sidewall of the cartridge, each rear end of the plunger having a pocket to receive a respective pushing piston from the dispensing pen; and
[0136] FIG. 23 is a top view of the present invention dispensing pen in the closed position.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0137] Although specific embodiments of the present invention will now be described with reference to the drawings, it should be understood that such embodiments are by way of example only and merely illustrative of but a small number of the many possible specific embodiments which can represent applications of the principles of the present invention. Various changes and modifications obvious to one skilled in the art to which the present invention pertains are deemed to be within the spirit, scope and contemplation of the present invention as further defined in the appended claims.
[0138] The variations on the single use cartridges have been summarized in detail in the summary of the invention section. The cartridge variations are summarized as follows:
[0139] (1) a single use cartridge having a single interior chamber housing a compound. This variations has two sub-variations: (a) the single use cartridge is within a chamber within the mechanical dispensing pen with a nozzle extending out of an opening in the dispensing pen; and (b) the single use cartridge is threaded onto threads adjacent the opening of the mechanical dispensing pen and is outside of the dispensing pen. In both sub-variations, the nozzle from the single use cartridge is threaded onto an applicator or brush.
[0140] (2) A single use cartridge having a double interior chamber divided by a dividing wall so that a respective compound is in each separate chamber of the dual chamber single use cartridge. This variations also has the same two sub-variations: (a) the single use cartridge is within a chamber within the mechanical dispensing pen with a nozzle extending out of an opening in the mechanical dispensing pen; and (b) the single use cartridge is threaded onto threads adjacent the opening of the dispensing pen and is outside of the dispensing pen. In both sub-variations, the nozzle from the single use cartridge is threaded onto a mixing chamber where the two compounds are mixed after being dispensed from the single use cartridge, and the mixing chamber has a nozzle which is threaded onto an applicator or brush after the mixing process. These variations and sub-variations will be described after discussion of the new innovations in this invention.
[0141] The variations are all utilized with the innovative new mechanical ratchet mechanism for advancing the piston within the dispensing pen to push against a pocket in a sealing plunger located adjacent the interior rear of the single use cartridge. For the variation where the single use cartridge has one chamber, the sealing pushing plunger has one pocket to receive one pushing piston. For the variation where the single use cartridge has a dual chamber, the sealing pushing plunger has two pockets to respectively receive a respective one of the dual pushing pistons to push a respective half of a the sealing plunger to dispense each respective compound. In either variation, the new and novel ratchet mechanism to push either a single or dual pushing piston is the same.
[0142] The dispensing pen has two variations, one where there is an interior chamber to receive the single use cartridge within the dispensing pen. This variation will be described first. FIG. 1 is a cross-sectional view of the dispensing pen 1000 which retains a single use cartridge 10 A within the dispensing pen. A cross-sectional view of the new and novel ratchet mechanism 1100 is disclosed in the cross-sectional view of FIG. 1 . FIG. 2 is a top left perspective view of the dispensing pen with the dispensing pen illustrated in a transparent exterior to enable illustration of a portion of the operating mechanism of the present invention. FIG. 3 is a top left enlarged perspective view of a section of the dispensing pen with the enlarged section of the dispensing pen illustrated in a transparent exterior to enable illustration of an enlarged portion of the operating mechanism of the present invention. FIG. 4 is a top right enlarged perspective view of a section of the dispensing pen with the enlarged section of the dispensing pen illustrated in a transparent exterior to enable illustration of an enlarged portion of the operating mechanism of the present invention. FIG. 5 is a top right perspective view of the dispensing pen with the dispensing pen illustrated in a transparent exterior to enable illustration of a portion of the operating mechanism of the present invention.
[0143] Referring to FIGS. 1 through 5 , the dispensing pen 1000 has a circumferential wall 1020 with an exterior surface 1022 and an interior surface 1030 (See FIG. 2 ). The dispensing pen 1000 has an open rear end 1060 covered by a sealing cap 1200 . The dispensing pen has a front end wall 1080 with a front end opening 1090 extending from the front end wall 1080 . The interior surface 1030 and sealing cap 1200 surrounds an interior chamber 1300 which retains the ratchet operating mechanism 1400 which is comprised of the following components. An operating pushbutton 1410 which has a rear end 1420 and an arcuate lower surface 1430 about which the operating pushbutton 1410 pivots. The circumferential wall 1020 of the dispensing pen 1000 has an opening 1024 through which the front end 1432 and top surface wall 1436 of the operating pushbutton 1410 extend. Referring to FIG. 5 , the lower arcuate surface 1430 of the operating pushbutton 1410 rests on a pushbutton connection base 1440 having a seat 1442 on which the lower arcuate surface 1430 pivots. The pushbutton connection base 1440 (See FIG. 2 ) has a first foot 1444 A (see FIG. 4 ) extending from a width-wise first front and underside member 1444 B, the first foot member 1444 A has a longitudinal body 1444 C terminating in a slanted front face 1444 D and a parallel oppositely disposed second foot 1446 A extending from a width-wise second front and underside member 1446 B, the second foot member 1446 A has a longitudinal body 1446 C terminating in a slanted front face 1446 D. The pushbutton connection base 1440 has a rear end 1448 (see FIG. 4 ) with a longitudinal pivot member 1448 A (see FIG. 2 ) extending away from the rear end and against an interior location 1030 A of interior wall 1030 which serves as a connection point for the pushbutton connection base 1440 .
[0144] Beneath the pushbutton connection base 1440 is a longitudinal slide member 1550 having a longitudinal exterior surface 1552 with a first circumferential stop member or ring 1554 (see FIG. 2 ) encircling the longitudinal exterior surface 1552 at a spaced apart location from the front 1556 of the longitudinal slide member 1550 . A rear circumferential stop member or ring 1558 located at a rear end 1560 of the longitudinal slide member 1550 (see FIG. 4 ) and including an upper shaft holder 1562 (see FIG. 3 ) extending away from the rear end 1560 , the upper shaft holder having a downwardly extending clip 1562 A; a lower shaft holder 1564 extending away from the rear end 1560 and having an upwardly extending clip 1564 A The longitudinal exterior surface 1552 has a first or right flatted sidewall 1552 R with a first or right ramp 1552 RR extending from an interior surface section 15541 of first circumferential stop ring 1554 to adjacent a bottom longitudinal portion 1554 RB of the right flattened sidewall 1552 R and a second or left flattened sidewall 1552 L with a second or left ramp 1552 LR extending from an interior surface section 15541 of first circumferential stop ring 1554 to adjacent a bottom longitudinal portion 1552 LB of the left flattened sidewall 1552 L.
[0145] The longitudinal slide memberl 550 includes an interior longitudinal generally cylindrical opening 1550 - 0 extending for the entire length “L 1 ” of the longitudinal slide member 1550 and bounded by a longitudinal interior circumferential wall 1550 IW, and open at its front end 1550 -OF and open at its rear end 1550 -OR. A multi-section shaft 1570 has a smooth outer surface section 1772 which extend through the entire length of the interior longitudinal generally cylindrical opening 1550 - 0 and for a given distance beyond the open front end 1550 -OF adjacent a front interior wall 1070 has a cylindrical supporting arm 1070 A extending interiorly toward the longitudinal side member 1550 , and having a central opening 1070 - 0 which receives and supports a front end 1570 F of shaft 1570 . A first compression spring 1580 SP is supported by cylindrical supporting arm 1070 A at a front end and by a front section 1570 SF of the slide member 1570 , the slide member having a front cylindrical exterior separation wall which separates the rear of the first compression spring 1580 SF from the pushbutton 1410 when it is depressed.
[0146] The second section 1574 of the multi-section shaft 1570 has a multiplicity of adjoining ratchet teeth 1600 extends from a given distance “L 2 ” behind the opening at the rear end 1570 -OR of slide member 1570 to adjacent a rear multi-section end 1570 -RE of the multi-section shaft 1570 . The rear end 1570 -RE ends in a solid plug member 1560 which in turn in received in and supported by sealing cap 1200 . Each individual ratchet tooth is in the shaped of an isosceles triangle beginning with a sloped side and extending at an upward slant to a rear end for a shot straight edge of the triangle, a second section 1574 serving as the long straight edge of the triangle. The triangles are formed as identical mirror images of each other at a same location of the second section 1574 and respectively above and below the second section 1574 . Each ratchet tooth above the second section 1574 is referred to as an upper ratchet tooth 1600 -U with an upper vertical wall 1600 -UV and an upper forwardly slanted surface 1600 -USL. Each ratchet tooth below the second section 1574 is referred to an a lower ratchet tooth 1600 -L with a lower vertical wall 1600 -LV and a lower forwardly slated surfaced 1600 -LSL.
[0147] A second or rear compression spring 1580 SR extends around all of the multiplicity of ratchet teeth 1600 and is retained at a rear end on the solid plug member 1060 and retained on a front end is retained on upper shaft holder 1562 and on lower shaft holder 1564 .
[0148] In operation, the novel and unique improved mechanical ratchet operating mechanism 1400 is operated as follows. The first compression spring 1580 SP and the second compression spring 1580 SR are in their uncompressed state. The operating pushbutton 1410 is elevated in the uncompressed state. The downwardly extending clip 1562 A rests on an uppermost portion of an upper forwardly slanted surface 1600 -USL adjacent a vertical wall 1600 -UV of an upper ratchet tooth 1600 -U and an upwardly extending clip 1564 A rests on a lowermost portion of a lower forwardly slanted surface 1600 -LSL adjacent a lower vertical wall 1600 -LV of a lower ratchet tooth 1600 -L To begin the process of moving the multi-section shaft 1570 incrementally forward by a ratchet step (as will be described the front end 1570 F is connected to a single or double piston which pushes a sealing plunger in a cartridge forward to push the compound or compounds within the cartridge forward and eventually out of the cartridge), the operating pushbutton 1410 is pressed downwardly by pushing top surface wall 1436 adjacent a front location 1432 of the top surface wall 1536 towards the slide member 1570 . In this process, the downwardly pressed pushbutton 1410 causes its arcuate lower surface 1436 to pivot causing pushbutton connection base 1440 to move in the same downward direction which in turn causes slanted front faces 1444 D and 1446 D of the respective first foot member 1444 A and second foot member 1446 A to respectively slide down right ramp 1552 RR and left ramp 1552 LR of slide member 1550 . When the operating pushbutton 1410 is fully pressed all the way down, the first and second foot 1444 A and 1446 A of the pushbutton connection base 1440 have respectively slid down ramps 1552 RR and 1552 LR which caused the slide member 1570 to move forwardly by the horizontal distance of the ramps ( 1552 RR-HD and 1552 LR-HD). This in turn compresses first compression spring 1580 SP and advances the multi-section shaft 1570 forward by the a horizontal distance of a tooth ( 1600 -U and 1600 -L) which in turn compresses second spring 1580 SR. When the operating pushbutton is released, the clips 1662 A and 1664 A have slid down a respective slanted surface 1600 -USL and 1600 -RSL and respectively stop at the next vertical wall 1600 RV and 1600 -LV of a ratchet and holds the multi-sectioned shaft 1570 from moving backward. The slide member 1570 moves backwards due to the uncompressed first compression spring 1580 SB by first and second foot 1444 A and 1446 A sliding back up respective ramps 1552 RR and 1552 LR which then allows clips 1562 A and 1564 A to jump to the next slanted surface 1600 -USL and 1600 -RSL of the next tooth 1600 -U and 1600 -L.
[0149] This process continues as the operating pushbutton 1410 is pressed until the multi-section shaft 1570 is completely extended and the second compression spring 1580 SR is completely compressed.
[0150] To retract the multi-section shaft back to its original or starting point, it is necessary to disengage the ratchet teeth 1600 -U and 1600 -L from the downwardly extending ratch tooth engagement clip 1562 A and upwardly extending ratchet tooth engagement clip 1564 A. Surrounding the exterior surface 1022 of the exterior wall 1020 of the dispensing pen 1000 at a location between the slide member 1570 and the upper shaft holder 1562 -U and lower shaft holder 1564 -L is a rotational switch 1700 . Referring to FIGS. 2 and 3 , the rotational switch 1700 is connected to a locking element 1710 attached to a cylindrical locking member 1720 physically attached to the multi-section shaft 1570 . When the rotational switch 1700 is rotated, the locking element 1710 and cylindrical locking member 1720 also rotate, thereby causing the multi-section shaft 1570 to rotate until clips 1562 A and 1564 A are disengaged from the ratchet teeth 1600 -U and 1600 -L. Upon such disengagement, second compression spring 1580 SR retracts the multi-section shaft 1070 back to its starting position. The rotational switch 1700 is rotated in the opposite direction back to its original position, the locking element 1710 and cylindrical locking member 1720 are also rotated back to their original position, thereby causing the multi-section shaft 1570 to rotate back its original position until clips 1562 A and 1564 A are re-engaged with the ratchet teeth 1600 -U and 1600 -L to begin the starting position.
[0151] Referring to FIG. 6 , there is illustrated an exterior perspective view of a cartridge or capsule 10 A with a front cap 30 A attached, which is used when the cartridge is inserted into an interior chamber within the dispensing pen 1000 . The interior will vary as discussed above. For a single interior chamber cartridge, the letter “A” is used with a corresponding part. The letter “A” is not used when the interior of the cartridge 10 has a dual chamber. The exterior is the same for both. In FIGS. 6, 7 and 8 , the letter “A” is used since the cross-sectional view of FIG. 9 illustrates a cartridge 10 A with a single interior chamber.
[0152] Further referring to FIG. 7 , there is illustrated an exploded exterior view of a single use capsule or cartridge 10 A (the term capsule or cartridge are used interchangeably) with the cap 30 unscrewed. The single interior use cartridge 10 A contains an exterior surface 12 A which is generally cylindrical in shape and a rear surface 14 A which is generally flat. The front surface 18 A is generally frustum shaped extending from the body of the cylinder 10 A to a nozzle 32 A having a cylindrical surface 20 A extending from the frustum 18 A and extending to a dispensing nozzle tip 22 A having threads 24 A on the exterior surface and a frangible seal 26 A on the front end of the tip 22 A. The threaded cap 30 A is cylindrical with a front end 38 A with an interior chamber 40 A having a piercing tooth 42 A within the interior 40 A which extends inwardly from the front end 38 A of the sealing cap 30 A. In use, after the cartridge 10 A is placed in the dispensing pen 1000 as will be discussed, the front or tip 22 A of the single use cartridge 10 A extends through an opening in the dispensing pen and the threaded cap 30 A which is previously unscrewed from the threads 24 A of the capsule 30 A before the capsule or cartridge 10 A is inserted into the dispensing pen 1000 , is then rotated 180 degrees so that the sharp tooth 42 A penetrates the frangible seal 26 A so that the tip 22 A is opened and a selected compound 100 A is dispensed from the interior 50 A of the cartridge or capsule 10 A.
[0153] Referring to FIG. 8 , there is a illustrated bottom perspective view of the unidose single use cartridge 10 A. The difference between the top view and the bottom view is that bottom view shows an anti-rotation slit 44 A in the bottom of exterior surface 12 A. The slit 44 A does not extend so deep that it goes into the interior chamber as will be discussed. The purpose of the anti-rotation slit 44 A is to be inserted into a mating member in the pen to prevent the cartridge 10 A from rotating once it is placed into the interior chamber of the dispensing pen 1000 .
[0154] Referring to FIG. 9 , there is illustrated a side cross-sectional view of a first embodiment of the unidose single use cartridge with sealing cap affixed, illustrating a single interior chamber which retains one compound, and a rear plunger having an interior face to push the compound in the interior of the cartridge forward and out of the cartridge, and an angular sidewall ending in a rear wall forming a seal against the interior sidewall, the rear end of the plunger having a pocket to receive a single pushing piston. The cartridge 10 A has a single interior chamber 50 A with a single compound 100 A retained in the interior chamber 50 A. A rear plunger 54 A having an interior face 56 A is used to push the compound 100 A in the interior chamber 50 A forward and out of the cartridge 10 A. The rear plunger 54 A has a pair of opposed rear angular sides 60 A and 62 A extending from opposite ends of the interior face 56 A and respectively ending in rear sidewalls 64 A and 66 A forming a seal against the interior sidewall 51 A of the cartridge 10 A, the interior of each rear sidewall 64 A and 66 A of the plunger 54 A forming the sidewalls of a pocket 72 A to receive the pushing piston from the retaining pen.
[0155] Further referring to FIG. 9 , the single use capsule or cartridge (the term capsule or cartridge are used interchangeably) with the single interior chamber 51 A contains an exterior surface 12 A which is generally cylindrical in shape and a rear surface 14 A which is generally flat with an opening 16 A through which a pushing piston 210 S is inserted into pocket 72 A, a front surface 18 A which is generally frustum shaped extending from the body of the cylinder 10 A to a nozzle 32 A having a cylindrical surface 20 A extending from the frustum 18 A and extending to a dispensing nozzle tip 22 A having threads 24 A on the exterior surface and a frangible seal 26 A on the front end of the tip 22 A. A threaded cap 30 A is cylindrical with an interior surface 32 A with threads 34 A adjacent the rear 36 A of the sealing cap 30 A and a front end 38 A with an interior chamber 40 A having a piercing tooth 42 A within the interior 40 A which extends inwardly from the front end 38 A of the sealing cap 30 A. In use, after the cartridge 10 A is placed in the dispensing pen 1000 as will be discussed, the front or tip 22 A of the single use cartridge 10 A extends through an opening in the dispensing pen and the threaded cap 30 A which is previously unscrewed from the threads 24 A of the capsule 30 A before the capsule or cartridge 10 A is inserted into the dispensing pen 1000 , and is then rotated 180 degrees so that the sharp tooth 42 A penetrates the frangible seal 26 A so that the tip 22 A is opened and a selected compound 100 A is dispensed from the interior 50 A of the cartridge or capsule 10 A
[0156] Referring to FIG. 10 , there is illustrated the two types of pushing pistons attached to the front of the multi-sectional shaft 1570 described in detailed when discussing FIGS. 1 through 5 . The front 1570 F of the multi-sectional shaft 1570 has a first mating member 1570 SM which in an illustrative embodiment has male threads. There is a single piston 210 S with a shaft second mating portion. 210 SMT. For the illustrative embodiment where the first mating member 1570 SM of the multi-sectional shaft 1570 has male threads, the shaft second mating portion 210 SMT has mating female threads within the single piston 210 S. In an embodiment, the single pushing piston 210 S has a cylindrical exterior with a rounded bullet shaped front 210 SE which is inserted into pocket 72 A in the interior of single chamber cartridge 10 A. The single pushing piston 210 S has a partially hollow interior which would have the female mating threads. For a cartridge 10 having a dual chamber, the pushing piston 210 has a mating section 210 MMT which branches into a first piston 210 and a spaced apart second piston 220 . For the illustrative embodiment where the first mating member 1570 SM of the multi-sectional shaft 1570 has male threads, the mating section 210 MMT shaft second mating portion 210 SMT has a partially hollow interior which would have mating female threads within its interior 210 MSI. In an embodiment, the mating section 210 MMT has a cylindrical exterior which branches into first piston 210 having a bullet shaped front 210 DFB and a second piston 220 with a bullet shaped front 220 DFB which are respectively inserted in pushing plunger pockets as will be described.
[0157] FIG. 1 illustrates a cross-sectional view where a pushing piston is placed onto the front end 1570 F of the multi-sectioned shaft 1570 . As illustrated in FIG. 1 , in one variation, the single use cartridge is placed within an opening adjacent to front of the dispensing pen with the threaded nozzle extending through the opening in the front of the dispensing pen 1000 . For the single chamber cartridge 10 A illustrated in FIG. 7 , the single piston mating section 210 SMT is affixed to the front 1570 F of the multi-section shaft 1570 and the single pushing piston 2105 is guided into rear pocket 72 A. For the dual chamber cartridge 10 illustrated in FIG. 8 , the mating section 210 MMT is affixed to the front 1070 S of the multi-section shaft and a respective one of the dual pushing pistons 210 and 220 is guided into a respective pocket 68 and 70 .
[0158] Referring to FIG. 11 , the alternative cartridge 10 with a dual chamber interior is illustrated in a top cutaway view of the second embodiment of the unidose single use cartridge 10 containing the divided interior chamber 50 which retains two separate compounds 100 and 110 which are separated from each other while in the cartridge by a dividing wall 52 , and a rear plunger 54 having opposing interior faces 56 and 58 to push a compound 100 or 110 in a respective portion of the interior 50 of the cartridge forward and out of the cartridge 10 , and a pair of opposed angular sidewalls 60 and 62 ending in rear wall sidewalls 64 and 66 forming a seal against the interior sidewall 51 of the cartridge, each rear end 68 and 70 of the plunger 54 having a pocket 72 and 74 to receive a respective pushing piston from the dispensing pen 1000 . Referring to FIG. 8 , it can be seen that the chamber 50 is divided into two equal chambers 53 and 55 which contain different compounds which cannot come in contact with each other because the dividing wall 52 extends for the entire diameter “D 1 ” and Length “L 1 ” of the interior chamber 50 of the cartridge 10 . For dual compounds where less is need of one of the two compounds, the dividing wall 52 is thicker on one side to reduce the volume of compound in the smaller chamber, the design of the plunger is modified to accommodate the revised sidewall 52 . Figure also shows the frustum shaped front and threaded nozzle and threaded cap with a piercing tip. This portion of the cartridge 10 having a frustum shaped front leading to a threaded nozzle 32 with threads 20 and a frangible seal 26 and threaded cap 30 with interior mating threads 34 , a piercing element 42 in an interior 40 of front 38 of cap 30 .
[0159] Referring to FIG. 12 , there is illustrated a top right side view of the present invention unidose dispensing pen with the new and novel ratchet dispensing mechanism 1400 illustrated in FIGS. 1 through 5 retained within the dispensing pen 1000 including illustrating the operating pushbutton 1410 , the ratchet disengagement switch 1700 , the open chamber 301 A with an anti-rotation member 305 A and the opening 1090 . The cartridge 10 A with cap 30 A removed is inserted into chamber 301 A with anti-rotation member 305 A engaging anti-rotation slit 44 in the bottom surface of cartridge 10 A with threads 22 A protruding through opening 1090 . Single pushing piston 210 S is also illustrated.
[0160] FIG. 13 is a top left side perspective view of the present invention unidose dispensing pen 1000 with the new and novel mechanical ratchet dispensing mechanism 1400 illustrated in FIGS. 1 to 5 retained within the dispensing pen 1000 including illustrating the operating pushbutton 1410 , the ratchet disengagement rotational switch 1700 , a visible portion of an exterior of a pushing piston 210 S and a single use cartridge 10 A within the dispensing pen 1000 .
[0161] It will be appreciated that the dual chamber cartridge 10 is inserted the same way As illustrated in FIG. 1 , in one variation, the single use cartridge 10 A is placed within an opening 301 A adjacent to front 1080 of the dispensing pen 1000 with the threaded nozzle 20 A extending through the opening 1090 in the front 1080 of the dispensing pen 1000 . For the single chamber cartridge 10 A illustrated in FIG. 9 , the single piston mating section 210 SMT is affixed to the front 1570 F of the multi-section shaft 1570 and the single pushing piston 210 S is guided into rear pocket 72 A. For the dual chamber cartridge 10 illustrated in FIG. 11 , the mating section 210 MMT is affixed to the front 1570 F of the multi-section shaft 1570 and a respective one of the dual pushing pistons 210 and 220 is guided into a respective pocket 68 and 70 .
[0162] In operation, the multi-sectioned shaft 1570 in incrementally moved forward by the present invention operating ratchet mechanism illustrated in FIGS. 1 to 5 and discussed above. For the single chamber cartridge 10 A, pushing piston 210 A is used to engage a pocket 72 A of the single-pocket plunger 54 A used with a single chamber cartridge and the ratchet mechanism of the present invention moves the pushing piston 210 S in the forward direction to push the plunger 54 A forwardly to dispense a selected compound 100 out of the cartridge through nozzle 10 A For the dual chamber cartridge 10 , pushing pistons 210 and 220 are respectively used to engage a respective pocket 72 and 74 of the two-pocket plunger 54 used with the dual chamber cartridge and the ratchet mechanism of the present invention moves the two pushing pistons 210 and 220 in the forward direction to push the plunger 54 forwardly to dispense a selected compound 100 and 110 out of the cartridge through nozzle 10 . For the single chamber cartridge 10 A, the ratchet mechanism incrementally moves the move the pushing piston 2105 forwardly to move the plunger 54 A forwardly to push the compound 100 A out of the cartridge 10 S through nozzle 30 S. If the volume of he two compounds is different, the dividing wall 52 is thicker on one side to reduce the volume of compound in the smaller chamber, the design of the plunger is modified to accommodate the revised sidewall 52 .
[0163] FIG. 17 are the same as in FIGS. 5, 6, 7 and 8 with an “S” at the end of each number.
[0164] Except for combining two compounds in a mixing nozzle, the operation after the compound is pushed out of the cartridge is the same.
[0165] Referring to FIG. 1 , there is illustrated a top perspective view of the unidose single use cartridge 10 which contains a compound as defined above including compound selected from the group consisting of a tooth whitening compound, a dental bonding and filling compound, and an adhesive compound in a sealed condition with the cap 30 threadedly retained onto the single use cartridge 10 , and which cartridge is disposed of and replaced with a new single use cartridge for subsequent application of a compound.
[0166] Referring to FIG. 14 , there is illustrated a cross-sectional view of one half 400 H of the mixing nozzle 400 which is used with a dual chamber cartridge. The mixing nozzle 400 has internal threads 410 on its internal surface 420 adjacent its rear end 430 and on nuts external surface 418 external threads 440 adjacent its front end 450 and contains a multiplicity of semi-closed shelves 460 and also straight shelves 470 so that as the compounds 100 and 110 are driven through the mixing nozzle 400 , the angular shelves 460 and the straight shelves 470 cause the compounds 100 and 110 to mix together and go through a series of angular shelves 460 and straight shelves 470 to make sure that the compound is fully mixed when it gets to the opening 480 of the mixing chamber 400 . A rear opening 414 permits the compounds 100 and 110 to enter the mixing tip 400 after it is screwed onto the threads 24 of tip 26 of capsule 10 . FIG. 9 illustrates one half of the mixing nozzle. The opposite half is a mirror image of half 400 H. The two halves of sonic welded together along their longitudinal interior faces 412 to form a complete mixing nozzle 400 illustrated in FIG. 14A . Referring to FIG. 14 a , there an exterior view of the mixing nozzle with a seam line 408 illustrates the location of the sonic weld.
[0167] A key innovation of the present invention mixing nozzle 400 is that it is comprised of internal built in shelves which thoroughly mix the compound portions as they are forced through the mixing nozzle. This is a major improvement over the prior art where an insert is placed into a chamber and compounds mixed through the insert which leads to less mixing and much more inefficiency in the mixing.
[0168] Referring to FIGS. 15 and 16 , there is illustrated a straight applicator 500 which contains an exterior surface 510 and an interior chamber 528 which has a widened end 520 with interior threads 522 surrounding a rear opening 524 that either thread around the end of the mixing tip or thread around the threaded end of the compound capsule and a front opening 530 through which the compound is dispensed. The compound enters through rear opening 524 and exits through front opening 530 .
[0169] In an alternative embodiment illustrated in FIGS. 17 and 18 , the applicator is a horn-shaped applicator 600 which has an exterior wall 610 and an interior chamber 620 which has a rear opening 624 and a rear interior wall 526 having threads 622 which can be threaded onto the end of the mixing tip or threaded onto the end of the tooth whitening compound cartridge and also has an opening 630 in front end 640 which is bent at an angle so that the tooth whitening compound can be applied to rear surface or to teeth near the back of the patient's mouth, the dental bonding compound can be applied to rear teeth fillings and the adhesive compound can be applied at a rear area of objects to be bonded together. The selected compounds enter from rear opening 624 and exits through front opening 640 .
[0170] Referring to FIG. 12 (before the cartridge 10 or 10 A is inserted into the pen 1000 ) and FIG. 13 (after the cartridge 10 or 10 A is inserted into the pen 1000 ) there is illustrated an exploded view showing how the mixing pen operates. The cartridge 10 A containing the compound 100 is inserted into chamber 301 A near the front of the dispensing pen 1000 where the pocket 72 A of the plunger 54 A is retained against the single piston 210 S and the front tip 12 A of the cartridge 10 A extends out of the opening 1090 in the pen 1000 . The anti-rotation slit 44 on the cartridge is placed into the anti-rotation longitudinal stop shelf 305 A in chamber 301 A so the cartridge 10 A will not rotate once inside the dispensing pen 1000 . The sealing cap 30 A is shown removed from the cartridge 10 A. After the cartridge is inserted into the dispensing pen 1000 , the cap 30 A is used to penetrate the frangible seal 26 A of the tip 22 A of the cartridge 10 A which extends out of the opening 1090 in the dispensing pen 1000 and thereafter either the straight applicator 500 or the horn-shaped applicator 600 is threaded onto the threads 22 A of the cartridge 10 A so that as the ratchet mechanism causes the piston 210 S to move toward the front of the dispensing pen 1000 , the piston 210 S pushes on the back of the plunger 54 A causing the plunger 54 A to move the compound 100 out of the cartridge 10 A into an applicator. For the dual chamber interior cartridge 10 containing the compounds 100 and 110 is inserted into chamber 301 A near the front of the dispensing pen 1000 where the pockets 72 and 74 of the plunger 54 are retained against the dual pistons 210 and 220 and the front tip 12 of the cartridge 10 extends out of the opening 1090 in the pen 1000 . The anti-rotation slit 44 on the cartridge is placed into the anti-rotation longitudinal stop shelf 305 A in chamber 301 A so the cartridge 10 will not rotate once inside the dispensing pen 1000 . The sealing cap 30 is shown removed from the cartridge 10 . After the cartridge is inserted into the dispensing pen 1000 , the cap 30 is used to penetrate the frangible seal 26 of the tip 22 of the cartridge 10 which extends out of the opening 1090 in the dispensing pen 1000 and thereafter the mixing tip 400 is threaded onto the cartridge 10 e and either the straight applicator 500 or the horn-shaped applicator 600 is threaded onto the mixing tip 400 so that as the ratchet mechanism causes the pistons 210 and 220 to move toward the front of the dispensing pen 1000 , the pistons 210 and 220 push on the back of the plunger 54 causing the plunger 54 to move each compound 100 and 110 from each separate section of the cartridge 10 into the mixing tip 400 where the compounds 100 and 110 are mixed and then exit the mixing tip 400 into the applicator so that the mixed tooth whitening compound is either placed in a dental tray or placed on the patient's tooth.
[0171] Referring to FIG. 19 there is illustrated an applicator brush 800 which has interior mating threads which are threaded onto the exterior threaded nozzle of the single use cartridge from which compound is dispensed onto the brush or onto the mixing tip nozzle for the dual chamber cartridge.
[0172] In a variation of the cartridge location, referring to FIG. 20 , there is a perspective view of the dispensing pen 2000 which for the interior operating ratchet mechanism 1570 , functions the same as the previous dispensing pen 1000 . The difference is that instead of having the reusable cartridge 10 or 10 A within a chamber within the dispensing pen, the dispensing pen has a front section 2100 which has a threaded exterior surface 2150 having mating threads 2200 thereon. The multi sections movable shaft 1570 has its front end 1570 F pushed forwardly of the section 2100 through an opening 2300 through which the multi section shaft protrudes. The variation of the reusable cartridge is the same as shown in FIGS. 9 and 11 but instead has internal threads thereon. Referring to FIG. 21 , for the single use cartridge having a single chamber which will be described as 10 -SC, the single use cartridge having a single interior chamber has interior threads 80 AE which mate with the exterior threads 2200 at the front of the dispensing pen 2000 . As a result, instead of being within the chamber, the single use cartridge with internal threads 80 AE now is extending from the front of the cartridge. The operating mechanism is the same as before with the single piston 2105 affixed to the front 1570 F of multi-sectional shaft 1570 and moved forwardly in increments by the novel and unique operating ratchet mechanism of the present invention to move pocket 72 AE of pushing plunger 54 AE. The compound is moved through the exterior cartridge 10 A-SC through its exterior nozzle 20 AE which also has threads and then dispensed into any of the applicators or any identified in FIGS. 15 to 18 . The remaining components are numbered similar to the numbers in FIG. 9 but are numbered with AE.
[0173] Alternatively, for a dual chamber cartridge, the mechanism described in FIG. 22 is applied to the front of the pen 2000 so that multi section movable shaft 1570 extends into a respective pocket of the dual chamber cartridge which since it is an exterior cartridge will be referred to as 10 -DC. This exterior cartridge also has internal threads 80 E which are threaded onto the mating threads 2100 of the second variation of the reusable pen so that the respective pistons 210 and 220 is moved into a respective pocket 72 E and 74 E of the exterior dual chamber reusable cartridge so that the dual compound is respectively pushed through the cartridge and out the exterior nozzle 20 E and then into the mixing chamber which is threaded onto the exterior surface of the cartridge with the same process as previously discussed. The remaining components are numbered similar to FIG. 11 withy “E” after each number.
[0174] The compound that is used with the present invention can be any multiplicity of compounds as previously discussed. The single use cartridge, whether it is retained within the dispensing pen or 10 -SC which is exterior to the dispensing pen, can be any compound. If, by way of example, the compound 100 is a tooth whitening compound, then after being dispensed from the single use cartridge, the tooth whitening compound is placed in the dental tray where the tray is placed over the patient's teeth for a period of time or the tooth whitening compound is directly applied to the patient's teeth through a brush 800 as illustrated in FIG. 19 . Alternatively, if it is a dual chamber single use cartridge 10 , then two compounds 100 and 110 go through the chamber as tooth whitening compounds and then are combined together when they exit the nozzle 20 E and go into the mixing chamber 400 where the two tooth whitening compounds are combined together in the mixing chamber 400 before they can be dispensed into a dental tray or other dental applicator.
[0175] Similarly, the compounds can be any type of products such as a glue, an adhesive, a powder, a gel, a cream, paint, cosmetics, lipstick, non-medicated cosmetics, medicated cosmetics, construction material compounds and virtually any other compound. If the compound does not need to be mixed with another compound, then a single use cartridge is used. If the compound needs to be mixed with another compound, then the dual chamber cartridge is used where they are respectively pushed through the dual chamber cartridge and then through the front nozzle and into the mixing nozzle where the two compounds are mixed together before they then can be applied to any one of the applicators or brushes set forth in FIGS. 15 to 18 .
[0176] Referring to FIG. 23 , there is a perspective view of the revised dental dispensing pen 2000 illustrating an exterior cartridge 10 -SC or 10 -DC threaded onto the front of the dispensing pen 2000 where the ratchet removable switch 1700 and the pushbutton 1410 are illustrated. The operation of the mechanism is the same as before and the new and novel operating ratchet mechanism incrementally pushes a single piston or a dual piston through a respective pocket or dual receiving pocket in the single use chamber to push the compound through the chamber where it can be either sent to a mixing chamber for mixing or directly applied through an applicator. If it is first sent to a mixing chamber, then it is mixed and then applied to the applicators.
[0177] Of course the present invention is not intended to be restricted to any particular form or arrangement, or any specific embodiment, or any specific use, disclosed herein, since the same may be modified in various particulars or relations without departing from the spirit or scope of the claimed invention hereinabove shown and described of which the apparatus or method shown is intended only for illustration and disclosure of an operative embodiment and not to show all of the various forms or modifications in which this invention might be embodied or operated. | The present invention involves the field of numerous types of compounds including tooth whitening compounds and in particular, to specific apparatus which are used to retain tooth whitening compounds and then dispense them either into a dental tray where the tray is placed over the patient's teeth for a period of time or the tooth whitening compound is directly applied to the patient's teeth by the dentist or the dental assistant. More broadly described, the present invention includes compound and applicators used to dispense the compounds including tooth whitening compounds, dental bonding and filling compounds, adhesives, finely ground powder, jells, creams and paints. | 98,586 |
BACKGROUND OF THE INVENTION
[0001] 1. Technical Field
[0002] The invention relates generally to polypropylene and materials or articles made from polypropylene.
[0003] 2. Background of the Art
[0004] Polypropylene is used for a variety of different products or applications. These may include films, fibers or molded articles. Polypropylene used in such materials or articles is usually produced as an isotactic propylene polymer, which is a stereospecific polymer.
[0005] Stereospecific polymers are polymers that have a defined arrangement of molecules in space. Both isotactic and syndiotactic propylene polymers are stereospecific. Isotactic polypropylene is characterized by having all the pendant methyl groups oriented either above or below the polymer chain or backbone. Isotactic polypropylene can be illustrated by the following general chemical formula:
[0000]
[0006] Syndiotactic propylene polymers are those in which the methyl groups attached to the tertiary carbon atoms of successive monomeric units in the polymer chain lie on alternate sides of the plane of the polymer. Syndiotactic polypropylene can be illustrated by the following general structural formula:
[0000]
[0007] While both syndiotactic and isotactic polypropylene are semi-crystalline polymers, however, they each have different characteristics or properties.
[0008] Conventional polypropylene is usually prepared as an isotactic polymer from Ziegler-Natta polymer catalysts. The Ziegler-Natta catalysts produce a highly isotactic polypropylene that is easily processed and useful in preparing a wide variety of articles or products.
[0009] In certain applications, it is necessary that the polypropylene materials be sterilized. This is particularly true for materials used in medical and food handling and sterilization applications. One method of sterilizing such materials is through the use of high-energy radiation. Both gamma radiation and electron-beam (E-beam) radiation are commonly used for irradiating and sterilizing many materials and articles. While exposure to such radiation is effective in sterilizing such materials, the radiation may also have an effect on the material itself. In many cases, these effects are undesirable.
[0010] With respect to isotactic polypropylene prepared from conventional Ziegler-Natta catalysts, for example, exposure of the polypropylene to high-energy radiation can result in a degradation of the polymer. The polypropylene will often become brittle and may be discolored, turning to a light or deep yellow. Such changes in the polymer usually do not occur immediately after irradiation, but may occur slowly, appearing sometime later after sterilization.
[0011] The mechanism by which such degradation of polypropylene occurs is believed to be, without being limited to any one particular theory, an auto-oxidative reaction in which free radicals are formed that react with oxygen, usually from air, and which results in the degradation of the polymer. The reaction steps can be represented as follows:
[0000] R→R. (1)
[0000] R.+O2→RO2. (2)
[0000] RO2.+RH→ROOH+R. (3)
[0000] RO2.+R.→ROOR (4)
[0000] RO2.+RO2.→ROOR+O2 (5)
[0000] R.+R.→R—R (6)
[0000] where R is the irradiated polypropylene chain, and R. is the alkyl radical formed during irradiation. The alkyl radical R. is regenerated in equation 3 and each alkyl radical formed will consume numerous molecules of oxygen unless such radicals are terminated earlier as shown in equations 4-6.
[0012] As discussed earlier, degradation effects are usually seen over time. This may be a result, at least in part, due to slower radical migration from within the crystalline regions of the polymer towards the surface to react with ambient oxygen. Thus, polymer degradation may occur over time as a result of this radical migration. Polypropylene articles having high surface areas per unit volume will usually tend to degrade much faster than those having low surface areas per unit volume.
SUMMARY OF THE INVENTION
[0013] n one aspect, the invention is a polymer material including a blend of an isotactic propylene polymer and a syndiotactic propylene polymer wherein the isotactic propylene polymer has a molecular weight distribution (Mw/Mn) of 4.0 or less and a xylene solubles of 2 percent or less, and wherein the polymer material provides a SMS fabric material having a 50% or greater retention of machine direction elongation strength at a radiation dose of 3-5 Mrads.
[0014] In another aspect, the invention is a fabric including a network of fibers prepared using a polymer material including a blend of an isotactic propylene polymer and a syndiotactic propylene polymer wherein the isotactic propylene polymer has a molecular weight distribution (Mw/Mn) of 4.0 or less and a xylene solubles of 2 percent or less, and wherein the isotactic propylene polymer provides a SMS fabric material having a 50% or greater retention of machine direction elongation strength at a radiation dose of 3-5 Mrads.
[0015] In still another aspect, the invention is a fabric material in which at least two layers of fabric are laminated together wherein the layers of fabric include a network of fibers prepared using a polymer material including a blend of an isotactic propylene polymer and a syndiotactic propylene polymer wherein the isotactic propylene polymer has a molecular weight distribution (Mw/Mn) of 4.0 or less and a xylene solubles of 2 percent or less, and wherein the isotactic propylene polymer provides a SMS fabric material having a 50% or greater retention of machine direction elongation strength at a radiation dose of 3-5 Mrads.
[0016] Another embodiment of the invention is an article formed from a polymer material including a blend of an isotactic propylene polymer and a syndiotactic propylene polymer wherein the isotactic propylene polymer has a molecular weight distribution (Mw/Mn) of 4.0 or less and a xylene solubles of 2 percent or less, and wherein the isotactic propylene polymer provides a SMS fabric material having a 50% or greater retention of machine direction elongation strength at a radiation dose of 3-5 Mrads. The article is selected from a group consisting of diapers, incontinence products, sanitary towels, tampons, feminine hygiene pads, protective clothing, work clothing, disposable clothing, gowns, masks, insulating material, headwear, overshoes, flannels, bandages, bedcloths, wipes, syringes, tongue depressors, vacuum cleaner bags, tea bags, coffee filters, book covers, carpet underlay, wall coverings, bedclothes, table cloths, covers, mattress filing, covering material, furniture fabrics, cushion covers, upholstery, wadding, filters, air filters, gas filters, water filters, oil adsorbent materials, sanding material, cable sheaths, insulation tape, reinforcements, insulation, roof sealing, geotextile material, capillary mats, covering material for crop forcing, covering material for seedling protection, greenhouse shielding, packaging material, packaging material for fruits or vegetables, insulation material for automobiles, roof linings, battery separators and coating carriers, luggage, handbags, sacks, carrier bags, bags, self-adhesive materials, tents, cheese wrappers, artist's canvas and advertising articles.
DETAILED DESCRIPTION OF THE INVENTION
[0017] It has been found that addition of amounts of syndiotactic polypropylene as a blend with isotactic polypropylene, which may be either Ziegler-Natta or metallocene-catalyzed isotactic polypropylene, can increase the polymer's radiation resistance or reduce degradation of the polymer from radiation when compared to the same polymer without any syndiotactic polypropylene. These materials may show as much as 70%, 80% or even 90% retention in strength properties after exposure to high energy radiation dependent upon the dosage of radiation, the presence or absence of oxygen, and the use of antioxidants and mobilizing additives such as mineral oil.
[0018] The metallocene catalyst systems used with the invention may be selected from those useful for olefin preparation. Such metallocene catalyst systems may be characterized generally as coordination compounds incorporating one or more cyclopentadienyl (Cp) groups (which may be substituted or unsubstituted, each substitution being the same or different) coordinated with a transition metal through pi (or π) bonding.
[0019] The Cp substituent groups may be linear, branched or cyclic hydrocarbyl radicals. The cyclic hydrocarbyl radicals may further form other contiguous ring structures, including, for example indenyl, azulenyl and fluorenyl groups. These additional ring structures may also be substituted or unsubstituted by hydrocarbyl radicals, such as C 1 to C 20 hydrocarbyl radicals.
[0020] A specific example of a metallocene catalyst is a bulky ligand metallocene compound generally represented by the formula:
[0000] [L] m M[A] n
[0000] where L is a bulky ligand, A is a leaving group, M is a transition metal and m and n are such that the total ligand valency corresponds to the transition metal valency. For example, when the valence of M is 4, m may be from 1 to 3 and n may be from 1 to 3 and n+m=4.
The metal atom “M” of the metallocene catalyst compound, as described throughout the specification and claims, may be selected from Groups 3 through 12 atoms and lanthanide group atoms in one embodiment; and selected from Groups 3 through 10 atoms in a more particular embodiment, and selected from Sc, Ti, Zr, Hf, V, Nb, Ta, Mn, Re, Fe, Ru, Os, Co, Rh, Ir, and Ni in yet a more particular embodiment; and selected from Groups 4, 5 and 6 atoms in yet a more particular embodiment, and Ti, Zr, Hf atoms in yet a more particular embodiment, and Zr in yet a more particular embodiment. The oxidation state of the metal atom “M” may range from 0 to +7 in one embodiment; and in a more particular embodiment, is +1, +2, +3, +4 or +5; and in yet a more particular embodiment is +2, +3 or +4.
[0021] The bulky ligand generally includes a cyclopentadienyl group (Cp) or a derivative thereof. The Cp ligand(s) form at least one chemical bond with the metal atom M to form the “metallocene catalyst compound”. The Cp ligands are distinct from the leaving groups bound to the catalyst compound in that they are not highly susceptible to substitution/abstraction reactions.
[0022] The Cp group typically includes ring, fused ring(s) and/or substituted ring or fused ring systems. The ring(s) or ring system(s) typically include atoms selected from group 13 to 16 atoms, for example, carbon, nitrogen, oxygen, silicon, sulfur, phosphorous, germanium, boron, aluminum and combinations thereof, wherein carbon makes up at least 50% of the ring members. Non-limiting examples include cyclopentadienyl, cyclopentaphenanthreneyl, indenyl, 4,5-benzindenyl, 4,5-bis-benzindenyl, fluorenyl, cyclooctatetraenyl, cyclopentacyclododecene, phenanthrindenyl, 3,4-benzofluorenyl, 9-phenylfluorenyl, 8-H-cyclopent[a]acenaphthylenyl, 7-H-dibenzofluorenyl, indeno[1,2-9]anthrene, thiophenoindenyl, thiophenofluorenyl, hydrogenated versions thereof (e.g., 4,5,6,7-tetrahydroindenyl, or “H 4 Ind”), substituted versions thereof, and heterocyclic versions thereof.
[0023] Cp substituent groups may include hydrogen radicals, alkyls, alkenyls, alkynyls, cycloalkyls, aryls, acyls, aroyls, alkoxys, aryloxys, alkylthiols, dialkylamines, alkylamidos, alkoxycarbonyls, aryloxycarbonyls, carbomoyls, alkyl- and dialkyl-carbamoyls, acyloxys, acylaminos, aroylaminos, and combinations thereof. More particular non-limiting examples of alkyl substituents include methyl, ethyl, propyl, butyl, pentyl, hexyl, cyclopentyl, cyclohexyl, benzyl, phenyl, methylphenyl, and tert-butylphenyl groups and the like, including all their isomers, for example tertiary-butyl, isopropyl, and the like. Other possible radicals include substituted alkyls and aryls, optionally containing halogens such as, for example, fluoromethyl, fluoroethyl, difluoroethyl, iodopropyl, bromohexyl, chlorobenzyl and hydrocarbyl substituted organometalloid radicals including trimethylsilyl, trimethylgermyl, methyldiethylsilyl and the like; and halocarbyl-substituted organometalloid radicals including tris(trifluoromethyl)silyl, methylbis(difluoromethyl)silyl, bromomethyldimethylgermyl and the like; and disubstituted boron radicals including dimethylboron for example; and disubstituted Group 15 radicals including dimethylamine, dimethylphosphine, diphenylamine, methylphenylphosphine, Group 16 radicals including methoxy, ethoxy, propoxy, phenoxy, methylsulfide and ethylsulfide. Other substituents R include olefins such as but not limited to olefinically unsaturated substituents including vinyl-terminated ligands, for example 3-butenyl, 2-propenyl, 5-hexenyl and the like. In one embodiment, at least two R groups are joined to form a ring structure having from 3 to 30 atoms selected from the group consisting of carbon, nitrogen, oxygen, phosphorous, silicon, germanium, aluminum, boron and combinations thereof. Also, a substituent group R group such as 1-butanyl may form a bonding association to the element M.
[0024] Each anionic leaving group is independently selected and may include any leaving group, such as halogen ions, hydrides, C 1 to C 12 alkyls, C 2 to C 12 alkenyls, C 6 to C 12 aryls, C 7 to C 20 alkylaryls, C 1 to C 12 alkoxys, C 6 to C 16 aryloxys, C 7 to C 18 alkylaryloxys, C 1 to C 12 fluoroalkyls, C 6 to C 12 fluoroaryls, and C 1 to C 12 heteroatom-containing hydrocarbons and substituted derivatives thereof; hydride, halogen ions, C 1 to C 6 alkylcarboxylates, C 1 to C 6 fluorinated alkylcarboxylates, C 6 to C 12 arylcarboxylates, C 7 to C 18 alkylarylcarboxylates, C 1 to C 6 fluoroalkyls, C 2 to C 6 fluoroalkenyls, and C 7 to C 18 fluoroalkylaryls in yet a more particular embodiment; hydride, chloride, fluoride, methyl, phenyl, phenoxy, benzoxy, tosyl, fluoromethyls and fluorophenyls in yet a more particular embodiment; C 1 to C 12 alkyls, C 2 to C 12 alkenyls, C 6 to C 12 aryls, C 7 to C 20 alkylaryls, substituted C 1 to C 12 alkyls, substituted C 6 to C 12 aryls, substituted C 7 to C 20 alkylaryls and C 1 to C 12 heteroatom-containing alkyls, C 1 to C 12 heteroatom-containing aryls and C 1 to C 12 heteroatom-containing alkylaryls in yet a more particular embodiment; chloride, fluoride, C 1 to C 6 alkyls, C 2 to C 6 alkenyls, C 7 to C 18 alkylaryls, halogenated C 1 to C 6 alkyls, halogenated C 2 to C 6 alkenyls, and halogenated C 7 to C 18 alkylaryls in yet a more particular embodiment; fluoride, methyl, ethyl, propyl, phenyl, methylphenyl, dimethylphenyl, trimethylphenyl, fluoromethyls (mono-, di- and trifluoromethyls) and fluorophenyls (mono-, di-, tri-, tetra- and pentafluorophenyls) in yet a more particular embodiment; and fluoride in yet a more particular embodiment.
[0025] Other non-limiting examples of leaving groups include amines, phosphines, ethers, carboxylates, dienes, hydrocarbon radicals having from 1 to 20 carbon atoms, fluorinated hydrocarbon radicals (e.g., —C 6 F 5 (pentafluorophenyl)), fluorinated alkylcarboxylates (e.g., CF 3 C(O)O − ), hydrides and halogen ions and combinations thereof. Other examples of leaving groups include alkyl groups such as cyclobutyl, cyclohexyl, methyl, heptyl, tolyl, trifluoromethyl, tetramethylene, pentamethylene, methylidene, methyoxy, ethyoxy, propoxy, phenoxy, bis(N-methylanilide), dimethylamide, dimethylphosphide radicals and the like. In one embodiment, two or more leaving groups form a part of a fused ring or ring system.
[0026] L and A may be bridged to one another. In catalysts where there are two L groups, they may be bridged to each other. A bridged metallocene, for example may, be described by the general formula:
[0000] XCp A Cp B MA n
[0000] wherein X is a structural bridge, CP A and CP B each denote a cyclopentadienyl group, each being the same or different and which may be either substituted or unsubstituted, M is a transition metal and A is an alkyl, hydrocarbyl or halogen group and n is an integer between 0 and 4, and either 1 or 2 in a particular embodiment.
[0027] Non-limiting examples of bridging groups (X) include divalent hydrocarbon groups containing at least one Group 13 to 16 atom, such as but not limited to at least one of a carbon, oxygen, nitrogen, silicon, aluminum, boron, germanium and tin atom and combinations thereof; wherein the heteroatom may also be C 1 to C 12 alkyl or aryl substituted to satisfy neutral valency. The bridging group may also contain substituent groups as defined above including halogen radicals and iron. More particular non-limiting examples of bridging groups are represented by C 1 to C 20 alkylenes, substituted C 1 to C 6 alkylenes, oxygen, sulfur, R 2 C═, R 2 Si═, ——Si(R) 2 Si(R 2 )—, R 2 Ge═, RP═ (wherein “═” represents two chemical bonds), where R is independently selected from the group hydride, hydrocarbyl, substituted hydrocarbyl, halocarbyl, substituted halocarbyl, hydrocarbyl-substituted organometalloid, halocarbyl-substituted organometalloid, disubstituted boron, disubstituted Group 15 atoms, substituted Group 16 atoms, and halogen radical; and wherein two or more Rs may be joined to form a ring or ring system. In one embodiment, the bridged metallocene catalyst component has two or more bridging groups (X).
[0028] Other non-limiting examples of bridging groups include methylene, ethylene, ethylidene, propylidene, isopropylidene, diphenylmethylene, 1,2-dimethylethylene, 1,2-diphenylethylene, 1,1,2,2-tetramethylethylene, dimethylsilyl, diethylsilyl, methyl-ethylsilyl, trifluoromethylbutylsilyl, bis(trifluoromethyl)silyl, di(n-butyl)silyl, di(n-propyl)silyl, di(i-propyl)silyl, di(n-hexyl)silyl, dicyclohexylsilyl, diphenylsilyl, cyclohexylphenylsilyl, t-butylcyclohexylsilyl, di(t-butylphenyl)silyl, di(p-tolyl)silyl and the corresponding moieties, wherein the Si atom is replaced by a Ge or a C atom; dimethylsilyl, diethylsilyl, dimethylgermyl and/or diethylgermyl. The bridging groups may also have carbons or silicons having an olefinic substituent.
[0029] In another exemplary catalyst, the bridging group may also be cyclic, and include 4 to 10 ring members or 5 to 7 ring members in a more particular embodiment. The ring members may be selected from the elements mentioned above, and/or from one or more of B, C, Si, Ge, N and O in a particular embodiment. Non-limiting examples of ring structures which may be present as or part of the bridging moiety are cyclobutylidene, cyclopentylidene, cyclohexylidene, cycloheptylidene, cyclooctylidene and the corresponding rings where one or two carbon atoms are replaced by at least one of Si, Ge, N and O, in particular, Si and Ge. The bonding arrangement between the ring and the Cp groups may be cis-, trans-, or a combination thereof.
[0030] The cyclic bridging groups may be saturated or unsaturated and/or carry one or more substituents and/or be fused to one or more other ring structures. If present, the one or more substituents are selected from the group hydrocarbyl (e.g., alkyl such as methyl) and halogen (e.g., F, Cl) in one embodiment. The one or more Cp groups which the above cyclic bridging moieties may optionally be fused to may be saturated or unsaturated and are selected from the group of those having 4 to 10 ring members, more particularly 5, 6 or 7 ring members (selected from the group of C, N, O and S in a particular embodiment) such as, for example, cyclopentyl, cyclohexyl and phenyl. Moreover, these ring structures may themselves be fused such as, for example, in the case of a naphthyl group. Moreover, these (optionally fused) ring structures may carry one or more substituents. Illustrative, non-limiting examples of these substituents are hydrocarbyl (particularly alkyl) groups and halogen atoms.
[0031] The metallocene catalysts also include the CpFlu family of catalysts (e.g., a metallocene incorporating a substituted or unsubstituted Cp fluorenyl ligand structure) represented by the following formula:
[0000] X(CpR 1 n R 2 m )(FluR 3 p )
[0000] wherein Cp is a cyclopentadienyl group; Flu is a fluorenyl group; X is a structural bridge between Cp and Flu; R 1 is a substituent on the Cp; n is 0, 1, or 2; R 2 is a substituent on the Cp at carbons 3 or 4 (a position which is proximal to the bridge); m is 0, 1, or 2; each R 3 is the same or different and is a hydrogen or a hydrocarbyl group having from 1 to 20 carbon atoms with R 3 being substituted at carbons 2, 3, 4, 5, 6, or 7 (a nonproximal position on the fluorenyl group) and at least one other R 3 , if present, being substituted at an opposed position on the fluorenyl group; and p is 0, 1, 2, 3, or 4.
[0032] Exemplary CpFlu molecules include those having a general structure such as:
[0000]
[0000] wherein M is a metal, the X in this embodiment is a methylene structural bridge. Note that all rings are aromatic notwithstanding the placement of the double bonds in the general structure.
[0033] The bis-indenyl metallocene catalysts are also useful in olefin polymerization. A bridged metallocene, the bis-indenyls may be described by the general formula:
[0000] XCp A Cp B MA n
[0034] wherein X, M and A are as described above, but Cp A and Cp B each denote an indenyl group. These catalysts have been reported to be particularly useful for production of isotactic polypropylene in U.S. Pat. No. 6,414,095, the contents of which are incorporated herein by reference.
[0035] Exemplary bis-indenyl molecules include those having a general structure such as:
[0000]
[0000] wherein M is a metal, and the X in this embodiment is a methylene structural bridge.
[0036] Another family of the metallocene catalyst includes bridged mono-ligand metallocene compounds (e.g., mono cyclopentadienyl catalyst components). In this embodiment, the at least one metallocene catalyst component is a bridged “half-sandwich” metallocene catalyst. In yet another aspect of the invention, the at least one metallocene catalyst component is an unbridged “half sandwich” metallocene.
[0037] Described another way, the “half sandwich” metallocenes above are described in U.S. Pat. No. 6,069,213, U.S. Pat. No. 5,026,798, U.S. Pat. No. 5,703,187, and U.S. Pat. No. 5,747,406, including a dimer or oligomeric structure, such as disclosed in, for example, U.S. Pat. No. 5,026,798 and U.S. Pat. No. 6,069,213, which are incorporated by reference herein.
[0038] The metallocenes may be present as racemic or meso compositions. In some embodiments, the metallocene compositions may be predominantly racemic. In other applications, the metallocenes may be predominantly meso.
[0039] Non-limiting examples of metallocene catalyst components include: cyclopentadienylzirconiumA n , indenylzirconiumA n , (1-methylindenyl)zirconiumA n , (2-methylindenyl)zirconiumA n , (1-propylindenyl)zirconiumA n , (2-propylindenyl)zirconiumA n , (1-butylindenyl)zirconiumA n , (2-butylindenyl)zirconiumA n , methylcyclopentadienylzirconiumA n , tetrahydroindenylzirconiumA n , pentamethylcyclopentadienylzirconiumA n , cyclopentadienylzirconiumA n , pentamethylcyclopentadienyltitaniumA n , tetramethylcyclopentyltitaniumA n , (1,2,4-trimethylcyclopentadienyl)zirconiumA n , dimethylsilyl(1,2,3,4-tetramethylcyclopentadienyl)(cyclopentadienyl)zirconiumA n , dimethylsilyl(1,2,3,4-tetramethylcyclopentadienyl)(1,2,3-trimethylcyclopentadienyl)zirconiumA n , dimethylsilyl(1,2,3,4-tetramethylcyclopentadienyl)(1,2-dimethylcyclopentadienyl)zirconiumA n , dimethylsilyl(1,2,3,4-tetramethylcyclopentadienyl)(2-methylcyclopentadienyl)zirconiumA n , dimethylsilylcyclopentadienylindenylzirconiumA n , dimethylsilyl(2-methylindenyi)(9-fluorenyl)zirconiumA n , diphenylsilyl(1,2,3,4-tetramethylcyclopentadienyl)(3-propylcyclopentadienyl)zirconiumA n , dimethylsilyl(1,2,3,4-tetramethylcyclopentadienyl)(3-t-butylcyclopentadienyl)zirconiumA n , dimethylgermyl(1,2-dimethylcyclopentadienyl)(3-isopropylcyclopentadienyl)zirconiumA n , dimethylsilyl(1,2,3,4-tetramethylcyclopentadienyl)(3-methylcyclopentadienyl)zirconiumA n , diphenylmethylidene(cyclopentadienyl)(9-fiuorenyl)zirconiumA n , diphenylmethylidenecyclopentadienylindenylzirconiumA n , isopropylidenebiscyclopentadienylzirconiumA n , isopropylidene(cyclopentadienyl)(9-fluorenyl)zirconiumA n , isopropylidene(3-methylcyclopentadienyl)(9-fluorenyl)zirconiumA n , ethylenebis(9-fluorenyl)zirconiumA n , ethylenebis(1-indenyl)zirconiumA n , ethylenebis(2-methyl-1-indenyl)zirconiumA n , ethylenebis(2-methyl-4,5,6,7-tetrahydro-1-indenyl)zirconiumA n , ethylenebis(2-propyl-4,5,6,7-tetrahydro-1-indenyl)zirconiumA n , ethylenebis(2-isopropyl-4,5,6,7-tetrahydro-1-indenyl)zirconiumA n , ethylenebis(2-butyl-4,5,6,7-tetrahydro-1-indenyl)zirconiumA n , ethylenebis(2-isobutyl-4,5,6,7-tetrahydro-1-indenyl)zirconiumA n , dimethylsilyl(4,5,6,7-tetrahydro-1-indenyl)zirconiumA n , diphenyl(4,5,6,7-tetrahydro-1-indenyl)zirconiumA n , ethylenebis(4,5,6,7-tetrahydro-1-indenyl)zirconiumA n , dimethylsilylbis(cyclopentadienyl)zirconiumA n , dimethylsilylbis(9-fluorenyl)zirconiumA n , dimethylsilylbis(1-indenyl)zirconiumA n , dimethylsilylbis(2-methylindenyl)zirconiumA n , dimethylsilylbis(2-propylindenyi)zirconiumA n , dimethylsilylbis(2-butylindenyl)zirconiumA n , diphenylsilylbis(2-methylindenyl)zirconiumA n , diphenylsilylbis(2-propylindenyl)zirconiumA n , diphenylsilylbis(2-butylindenyl)zirconiumA n , dimethylgermylbis(2-methylindenyl)zirconiumA n , dimethylsilylbistetrahydroindenylzirconiumA n , dimethylsilylbistetramethylcyclopentadienylzirconiumA n , dimethylsilyi(cyclopentadienyl)(9-fluorenyl)zirconiumA n , diphenylsilyi(cyclopentadienyl)(9-fluorenyi)zirconiumA n , diphenylsilylbisindenylzirconiumA n , cyclotrimethylenesilyltetramethylcyclopentadienylcyclopentadienylzirconiumA n , cyclotetramethylenesilyltetramethylcyclopentadienylcyclopentadienylzirconiumA n , cyclotrimethylenesilyl(tetramethylcyclopentadienyl)(2-methylindenyl)zirconiumA n , cyclotrimethylenesilyl(tetramethylcyclopentadienyl)(3-methylcyclopentadienyl)zirconiumA n , cyclotrimethylenesilylbis(2-methylindenyl)zirconiumA n , cyclotrimethylenesilyl(tetramethylcyclopentadienyl) (2,3,5-trimethylclopentadienyl)zirconiumA n , cyclotrimethylenesilylbis(tetramethylcyclopentadienyl)zirconiumA n , dimethylsilyl(tetramethylcyclopentadieneyl)(N-tertbutylamido)titaniumA n , biscyclopentadienylchromiumA n , biscyclopentadienylzirconiumA n , bis(n-butylcyclopentadienyl)zirconiumA n , bis(n-dodecycicyclopentadienyl)zirconiumA n , bisethylcyclopentadienylzirconiumA n , bisisobutylcyclopentadienylzirconiumA n , bisisopropylcyclopentadienylzirconiumA n , bismethylcyclopentadienylzirconiumA n , bis(n-oxtylcyclopentadienyl)zirconiumA n , bis(n-pentylcyclopentadienyl)zirconiumA n , bis(n-propylcyclopentadienyl)zirconiumA n , bis(trimethylsilylcyclopentadienyl)zirconiumA n , bis(1,3-bis(trimethylsilyl)cyclopentadienyl)zirconiumA n , bis(1-ethyl-2-methylcyclopentadienyl)zirconiumA n , bis(1-ethyl-3-methylcyclopentadienyl)zirconiumA n , bispentamethylcyclopentadienylzirconiumA n , bispentamethylcyclopentadienylzirconiumA n , bis(1-propyl-3-methylcyclopentadienyl)zirconiumA n , bis(1-n-butyl-3-methylcyclopentadienyl)zirconiumA n , bis(1-isobutyl-3-methylcyclopentadienyl)zirconiumA n , bis(1-propyl-3-butylcyclopentadienyl)zirconiumA n , bis(1,3-n-butylcyclopentadienyl)zirconiumA n , bis(4,7-dimethylindenyl)zirconiumA n , bisindenylzirconiumA n , bis(2-methylindenyl)zirconiumA n , cyclopentadienylindenylzirconiumA n , bis(n-propylcyclopentadienyl)hafniumA n , bis(n-butylcyclopentadienyl)hafniumA n , bis(n-pentylcyclopentadienyl)hafniumA n , (n-propylcyclopentadienyl)(n-butylcyclopentadienyl)hafniumA n , bis[(2-trimethylsilyiethyl)cyclopentadienyl]hafniumA n , bis(trimethylsilylcyclopentadienyl)hafniumA n , bis(2-n-propylindenyl)hafniumA n , bis(2-n-butylindenyl)hafniumA n , dimethylsilylbis(n-propylcyclopentadienyl)hafniumA n , dimethylsilylbis(n-butylcyclopentadienyl)hafniumA n , bis(9-n-propylfluorenyl)hafniumA n , bis(9-n-butylfluorenyl)hafniumA n , (9-n-propylfluorenyl)(2-n-propylindenyl)hafniumA n , bis(1-n-propyl-2-methylcyclopentadienyl)hafniumA n , (n-propylcyclopentadienyl)(1-n-propyl-3-n-butylcyclopentadienyl)hafniumA n , dimethylsilyltetramethylcyclopentadienylcyclopropylamidotitaniumA n , dimethylsilyltetramethylcyclopentadienylcyclobutylamidotitaniumA n , dimethylsilyltetramethylcyclopentadienylcyclopentylamidotitaniumA n , dimethylsilyltetramethylcyclopentadienylcyclohexylamidotitaniumA n , dimethylsilyltetramethylcyclopentadienylcycloheptylamidotitaniumA n , dimethylsilyltetramethylcyclopentadienylcyclooctylamidotitaniumA n , dimethylsilyltetramethylcyclopentadienylcyclononylamidotitaniumA n , dimethylsilyltetramethylcyclopentadienylcyclodecylamidotitaniumA n , dimethylsilyltetramethylcyclopentadienylcycioundecylamidotitaniumA n , dimethylsilyltetramethylcyclopentadienylcyclododecylamidotitaniumA n , dimethylsilyltetramethylcyclopentadienyl(sec-butylamido)titaniumA n , dimethylsilyl(tetramethylcyclopentadienyl)(n-octylamido)titaniumA n , dimethylsilyl(tetramethylcyclopentadienyl)(n-decylamido)titaniumA n , dimethylsilyl(tetramethylcyclopentadienyl)(n-octadecylamido)titaniumA n , methylphenylsilyltetramethylcyclopentadienylcyclopropylamidotitaniumA n , methylphenylsilyltetramethylcyclopentadienylcyclobutylamidotitaniumA n , methylphenylsilyltetramethylcyclopentadienylcyclopentylamidotitaniumA n , methylphenylsilyltetramethylcyclopentadienylcyclohexylamidotitaniumA n , methylphenylsilyltetramethylcyclopentadienylcycloheptylamidotitaniumA n , methylphenylsilyltetramethylcyclopentadienylcyclooctylamidotitaniumA n , methylphenylsilyltetramethylcyclopentadienylcyclononylamidotitaniumA n , methylphenylsilyltetramethylcyclopentadienylcyclodecylamidotitaniumA n , methylphenylsilyltetramethylcyclopentadienylcycloundecylamidotitaniumA n , methylphenylsilyltetramethylcyclopentadienylcyclododecylamidotitaniumA n , methylphenylsilyl(tetramethylcyclopentadienyl)(sec-butylamido)titaniumA n , methylphenylsilyl(tetramethylcyclopentadienyl)(n-octylamido)titaniuman, methylphenylsilyl(tetramethylcyclopentadienyl)(n-decylamido)titaniuman, methylphenylsilyl(tetramethylcyclopentadienyl)(n-octadecylamido)titaniumA n , diphenylsilyltetramethylcyclopentadienylcyclopropylamidotitaniumA n , diphenylsilyltetramethylcyclopentadienylcyclobutylamidotitaniumA n , diphenylsilyltetramethylcyclopentadienylcyclopentylamidotitaniumA n , diphenylsilyltetramethylcyclopentadienylcyclohexylamidotitaniumA n , diphenylsilyltetramethylcyclopentadienylcycloheptylamidotitaniumA n , diphenylsilyltetramethylcyclopentadienylcyclooctylamidotitaniumA n , diphenylsilyltetramethylcyclopentadienylcyclononylamidotitaniumA n , diphenylsilyltetramethylcyclopentadienylcyclodecylamidotitaniumA n , diphenylsilyltetramethylcyclopentadienylcycloundecylamidotitaniumA n , diphenylsilyltetramethylcyclopentadienylcyclododecylamidotitaniumA n , diphenylsilyl(tetramethylcyclopentadienyl)(sec-butylamido)titaniumanA n , diphenylsilyl(tetramethylcyclopentadienyl)(n-octylamido)titaniumA n , diphenylsilyl(tetramethylcyclopentadienyl)(n-decylamido)titaniumA n , diphenylsilyl(tetramethylcyclopentadienyl)(n-octadecylamido)titaniumA n , and derivatives thereof.
[0040] As used herein, the term “metallocene activator” is defined to be any compound or combination of compounds, supported or unsupported, which may activate a single-site catalyst precursor compound (e.g., metallocenes, Group 15 containing catalysts, etc) to form the metallocene catalyst system. Typically, this involves the abstraction of at least one leaving group (A group in the formulas/structures above, for example) from the metal center of the catalyst component. The catalyst components of the present invention are thus activated towards olefin polymerization using such activators. Embodiments of such activators include Lewis acids such as cyclic or oligomeric polyhydrocarbylaluminum oxides and so called non-coordinating ionic activators (“NCA”), alternately, “ionizing activators” or “stoichiometric activators”, or any other compound that may convert a neutral metallocene catalyst component to a metallocene cation that is active with respect to olefin polymerization.
[0041] More particularly, it is within the scope of this invention to use Lewis acids such as the aluminoxanes as activators. Aluminoxanes are well known in the art and can be made by conventional methods, such as, for example admixing an aluminum alkyl with water. Nonhydrolytic routes to form these materials are also known. Traditionally, the most widely used aluminoxane is methylaluminoxane (MAO), an aluminoxane compound in which the alkyl groups are methyls. Aluminoxanes with higher alkyl groups include hexaisobutylalumoxane (HIBAO) isobutylaluminoxane, ethylaluminoxane, butylaluminoxane, heptylaluminoxane and methylbutylaluminoxane; and combinations thereof. Modified aluminoxanes (e.g., “MMAO”), may also be used. The use of MAO and other aluminum-based activators in polyolefin polymerizations as activators are well known in the art.
[0042] Ionizing activators are well known in the art and are described by, for example, Eugene You - Xian Chen & Tobin J Marks, Cocatalysts for Metal - Catalyzed Olefin Polymerization: Activators, Activation Processes, and Structure - Activity Relationships 100(4) CHEMICAL REVIEWS 1391-1434 (2000). Examples of neutral ionizing activators include tri-substituted compounds, in particular, tri-substituted boron, tellurium, aluminum, gallium and indium compounds, and mixtures thereof (e.g., tri(n-butyl)ammonium tetrakis(pentafluorophenyl)boron and/or trisperfluorophenyl boron metalloid precursors). The three substituent groups are each independently selected from alkyls, alkenyls, halogen, substituted alkyls, aryls, arylhalides, alkoxy and halides. In one embodiment, the three groups are independently selected from the group of halogen, mono or multicyclic (including halosubstituted) aryls, alkyls, and alkenyl compounds and mixtures thereof. In another embodiment, the three groups are selected from the group alkenyl groups having 1 to 20 carbon atoms, alkyl groups having 1 to 20 carbon atoms, alkoxy groups having 1 to 20 carbon atoms and aryl groups having 3 to 20 carbon atoms (including substituted aryls), and combinations thereof. In yet another embodiment, the three groups are selected from the group alkyls having 1 to 4 carbon groups, phenyl, naphthyl and mixtures thereof. In yet another embodiment, the three groups are selected from the group highly halogenated alkyls having 1 to 4 carbon groups, highly halogenated phenyls, and highly halogenated naphthyls and mixtures thereof. By “highly halogenated”, it is meant that at least 50% of the hydrogens are replaced by a halogen group selected from fluorine, chlorine and bromine. In yet another embodiment, the neutral stoichiometric activator is a tri-substituted Group 13 compound comprising highly fluorinated aryl groups, the groups being highly fluorinated phenyl and highly fluorinated naphthyl groups.
[0043] Illustrative, not limiting examples of ionic ionizing activators include trialkyl-substituted ammonium salts such as:
triethylammoniumtetraphenylboron, tripropylammoniumtetraphenylboron, tri(n-butyl)ammoniumtetraphenylboron, trimethylammoniumtetra(p-tolyl)boron, trimethylammoniumtetra(o-tolyl)boron, tributylammoniumtetra(pentafluorophenyl)boron, tripropylammoniumtetra(o,p-dimethylphenyl)boron, tributylammoniumtetra(m,m-dimethylphenyl)boron, tributylammoniumtetra(p-tri-fluoromethylphenyl)boron, tributylammoniumtetra(pentafluorophenyl)boron, tri(n-butyl)ammoniumtetra(o-tolyl)boron, and the like; N,N-dialkylanilinium salts such as: N,N-dimethylaniliniumtetraphenylboron, N,N-diethylaniliniumtetraphenylboron, N,N-2,4,6-pentamethylaniliniumtetraphenylboron and the like; dialkyl ammonium salts such as: diisopropylammoniumtetrapentafluorophenylboron, dicyclohexylammoniumtetraphenylboron and the like; triaryl phosphonium salts such as: triphenylphosphoniumtetraphenylboron, trimethylphenylphosphoniumtetraphenylboron, tridimethylphenylphosphoniumtetraphenylboron, and the like, and their aluminum equivalents.
[0066] In yet another embodiment, an alkylaluminum may be used in conjunction with a heterocyclic compound. The ring of the heterocyclic compound may include at least one nitrogen, oxygen, and/or sulfur atom, and includes at least one nitrogen atom in one embodiment. The heterocyclic compound includes 4 or more ring members in one embodiment, and 5 or more ring members in another embodiment.
[0067] The heterocyclic compound for use as an activator with an alkylaluminum may be unsubstituted or substituted with one or a combination of substituent groups. Examples of suitable substituents include halogen, alkyl, alkenyl or alkynyl radicals, cycloalkyl radicals, aryl radicals, aryl substituted alkyl radicals, acyl radicals, aroyl radicals, alkoxy radicals, aryloxy radicals, alkylthio radicals, dialkylamino radicals, alkoxycarbonyl radicals, aryloxycarbonyl radicals, carbomoyl radicals, alkyl- or dialkyl-carbamoyl radicals, acyloxy radicals, acylamino radicals, aroylamino radicals, straight, branched or cyclic, alkylene radicals, or any combination thereof. The substituents groups may also be substituted with halogens, particularly fluorine or bromine, or heteroatoms or the like.
[0068] Non-limiting examples of hydrocarbon substituents include methyl, ethyl, propyl, butyl, pentyl, hexyl, cyclopentyl, cyclohexyl, benzyl or phenyl groups and the like, including all their isomers, for example tertiary butyl, isopropyl, and the like. Other examples of substituents include fluoromethyl, fluoroethyl, difluoroethyl, iodopropyl, bromohexyl or chlorobenzyl.
[0069] In one embodiment, the heterocyclic compound is unsubstituted. In another embodiment one or more positions on the heterocyclic compound are substituted with a halogen atom or a halogen atom containing group, for example a halogenated aryl group. In one embodiment the halogen is selected from the group consisting of chlorine, bromine and fluorine, and selected from the group consisting of fluorine and bromine in another embodiment, and the halogen is fluorine in yet another embodiment.
[0070] Non-limiting examples of heterocyclic compounds utilized in the activator of the invention include substituted and unsubstituted pyrroles, imidazoles, pyrazoles, pyrrolines, pyrrolidines, purines, carbazoles, and indoles, phenyl indoles, 2,5,-dimethylpyrroles, 3-pentafluorophenylpyrrole, 4,5,6,7-tetrafluoroindole or 3,4-difluoropyrroles.
[0071] Other activators include those described in WO 98/07515 such as tris(2,2′,2″-nonafluorobiphenyl) fluoroaluminate, which is incorporated by reference herein. Combinations of activators are also contemplated by the invention, for example, alumoxanes and ionizing activators in combinations. Other activators include aluminum/boron complexes, perchlorates, periodates and iodates including their hydrates; lithium (2,2′-bisphenyl-ditrimethylsilicate)-4T-HF; silylium salts in combination with a non-coordinating compatible anion. Also, methods of activation such as using radiation, electro-chemical oxidation, and the like are also contemplated as activating methods for the purposes of rendering the neutral metallocene-type catalyst compound or precursor to a metallocene-type cation capable of polymerizing olefins. Other activators or methods for activating a metallocene-type catalyst compound are described in for example, U.S. Pat. Nos. 5,849,852 5,859,653 and 5,869,723; and WO 98/32775.
[0072] In general, the activator and catalyst component(s) may be combined in mole ratios of activator to catalyst component from 1000:1 to 0.5:1 in one embodiment, and from 300:1 to 1:1 in a more particular embodiment, and from 150:1 to 1:1 in yet a more particular embodiment, and from 50:1 to 1:1 in yet a more particular embodiment, and from 10:1 to 0.5:1 in yet a more particular embodiment, and from 3:1 to 0.3:1 in yet a more particular embodiment, wherein a desirable range may include any combination of any upper mole ratio limit with any lower mole ratio limit described herein. When the activator is a cyclic or oligomeric poly(hydrocarbylaluminum oxide) (e.g., “MAO”), the mole ratio of activator to catalyst component ranges from 2:1 to 100,000:1 in one embodiment, and from 10:1 to 10,000:1 in another embodiment, and from 50:1 to 10,000:1 in a more particular embodiment. When the activator is a neutral or ionic ionizing activator such as a boron alkyl and the ionic salt of a boron alkyl, the mole ratio of activator to catalyst component ranges from 0.5:1 to 10:1 in one embodiment, and from 1:1 to 5:1 in yet a more particular embodiment.
[0073] More particularly, the molar ratio of Al/metallocene-metal (e.g., Al from MAO:Zr from metallocene) ranges from 40 to 1000 in one embodiment, ranges from 50 to 750 in another embodiment, ranges from 60 to 500 in yet another embodiment, ranges from 70 to 300 in yet another embodiment, ranges from 80 to 175 in yet another embodiment; and ranges from 90 to 125 in yet another embodiment, wherein a desirable molar ratio of Al(MAO) to metallocene-metal “M” may be any combination of any upper limit with any lower limit described herein.
[0074] The activators may or may not be associated with or bound to a support, either in association with the catalyst component (e.g., metallocene) or separate from the catalyst component, such as described by Gregory G. Hlalky, Heterogeneous Single - Site Catalysts for Olefin Polymerization 100(4) CHEMICAL REVIEWS 1347-1374 (2000).
[0075] Metallocene catalysts may be supported or unsupported. Typical support materials may include talc, inorganic oxides, clays and clay minerals, ion-exchanged layered compounds, diatomaceous earth compounds, zeolites or a resinous support material, such as a polyolefin.
[0076] Specific inorganic oxides include silica, alumina, magnesia, titania and zirconia, for example. The inorganic oxides used as support materials may have an average particle size of from 5 microns to 600 microns, or from 10 microns to 100 microns, a surface area of from 50 m 2 /g to 1,000 m 2 /g, or from 100 m 2 /g to 500 m 2 /g, a pore volume of from 0.5 cc/g to 3.5 cc/g, or from 0.5 cc/g to 2 cc/g.
[0077] Desirable methods for supporting metallocene ionic catalysts are known in the art and described in, for example, U.S. Pat. No. 5,643,847, which is incorporated by reference herein. The methods generally include reacting neutral anion precursors that are sufficiently strong Lewis acids with the hydroxyl reactive functionalities present on the silica surface such that the Lewis acid becomes covalently bound.
[0078] When the activator for the metallocene supported catalyst composition is a NCA, desirably the NCA is first added to the support composition followed by the addition of the metallocene catalyst. In some processes, when the activator is MAO, the MAO and metallocene catalyst may be dissolved together in solution. The support is then contacted with the MAO/metallocene catalyst solution. In another embodiment of the process, MAO is first reacted with silica and then a metallocene is added to prepare a catalyst. Other methods and order of addition will be apparent to those skilled in the art. Such processes are known in the art and disclosed in, for example, U.S. Pat. Nos. 6,777,366 and 6,777,367, both to Gauthier, et al., and incorporated herein by reference.
[0079] In one embodiment, the heterocyclic compound described above is combined with an alkyl aluminum scavenger. The alkyl aluminum compounds can remove or mitigate materials such as water and oxygen that could otherwise interfere with the metallocene catalysts. Non-limiting examples of alkylaluminums include trimethylaluminum, triethylaluminum (TEAL), triisobutylaluminum (TIBAL), tri-n-hexylaluminum, tri-n-octylaluminum, tri-iso-octylaluminum, triphenylaluminum, and combinations thereof. While most often used as scavengers, the compounds can also, in some applications, function as cocatalysts or activators also. One of ordinary skill in the art of performing metallocene catalyzed polyolefin polymerizations will be versed in selecting and employing such scavengers.
[0080] Metallocene catalysts may be supported or unsupported. Typical support materials may include talc, inorganic oxides, clays and clay minerals, ion-exchanged layered compounds, diatomaceous earth compounds, zeolites or a resinous support material, such as a polyolefin. Specific inorganic oxides include silica, alumina, magnesia, titania and zirconia, for example. The inorganic oxides used as support materials may have an average particle size of from 5 microns to 600 microns, or from 10 microns to 100 microns, a surface area of from 50 m 2 /g to 1,000 m 2 /g, or from 100 m 2 /g to 400 m 2 /g, a pore volume of from 0.5 cc/g to 3.5 cc/g, or from 0.5 cc/g to 2 cc/g.
[0081] Desirable methods for supporting metallocene ionic catalysts are known in the art and described in, for example, U.S. Pat. No. 5,643,847, which is fully incorporated by reference herein. The methods generally include reacting neutral anion precursors that are sufficiently strong Lewis acids with the hydroxyl reactive functionalities present on the silica surface such that the Lewis acid becomes covalently bound. Activators may also be incorporated onto the support, using processes such as those disclosed in, for example, U.S. Pat. Nos. 6,777,366 and 6,777,367, both to Gauthier, et al., both of which are fully incorporated herein by reference.
[0082] To prepare a polymer it is necessary, in general, to contact the monomer or mixture of monomers and the given metallocene catalyst and the described cocatalyst(s). In certain cases it is desirable that the catalyst has been preactivated. Those skilled in the art will understand that this refers to subjecting the metallocene catalyst to conditions that promote the desired interaction between the activator or cocatalyst and the metallocene. The most commonly employed method of activating a catalyst is simply heating it to a sufficient temperature and for a sufficient time, determined as a matter of routine experimentation. This is discussed further in, for example, U.S. Pat. No. 6,180,732, the disclosure of which is fully incorporated herein by reference. Other methods can be used. Those skilled in the art will appreciate that modifications in the above generalized preparation method may be made without altering the outcome. Therefore, it will be understood that additional description of methods and means of preparing the catalyst are outside of the scope of the invention, and that it is only the identification of the prepared catalysts, as defined herein, that is necessarily described herein.
[0083] The metallocene catalysts described herein may be used to make copolymers using monomers including ethylene and propylene. A variety of processes may be employed to prepare the copolymers. Among the varying approaches that may be used include procedures set forth in, for example, U.S. Pat. No. 5,525,678, which is fully incorporated herein by reference. The equipment, process conditions, reactants, additives and other materials will, of course, vary in a given process, depending on the desired composition and properties of the polymer being formed. For example, the processes discussed in any of the following patents may be useful, each of which is fully incorporated herein by reference: U.S. Pat. Nos. 6,420,580; 6,380,328; 6,359,072; 6,346,586; 6,340,730; 6,339,134; 6,300,436; 6,274,684; 6,271,323; 6,248,845; 6,245,868; 6,245,705; 6,242,545; 6,211,105; 6,207,606; 6,180,735; and 6,147,173.
[0084] The catalyst systems described herein, including the identified family of cocatalysts, may be used over a wide range of temperatures and pressures. The temperatures may be in the range of from about 20° C. to about 280° C., or from about 50° C. to about 200° C. and the pressures employed may be in the range of from 1 atmosphere to about 500 atmospheres (0.10 mPa to 50.66 mPa) or higher. Such polymerization processes include solution, bulk, gas phase, slurry phase, high pressure processes, and combinations thereof.
[0085] Examples of solution processes are described in U.S. Pat. Nos. 4,271,060; 5,001,205; 5,236,998; and 5,589,555; and are fully incorporated herein by reference.
[0086] One example of a gas phase polymerization process generally employs a continuous cycle, wherein a cycling gas stream (otherwise known as a recycle stream or fluidizing medium) is heated in a reactor by heat of polymerization. The heat is removed from the recycle stream in another part of the cycle by a cooling system external to the reactor. The gaseous stream containing one or more monomers may be continuously cycled through a fluidized bed in the presence of a catalyst under reactive conditions. The gaseous stream is withdrawn from the fluidized bed and recycled back into the reactor. Simultaneously, polymer product is withdrawn from the reactor and fresh monomer is added to replace the polymerized monomer. See, for example, U.S. Pat. Nos. 4,543,399; 4,588,790; 5,028,670; 5,317,036; 5,352,749; 5,405,922; 5,436,304; 5,456,471; 5,462,999; 5,616,661; and 5,668,228 are fully incorporated herein by reference.
[0087] The reactor pressure in a gas phase process may vary from about 100 psig to about 500 psig (about 689.47 kPa to about 3,447.38 kPa), or from about 200 to about 400 psig (1378.95 kPa to 2757.90 kPa), or from about 250 to about 350 psig (1723.69 kPa to 2413.16 kPa). The reactor temperature in a gas phase process may vary from 30° C. to 120° C. in one embodiment, or 60° C. to 115° C. in an additional embodiment, or 70° C. to 110° C. or 70° C. to 95° C. in further embodiments.
[0088] Other gas phase processes contemplated by the process includes those described in U.S. Pat. Nos. 5,627,242; 5,665,818; and 5,677,375; and European publications EP-A-0 794 200; EP-A-0 802 202; and EP-B-634 421; all of which are fully incorporated herein by reference.
[0089] Slurry processes generally include forming a suspension of solid, particulate polymer in a liquid polymerization medium, to which monomers and optionally hydrogen, along with catalyst, are added. The suspension, including the polymerization diluent, may be intermittently or continuously removed from the reactor where the volatile components may be separated from the polymer and recycled, optionally after a distillation, to the reactor. The liquefied diluent employed in the polymerization medium is typically an alkane having from 3 to 7 carbon atoms, preferably a branched alkane. The medium employed should be liquid under the conditions of polymerization and relatively inert, such as hexane or, in one particularly desirable embodiment, isobutane.
[0090] The catalyst as a slurry or as a dry free flowing powder may be injected regularly to the reactor loop, which can itself be filled with circulating slurry of growing polymer particles in a monomer. Hydrogen, optionally, may be added as a molecular weight control. The reactor may be maintained at a pressure of from about 27 bar (2.7 mPa) to about 45 bar (4.5 mPa) (and a temperature of from about 38° C. to about 121° C. Reaction heat can be removed through the loop wall since much of the reactor is in the form of a double-jacketed pipe. The slurry may exit the reactor at regular intervals or continuously to a heated low pressure flash vessel, rotary dryer and a nitrogen purge column in sequence for removal of unreacted monomer and comonomers. The resulted hydrocarbon free powder can then be compounded for use in various applications. Alternatively, other types of slurry polymerization processes can be used, such stirred reactors is series, parallel or combinations thereof.
[0091] A slurry and/or polymerization process generally includes pressures in the range of 1 to 50 atmospheres (0.10 to 5.06 mPa) and even greater and temperatures of from about 0° C. to about 120° C.
[0092] A solution process can also be used. Examples of solution processes are described in U.S. Pat. Nos. 4,271,060; 5,001,205; 5,236,998; and 5,589,555, all of which are fully incorporated herein by reference.
[0093] In one embodiment the invention may be a copolymer prepared using a metallocene catalyst wherein the metallocene catalyst includes a bis-indenyl metallocene. The copolymer may be a random copolymer of propylene and ethylene. Ethylene may be present at weight percentage of from about 3 to about 5 percent. The copolymer may have a ductile/brittle transition of from about −7° C. to about 0° C. The copolymer may have a melting point of from about 108 to about 120 and, in one embodiment, has a melting point of about 114° C.
[0094] In another embodiment, the invention may be a copolymer prepared using a metallocene catalyst wherein the metallocene catalyst includes a CpFlu metallocene. The copolymer may be a random copolymer of propylene and ethylene. Ethylene may be present at weight percentage of from about 1.8 to about 3 percent. The copolymer may have a ductile/brittle transition of from about −7° C. to about 0° C. The copolymer may have a melting point of from about 108 to about 120 and, in one embodiment, may have a melting point of about 113° C.
[0095] The metallocene random copolymer may have an ethylene content, typically greater than about 2.0 weight %, alternatively greater than about 5 wt %, alternatively greater than about 6 wt %, and even about 6.5 wt %, as measured by carbon-13 nuclear magnetic resonance spectroscopy ( 13 C-NMR). All weight percentages (wt %) are per total weight of the copolymer. Metallocene random copolymers of the invention may be produced and marketed under the same name but different lots might have differences in the levels of ethylene and in other characteristics. As with other random copolymers, the ethylene may be in the backbone of the polymer chain, randomly inserted in the repeating propylene units.
[0096] The processes useful in preparing metallocene random copolymers having good impact resistance and high clarity are well known in the art of preparing such copolymers and may be made by using processes such as those disclosed in U.S. Pat. Nos. 5,158,920; 5,416,228; 5,789,502; 5,807,800; 5,968,864; 6,225,251; and 6,432,860; all of which are fully incorporated herein by reference. Standard equipment and procedures as are well known in the art may be used to polymerize the propylene and ethylene into the metallocene random copolymer.
[0097] A clarifier may optionally be added to the metallocene random copolymer for clarity enhancement. Since the clarifier is not necessarily included in the metallocene random copolymer, the lower limit on the amount of clarifier is 0 parts per million (ppm) by weight. The upper limit may be typically the U.S. Food and Drug Administration limit on such materials, which in this case is 4000 ppm. A desirable range for the clarifier may be 1000 ppm to 3000 ppm. A more desirable clarifier level may be about 2000 ppm. Suitable clarifiers include dibenzylidene sorbitols (CDBS), organophosphate salts, and phosphate esters. Examples of a commercially available clarifiers are Millad 3988, 3905, and 3940, powdered sorbitols available from Milliken Chemical of Spartanburg, S.C.; NA-11 and NA-21 phosphate esters available from Asahi Denka Kogyo; NC-4 from Mitsui Chemicals; HPN-68, a norbornane carboxylic-acid salt available from Milliken Chemical; and Irgaclear D or DM sorbitol based clarifiers available from Ciba Specialty Chemicals. Of course other clarifiers known to one skilled in the art for such purposes can also be used.
[0098] If the clarifier is to be included in the metallocene random copolymer, the clarifier, typically in the form of a powder or pellet, may be added to the copolymer after the polymerization process described above but before the copolymer is melted and formed into pellets. The copolymer and the clarifier are typically dry blended into a polymer blend for subsequent forming into end-use articles. Examples of apparatus suitable for blending the materials include a Henschel blender or a Banbury mixer, or alternatively low shear blending equipment of the type that typically accompanies a commercial blow molding or sheet extrusion line. The clarifier increases clarity by greatly increasing the rate of crystal formation in the copolymer. During the normal, slower crystallization process, relatively large crystals tend to form. These large crystals refract light and thus reduce the clarity of a copolymer. When the clarifier is added, the higher rate of crystal formation results in a greater number of smaller-sized crystals. The smaller crystals allow light to pass without refraction, thus increasing the clarity of the copolymer.
[0099] In addition to the clarifier, other additives may optionally be added to the metallocene random copolymer. The additives may include stabilizers, ultraviolet screening agents, oxidants, antioxidants, anti-static agents, ultraviolet light absorbents, lubricants, fire retardants, processing oils, mold release agents, coloring agents, pigments, nucleating agents, fillers, and the like. Additives may be suited for the particular needs or desires of a user or maker and various combinations of the additives may be used.
[0100] In some embodiments of the invention, the additives used may include a neutralizer such as Irganox 1076 and/or Irgafos 168, which are commercially available from the Ciba-Geigy Corporation. In other embodiments, the additive used may include Ethanox 330, an antioxidant available from Ethyl. In another embodiment, the additives used may include a hydrotalcite such as those with the trade name DHT4A, available from Kyowa Chemical Industries Co., LTD, for example. Another neutralizer that may be used with the invention is calcium stearate.
[0101] The radiation exposure may be from, for example, Co 60 gamma radiation or lower level radiation, such as that from E-beam radiation. The radiation exposure may be that used in sterilization techniques for medical or food handling applications. The materials of the invention may have application where radiation exposure is usually in the range of 1-6 mega rads (Mrads).
[0102] Ziegler-Natta catalysts also useful in the preparation of isotactic polypropylene are typically derived from a halide of a transition metal, such as titanium, chromium or vanadium with a metal hydride and/or metal alkyl, typically an organoaluminum compound as a co-catalyst. The catalyst is usually comprised of a titanium halide supported on a magnesium compound. Ziegler-Natta catalysts, such as titanium tetrachloride (TiCl 4 ) supported on an active magnesium dihalide, such as magnesium dichloride or magnesium dibromide, as disclosed, for example, in U.S. Pat. Nos. 4,298,718 and 4,544,717, both to Mayr et al., and which are fully incorporated herein by reference, are supported catalysts. Silica may also be used as a support. The supported catalyst may be employed in conjunction with a co-catalyst or electron donor such as an alkylaluminum compound, for example, triethylaluminum (TEAI), trimethyl aluminum (TMA) and triisobutyl aluminum (TiBAI). Ziegler-Natta catalyst systems incorporating diethers and succinates may also be used with the invention.
[0103] The isotactic polypropylene used in the present invention may be a propylene homopolymer, which may be prepared from either Ziegler-Natta or metallocene catalyst useful in preparing istotactic polymers. As used herein, “homopolymer” shall mean those polymers having less than about 0.1% by weight of polymer of other comonomers. The isotactic polypropylene component employed will typically have a meso dyad content, as determined by 13 C-NMR spectra, of at least 75%, and may be at least 95% or more. For metallocene-catalyzed isotactic polypropylene the polymer will typically have a molecular weight distribution or polydispersity index (Mw/Mn) of less than about 4.0, with from about 2.5 to about 3.5 being typical. Reactor grade metallocene-catalyzed polypropylenes typical have a melt flow rate of from about 0.5 g/10 minutes to about 48 g/10 min, but is often further treated to produce melt flow rates targeted for specific applications. For example, polymers to be employed in spunbond applications may typically have a melt flow rate of from about 14 to about 37 g/10 minutes. In another embodiment, the polymer to be used in a melt blown application may have a melt flow rate of from about 50 to about 1700 g/10 minutes, as measured by ASTM-D1238, Condition L at 230° C. The metallocene-catalyzed isotactic polypropylene may have a xylene solubles of less than about 1 weight percent, with from about 0.2 to about 0.5 being typical, as measured by ASTM-D5492.
[0104] For Ziegler-Natta isotactic polypropylene, the polymer may typically have a molecular weight distribution of from about 4 to about 15. Controlled rheology Ziegler-Natta polypropylene polymers typically have a higher xylene solubles compared to miPP. The ZNiPP will typically have xylene solubles of greater than 1, more typically from about 1.5 to about 5.0, with 2% being common. Because reactor-grade ZN-iPP typically has a fairly broad molecular weight distribution, it is often necessary for the polymer to undergo further processing to narrow its molecular weight distribution, such as for use in high speed melt spinning.
[0105] The isotactic polypropylene used in the present invention may also include isotactic propylene random copolymers, which may be prepared from either Ziegler-Natta or metallocene catalysts useful in the preparation of isotactic polymers. As used herein, “copolymers” shall mean those propylene polymers having 0.1% or more by weight of polymer of other comonomers. The isotactic propylene component of the random copolymers employed will typically have a meso dyad content, as determined by 13 C-NMR spectra, of at least 75%, and may be at least 95%. Those isotactic copolymers typically used in the present invention are those propylene copolymers of the olefin monomers having from 2 to 10 carbon atoms, with ethylene being the most typical comonomer employed. Typically, the comonomer will make up from about 0.1% to about 10% by weight of polymer, with from about 0.5% to about 6% being typical, and from 1% to about 3% being more typical. Copolymers will often have higher xylene solubles content.
[0106] The syndiotactic polypropylene used in the present invention may be a polypropylene homopolymer or polypropylene random copolymer. The syndiotactic polypropylene component typically has a racemic dyad content, as measured by 13 C-NMR spectra, of at least 75%, and may be at least 90% or more. The syndiotactic polypropylene will typically have a molecular weight distribution (MWD) or polydispersity index (Mw/Mn) of less than about 5, and may typically range from 2 to about 4.5. The melt flow rate of the syndiotactic polypropylene will usually be from about 5 g/10 minutes to about 30 g/10 minutes, with from about 10 g/10 minutes to about 20 g/10 minutes being more typical. The melt flow rate of the syndiotactic polypropylene may vary, however, depending upon the particular application. The metallocene-catalyzed syndiotactic polypropylene may have a xylene solubles of less than about 9, with from about 4 to about 9 being typical.
[0107] The syndiotactic polypropylene may also include copolymers of olefin monomers having from 2 to 10 carbon atoms, with ethylene being the most common comonomer employed. Typically, the comonomer will make up from about 0.1% to about 10% by weight of polymer, with from about 0.5% to about 6% being typical, and from 1% to about 3% being more typical.
[0108] The addition of syndiotactic polypropylene as a blend with isotactic polypropylene, either Ziegler-Natta or metallocene-catalyzed isotactic polypropylene has been found to increase the polymer's radiation resistance or reduce degradation of the polymer from radiation when compared to the same polymer without the syndiotactic polypropylene. Where such blends are employed, the amount of syndiotactic polypropylene may be less than 20% by total weight of polymer, with from about 0.5% to about 10% being more typical. The polymer blends may be melt blended within an extruder, such as during extrusion of the polymer sheet. Alternatively, the polymer blends may be reactor blended, such as described in U.S. Pat. No. 6,362,125, which is fully incorporated herein by reference.
[0109] The final melt flow rate of the polypropylene materials may vary, depending upon the particular application. In certain cases the propylene polymers may be modified or degraded to further change the characteristics of the polymer through controlled rheology techniques, which are known to those skilled in the art. This is typically done to adjust the polymer's final melt flow characteristics so that it has a higher melt flow rate. This may be particularly true with respect to ZN-iPP, which typically has a low MFI without CR'ing. Modification of the polymer may be accomplished through the addition of peroxides or other free-radical initiators, which degrade the polymer to thereby increase its melt flow rate.
[0110] The isotactic and syndiotactic propylene polymers may contain radiation stabilization additives or combinations of such stabilizers. These additives or stabilizers react with the alkyl radicals formed during irradiation and thereby terminate the chain reaction early on and thus reduce loss of polymer properties.
[0111] Such radiation stabilizers include the non-phenolic compounds of benzhydrols or derivatives of benzhydrol. Such compounds are aromatic compounds and are described in U.S. Pat. No. 4,431,497, which is herein incorporated by reference. Such stabilizers typically used in amounts of from about 500 to about 5000 ppm although these amounts may vary.
[0112] The stabilizers may also include the hindered amine light stabilizer (HALS) compounds, such the tetraalkyl-piperidene-containing polytriazine compounds, including the derivatives of 2,2,6,6-tetramethylpiperidine. Such compounds are described in U.S. Pat. Nos. 4,086,204, 4,234,707, 4,331,586, 4,335,242, 4,459,395, 4,492,791, 5,204,473 and 6,409,941, as well as EP0053775, EP0357223, EP0377324, EP0462069, EP0782994, and GB 2,301,106, all of which are herein incorporated by reference. An example of a suitable stabilizer is:
poly[[6-[(1,1,3,3-tetramethylbutyl)amino]-1,3,5-triazine-2,4-diyl][(2,2,6,6-tetramethl-4-piperidinyl)imino-1,6-hexanediyl[2,2,6,6-tetramethyl-4-piperidinyl)imino]]),
which is commercially available as CHIMASSORB 944, from Ciba Specialty Chemicals, Inc. Such compounds are typically used in amounts of from about 0.05 to about 1.0% by weight of polymer, although these amounts may vary.
[0114] Another useful stabilizer is the benzofuran-2-one type compounds. Such compounds are described in U.S. Pat. Nos. 4,325,863; 4,388,244; 5,175,312; 5,252,643; 5,216,052; 5,369,159; 5,488,117; 5,356,966; 5,367,008; 5,428,162; 5,428,177; 5,516,920 and 6,140,397, all of which are herein incorporated by reference. Such stabilizers are carbon-centered free radical scavengers may be used alone, or in combination with other stabilizers. The benzofuran-2-one type compounds may be used to regenerate such compounds in a regeneration cycle, where such compounds would be otherwise depleted during use. An example of a useful benzofuran-2-type compound is 5,7-di-t-butyl-3-(3,4 di-methylphenyl)-3H-benzofuran-2-one, which is commercially available as HP-136, from Ciba Specialty Chemicals, Inc. Such compounds are typically used in amounts of from 0.005 to about 0.05% by weight of polymer, although these amounts may vary.
[0115] Other additives may include such things as acid neutralizers, anti-static agents, lubricants, filler materials, mobilizing agents such as hydrocarbons, halogenated hydrocarbons, phthalates, polymeric fats, vegetable oils, silicone oils, and the like, which are well known to those skilled in the art.
[0116] The choice of radiation stabilizers or other additives may depend upon the type of polypropylene employed. Certain stabilizers or additives may react with peroxide used during controlled rheology so that they are consumed or are less effective. With respect to the radiation stabilizers or antioxidants, these may be consumed by the reaction with peroxide so that their effectiveness in preventing degradation from radiation exposure is reduced or eliminated.
[0117] Because reactor-grade metallocene-catalyzed polypropylene materials may have a higher melt flow rate than reactor-grade Ziegler-Natta-catalyzed polypropylenes, it may not be necessary for the miPP or msPP materials to be processed further through controlled rheology techniques. The addition of peroxide to the polymer during controlled rheology to increase the polymer's melt flow rate may thus be eliminated in these materials. Thus, the metallocene-catalyzed polymers may contain little or no peroxide or peroxide residues to react with the radiation stabilizers or other antioxidants.
[0118] Polypropylene fibers prepared from the radiation resistant polypropylene material may be used in fabrics and textiles and can be prepared using a variety of different methods. Such methods include spinning, melt blowing and the fibrillation of films into fibers. The polypropylene fibers may have different deniers, lengths and cross-sectional configurations and can be consolidated or networked in many different ways to provide fabrics and textiles having different characteristics and properties. The fibers may be formed into both woven and non-woven fabrics. Woven fabrics are formed through the conventional weaving or knitting techniques.
[0119] Non-woven materials may be produced using spunbonding or melt blowing techniques, in which the fabric is formed from generally continuous polymer fibers that are joined together at random cross-over points. Melt blown fibers typically have a denier of from about 50 to about 2000. They may be formed using polypropylene polymers having a final melt flow of about 700 to about 2000 g/10 min, more typically from about 800 to about 1500 g/10 minutes and with a molecular weight distribution of from about 2.5-4.5. Spunbond fibers typically have a denier of from about 20 to about 40. They may be formed from polypropylene having a final melt flow of about 15 to about 45 g/10 minutes, more typically from about 20 to about 35 g/10 minutes and having a molecular weight distribution of from about 2 to 4.5.
[0120] Additionally, staple fibers, which are filaments or fibers that are cut into smaller lengths or “staples,” can be formed into non-woven fabric material. Staple fibers typically have a denier of from about 1.5 to about 5.0. They may be formed from polypropylene having a final melt flow of about 4 to about 20 g/10 min, more typically from about 5 to about 15 g/10 minutes and having a molecular weight distribution of from about 2 to about 10, more typically from about 2 to about 8. Such staple fibers may be carded and joined together, such as through thermal bonding or by needle punch. The fibers may also be entangled or otherwise networked into a fabric material, such as through hydroentaglement or otherwise.
[0121] Different materials may be laminated or formed into composite materials. Two or more fabric materials may be joined together. Further, one or more fabrics may be joined to a layer or layers of film or to other non-fabric materials, such as superabsorbents or activated charcoal. The polypropylene or polymer materials are typically joined together through thermal bonding, however, resin bonding or other bonding methods may be employed as well.
[0122] One particular laminated or composite fabric that is commonly manufactured is spunbonded-meltblown-spunbonded (SMS) composite fabric material. This material utilizes outer layers of spunbonded nonwoven fabric, which provide strength to the fabric. The outer layers of spunbonded fabric are laminated to an inner layer of meltblown nonwoven fabric material, which serves as a barrier layer. The resulting composite fabric has good strength and barrier properties. SMS fabrics are often employed in medical and surgical environments in which the material must be sterilized. As a result, it is important for such materials to have good resistance to radiation.
[0123] The polypropylene materials may be used for or in a variety of different products or articles. Non-limiting examples include materials for diapers or incontinence products, sanitary towels, tampons and pads, protective and work clothing, disposable clothing, gowns, masks, insulating material, headwear, overshoes, flannels, bandages, bedcloths, wipes, syringes, tongue depressors, vacuum cleaner bags, tea bags and coffee filters, book covers, carpet underlay, wall coverings, bedclothes, table cloths, covers, mattress filing and covering material, furniture fabrics, cushion covers, upholstery and wadding, filters, air filters, gas filters, water filters, oil adsorbent materials, sanding material, cable sheaths, insulation tape, reinforcements, insulation, roof sealing. They may be used in geotextiles, such as in road and railway construction, dyke and canal construction, soil stabilization, drainage systems, golf, park and sporting ground surfacings, capillary mats in farming and agriculture, covering material for crop forcing and seedling protection. The materials may be used for greenhouse shielding and as packaging materials for fruits, vegetables or produce. The materials may be used in the automobile industry as insulation material, roof linings, battery separators and coating carriers. They may be used for luggage and handbags, sacks, carrier bags, bags, packaging. They may be used in self-adhesive materials, tents, cheese wrappers, artist's canvas and in advertising articles.
[0124] Metallocene catalyzed isotactic and syndiotactic polypropylene homopolymers, ethylene propylene random copolymers, and heterophasic copolymers offer superior properties after irradiation in other applications. Ziggler-Natta catalyzed polypropylene polymers and copolymers are often used in gamma resistant applications requiring moderate impact resistance after irradiation such as but not limited to: sterilization of food packaging, laboratory equipment, and medical applications. Metallocene catalyzed polymers and copolymers are more resistant to the degradation caused by irradiation. Many medical or food applications such as these require low odor and low aqueous or chemical extractables, thus metallocenes that do not use peroxides or use less peroxide may be particularly useful.
[0125] Other reasons why metallocenes catalyzed polymers and copolymers are well suited for these applications include 1) they have less extractables relative to Ziegler-Natta catalyzed resins with similar copolymer content, 2) they retain their clarity at ethylene levels above 3 wt % by NMR, and 3) improved mixing with other polymers and copolymers and color concentrates because of narrow molecular weight distribution. In these applications, the metallocene catalyzed polymers and copolymers may be either neat or blended with other non-metallocene polymers and copolymers.
[0126] The following examples are provided to more fully illustrate the invention. As such, they are intended to be merely illustrative and should not be construed as being limitative of the scope of the invention in any way. Those skilled in the art will appreciate that modifications may be made to the invention as described without altering its scope. For example, selection of particular monomers or combinations of monomers; and modifications such as of catalyst concentration, feed rate, processing temperatures, pressures and other conditions, and the like, not explicitly mentioned herein but falling within the general description hereof, will still fall within the intended scope of both the specification and claims appended hereto.
EXAMPLES
[0127] Various polypropylene materials were prepared for use in fabric materials. The characteristics and properties of the polypropylene materials used are presented in Table 1, below. Unless otherwise specified, all percentages are by total weight of polymer.
[0000]
TABLE 1
Resin Sample
1
3
ZN-iPP
2
ZN-iPP
4
(Spunbond)
m-sPP
(Melt Blown)
m-iPP
Initial MFR (g/10 min)
1.5
4
350
30
Final MFR (g/10 min)
22
4.5
918
32
Additives
DHT-4A, (%) A
0.02
0.02
0.02
0.02
Milliken RS200 (%)
0.2
0.2
0.2
0.2
Chimasorb 944 (%)
0.2
0.2
0.2
0.2
Lupersol 101 (%)
0.05
0
n.a. B
0
GMS (%) C
0.04
0.04
0.04
0.04
EBS (%) D
0
0.1
0
0
A Stabilizer from Kyowa Chemical Industry Co
B Amount not precisely known but estimated to be about 600–800 ppm
C Glycerol monostearate
D Ethylene bisstearamide
[0128] The above materials are used in forming either spunbonded or melt blown fiber materials. The syndiotactic polypropylene of Sample 2 was combined with isotactic polypropylene of both Samples 1 and 4 in amounts of approximately 5% by total weight of polymer by pellet/pellet tumble blending. Table 2 sets forth the make up of the different fabric samples. These materials are then used to prepare a spunbonded/meltblown/spunbonded (SMS) laminated fabric. The SMS fabric is produced on a 1.5 meter STP Impianti SMS fabric line, which utilizes two spunbonded beams and a single melt blown die. The spunbond unit had a slot-design aspirator unit to draw down the fibers at approximately 2000 m/min. The melt spinning temperatures at the spunbond beam were held constant at approximately 235° C.
[0000] TABLE 2 SMS Fabric 1 st Spunbond Melt Blown 2 nd Spunbond Sample Layer Layer Layer 1* ZN-iPP ZN-iPP ZN-iPP (Sample 1) (Sample 3) (Sample 1) 2 ZN-iPP (Sample 1) + ZN-iPP (Sample ZN-iPP (Sample 5 wt % m-sPP 3) 1) + 5 wt % m- (Sample 2) sPP (Sample 2) 3* m-iPP (Sample 4) ZN-iPP m-iPP (Sample 3) (Sample 4) 4 m-iPP (Sample 4) + ZN-iPP (Sample m-iPP (Sample 5 wt % m-sPP 3) 4) + 5 wt % m- (Sample 2) sPP (Sample 2) *Comparative example, not an example of the invention.
The SMS fabric samples are then subjected to gamma radiation using a Cobalt 60 radiation source at the dosage levels set forth in Table 3. In certain cases, the fabric was oven aged in a convection oven at a temperature of approximately 60° C. for six weeks. Various properties of the SMS fabric material were then measured and are set forth in Tables 3 A&B below. These included machine-direction (MD) and cross-direction (CD) grab strength, tear strength, and elongation. The term “trap” refers to the test specimen shape. In Table 3C, the percent elongation retained in both the machine direction and the cross machine direction are calculated and displayed. Sample 2 is then compared to Sample 1 and Sample 4 is compared to Sample 3 and the comparative retained elongation is calculated and displayed in Table 3C. Overall average percent elongation retention is also calculated and displayed in Table 3C.
[0000]
TABLE 3A
CD-
SMS
Basis
CD
MD-Trap
Trap
Fabric
Radiation
Weight
MD Grab
Grab
Tear
Tear
Sample
and Aging Conditions
(oz./yd)
(lb/in)
(lb/in)
(g)
(g)
1
Non-Irradiated
1.46
28
20
14
11
3 Mrads
1.46
21
14
10
6
3 Mrads + 6 wks. Oven Aging
1.46
19
13.5
6.2
4
6 Mrads
1.46
17
12
8
4
6 Mrads + 6 wks. Oven Aging
1.42
13.1
8.8
3.2
2.2
10 Mrads
1.42
11
6
2.3
1.5
2
Non-Irradiated
1.52
28
20
14
9
3 Mrads
1.52
18
14
13
7
3 Mrads + 6 wks. Oven Aging
1.48
18.1
14.6
7.4
4.5
6 Mrads
1.48
18
17
8
5
6 Mrads + 6 wks. Oven Aging
1.59
13.7
7.7
3.3
2.3
10 Mrads
1.59
15
10
7
3.4
3
Non-Irradiated
1.39
25
18
12
8
3 Mrads
1.39
22
17
11
7
3 Mrads + 6 wks. Oven Aging
1.37
16.7
13.5
6.7
4.5
6 Mrads
1.37
19
13
7
5
6 Mrads + 6 wks. Oven Aging
1.33
14.2
9.6
4.3
2.6
10 Mrads
1.33
15
11
6
3
4
Non-Irradiated
1.48
25
18
15
9
3 Mrads
1.48
18
16
10
6
3 Mrads + 6 wks. Oven Aging
1.50
21
14.7
7.1
5.1
6 Mrads
1.50
19
13
8
6
6 Mrads + 6 wks. Oven Aging
1.53
15.1
11.1
4.5
3.1
10 Mrads
1.53
13
8.6
6
3
[0000]
TABLE 3B
SMS
MD-
CD-
Fabric
Radiation
Elong.
Elong.
Air Perm.
Sample
and Aging Conditions
(%)
(%)
(cfm/ft 2 )
1
Non-Irradiated
80
93
154
3 Mrads
45
54
143
3 Mrads + 6 wks. Oven Aging
36.4
43
145
6 Mrads
39
41
138
6 Mrads + 6 wks. Oven Aging
22.9
23.5
143
10 Mrads
17
19
143
2
Non-Irradiated
79
93
138
3 Mrads
68
64
168
3 Mrads + 6 wks. Oven Aging
38.8
43.4
165
6 Mrads
49
43
150
6 Mrads + 6 wks. Oven Aging
22.7
31.4
178
10 Mrads
35
49
148
3
Non-Irradiated
101
103
136
3 Mrads
57
62
138
3 Mrads + 6 wks. Oven Aging
40.8
42.6
169
6 Mrads
40
42
142
6 Mrads + 6 wks. Oven Aging
30.5
36.8
174
10 Mrads
28
29
139
4
Non-Irradiated
93
94
136
3 Mrads
61
70
144
3 Mrads + 6 wks. Oven Aging
38.7
41
153
6 Mrads
48
53
143
6 Mrads + 6 wks. Oven Aging
28.5
32.8
124
10 Mrads
30
40
130
[0000] TABLE 3C SMS MD- MD CD- CD Overall Fabric Radiation % Elong. Comp % % Elong Comp % Avg Sample and Aging Conditions Retained Retained Retained Retained MD/CD 1 Non-Irradiated — — 3 Mrads 56 58 3 Mrads + 6 wks. Oven Aging 45 46 6 Mrads 48 44 6 Mrads + 6 wks. Oven Aging 28 25 10 Mrads 21 20 2 Non-Irradiated — — — — 15.6/11.0 3 Mrads 86 36 69 11 3 Mrads + 6 wks. Oven Aging 49 5 47 1 6 Mrads 62 14 46 2 6 Mrads + 6 wks. Oven Aging 28 0 34 9 10 Mrads 44 23 52 32 3 Non-Irradiated — — 3 Mrads 56 60 3 Mrads + 6 wks. Oven Aging 41 41 6 Mrads 40 41 6 Mrads + 6 wks. Oven Aging 30 36 10 Mrads 28 28 4 Non-Irradiated — — — — 5.4/8.2 3 Mrads 66 10 74 14 3 Mrads + 6 wks. Oven Aging 41 0 44 3 6 Mrads 52 12 56 15 6 Mrads + 6 wks. Oven Aging 31 1 33 −3 10 Mrads 32 4 34 6
The SMS fabric samples incorporating 5 percent metallocene polypropylene components in the spunbond layers out performed those fabric samples that did not incorporate 5 percent metallocene polypropylene components at retaining toughness after exposure to radiation and after exposure to both radiation and oven heat aging. For example, the SMS fabrics of the invention have a 50% or greater retention of machine direction elongation strength at a radiation dose of 3-6 Mrads
[0129] While the invention has been shown in only some of its forms, it should be apparent to those skilled in the art that it is not so limited, but is susceptible to various changes and modifications without departing from the scope of the invention. Accordingly, it is appropriate that the appended claims be construed broadly and in a manner consistent with the scope of the invention. | A polypropylene material is provided having increased radiation resistance compared to solely isotactic polypropylene. The material is formed by utilizing a syndiotactic polypropylene. The isotactic polypropylene may be an isotactic metallocene or Ziegler-Natta catalyzed polypropylene and may include an amount of syndiotactic polypropylene. The material may be used in forming a variety of materials that may undergo exposure to radiation, such as sterilization procedures using radiation. It is emphasized that this abstract is provided to comply with the rules requiring an abstract which will allow a searcher or other reader to quickly ascertain the subject matter 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. | 97,149 |
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] The present invention is related to the following applications entitled: “Method and Apparatus for Publishing and Monitoring Entities Providing Services in a Distributed Data Processing System”, Ser. No. ______, attorney docket no. YOR920020173US1; “Method and Apparatus for Automatic Updating and Testing of Software”, Ser. No. ______, attorney docket no. YOR920020174US1; “Composition Service for Autonomic Computing”, Ser. No. ______, attorney docket no. YOR920020176US1; and “Adaptive Problem Determination and Recovery in a Computer System”, Ser. No. ______, attorney docket no. YOR920020194US1; all filed even date hereof, assigned to the same assignee, and incorporated herein by reference.
BACKGROUND OF THE INVENTION
[0002] 1. Technical Field
[0003] The present invention relates generally to an improved data processing system, and in particular, to a method and apparatus for managing hardware and software components. Still more particularly, the present invention provides a method and apparatus for automatically identifying and self-managing hardware and software components to achieve functionality requirements.
[0004] 2. Description of Related Art
[0005] Modern computing technology has resulted in immensely complicated and ever-changing environments. One such environment is the Internet, which is also referred to as an “internetwork.” The Internet is a set of computer networks, possibly dissimilar, joined together by means of gateways that handle data transfer and the conversion of messages from a protocol of the sending network to a protocol used by the receiving network. When capitalized, the term “Internet” refers to the collection of networks and gateways that use the TCP/IP suite of protocols. Currently, the most commonly employed method of transferring data over the Internet is to employ the World Wide Web environment, also called simply “the Web”. Other Internet resources exist for transferring information, such as File Transfer Protocol (FTP) and Gopher, but have not achieved the popularity of the Web. In the Web environment, servers and clients effect data transaction using the Hypertext Transfer Protocol (HTTP), a known protocol for handling the transfer of various data files (e.g., text, still graphic images, audio, motion video, etc.). The information in various data files is formatted for presentation to a user by a standard page description language, the Hypertext Markup Language (HTML). The Internet also is widely used to transfer applications to users using browsers. Often times, users of may search for and obtain software packages through the Internet.
[0006] Other types of complex network data processing systems include those created for facilitating work in large corporations. In many cases, these networks may span across regions in various worldwide locations. These complex networks also may use the Internet as part of a virtual product network for conducting business. These networks are further complicated by the need to manage and update software used within the network.
[0007] As software evolves to become increasingly ‘autonomic’, the task of managing hardware and software will, more and more, be performed by the computers themselves, as opposed to being performed by administrators. The current mechanisms for managing computer systems are moving towards an “autonomic” process, wherein computer systems are self-configuring, self-optimizing, self-protecting, and self-healing. For example, many operating systems and software packages will automatically look for particular software components based on user-specified requirements. These installation and update mechanisms often connect to the Internet at a preselected location to see whether an update or a needed component is present. If the update or other component is present, the message is presented to the user in which the message asks the user whether to download and install the component. An example of such a system is the package management program “dselect” that is part of the open-source Debian GNU/Linux operating system. Some virus checking programs run in the background (as a “daemon” process, to use Unix parlance) and can automatically detect viruses, remove them, and repair damage.
[0008] A next step towards “autonomic” computing involves identifying, installing, and managing necessary hardware and software components without requiring user intervention. Thus, a need exists in the art for more automated processes for identifying, installing, configuring and managing hardware and software components.
SUMMARY OF THE INVENTION
[0009] The present invention is directed toward a method, computer program product, and data processing system for constructing a self-managing distributed computing system comprised of “autonomic elements.” An autonomic element provides a set of services, and may provide them to other autonomic elements. Relationships between autonomic elements include the providing and consuming of such services. These relationships are “late bound,” in the sense that they can be made during the operation of the system rather than when parts of the system are implemented or deployed. They are dynamic, in the sense that relationships can begin, end, and change over time. They are negotiated, in the sense that they are arrived at by a process of mutual communication between the elements that establish the relationship. Policies, including constraints and preferences, may be specified to an autonomic element. Any relationship established by an autonomic element must be consistent with the policy of that autonomic element. During the course of a relationship, an autonomic element must attempt to adjust its behavior to be consistent with the policy.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] 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:
[0011] [0011]FIG. 1 is a diagram of a networked data processing system in which the present invention may be implemented;
[0012] [0012]FIG. 2 is a block diagram of a server system within the networked data processing system of FIG. 1;
[0013] [0013]FIG. 3 is a block diagram of a client system within the networked data processing system of FIG. 1;
[0014] [0014]FIG. 4 is a diagram of an autonomic element in accordance with a preferred embodiment of the present invention;
[0015] [0015]FIG. 5 is a diagram a mechanism for establishing service-providing relationships between autonomic elements in accordance with a preferred embodiment of the present invention;
[0016] [0016]FIG. 6 is a diagram providing a legend for symbols in E-R (entity-relationship diagrams) as used in this document;
[0017] [0017]FIG. 7 is a diagram of an example database schema for a directory service in accordance with a preferred embodiment of the present invention;
[0018] FIGS. 8 - 9 diagrams depicting an example of an autonomic element utilizing the services of another autonomic element in accordance with a preferred embodiment of the present invention;
[0019] [0019]FIG. 10 is an E-R diagram depicting how the terms of a relationship between two autonomic elements may be governed by a policy in accordance with a preferred embodiment of the present invention;
[0020] [0020]FIG. 11 is a flowchart representation of a process of negotiating terms of a relationship between two autonomic elements as seen from the perspective of one of the elements in accordance with a preferred embodiment of the present invention;
[0021] FIGS. 12 - 15 are diagrams depicting an example of fault detection and handling in an autonomic computing system in accordance with a preferred embodiment of the present invention; and
[0022] [0022]FIG. 16 is a flowchart representation of a process of recovery from a fault or compromise in accordance with a preferred embodiment of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0023] With reference now to the figures, FIG. 1 depicts a pictorial representation of a network of data processing systems in which the present invention may be implemented. Network data processing system 100 is a network of computers in which the present invention may be implemented. Network data processing system 100 contains a network 102 , which is the medium used to provide communications links between various devices and computers connected together within network data processing system 100 . Network 102 may include connections, such as wire, wireless communication links, or fiber optic cables.
[0024] In the depicted example, server 104 is connected to network 102 along with storage unit 106 . In addition, clients 108 , 110 , and 112 are connected to network 102 . These clients 108 , 110 , and 112 may be, for example, personal computers or network computers. In the depicted example, server 104 provides data, such as boot files, operating system images, and applications to clients 108 - 112 . Clients 108 , 110 , and 112 are clients to server 104 . Network data processing system 100 may include additional servers, clients, and other devices not shown. In the depicted example, network data processing system 100 is the Internet with network 102 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 100 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). FIG. 1 is intended as an example, and not as an architectural limitation for the present invention.
[0025] Referring to FIG. 2, a block diagram of a data processing system that may be implemented as a server, such as server 104 in FIG. 1, is depicted in accordance with a preferred embodiment of the present invention. Data processing system 200 may be a symmetric multiprocessor (SMP) system including a plurality of processors 202 and 204 connected to system bus 206 . Alternatively, a single processor system may be employed. Also connected to system bus 206 is memory controller/cache 208 , which provides an interface to local memory 209 . I/O bus bridge 210 is connected to system bus 206 and provides an interface to I/O bus 212 . Memory controller/cache 208 and I/O bus bridge 210 may be integrated as depicted.
[0026] Peripheral component interconnect (PCI) bus bridge 214 connected to I/O bus 212 provides an interface to PCI local bus 216 . A number of modems may be connected to PCI local bus 216 . Typical PCI bus implementations will support four PCI expansion slots or add-in connectors. Communications links to clients 108 - 112 in FIG. 1 may be provided through modem 218 and network adapter 220 connected to PCI local bus 216 through add-in boards.
[0027] Additional PCI bus bridges 222 and 224 provide interfaces for additional PCI local buses 226 and 228 , from which additional modems or network adapters may be supported. In this manner, data processing system 200 allows connections to multiple network computers. A memory-mapped graphics adapter 230 and hard disk 232 may also be connected to I/O bus 212 as depicted, either directly or indirectly.
[0028] Those of ordinary skill in the art will appreciate that the hardware depicted in FIG. 2 may vary. For example, other peripheral devices, such as optical disk drives and the like, also may be used in addition to or in place of the hardware depicted. The depicted example is not meant to imply architectural limitations with respect to the present invention.
[0029] The data processing system depicted in FIG. 2 may be, for example, an IBM eServer pSeries system, a product of International Business Machines Corporation in Armonk, N.Y., running the Advanced Interactive Executive (AIX) operating system or LINUX operating system.
[0030] With reference now to FIG. 3, a block diagram illustrating a data processing system is depicted in which the present invention may be implemented. Data processing system 300 is an example of a client computer. Data processing system 300 employs a peripheral component interconnect (PCI) local bus architecture. Although the depicted example employs a PCI bus, other bus architectures such as Accelerated Graphics Port (AGP) and Industry Standard Architecture (ISA) may be used. Processor 302 and main memory 304 are connected to PCI local bus 306 through PCI bridge 308 . PCI bridge 308 also may include an integrated memory controller and cache memory for processor 302 . Additional connections to PCI local bus 306 may be made through direct component interconnection or through add-in boards. In the depicted example, local area network (LAN) adapter 310 , SCSI host bus adapter 312 , and expansion bus interface 314 are connected to PCI local bus 306 by direct component connection. In contrast, audio adapter 316 , graphics adapter 318 , and audio/video adapter 319 are connected to PCI local bus 306 by add-in boards inserted into expansion slots. Expansion bus interface 314 provides a connection for a keyboard and mouse adapter 320 , modem 322 , and additional memory 324 . Small computer system interface (SCSI) host bus adapter 312 provides a connection for hard disk drive 326 , tape drive 328 , and CD-ROM drive 330 . Typical PCI local bus implementations will support three or four PCI expansion slots or add-in connectors.
[0031] An operating system runs on processor 302 and is used to coordinate and provide control of various components within data processing system 300 in FIG. 3. The operating system may be a commercially available operating system, such as Windows XP, which is available from Microsoft Corporation. An object oriented programming system such as Java may run in conjunction with the operating system and provide calls to the operating system from Java programs or applications executing on data processing system 300 . “Java” is a trademark of Sun Microsystems, Inc. Instructions for the operating system, the object-oriented operating system, and applications or programs are located on storage devices, such as hard disk drive 326 , and may be loaded into main memory 304 for execution by processor 302 .
[0032] Those of ordinary skill in the art will appreciate that the hardware in FIG. 3 may vary depending on the implementation. Other internal hardware or peripheral devices, such as flash read-only memory (ROM), equivalent nonvolatile memory, or optical disk drives and the like, may be used in addition to or in place of the hardware depicted in FIG. 3. Also, the processes of the present invention may be applied to a multiprocessor data processing system.
[0033] As another example, data processing system 300 may be a stand-alone system configured to be bootable without relying on some type of network communication interfaces As a further example, data processing system 300 may be a personal digital assistant (PDA) device, which is configured with ROM and/or flash ROM in order to provide non-volatile memory for storing operating system files and/or user-generated data.
[0034] The depicted example in FIG. 3 and above-described examples are not meant to imply architectural limitations. For example, data processing system 300 also may be a notebook computer or hand held computer in addition to taking the form of a PDA. Data processing system 300 also may be a kiosk or a Web appliance.
[0035] The present invention is directed to a method and apparatus for constructing a self-managing distributed computing system. The hardware and software components making up such a computing system (e.g., databases, storage systems, Web servers, file servers, and the like) are self-managing components called “autonomic elements.” Autonomic elements couple conventional computing functionality (e.g., a database) with additional self-management capabilities. FIG. 4 is a diagram of an autonomic element in accordance with a preferred embodiment of the present invention. According to the preferred embodiment depicted in FIG. 4, an autonomic element 400 comprises a management unit 402 and a functional unit 404 . One of ordinary skill in the art will recognize that an autonomic element need not be clearly divided into separate units as in FIG. 4, as the division between management and functional units is merely conceptual.
[0036] Management unit 402 handles the self-management features of autonomic element 400 . In particular, management unit 402 is responsible for adjusting and maintaining functional unit 404 pursuant to a set of goals for autonomic element 400 , as indicated by monitor/control interface 414 . Management unit 402 is also responsible for limiting access to functional unit 404 to those other system components (e.g., other autonomic elements) that have permission to use functional unit 404 , as indicated by access control interfaces 416 . Management unit 402 is also responsible for establishing and maintaining relationships with other autonomic elements (e.g., via input channel 406 and output channel 408 ).
[0037] Functional unit 404 consumes services provided by other system components (e.g., via input channel 410 ) and provides services to other system components (e.g., via output channel 412 ), depending on the intended functionality of autonomic element 400 . For example, an autonomic database element provides database services and an autonomic storage element provides storage services. It should be noted that an autonomic element, such as autonomic element 400 , may be a software component, a hardware component, or some combination of the two. One goal of autonomic computing is to provide computing services at a functional level of abstraction, without making rigid distinctions between the underlying implementations of a given functionality.
[0038] Autonomic elements operate by providing services to other components (which may themselves be autonomic elements) and/or obtaining services from other components. In order for autonomic elements to cooperate in such a fashion, one requires a mechanism by which an autonomic element may locate and enter into relationships with additional components providing needed functionality. FIG. 5 is a diagram depicting such a mechanism constructed in accordance with a preferred embodiment of the present invention.
[0039] A “requesting component” 500 , an autonomic element, requires services of another component in order to accomplish its function. In a preferred embodiment, such function may be defined in terms of a policy of rules and goals. Policy server component 502 is an autonomic element that establishes policies for other autonomic elements in the computing system. In FIG. 5, policy server component 502 establishes a policy of rules and goals for requesting component 500 to follow and communicates this policy to requesting component 500 . In the context of network communications, for example, a required standard of cryptographic protection may be a rule contained in a policy, while a desired quality of service (QoS) may be a goal of a policy.
[0040] In furtherance of requesting component 500 's specified policy, requesting component 500 requires a service from an additional component (for example, encryption of data). In order to acquire such a service, requesting component 500 consults directory component 504 , another autonomic element. Directory component 504 is preferably a type of database that maps functional requirements into components providing the required functionality. An example of a database schema for a directory service is provided in FIG. 7.
[0041] In a preferred embodiment, directory component 504 may provide directory services through the use of standardized directory service schemes such as Web Services Description Language (WSDL) and systems such as Universal Description, Discovery, and Integration (UDDI), which allow a program to locate entities that offer particular services and to automatically determine how to communicate and conduct transactions with those services. WSDL is a proposed standard being considered by the WorldWide Web Consortium, authored by representatives of companies, such as International Business Machines Corporation, Ariba, Inc., and Microsoft Corporation. UDDI version 3 is the current specification being used for Web service applications and services. Future development and changes to UDDI will be handled by the Organization for the Advancement of Structured Information Standards (OASIS).
[0042] Directory component 504 provides requesting component 500 information to allow requesting component 500 to make use of the services of a needed component 506 . Such information may include an address (such as a network address) to allow needed component 506 to be communicated with, downloadable code or the address to downloadable code to allow requesting component 500 to bind to and make use of needed component 506 , or any other suitable information to allow requesting component 500 to make use of the services of needed component 506 .
[0043] An example database schema for a directory service such as directory component 504 is provided in FIG. 7 in the form of an entity-relationship (E-R) diagram. The E-R (entity-relationship) approach to database modeling provides a semantics for the conceptual design of databases. With the E-R approach, database information is represented in terms of entities, attributes of entities, and relationships between entities, where the following definitions apply. The modeling semantics corresponding to each definition is illustrated in FIG. 6. FIG. 6 is adapted from Elmasri and Navathe, Fundamentals of Database Systems, 3rd Ed., Addison Wesley (2000), pp. 41-66, which contains additional material regarding E-R diagrams and is hereby incorporated by reference.
[0044] Entity: An entity is a principal object about which information is collected. For example, in a database containing information about personnel of a company, an entity might be “Employee.” In E-R modeling, an entity is represented with a box. An entity may be termed weak or strong, relating its dependence on another entity. A strong entity exhibits no dependence on another entity, i.e. its existence does not require the existence of another Entity. As shown in FIG. 6, a strong entity is represented with a single unshaded box. A weak entity derives its existence from another entity. For example, an entity “Work Time Schedule” derives its existence from an entity “Employee” if a work time schedule can only exist if it is associated with an employee. As shown in FIG. 6, a weak entity is represented by concentric boxes.
[0045] Attribute: An attribute is a label that gives a descriptive property to an entity (e.g., name, color, etc.). Two types of attributes exist. Key attributes distinguish among occurrences of an entity. For example, in the United States, a Social Security number is a key attribute that distinguishes between individuals. Descriptor attributes merely describe an entity occurrence (e.g., gender, weight). As shown in FIG. 6, in E-R modeling, an attribute is represented with an oval tied to the entity (box) to which it pertains.
[0046] In some cases, an attribute may have multiple values. For example, an entity representing a business may have a multivalued attribute “locations.” If the business has multiple locations, the attribute “locations” will have multiple values. A multivalued attribute is represented by concentric ovals, as shown in FIG. 6. In other cases, an composite attribute may be formed from multiple grouped attributes. A composite attribute is represented by a tree structure, as shown in FIG. 6. A derived attribute is an attribute that need not be explicitly stored in a database, but may be calculated or otherwise derived from the other attributes of an entity. A derived attribute is represented by a dashed oval as shown in FIG. 6.
[0047] Relationships: A relationship is a connectivity exhibited between entity occurrences. Relationships may be one to one, one to many, and many to many, and participation in a relationship by an entity may be optional or mandatory. For example, in the database containing information about personnel of a company, a relation “married to” among employee entity occurrences is one to one (if it is stated that an employee has at most one spouse). Further, participation in the relation is optional as there may exist unmarried employees. As a second example, if company policy dictates that every employee have exactly one manager, then the relationship “managed by” among employee entity occurrences is many to one (many employees may have the same manager), and mandatory (every employee must have a manager).
[0048] As shown in FIG. 6, in E-R modeling a relationship is represented with a diamond. Relationships may involve two or more entities. The cardinality ratio (one-to-one, one-to-many, etc.) in a relationship is denoted by the use of the characters “1” and “N” to show 1:1 or 1:N cardinality ratios, or through the use of explicit structural constraints, as shown in FIG. 6. When all instances of an entity participate in the relationship, the entity box is connected to the relationship diamond by a double line; otherwise, a single line connects the entity with the relationship, as in FIG. 6. In some cases, a relationship may actually identify or define one of the entities in the relationship. These identifying relationships are represented by concentric diamonds, also shown in FIG. 6.
[0049] Turning now to FIG. 7, an example database schema for a directory service in accordance with a preferred embodiment of the present invention is provided. It should be noted that the example schema provided in FIG. 7 is merely illustrative in nature and is not intended to limit the scope of the present invention to any particular database structure. FIG. 7 is merely intended to illustrate possible contents and organization of a directory service database in accordance with a preferred embodiment of the present invention.
[0050] A component entity 700 represents individual autonomic elements in the computing system. Each component ( 700 ) provides (provides relationship 702 ) a number of services (services entity 704 ). In order for a component to provide desired services, however, the component must be “used” in a particular way, represented by usage entity 706 , which forms the third participant in the ternary relationship provides 702 . Usage entity 706 represents instructions for utilizing the services of the component in question. These instructions may include the executable code of the component in the case of a software-based autonomic element, an address at which the component may be communicated with, or any other information that would allow an autonomic element to enter into a relationship with the component in question.
[0051] A database schema such as the schema described in FIG. 7 may be implemented using a database management system, such as a relational, object-oriented, object-relational, or deductive database management system. Other data storage paradigms are also possible within a preferred embodiment of the present invention as are available in the art.
[0052] FIGS. 8 - 9 provide an example of an autonomic element utilizing the services of another autonomic element in accordance with a preferred embodiment of the present invention. Turning to FIG. 8, a computing system 800 comprising various autonomic elements is depicted. One such autonomic element, a web server element 802 , requires storage space for holding web pages. In order to utilize storage services, web server element 802 consults directory component 804 , which catalogs all of the available autonomic elements' services in computing system 800 .
[0053] In FIG. 8, storage element 806 has storage space available for web server element 802 's use. Directory component 804 will reflect this availability of space and return instructions to web server element 802 for using storage component 806 for web server element 802 's storage needs. In FIG. 9, web server element 802 is shown as having entered into a relationship with storage element 806 in accordance with the instructions provided by directory component 804 .
[0054] In entering into a relationship with storage element 806 , web server element 802 will, in a preferred embodiment, negotiate the terms of the relationship in accordance with the policies of storage element 806 and web server element 802 . One skilled in the art will recognize that such terms will vary, depending on the particular services being utilized. Generally speaking, however, the terms of a relationship will be derived in a back-and-forth exchange between two autonomic elements. This exchange may, in a preferred embodiment, take place using a data interchange language such as XML (eXtensible Markup Language), XML Schema, or some other language for exchanging machine-readable structured information.
[0055] In general, the terms of a relationship between two autonomic elements may be expressed as attribute-value pairs, and a policy may provide rules and goals that set bounds on acceptable and recommended values, as well as default values that may be applied in the absence of strong requirements by either side. FIG. 10 is an E-R diagram depicting how the terms of a relationship between two autonomic elements may be governed by a policy in accordance with a preferred embodiment of the present invention.
[0056] With respect to one of the autonomic elements in a relationship, a term of the relationship (for example, quality of service in a network connection) is represented by term entity 1000 . Each term ( 1000 ) has a type, represented by term type entity 1004 and “has type” relationship 1002 . For example, in the case of a term representing quality of service, the term type is “quality of service.” Term types are identified by their “name” in this example (name attribute 1006 ). Each negotiated term ( 1000 ) may have multiple values (values attribute 1014 ) that are consistent with the agreed-upon terms of the relationship. For example, two autonomic elements may, through negotiation, agree that two different speeds of data transfer will be allowed; in such a case, the “data transfer speed” term will have two different values, representing different speeds.
[0057] In a particular autonomic element's policy, each term type ( 1014 ) may have mandatory constraints (mandatory constraints attribute 1008 ), recommended values (recommended values attribute 1010 ), default values (default values attribute 1012 ), or some combination of these three attributes. Optionally, each setting of values may have associated with it a scalar utility that represents the relative desirability of that setting of values; the mapping from each possible setting of values to the utility is known as the utility function (utility function 1016 ). Mandatory constraints ( 1008 ) represent inviolable constraints on the value(s) which a term of the particular type in question may hold in accordance with the policy of the autonomic element in question. Recommended values ( 1010 ) represent preferred values or ranges of values that the term of the particular type should hold in accordance with the policy of the autonomic element in question, but these recommended values are not requirements (i.e., they are negotiable). Default values ( 1012 ) represent “off-the-shelf” values for particular terms that may be filled in when the other party (autonomic element) to a relationship expresses no preference with respect to that term; default values allow less important details of a relationship to be definitively determined in the negotiation process. The utility function may be a fixed relationship that is established when the autonomic element is first composed or deployed, or it may be input by a human at any time during or after the deployment of the autonomic element, or it may be computed dynamically from models that the autonomic element may employ to assess the impact of obtaining or providing a service with a proposed setting of values.
[0058] [0058]FIG. 11 is a flowchart representation of a process of negotiating terms of a relationship between two autonomic elements as seen from the perspective of one of the elements in accordance with a preferred embodiment of the present invention. An offer of terms to govern a relationship between the two elements is presented to the other element (block 1100 ). A response is received from the other autonomic element (block 1102 ). If the response is an acceptance of the original offer (block 1104 :Yes), then an acknowledgement is sent to the other autonomic element to indicate that the relationship will begin according to the agreed-upon terms (block 1106 ).
[0059] If the response was not an acceptance (block 1104 :No), a determination is then made as to whether the response was, in fact, a counteroffer providing terms that differ from the last set of terms offered (block 1108 ). If the response is not a counteroffer (block 1108 :No), then negotiations have failed, and the process terminates. If the response is a counteroffer (block 1108 :Yes), then a determination is made as to whether the terms of the counteroffer meet the requirements of the policy (i.e., they comply with any mandatory constraints) (block 1110 ). If the terms do not meet policy requirements (block 1110 :No), an attempt is made to generate a new counteroffer that does comply with policy requirements (block 1112 ). If the attempt is successful (block 1114 :Yes), the counteroffer is presented to the other autonomic component and the process cycles to block 1102 to receive the next response. If the attempt does not succeed (block 1114 :No), the process terminates in failure.
[0060] If the counteroffer received in block 1102 does meet the requirements, however, (block 1110 :Yes), the policy is consulted to determine whether it would be advisable to seek improved terms (i.e., terms that better meet recommended values) (block 1118 ). If so (block 1118 :Yes), an attempt is made to generate a new counteroffer with more desirable terms (block 1120 ). For example, if a utility function is being used, an attempt would be made to generate a new counteroffer that has a higher utility. If this attempt is successful, the counteroffer is sent to the other autonomic element (block 1116 ) and the process cycles to block 1102 to receive the next response. If the attempt to form a new counteroffer was not successful (block 1122 :No) or it was determined that seeking improved terms was not advisable (block 1118 ), an acceptance of the other element's terms is sent to the other autonomic element (block 1124 ).
[0061] In a second preferred embodiment, the negotiation may take a more asymmetric form. In the asymmetric negotiation, only one party generates proposed offers, and the other either accepts or rejects them. More specifically, a first party may at each stage of the negotiation propose one or more offers, or terminate the negotiation. The second party may refuse all of the proposed offers, accept at most one of them, or signal that it wishes to terminate the negotiation. The negotiation proceeds until one party or the other explicitly terminates it. Even if the second party accepts an offer, the first party may at the next stage propose a new set of offers that are more beneficial to it, in hopes that one of them will also prove more desirable to the second party. When the negotiation terminates, the most recently accepted offer will be taken as the agreement; if there is no accepted offer then the two parties have failed to reach an agreement.
[0062] An important aspect of self-management is the ability to detect and handle faults that may occur in a computing system. Various fault-tolerance schemes may be incorporated into the present invention to allow for self-management of faults. A fault in a computing system may be the result of a malfunction in one or more components. For example, a disk drive may physically break, rendering a storage element inoperable. Another source of faults is an active attack. In an active attack, one or more components are targeted and sabotaged. This may be the result of computer viruses, network attacks (such as denial of service attacks), security breaches, and the like. A truly autonomic computing system should be capable of automatically detecting and handling faults in real time.
[0063] FIGS. 12 - 15 provide an example of fault detection and handling in an autonomic computing system in accordance with a preferred embodiment of the present invention. It is important to realize that the fault-tolerance techniques depicted in FIGS. 12 - 15 are merely an example of fault detection and handling in a preferred embodiment of the present invention and are not intended to be limiting.
[0064] [0064]FIG. 12 is a diagram of a computing system 1200 comprising a number of autonomic elements. Database element 1202 provides database services and utilizes the storage services of storage element 1206 and redundant storage element 1204 . As indicated in the diagram, storage element 1206 has become inoperable. Database element 1202 , which maintains communication with storage element 1206 , will detect the malfunction of storage element 1206 and terminate its relationship with storage element 1206 , as shown in FIG. 13.
[0065] In FIG. 13, in response to terminating the relationship with storage element 1206 , database element 1202 consults directory element 1300 to locate additional storage services in computing system 1200 . Directory element 1300 indicates to database element 1202 that storage element 1302 is available for use. In response to directory element 1300 's identifying storage element 1302 as an available storage element, database element 1202 enters into a relationship with storage element 1302 , as shown in FIG. 14.
[0066] In order to reestablish redundant services in preparation for any future fault that may occur, database element 1202 copies state information from storage element 1204 to storage element 1302 , as shown in FIG. 14. Once the state information from database element 1202 is copied to storage element 1302 , storage element 1302 now functions in place of the inoperable storage element 1206 , as shown in FIG. 15.
[0067] [0067]FIG. 16 is a flowchart representation of a process of recovery from a fault or compromise in accordance with a preferred embodiment of the present invention. If a compromise of one or more components in the computing system is detected, either via attack or malfunction (block 1600 ), the services that are potentially compromised thereby are identified (block 1602 ). Those services are then terminated (block 1604 ). If any particular vulnerabilities making the affected services susceptible to compromise can be identified, such vulnerabilities are diagnosed (block 1606 ). A plan of action for remediating the compromised state of the computing system is formulated (block 1608 ); examples of such remediation plans include increasing security measures, increasing the level of redundancy or error correction, and the like. The plan is then executed to reprovision the compromised elements and restore service (block 1610 ). If any of the compromised services are stateful (i.e., they require state information) (block 1612 :Yes), the state information is restored to the reprovisioned services (block 1614 ). In any case, the process will finally cycle to block 1600 in preparation for any future faults.
[0068] 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 or other functional descriptive material and in a variety of other forms and that the present invention is equally applicable regardless of the particular type of signal bearing media actually used to carry out the distribution. Examples of computer readable media include recordable-type media, such as a floppy disk, a hard disk drive, a RAM, CD-ROMs, DVD-ROMs, and transmission-type media, such as digital and analog communications links, wired or wireless communications links using transmission forms, such as, for example, radio frequency and light wave transmissions. The computer readable media may take the form of coded formats that are decoded for actual use in a particular data processing system. Functional descriptive material is information that imparts functionality to a machine. Functional descriptive material includes, but is not limited to, computer programs, instructions, rules, facts, definitions of computable functions, objects, and data structures.
[0069] The description of the present invention has been presented for purposes of illustration and description, and 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.
[0070] For purposes of this application a set is defined as zero or more things. A plurality is defined as one or more things. A subset of a set or plurality is defined as a set comprising zero or more things, all of which are taken from the original set or plurality. | A method, computer program product, and data processing system for constructing a self-managing distributed computing system comprised of “autonomic elements” is disclosed. An autonomic element provides a set of services, and may provide them to other autonomic elements. Relationships between autonomic elements include the providing and consuming of such services. These relationships are “late bound,” in the sense that they can be made during the operation of the system rather than when parts of the system are implemented or deployed. They are dynamic, in the sense that relationships can begin, end, and change over time. They are negotiated, in the sense that they are arrived at by a process of mutual communication between the elements that establish the relationship. | 43,786 |
REFERENCE TO RELATED APPLICATION
This application claims the priority of an earlier filed co-pending provisional patent application of Roger Alan Resh, Ser. No. 60/021,507, filed Jul. 10, 1996 entitled HYGROSCOPICALLY BALANCED GIMBAL STRUCTURE.
REFERENCE TO RELATED APPLICATION
This application claims the priority of an earlier filed co-pending provisional patent application of Roger Alan Resh, Ser. No. 60/021,507, filed Jul. 10, 1996 entitled HYGROSCOPICALLY BALANCED GIMBAL STRUCTURE.
BACKGROUND OF THE INVENTION
The present invention relates to disc drives. More specifically, the present invention relates to a hygroscopically balanced gimbal structure for supporting a hydrodynamic air bearing over a rotating magnetic medium.
Disc drives are the primary devices employed for mass storage of computer programs and data used in computer systems. Within a disc drive, a load beam supports a hydrodynamic air bearing (or slider) proximate a rotating magnetic disc. The load beam supplies a downward force that counteracts the hydrodynamic lifting force developed by the air bearing. The slider carries a magnetic transducer for communicating with individual bit positions on the rotating magnetic disc.
The load beam is coupled to an actuator arm which is, in turn, coupled to an actuator system. The actuator system positions the slider, and hence the transducer, relative to the disc to access desired tracks on the disc.
A gimbal structure is typically located between the load beam and the slider. The gimbal resiliently supports the slider and allows it to pitch and roll while it follows the topography of the rotating disc.
Traditionally, the magnetic transducer was electrically coupled to the remainder of the disc drive electronic by means of twisted pair wires. However, the wires exerted a bias force on the slider to such an extent that the fly height of the slider (and possibly other flying characteristics) was adversely affected.
Recent advances have addressed the limitations of twisted pair wire connections by employing an etched circuit on the gimbal. The etched circuit is referred to as a trace suspension assembly. The etched circuit is typically comprised of etched copper conductors bonded to a dielectric material. The dielectric material is, in turn, bonded to the gimbal. The circuit can be built very thin, often less than 0.002 inches thick. The circuit is attached to the gimbal and electrically couples the magnetic transducer to the disc drive electronics. Because the circuit can be built so thin, bias force on the slider is reduced from that of the twisted pair wires. However, the introduction of the dielectric material to the gimbal assembly has created new problems.
The dielectric material absorbs moisture from the air, and swells as a result. However, metals such as stainless steel (typically used for gimbals) and copper (typically used for conductors) do not possess the same hygroscopic expansion characteristics as the dielectric material and thus do not absorb moisture and swell. The differences in hygroscopic expansion coefficients of the different materials in the gimbal assembly yields a gimbal assembly that deflects in response to changes in relative humidity. Such deflection can change the attitude of the slider and thus cause variation in the slider fly height with variations in relative humidity. If the slider flies too low, it crashes on the magnetic disc, potentially destroying both the transducer and the disc itself. Conversely, if the slider flies too high, the magnetic transducer is not able to read the magnetic fields at each bit position, and data transmission ceases.
SUMMARY OF THE INVENTION
There is a need to provide a gimbal assembly that is essentially unaffected by changes in relative humidity while remaining sufficiently resilient to allow the slider to follow the topography of the disc.
The present invention is directed to a gimbal structure which reduces hygroscopic deformation. The gimbal structure comprises a gimbal, a dielectric layer attached to the gimbal, and a plurality of conductors attached to the dielectric layer. Hygroscopic balancers are attached to the gimbal and are configured to reduce hygroscopic deformation of the gimbal assembly.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a plan view of a portion of a disc drive in which a load arm supports a head gimbal assembly, embodying features of the present invention, over a magnetic disc.
FIGS. 2A-2C show different layers of a gimbal structure.
FIG. 2D shows the layers of FIGS. 2A-2C assembled with respect to one another.
FIGS. 2E and 2F illustrate hygroscopic deflection of the gimbal structure shown in FIGS. 2A-2D.
FIGS. 3A-3C illustrate layers of a gimbal structure according to the present invention.
FIGS. 3D and 3E show the layers of FIGS. 3A-3C assembled with respect to one another.
FIG. 4A is a cross-sectional view of a portion of the gimbal structure shown in FIGS. 3D and 3E.
FIGS. 4B-4E illustrate hygroscopic balancing of the gimbal structure shown in FIGS. 3A-3E.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 illustrates a portion of a disc drive 8 according to the present invention. Disc drive 8 includes actuator 10, actuator arm assembly 12 and head/gimbal assembly 13. Actuator arm assembly 12 includes actuator arm 18 which is coupled to actuator 10 and has load beam supporting portion 20 at one end thereof. Load beam 22 is coupled to actuator arm 18 at end 20, and is also coupled to head gimbal assembly 13. Head gimbal assembly 13 includes gimbal (or flexure) 24, slider 26 and a transducer (not shown) . Gimbal 24 couples slider 26 to load beam 22. Gimbal 24 can either be a separate flexure assembly or an integrated suspension assembly which is integrated with load beam 22.
In operation, actuator arm assembly 12 and load beam 22 support head gimbal assembly 13 relative to a surface of disc 16. The attitude of the hydrodynamic bearing surface of slider 26 relative to the surface of disc 16 affects the flying characteristics (including the fly height) of head gimbal assembly 13. As disc 16 rotates, slider 26, which includes a hydrodynamic bearing surface, develops a hydrodynamic lifting force causing slider 26 to "fly" above the surface of disc 16. road beam 22 exerts a counteracting bias force holding slider 26, and hence the transducer coupled to slider 26, at a desired position over the surface of disc 16. In the embodiment shown in FIG. 1, actuator 10 is a rotary actuator which rotates causing head gimbal assembly 13 to move about arc 14 to access various tracks on the surface of disc 16.
FIGS. 2A-2C show three layers of a trace suspension assembly which forms the gimbal structure. In the embodiment shown in FIGS. 2A-2C, gimbal (or flexure) 24 comprises a stainless steel integrated suspension assembly, rather than a separate gimbal member. Of course, the present invention can also be implemented in a system in which the gimbal is comprised of a gimbal member which is separate from, but attached to, the load beam. Such systems are well known. Gimbal 24 includes dimple tongue 28 which extends away from load beam 22. Dimple tongue 28 includes dimple 30 in one end thereof. Gimbal 24 also includes a plurality of struts 32 and 34 which extend away from load beam 22 and which support cross-member 36. Cross-member 36 extends back toward dimple tongue 28 to form slider mounting tongue 38. In one preferred embodiment, slider 26 is attached to slider mounting tongue 38 and abuts dimple 30. Therefore, slider 26 can pitch and roll about (i.e., gimbal about) dimple 30 to follow the topography of the surface of disc 16.
FIG. 2B shows a dielectric layer 40. In the preferred embodiment, dielectric layer 40 is a polyimide material. Dielectric layer 40 lies over gimbal 24 to provide insulation between gimbal 24 and the conductors which provide electrical contact between the transducer mounted on slider 26 and the rest of the drive electronics. In the preferred embodiment, dielectric layer 40 is configured (material is actually etched away) to include outboard struts 42 and 44, neck 46 and tab 48.
FIG. 2C illustrates a plurality of conductors (collectively designated by numeral 50) which lie over dielectric layer 40. Conductors 50 are preferably etched or deposited copper material and terminate in bonding pads 52 which can be easily bonded to desired locations on slider 26 to make electrical contact with the transducer carried by slider 26.
FIG. 2D illustrates the gimbal layer 24, dielectric layer 40 and conductor 50 coupled to one another. It can be seen that outboard struts 42 and 44 of dielectric layer 40 are positioned such that they lie outboard of (i.e., are not supported by) struts 32 and 34 substantially along the entire length thereof. It can also be seen that conductors 50 are positioned such that they lie on top of dielectric layer 40 so that they do not make electric contact with gimbal 24.
FIGS. 2E and 2F illustrate hygroscopic deflection which the gimbal structure shown in FIGS. 2A-2C can undergo under varying humidity conditions. FIG. 2E illustrates a portion of dielectric strut 44 (which is preferably polyimide) with conductors 50 (which are preferably copper) disposed thereon. FIG. 2E illustrates the materials shown therein in a first, relatively low, relative humidity environment.
As the humidity in the environment increases, the polyimide dielectric material forming strut 44 has hygroscopic characteristics which cause it to absorb moisture from the environment. As dielectric layer 40 absorbs moisture, strut 44 begins to swell. However, since copper does not share the same hygroscopic expansion coefficient as polyimide (e.g., copper does not absorb moisture from the atmosphere and swell), the swelling of strut 44 induces deflection forces in the structure. As layer 44 absorbs moisture from the environment, bowing of the material combination occurs. This is illustrated in FIG. 2F. Similar bowing occurs in strut 42 on the opposite side of the gimbal structure.
When this bowing occurs, a bias torque arises on the air bearing. This bias torque causes an undesirable change in fly height of the air bearing surface of the slider 26 relative to the surface of the disc 16.
Attempts have been made to reduce this type of hygroscopic deformation of the gimbal structure by increasing the stiffness of the gimbal structure. This has been attempted by either increasing the thickness of the copper conductors 50, or increasing the thickness of the stainless steel gimbal 24, or both. However, the resultant increase in stiffness of the gimbal structure increased torque on the slider and reduced the gimbal structure's ability to allow the slider 26 to fly at the desired spacing from the disc 16. It also affected the gimbal structure's ability to allow the slider 26 to pitch and roll and thus limited the ability of the slider 26 to follow the topography of the surface of disc 16.
FIGS. 3A-3C show layers of a gimbal structure according to the present invention. Similar items are similarly numbered to those shown in FIGS. 2A-2C. The gimbal 24 and conductors 50 shown in FIGS. 3A and 3C are substantially identical to those shown in FIGS. 2A and 2C. Also, a large portion of the dielectric layer 54 shown in FIG. 3B is similar to the dielectric layer 40 shown in FIG. 2B. However, dielectric layer 54 also includes a pair of hygroscopic balancers 56 and 58.
In the preferred embodiment, all of the three layers shown in FIGS. 3A-3C are provided as one laminated sheet of material. In other words, the material is provided as a layer of copper and a layer of stainless steel which are laminated on opposite sides of a layer of polyimide dielectric material. Various portions of each material are removed by etching to obtain the structure shown in the figures. Therefore, in the preferred embodiment, hygroscopic balancers 56 and 58 are preferably portions of dielectric layer 54 which are masked so that they are not etched away during the formation process.
FIGS. 3D and 3E illustrate the layers of FIGS. 3A-3C coupled relative to one another in the preferred manner. FIGS. 3D and 3E illustrate that, in the preferred embodiment, hygroscopic balancers 56 and 58 are positioned such that they directly overlie struts 32 and 34 of gimbal 24. However, outboard of struts 32 and 34, the dielectric layer includes struts 42 and 44 which support the copper conductors. The copper conductors on the outboard struts 42 and 44 lie on a side of the dielectric layer 54 which is opposite that of the stainless steel gimbal structure 24 which underlies hygroscopic balancers 56 and 58. This yields the configuration shown in FIG. 4A.
FIG. 4A is a cross-sectional view of a portion of the gimbal structure shown in FIGS. 3D and 3E, and taken along section lines 4A--4A. FIG. 4A more clearly shows that a stainless steel strut 32 of gimbal 24 lies on a first side of the portion of dielectric layer 54 which forms hygroscopic balancer 58. FIG. 4A also shows that the copper conductors 50 lie on an opposite side of a portion of dielectric layer 54 which forms the outboard strut 44.
FIGS. 4B-4E illustrate the balancing affect provided by hygroscopic balancers 56 and 58. FIG. 4B illustrates a strut 44 and conductor 50 residing thereon in an environment having a first humidity, such as a relatively low humidity FIG. 4C illustrates the same portion of the gimbal structure in an environment in which the humidity has significantly increased. As discussed with respect to FIGS. 2E and 2F, this causes deflection forces to be induced in the gimbal structure which can tend to cause outboard strut 44 of dielectric layer 54 and conductors 50 residing thereon to deflect. The hygroscopic growth of strut 44 coupled with the hygroscopic stability of conductor 50 tends to cause the combination to deflect concavely toward the conductor 50.
However, FIG. 4D illustrates a portion of stainless steel gimbal strut 32 with hygroscopic balancer 58 disposed thereon. In FIG. 4D, hygroscopic balancer 58 and gimbal strut 32 are provided in the same environment as that in FIG. 4B. However, FIG. 4E shows the tendency of hygroscopic balancer 58 and stainless steel strut 32 in an environment which has a relative humidity that has substantially increased over that shown in FIG. 4D. In such environment, hygroscopic balancer 58 absorbs moisture and swells and tends to exert a deflection force on the gimbal structure so that it deflects as shown in FIG. 4E.
It can be seen that the deflection forces exerted by the portions of dielectric layer 54 on the gimbal structure are directly opposite one another in the portion of the gimbal structure which contains hygroscopic balancers 56 and 58, and the portion of the gimbal structure which contains dielectric struts 42 and 44. Because the hygroscopic deformation force induced by hygroscopic balancers 56 and 58 opposes the hygroscopic deformation force induced in the area of conductors 50 and struts 42 and 44, the two deformations forces (when the balancers 56 and 58 are sized appropriately) directly cancel one another out to provide a flat gimbal structure under substantially all humidity conditions.
In the preferred embodiment, the copper conductors 50 can be any suitable thickness but are preferably on the order of 0.71 mils. In addition, as with the copper conductors, the dielectric layer 54 can also be any suitable thickness but is also on the order of 0.71 mils in thickness. Further, the stainless steel gimbal 24 is of a suitable thickness, preferably on the order of 2.5 to 0.91 mils.
The present invention was tested using finite element simulations. The pitch stiffness and roll stiffness for the gimbal structure shown in FIGS. 2A-2D was measured. Also, the change in the pitch angle of a slider mounted to the gimbal structure of FIGS. 2A-2D was measured at a first relative humidity and a second relative humidity wherein the second relatively humidity was 85% higher than the first relative humidity. The pitch stiffness of that embodiment was 0.73 μN-m/deg, the roll stiffness was 1.67 μN-m/deg and the change in pitch angle between the two relative humidities was 0.560°.
The same simulations were conducted for the gimbal structure shown in FIGS. 3A-3E. The simulations indicated that the pitch stiffness was 0.77 μN-m/deg, the roll stiffness was 1.72 μN-m/deg but the pitch angle only increased by 0.02°. Thus, the embodiment shown in FIGS. 3A-3E has substantially no effect or impact on gimbal stiffness. Further, the small increase in stiffness, combined with the large reduction in pitch angle change indicates that the risk of fly height change from a change in relative humidity is greatly reduced over the embodiment shown in FIGS. 2A-2D. It should also be noted that, in a preferred embodiment, hygroscopic balancers 56 and 58 can be obtained substantially without adding any production costs. Substantially, the only additional steps which must be followed to implement the present is that the areas corresponding to balancers 56 and 58 must be masked during the etching process. Thus, the present invention provides significant advantages in a very economic and efficient way.
The amount of balancing torque provided by the hygroscopic balancers according to the present invention is proportional to the length, width and thickness of the balancers. Finite element models, using computer simulation, can easily be used to obtain the necessary dimensions of the hygroscopic balancers in order to obtain a zero angle hygroscopic deflection.
Although the present invention has been described with reference to preferred embodiments, workers skilled in the art will recognize that changes may be made in form and detail without departing from the spirit and scope of the invention. | A gimbal structure comprises a gimbal, a dielectric layer attached to the gimbal and subjecting the gimbal to hygroscopic deformation, and a plurality of conductors attached to the dielectric layer. A hygroscopic balancer is attached to the gimbal and hygroscopically opposes the hygroscopic deformation subjected by the dielectric layer to reduce net hygroscopic deformation of the gimbal. | 18,155 |
RELATED APPLICATIONS
This application is a continuation-in-part of U.S. Pat. No. 08/693,767 filed on Aug. 7, 1996 by J. P. Dunn, D. H. Dvorak, and M. A. Lassig entitled “Special Call Detection”, and is related to U.S. patent application Ser. No. 08/693,768 filed Aug. 7, 1996 by J. P. Dunn, D. H. Dvorak, and M. A. Lassig, entitled “Detecting High Usage Telecommunications Lines”, filed Aug. 7, 1996, and both applications assigned to the same assignee as this application.
TECHNICAL FIELD
This invention relates to the field of telecommunications, and more specifically, to detection of specialized calls, such as data calls in telecommunication systems, and to differential billing for data and voice calls.
BACKGROUND
For many year it has been the policy in the United States and Canada to provide telecommunications service and to make billing for such services independent of the content of the communication. While this policy has served admirably to support the building of universal voice telephone service and to expand greatly the use of the telecommunications network for data services, there are signs that this type of policy may no longer be as strongly favored by the regulatory authorities. One sign of such discrimination has been a recent decision in Canada to have a different inter-carrier compensation for a data call than for a voice call, provided the originating carrier can demonstrate that a call is a data call. Regulatory and social factors which may influence separate treatment of such calls are the different economic and/or social values of data calls as contrasted with voice calls. There still is a very strong pressure to minimize charges for minimum local service and to insure that even high usage local service remains within the economic means of the elderly or the poor. For example, it is possible that a different time sensitive tariff may be imposed on short haul data calls.
A partial solution to this problem has been implemented in some cases by examining the destination number of telephone calls as part of the bill calculation process; this process then distinguishes calls known on the basis of the called number to be data calls from other calls and therefore gives such calls appropriate billing treatment. This solution is quite unsatisfactory because so many, even of the frequently used data destinations, are not announced by their customers as being data destinations, and therefore escape whatever negative effect an identification of a call through these destinations would have on the callers.
Another partial solution is provided by monitoring out of band signalling calls. However, this only detects a fraction of the data calls currently being made.
Another serious problem, however, is that on-line or Internet service providers are offering monthly flat fee packages. As a result, data users are staying on a telephone line for hours or even days at a time. On the other hand, the current telephone network is designed for voice calls, which average two minutes. Thus, the voice telephone network is highly concentrated so that expensive capital equipment is not purchased and then used minimally. These assumptions are no longer fully valid. With more and more people using telephone lines for data services, and these people are staying on-line for longer periods of time, the network occasionally (and more and more frequently) becomes congested, and some customers do not receive service, or even dial tone. This may be disastrous in the event of an emergency.
SUMMARY OF THE INVENTION
We have recognized that a problem of the prior art is that a satisfactory and economical arrangement for distinguishing between in-band signalled data calls and voice calls on a per call basis, and for charging differently for data calls does not exist.
The above problem is solved and an advance is made over the prior art in accordance with this invention wherein data calls are identified by connecting a signal detector during or subsequent to the establishment of a connection and the recognition of an answer signal by the called station. Advantageously, the holding time of such a signal detector which is connected on every call is small so that the cost is kept low. After a determination of a data or a voice call is made, then the call can be billed so that a traditional voice call is treated according to the prior art, but the data call is billed differently, either according to time, or with a higher charge, or both. With such charges possible, it is also possible to offer flat rate data service with a much higher flat rate charge.
In accordance with one aspect of Applicants' invention, a signal detector is implemented using a signal processor capable of examining the digit stream representing the signal generated by callers and called customers for many calls simultaneously. Advantageously, this type of arrangement sharply reduces the cost of the tone detection process.
Advantageously, these arrangements allow for a billing mark to be entered on every call record for a data call, thus simplifying the processing of these billing records to produce customer statements. In accordance with another feature of this invention, a data set is adapted to provide an initial tone. Advantageously, this arrangement permits a data call to be recognized immediately and allows vertical services, such as the use of specially conditioned transmission facilities, to be readily implemented.
In Applicants' preferred embodiment, an enhanced digit detector detects the tone signals characteristic of a data call. If such signals are not detected, the call is determined to be a voice call, and normal local billing procedures may be used. If a data call is detected, then usage based charges such as those often used for long distance calls or, alternatively, some minimum special charge, may be used; alternatively, the regular voice billing charge can be used for a data call shorter than a pre-specified limit. Advantageously, voice calls may be rechecked for data at random or predetermined intervals to prevent fraud and thus, enhance revenue and discourage unnecessary usage of the telephone network.
These arrangements can also be used to further discriminate among data type calls, e.g., to distinguish from Internet usage from facsimile calls, provided that each type call has a characteristic signal or set of signals. Each distinguishable type of call may be billed with its own billing rate scheme. For example, Internet type calls may be billed on a per-minute basis, while a first portion, e.g., the first ten minutes, of a long facsimile call may be free or may cost a single unit if the caller has unlimited duration voice calling in a particular area, and may be billed thereafter at a per-minute facsimile rate.
BRIEF DESCRIPTION OF THE DRAWING
A more complete understanding of the invention may be obtained from a consideration of the following description in conjunction with the drawings, in which:
FIG. 1 is a block diagram illustrating Applicants' invention;
FIG. 2 is a block diagram illustrating a preferred embodiment of a data call signal detector; and
FIGS. 3 and 4 are flow diagrams illustrating the method of Applicants' invention.
DETAILED DESCRIPTION
FIG. 1 is a block diagram illustrating the basic operation of Applicants' invention. A switching network 3 , including any special adjuncts for connecting service circuits, such as digital detectors, to the lines or trunks, is used to interconnect stations 1 , . . . , 2 with outgoing trunks, digit/signal detectors 5 , or signal detectors 6 . While the digit/signal detectors are shown separately, in practice, the best arrangement is likely to be one wherein any of the digit/signal detectors 5 and signal detectors 6 can be used for both functions, i.e., the function of detecting dialed or keyed digits from customers and the function of detecting the signals which characterize a data connection. In Applicants' preferred embodiment, the signals are tones and only a single type of detector is used. This detector is the conventional digit/tone detector 5 used for detecting dialed or keyed digits augmented to recognize the additional tones of a data connection.
FIG. 2 is a preferred implementation for such detectors. It consists of a signal processor 25 which is connected to a plurality of ports 21 , . . . , 22 of the switching network 3 . Signal processor 25 has sufficient capacity to process the signals received from the switching network for a substantial number of channels terminated at ports 21 , . . . , 22 .
Most current data calls using in-band signalling are identified by special unmodulated tones. However, other types of signals can be used to identify such calls, For example, a tone modulated by frequency or phase shift keying or a tone modulated by amplitude or frequency modulation can be used to identify a data call. The signal processor 25 can be readily programmed to detect such signals. In addition, if a data set is arranged to emit an initial tone, this can be recognized immediately in detector 5 , and vertical services, such as the use of specially conditioned transmission facilities, or the option to use a specialized data carrier, can be offered to the caller.
Switching network 3 , (FIG. 1 ), in the preferred embodiment, is a digital network which transmits digital signals between lines connected to stations 1 , . . . , 2 and trunks 4 , or detectors 5 , 6 . Such a network can readily transmit the digital signals which represent an analog signal from one source to a number of destinations. This makes it easy to connect a detector as well as a line, to an outgoing trunk 4 . Thus, for an outgoing call, switching network 3 originally establishes path 11 between station 1 and digit/tone detector 5 . After the customer has dialed the requested number, the connection 12 is established between station 1 and outgoing trunk 4 ; when answer is received, tone detector 6 or digit/tone detector 5 is bridged on to this connection by connection 13 so that the tone detector can detect whether any of the tones characteristic of a data connection are present. While the connection 13 is shown in FIG. 1 as being to the trunk 4 , it can be to any point in the connection between trunk 4 and the line connected to station 1 . Alternatively, a speech detector can be used and a call can be determined to be a data or fax call if no speech is detected.
The switching network operates under the control of processor 30 . Processor 30 includes memory 31 for storing a control program and billing data, and a central processing unit (CPU) 32 for controlling network 3 and for receiving information from detectors 5 and 6 . The programs shown in flow diagram 3 is executed in processor 30 . The diagram illustrates only an outgoing call. For an incoming call and for an intra-office call, the tone detector 6 or digit/tone detector 5 can also be bridged across a connection; the tone detector is bridged to a connection from an incoming trunk in the same way as it is bridged to a connection to an outgoing trunk and it is bridged across a connection between two lines in a bridging connection, (not shown) since two lines can also be interconnected by switching network 3 . Processor 30 , switching network 3 , trunk 4 , and detectors 5 and 6 are all part of switching system 10 .
Processor 30 is also connected to a billing recorder 8 for recording billing data. This data is subsequently processed in a billing center 9 for generating customer bills. The billing record of a call determines the charge that the billing center will generate for that call. Effectively, by recording one type of indication, e.g., “data call” or a default indication, e.g., “voice call”, the processor can cause one or the other type of charge to be billed for that call. The act of entering a billing indication is therefore the means for billing different types of calls, e.g., flat rate or time metered calls.
In the future, it may be important to be able to monitor incoming as well as outgoing calls and intra-office calls. This would allow terminating vertical services, such as an announcement of a data call, to be implemented. Further, if charges were to be shared between originating and terminating parties for some or all data calls, it would be necessary to monitor terminating calls to detect data calls.
FIG. 3 illustrates the process of handling a call in accordance with the principles of the invention. After a call has been set up, answer for the call is detected (Action Block 301 ). Note that while the initial applications of the invention may continue the present practice wherein (except for 800 calls, collect calls, bill to third party calls), the calling customer is charged for the call, it would be very straightforward to have the terminating switch also detect an answer signal, monitor the call, and make a special billing entry if the call was found to be a data call through the use of a tone detector. U.S. Pat. No. 5,381,467 issued to Rosinski et al, incorporated herein by reference, discloses arrangements for permitting a called party to signal a request to share call charges by keying dual tone multifrequency (DTMF) tones on a received call.
When answer is detected, a tone detector is attached to the connection (Action Block 309 ), as noted above. The attachment of a tone detector which is only in the listening mode is very straightforward in a digital network; the signals are sent from a source to the normal destination and also the alternate destination tone detector. Test 311 is used to determine whether the tone detector has detected a data or fax call by having detected the data or fax call tones.
Alternatively, or additionally, the switching system may, if the result of Test 311 is that a fax or data tone has been detected, use Test 312 to determine whether the call has the protocol of a fax call. If so, Test 312 determines that this is a fax call, then the billing record is marked to indicate that the call is a fax call (Action Block 313 ). If the result of Test 312 indicates that this is not a fax call, then the billing record is marked to indicate that this is a data call (Action Block 315 ). Following both Action Blocks 313 and 315 , answer processing continues (Action Block 305 ). If the tone detector does not detect data calls, then answer processing is continued (Action Block 306 ).
Following the use of Action Block 306 , (in contrast to Action Block 305 ), at random or fixed intervals thereafter, a tone detector is attached to the call to determine whether the call is now a data call (Action Block 307 ). This is to prevent the differential charging of data calls from being by-passed by having an initial short period without data tones. By using a random testing interval, it is possible to catch data calls made by sophisticated users who arrange to have data signal interrupted at the critical times when a periodic test for data calls might be made. The length of time of the random or periodic interval for testing, depends to some extent on the objective of the test. If the objective is primarily to insure that all data calls are appropriately charged, then the testing interval can be short. If the primary objective is to insure that very long data calls are charged appropriately, then the use of Action Block 307 can be invoked at less frequent intervals.
Following the attachment of the tone detector in Action Block 307 , Test 308 is used to determine whether the tone detector has detected data tone calls. If so, then the billing record for this call is marked as a data call (Action Block 316 ). If the result of Test 308 is negative, i.e., no data call tones detected, then after a suitable interval, Action Block 307 is re-entered to try again.
The result of the above steps is that data calls and fax calls are detected and the billing record for these calls is appropriately marked for subsequent processing in a billing center. Further, following Action Blocks 315 or 316 (FIG. 3 ), vertical services, such as the use of special transmissions facilities can be offered. Note that if a data station emits a characteristic signal before it is connected to the called party, then the originating caller can be immediately offered vertical services, such as the use of specially conditioned transmission facilities, if the call is initially recognized to be a data call.
FIG. 4 illustrates the actions performed in the billing center. In the billing center, the billing record of a call is examined (Action Block 401 ). Test 403 determines whether or not this is a data or fax call. If not, then the billing record is processed conventionally, i.e., as in the prior art, (Action Block 405 ). If this is a data or a fax call, then the call is processed as a data or fax call, (Action Block 407 ).
Action Blocks 409 , 411 , 413 , and 415 indicate some of the options that a particular telephone administration can implement as part of the processing of data or fax calls. Action Block 409 indicates that a surcharge can be added to the call. The surcharge can be different for data and fax calls. Action Block 411 indicates that the call may be optionally charged as a metered call, i.e., charged according to the length of time of the call. Action Block 413 indicates that the charges for fax calls may be different from those for data calls. For example, the charge for fax calls may be the same as the charge for voice calls. For another example, the charge for fax calls may be the same as voice calls if the duration of the fax call is less than some predetermined period of time. Another option is to charge data calls shorter than n seconds, either conventionally (i.e., the same as for a voice call), or to have a separate charge which can be either less or more than the charge for a short voice call (Action Block 415 ).
The example of Action Blocks 409 , 411 , 413 , and 415 are only some of the options available to telephone administrations for having different charges for data calls and fax calls, in contrast to voice calls. The same principles can also be applied to any other call which can be detected through the use of signal detectors, and for which in response to this detection, an indication of the special call is made in the billing record of that call.
It is to be understood that the above described embodiments are merely illustrative principles of the invention and that many variations may be devised by those skilled in the art without departing from the scope of the invention. It is, therefore, intended that such variations be included within the scope of the Claims. | It is desirable to be able to recognize data calls so that different charges can be applied to such calls and that vertical services, such as the use of special transmission facilities, may be offered to data callers. This recognition is accomplished by attaching a tone detector to a call in order to detect the special tones characteristic of a data call. Advantageously, this permits different charges to be imposed on data calls. | 19,104 |
.Iadd.This application is a continuation of application Ser. No. 08/141,227 filed 21 Oct. 1994 now abandoned. .Iaddend.
TECHNICAL FIELD OF THE INVENTION
The present invention relates generally to the folding of flexible, multi-layer, sheet-like articles, such as bags. More specifically, the present invention relates to folding vehicular air bags.
BACKGROUND OF THE INVENTION
Vehicular air bags are among the latest safety enhancements for automobiles and other vehicles. Their use in vehicles is increasing dramatically. Generally, such air bags are located within a steering wheel or column, dashboard, control panel, or other out-of-the-way location which is near a vehicle's occupant. Sensors located in the vehicle detect when a crash is occurring and activate the air bag(s). When activated, the air bags rapidly inflate between the vehicle's occupant and a potentially injurious or deadly surface, such as a steering wheel. As the crash progresses, the force of the crash may hurl the occupant toward the injurious or deadly surface, but the occupant first encounters the air bag, which prevents or otherwise lessens injury to the occupant.
In order for the air bag to be effective, it must be stored in an out-of-the-way location until needed. Moreover, it must be stored in such a manner that it can be rapidly activated to do its job. Due to the continual down-sizing of vehicles, the out-of-the-way locations where air bags are typically located are usually rather small. Thus, an air bag must be folded into a small package so that it fits into a small location. But, the technique used to fold the air bag affects its deployment when activated. To minimize the possibility of harm to a vehicle occupant, the air bag preferably deploys evenly in a spreading out (side-to-side) manner rather than shooting first toward one side then the other or shooting straight out then filling in from side-to-side.
The conventional process for folding vehicular air bags relies almost exclusively on manual labor. This conventional process is plagued with problems. For example, approximately 12 minutes are required to fold an air bag using manual labor. With the large number of air bags now being used in vehicles, a tremendous amount of labor and expense is required to fold air bags. Moreover, the folding of air bags requires a large number of highly repetitive manual motions. Such repetitive motions are potentially hazardous to the health of the manual laborers. In addition, such repetitive motions lead to boredom, which in turn leads to a poor performance of the job.
Another problem relates to the consistency with which bags are folded using the conventional process. While some bags get folded acceptably, others tend to be folded using a less-than-optimal folding pattern or in a manner which results in an overly large package. This lack of consistency results in a considerable amount of rework, which is expensive, and inconsistent bag deployment patterns, which may pose unnecessary dangers to vehicle occupants.
SUMMARY OF THE INVENTION
Accordingly, it is an advantage of the present invention that an automated system for folding air bags is provided.
Another advantage of the present invention is that a system for folding bags quickly is provided.
Yet another advantage of the present invention is that a system for folding air bags in a consistent fold pattern is provided.
Still another advantage of the present invention is that a system for folding air bags to consistently achieve a desirable deployment pattern is provided.
Still another advantage of the present invention is that a system for consistently folding air bags to achieve a small folded-bag profile is provided.
The above and other advantages of the present invention are carried out in one form by a method of automatically folding an air bag. The air bag characteristically has top and bottom sections, and the folding method achieves a folded-bag profile that is suitable for vehicular installation along with effective bag deployment in the event of a vehicle crash. The method calls for clamping the top and bottom sections of the bag together. This clamping action occurs near an edge portion of the bag and substantially restricts inflation of the edge portion but leaves a central portion of the bag unclamped. After clamping, the central portion is inflated so that the top section of the air bag separates from the bottom section. When the top and bottom sections have been separated, the clamped edge portion is inserted into the central portion between the top and bottom sections.
BRIEF DESCRIPTION OF THE DRAWINGS
A more complete understanding of the present invention may be derived by referring to the detailed description and claims when considered in connection with the FIGURES, wherein like reference numbers refer to similar items throughout the FIGURES, and:
FIG. 1 shows a perspective view of a preferred embodiment of the present invention in connection with an air bag and prior to a first stage in the preferred process for folding the air bag;
FIG. 2 shows a block diagram of the preferred embodiment of the present invention;
FIG. 3 shows a cross sectional view of the preferred embodiment of the present invention after a second stage in the preferred process for folding the air bag;
FIG. 4 shows a cross sectional view of the preferred embodiment of the present invention after a third stage in the preferred process for folding the air bag;
FIG. 5 shows a cross sectional view of the preferred embodiment of the present invention after a fourth stage in the preferred process for folding the air bag;
FIG. 6 shows a cross sectional view of the preferred embodiment of the present invention after a fifth stage in the preferred process for folding the air bag;
FIG. 7 shows a cross sectional view of the preferred embodiment of the present invention after a sixth stage in the preferred process for folding the air bag;
FIG. 8 shows a cross sectional view of the preferred embodiment of the present invention after a seventh stage in the preferred process for folding the air bag;
FIG. 9 shows a cross sectional view of the preferred embodiment of the present invention after an eighth stage in the preferred process for folding the air bag;
FIG. 10 shows a cross sectional view of the preferred embodiment of the present invention after a ninth stage in the preferred process for folding the air bag;
FIG. 11 shows a cross sectional view of the preferred embodiment of the present invention after a tenth stage in the preferred process for folding the air bag;
FIG. 12 shows a cross sectional view of the preferred embodiment of the present invention after an eleventh stage in the preferred process for folding the air bag;
FIG. 13 shows a cross sectional view of the preferred embodiment of the present invention after a twelfth stage in the preferred process for folding the air bag;
FIG. 14 shows a cross sectional view of the preferred embodiment of the present invention after a thirteenth stage in the preferred process for folding the air bag;
FIG. 15 shows a cross sectional view of the preferred embodiment of the present invention after a fourteenth stage in the preferred process for folding the air bag;
FIG. 16 shows a cross-section of the air bag folded in accordance with the preferred process; and
FIGS. 17A-17F together show exemplary vertical folds which may be utilized to place the air bag in a final stage.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
In the following description certain items are either identical to or mirror images of other items. This description distinguishes such items from their counterparts by the use of lower case alphabetic characters ("a", "b", and so on) which are appended to a common reference number. When an alphabetic character is omitted, the description refers to any one of such items or their counterparts individually or to all of them collectively.
FIG. 1 shows a perspective view of a preferred embodiment of a bag folding machine 10 configured in accordance with the present invention. FIG. 1 further shows a deflated air bag assembly 12 positioned on machine 10. FIG. 1 illustrates the state of machine 10 and bag assembly 12 prior to a first stage (discussed below) in a preferred process for folding bag assembly 12.
Machine 10 includes a top blade 14, which is rotatable from an upright position, shown in FIG. 1, to a lowered position, in which blade 14 closely overlies bag assembly 12. The central region of blade 14 carries pins 16a, 16b, 16c, and 16d. Pins 16 couple to and extend perpendicularly away from blade 14. Furthermore, pins 16 are movable from a raised position relative to blade 14, shown in FIG. 1, to a lowered position, discussed below. In viewing FIG. 1, pins 16a and 16b reside on the left side of blade 14 while pins 16c and 16d reside on the right. Elastic band 18a is looped around pins 16a and 16c underneath blade 14, and elastic band 18b is looped around pins 16b and 16d underneath blade 14.
Machine 10 additionally includes an edge folding assembly (EFA) 20, which is shown positioned behind bag assembly 12 in FIG I EFA 20 is moveable from its rearward position shown in FIG. 1 to a forward position where it engages bag assembly 12.
EFA 20 carries five arms which move together between the rearward and forward positions. These five arms include a center arm 22, left and right fork arms 24a and 24b, respectively, and left and right outer blades 26a and 26b, respectively. Center arm 22 remains stationary relative to EFA 20. In other words, arm 22 moves only inward and outward with the entire EFA 20 and does not move any substantial distance either upward, downward, left, or right.
Fork arms 24 each reside between respective outer blades 26 and center arm 22. Each fork 24 resembles a U-channel having an upper plate or tine 28a and an opposing lower plate or tine 28b. For each fork 24, tines 28 are spaced apart form one another by a gap 30, and the U-channel opening, hereinafter referred to as an entrance edge 32, faces away from the center of machine 10. Each fork 24 may move upward from its downward position, shown in FIG. 1, with respect to EFA 20. In other words, forks 24 move forward and backward with the entire EFA 20 as well as upward and downward.
Outer blades 26 are positioned vertically at a level slightly above center arm 22. Each blade 26 is configured to move from an outward position, shown in FIG. 1, to an inward position with respect to EFA 20. As discussed in more detail below, when forks 24 are in their upward positions, gaps 30 are vertically aligned with outer blades 16, and when outer blades 26 move to their inward position, they mesh with gaps 30.
Machine 10 additionally includes pleat clamps 34a and 34b located to the left and right, respectively, of outer blades 26 from EFA 20 and at roughly the same vertical level as outer blades 26. FIG. 1 shows pleat clamps 34 in their extreme outer positions. However, pleat clamps 34 are each movable to an intermediate position and an extreme inner position, as will be discussed below.
As a whole, pleat clamps 34 remain substantially stationary in the vertical dimension. However, each of pleat clamps 34 carries upper and lower plates or fingers 36a and 36b, respectively. The horizontal length (generally from left-to-right in FIG. 1) of fingers 36 is slightly greater than the sum of the horizontal lengths of one outer blade 26 and one fork arm 24. Fingers 36 move vertically with respective to one another. FIG. 1 shows an opening 38 between fingers 36 at its widest. As is discussed below, fingers 36 move vertically toward one another so that opening 38 disappears and a clamping force is exerted between fingers 36. Fingers 36 additionally exhibit a position in which opening 38 is very small and at which no clamping force is exerted between fingers 36.
Each of fingers 36 includes two notches 39 which accommodate pins 16, as discussed below. Notches 39 extend left-to-right from inward edges (facing the center of machine 10) of fingers 36 outward into the interior of their corresponding fingers 36.
FIG. 1 shows air bag assembly 12 in a deflated and unfolded state, which causes bag assembly 12 to roughly resemble a thin pancake. In viewing bag assembly 12 vertically from bottom to top, assembly 12 includes a base plate 40 secured to a sealed, flexible bag 42. Bag 42 includes a bottom section 44, which attaches to base plate 40 and a top section 46, which overlies bottom section 44 in the deflated state illustrated in FIG. 1. In viewing bag 42 horizontally, left edge portion 48a and right edge portion 48b are separated from one another by central portion 50. Base plate 40 attaches to bag 42 only in the central region of central portion 50 and not in end portions 48.
Base plate 40 of air bag assembly 12 couples to a worksurface 52 of machine 10. Although not visible in FIG. 1, base plate 40 includes a pneumatic passage which is continued through worksurface 52, through a valve arrangement 54, to pressure and vacuum reservoirs 56 and 58, respectively. Accordingly, valve 54 may be operated to apply pneumatic pressure to air bag assembly 12, seal air bag assembly 12, or apply pneumatic vacuum to air bag assembly 12.
FIG. 2 shows a block diagram of the preferred embodiment machine 10. As discussed above in connection with FIG 1, numerous blades, arms, and fingers of machine 10 are moveable. FIG. 1 shows that machine 10 employs a controller 60 to coordinate such movements. Those skilled in the art will appreciate that any suitable programmable controller, personal computer, or similar item may suffice for controller 60.
Controller 60 couples, through an appropriate control bus 62, to numerous actuators which control the above-discussed movements. In particular, an actuator 64 mechanically couples to and controls the upward and downward movement of top blade 14; an actuator 66 mechanically couples to and controls the upward and downward movements of pins 16; an actuator 68 mechanically couples to and controls the forward and backward movements of EFA 20; an actuator 70 mechanically couples to and controls the upward and downward movements of EFA forks 24; an actuator 72 mechanically couples to and controls the left and right movements of EFA outer blades 26; an actuator 74 mechanically couples to and controls the left and right movements of pleat clamps 34; an actuator 76 mechanically couples to and controls the upward and downward movement of pleat clamp fingers 36; and, an actuator 78 couples to valve 54 to close valve 54, or to control the application of pressure or vacuum.
Those skilled in the art will appreciate that the precise programming instructions and the nature of the control imparted through controller 60 and actuators 64-78 has little bearing on the present invention, other than in accomplishing the below-discussed process. For example, while the preferred embodiment of the present invention primarily uses pneumatic actuators, those skilled in the art may adapt hydraulic or solenoid actuators to impart the above-discussed movements. Moreover, those skilled in the art will fully appreciate that limit or position switches or sensors may be employed in a conventional fashion within machine 10 to indicate to controller 60 when desired positions (discussed below) are achieved through such movements. Moreover, multiple actuators may be employed to move arms, such as EFA outer blades 26, individually rather than as a unit. And, other well known mechanical devices, such as slides, levers, gears, belts, and the like, may be employed to transfer and guide the arm motions discussed herein.
FIG. 1 and FIGS. 3-15 together present various states or stages through which machine 10 and air bag assembly 12 progress in making horizontal folds in air bag 42. As discussed above, FIG. 1 illustrates machine 10 and bag assembly 12 prior to a first stage in the horizontal folding process. Prior to the first stage, center portion 50 of bag 42 is supported, but nothing supports edge portions 48 of bag 42 Thus, edge portions 48 droop downward. The first stage results from moving top blade 14 from its upper position to its lower position. In its lower position, top blade 14 overlies and is spaced a distance apart from the top of central portion 50 of bag 42. Top blade 14 carries pins 16, which will be used later in the folding process.
FIG. 3 illustrates machine 10 and bag assembly 12 after a second stage, which occurs immediately after the first state. In the second stage, EFA 20 moves forward where it engages bag 42. In particular, center arm 22 of EFA 20 slides over central portion 50 of bag 42 and underneath top blade 14, EFA forks 24 move underneath corresponding edge portions 48 of bag 42, and outer blades 26 move over bag 42. As shown in FIG. 3, due to the droop in bag 42 forks 24a and 24b actually reside to the inside (right and left) of end portions 48a and 48b, respectively. For the same reason, outer blades 26a and 26b currently reside above and to the outside (left and right) of end portions 48a and 48b, respectively.
FIG. 4 illustrates machine 10 and bag assembly 12 after a third stage, which occurs immediately after the second stage. In the third stage, EFA forks 24a and 24b have moved to their upper positions. In these upper positions, the central regions of gaps 30 in forks 24 reside at approximately the same vertical height as outer blades 26. All outer blades 26 and forks 24 are positioned vertically above center arm 22. This movement of forks 24 removes some of the droop in bag 42. However, the outermost regions of end portions 48a and 48b now extend vertically downward through and past gaps 80, which define the horizontal spaces between outer blades 26 and corresponding forks 24.
FIG. 5 illustrates machine 10 and bag assembly 12 after a fourth stage, which occurs immediately after the third stage. In the fourth stage, vacuum is applied to bag 42. Outer blades 26a and 26b move into, or mesh with, gaps 30 in forks 24a and 24b, respectively. Bends, folds, or pleats 82a, 82b, 84a, and 84b are formed in end portions 48 of bag 42 as a result of this relative movement between outer blades 26 and forks 24.
In particular, as outer blades 26 move into gaps 30, the outermost regions of end portions 48 are tucked between tines 28 of forks 24. The much of the excess material of bag 42 that drooped vertically downward past gaps 80 after the third stage is now drawn into gaps 30. Only the very ends of bag 42 extend out and droop down from the entrance edges of forks 24. Moving from the outermost edges of bag 42 inward, pleats 82a and 82b reside at leading edges 86a and 86b of outer blades 26a and 26b, respectively, as bag 42 bends back on itself and is juxtaposed on opposing sides of blades 26a and 26b. Pleats 84a and 84b reside at entrance edges 32 of tines 28a of forks 24a and 24b, respectively, as bag 42 bends back on itself again and is juxtaposed on opposing sides of tines 28a of forks 24a and 24b.
FIG. 6 illustrates machine 10 and bag assembly 12 after a fifth stage, which occurs immediately after the fourth stage. In the fifth stage, pleat clamps 34a and 34b, each with their fingers 36 opened to their maximum amount of extension, move inward toward the central portion 50 of bag 42. In this stage, pleat clamps 34 each stop at their intermediate positions. This causes the outer ends of bag 42 to be folded under forks 24. At the current point in the process, openings 38 between fingers 36 are sufficiently wide to loosely accommodate corresponding forks 24 and two thicknesses of bag 42. Inner tips 88 of fingers 36 are now positioned around points vertically above and below leading edges 86 of outer blades 26.
FIG. 7 illustrates machine 10 and bag assembly 12 after a sixth stage, which occurs immediately after the fifth stage. In the sixth stage, outer blade 26b is retracted from gap 30 in fork 24b by moving horizontally outward. Outer blade 26a remains positioned within gap 30 of fork 24a to reduce bag distortion in subsequent stages. The natural stiffness of bag 42 along with the friction of bag 42 against interior walls of forks 24 causes bag 42 to remain within gap 30 of fork 24b rather than be drawn outward with outer blade 26b. As shown in FIG. 7, the length of fingers 36 accommodates both fork 24b, outer blade 26b in its retracted state, and gap 80.
FIG. 8 illustrates machine 10 and bag assembly 12 after a seventh stage, which occurs immediately after the sixth stage. In the seventh stage, EFA 20, which includes outer blades 26, forks 24, and center arm 22, is removed from engagement with bag 42 by moving backward. The vacuum previously applied to bag 42 along with the natural stiffness of bag 42 prevents distortion of pleats 82 and 84 previously formed in bag 42 or other significant disturbances of bag 42. At this point, the folds previously made in end portions 48 of bag 42 are supported by lower fingers 36b of pleat clamps 34.
FIG. 9 illustrates machine 10 and bag assembly 12 after an eighth stage, which occurs immediately after the seventh stage. In the eighth stage, pleat clamp fingers 36 have been urged together by being moved to their clamped position. In other words, a clamping force is exerted between fingers 36 thereby entrapping pleats 82 and 84 within fingers 36. These clamping forces are sufficiently great to prevent any substantial inflation of the portions of bag 42 residing within pleat clamps 34. This clamped portion of bag 42 currently resides slightly above central portion 50 of bag 42.
FIG. 10 illustrates machine 10 and bag assembly 12 after a ninth stage, which occurs immediately after the eighth stage, in the ninth stage, the previously applied vacuum is removed and then pneumatic pressure is introduced to bag assembly 12, thereby inflating bag 42. Of course, pleat clamps 34 prevent those portions of bag 42 which are entrapped therein to become inflated at this stage. Consequently, primarily the central portion of bag 42 becomes inflated. By inflating bag assembly 12, top section 46 of bag 42 becomes separated from bottom section 44 and moves upward. In fact, top section 46 now resides above the portions of bag 42 that are trapped within pleat clamps 34 while bottom section 44 resides below the portions of bag 42 that are trapped within pleat clamps 34. Blade 14 limits top section 46 of tag 42 from extending further upward. Consequently, the shape of bag 42 is bound in the vertical dimension by plate 40 on the bottom and blade 14 on the top.
FIG. 11 illustrates machine 10 and bag assembly 12 after a tenth stage, which occurs immediately after the ninth stage. In the tenth stage, pleat clamps 34 move further inward toward central portion 50 of bag 42. Top blade 14 and bottom plate 40 prevent the bag from distorting outward in the vertical dimension during this operation. Pleat clamps 34 each stop at their extreme inward positions, in which inner tips 88 of fingers 36 nearly touch each other but are still spaced a small distance apart. Of course, the portions of bag 42 which have been entrapped within fingers 36 by clamping move inward with pleat clamps 34. Consequently, the entire edge portions 48 of bag 42 have been poked into the central portion 50 of bag 42.
FIG. 12 illustrates machine 10 and bag assembly 12 after an eleventh stage, which occurs immediately after the tenth stage In the eleventh stage, vacuum is applied to bag assembly 12 to deflate bag 42. In addition, pins 16 are moved downward through slots 39 in pleat clamp fingers 36. As pins 16 move downward, elastic bands 18 stretch over the top of central portion 50 of bag 42. This stretching of bands 18 exerts a corresponding downward force on top section 46 of bag 42. As bag 42 deflates, this downward force overcomes the natural stiffness of bag 42 causing bag 42 to collapse and top section 46 to move downward as vacuum is applied.
FIG. 13 illustrates machine 10 and bag assembly 12 after a twelfth stage, which occurs immediately after the eleventh stage. In the twelfth stage, fingers 36 of pleat clamps 34 are moved to their intermediate state in which clamping forces are removed and fingers 36 are spaced only a small distance apart. In short, pleat clamps 34 are loosened, thereby abandoning the grip they previously had on the entrapped portions of bag 42.
FIG. 14 illustrates machine 10 and bag assembly 12 after a thirteenth stage, which occurs immediately after the twelfth stage. In the thirteenth stage, pleat clamps 34 are disengaged from bag 42 by moving horizontally outward. In this stage, clamps 34 are moved to their extreme outward positions. Fingers 36 may additionally be moved to the positions where they are spaced furthest apart in preparation for a subsequent folding process. Notches 39 (see FIG. 1) in fingers 36 permit this outward movement while pins 16 remain in their downward position. Since clamps 34 had previously been loosened, scant frictional forces oppose this retraction of pleat clamps 34. Thus, pins 16, the vacuum applied to bag 42, and the natural stiffness of bag 42 together serve to prevent any significant disturbance of the folds previously formed in bag 42.
FIG. 15 illustrates machine 10 and bag assembly 12 after a fourteenth stage, which occurs immediately after the thirteenth stage. In the fourteenth stage, top blade 14, pins 16, and elastic bands 18 are disengaged from bag assembly 12 primarily by raising top blade 14. Pins 16 may additionally be retracted to their raised position in preparation for a subsequent folding process.
As a result of the process described above, bag assembly 12 has undergone a horizontal folding process. The resulting folded-bag profile is shown in cross section in FIG. 16, As shown in FIG. 16, bag 42 of bag assembly 12 fits within the profile defined by base plate 40. This fold pattern is desirable because it produces an effective deployment pattern. In particular, the central joint region 90 together with top and bottom joints 92 and 94, respectively, cause bag assembly 12 to inflate evenly in a left-to-right direction while bag assembly 12 is expanding away from plate 40. In addition, the overall folding process is performed quickly.
FIGS. 17A-17F together illustrate vertical folds which may be performed either manually or automatically to completely fold bag 42 onto the profile defined by base plate 40. After vertical folds have been completed, folded bag assembly 12 is ready for installation in a vehicle.
In summary, the present invention provides an automated system for folding air bags. An air bag can be installed on machine 10 in around 4 seconds and then, under the direction and coordination of controller 60 (see FIG. 2), folded in about 20 seconds. An additional 15-17 seconds are required for an operator to make the vertical folds and unload machine 10. Consequently, machine 10 and the process by which bag assemblies 12 are folded result in a system which quickly folds bags and achieves significant time savings over the conventional manual folding process. Moreover, the automated nature of the system of the present invention leads to a consistent fold pattern. In other words, each bag is folded in substantially the same way as every other bag. This consistent fold pattern achieves a desirable deployment pattern along with a small folded-bag profile, which is entirely contained within the area of base plate 40.
The present invention has been described above with reference to preferred embodiments. However, those skilled in the art will recognize that changes and modifications may be made in these preferred embodiments without departing from the scope of the present invention. For example, the above description uses the terms left, right, forward, backward, top bottom, up, down, raised, lowered, horizontal, vertical, and the like, to indicate relative direction with respect to the FIGURES. Those skilled in the art will understand that such relative terms are used to clarify the description and do not limit the scope of the present invention to any particular orientation. These and other changes, modifications, or altered orientations which are obvious to those skilled in the art are intended to be included within the scope of the present invention. | An automated system is disclosed for folding vehicle air bags so that a small folded-bag profile and a desirable bag deployment pattern results. A machine having numerous moveable arms is controlled by a controller. An edge folding assembly (EFA) of the machine has five arms, including a center arm, two outer blades, and two outwardly facing U-channel forks, which reside between respective outer blades and the center arm. The EFA moves forward so that all of its five arms engage an unfolded air bag. The forks then raise upward to a level at which the outer blades are aligned with a gap between tines in the forks. The outer blades mesh with this gap causing two pleats to be formed in the edge of the bag. Pleat clamps then move inwardly sideways to engage the two pleats and form a third pleat. Then, the EFA is removed from the bag. The pleat clamps clamp top and bottom sections of the bag together while tightly gripping the pleats. The bag is then inflated, except that the pleat clamps prevent inflation of the pleated section. Next, the pleat clamps move closer together to poke the pleats into the center of the otherwise inflated bag. The bag is then deflated, and the pleat clamps are withdrawn from the bag. | 28,802 |
This Nonprovisional application claims priority under 35 U.S.C. § 119(e) on U.S. Provisional Application No. 60/532,884 filed on Dec. 29, 2003 and under 35 U.S.C. § 119(a) on Patent Application No. 2003-424023 filed in Japan on Dec. 22, 2003, the entire contents of which are hereby incorporated by reference.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention relates to a gas generator for an airbag, used in an airbag system installed in a vehicle to release a gas for inflating the airbag in the event of a collision, and preferably relates to a gas generator for an airbag, which is used in an airbag system for developing an airbag over the lateral side of a vehicle occupant.
2. Description of the Related Art
As gas generators for air bags installed in automobiles and other vehicles, various types of gas generators such as for a driver side air bag, for a front passenger side air bag, for a side air bag, for a curtain air bag or for a pretensioner has been provided, suitable to installation locations, purposes and so forth.
Among them, a gas generator used for a side airbag serves to inflate an airbag that provides protection against an impact from the lateral side of an occupant, which improves safety in the event of a lateral collision of the vehicle, for instance, and in most cases, is installed in a seat back, a B-pillar (the center pillar), or the like.
In particular, in the case of a side airbag gas generator or other small gas generator, in order to ensure enough installation space, or to reduce the weight of the gas generator itself, a pyrotechnic gas generator, which uses a solid gas generating agent, have been used as the gas generation source for inflating the bag. In such a gas generator, the gas for inflating the airbag is produced by combustion of the solid gas generating agent serving as the gas generation source. This gas is very hot and combustion by-products are also produced during the combustion, and therefore, a filter is generally used for purifying and cooling the gas produced by combustion. Even in this case, the problem of ensuring enough installion space in the vehicle has to be solved, and the purification and cooling efficiency has to be enhanced. Furthermore, in case of a gas generator for a side airbag, the airbag has to be inflated more quickly because there is less space between the occupant and the structural members inside the vehicle. Accordingly, a filter used for such a gas generator needs to be as little an obstacle as possible in the release of the gas.
In addition, the structure of the gas generator itself needs to be simple in order to avoid difficulty in the manufacture of the gas generator and to eliminate problems that would otherwise be caused by a complicated structure, for example.
A conventional gas generator for a side air bag is disclosed in U.S. Pat. No. 5,542,702, for example.
Also, a gas generator using a filter is disclosed in U.S. Pat. No. 4,005,768, for example.
SUMMARY OF THE INVENTION
The gas generator disclosed in the above U.S. Pat. No. 5,542,702 uses pressurized gas as the gas supply source, and therefore does not use a filter. The gas generator disclosed in the above U.S. Pat. No. 4,005,768 is formed using a plurality of members, so the structure is complicated, and furthermore, the igniter is disposed in the direction in which the gas is released and therefore interferes with or blocks attachment of the airbag. Also, the space in which the gas generating agent is stored approximates a drum shape, and is too constricted in its middle, so as the ignition flame from the gas generating agent spreads throughout the gas generating agent storing space, this constricted inside diameter portion impedes the smooth propagation of the ignition flame. Thus, the above-mentioned problem is not solved by this gas generator, either. In particular, when gas needs to be generated early in the actuation of the gas generator, or when a large quantity of gas needs to be generated in the initial stage of the actuation of the gas generator, it is undesirable for such a constricted portion to be formed within the space storing the gas generating agent.
Accordingly, it is a purpose of the invention to provide a gas generator for an air bag, particularly used as a gas generator for a side air bag and small gas generators, which can solve effectively a problem in obtaining an installation space, in other words reduction in size, or reducing the weight. In addition, a pyrotechnic gas generator utilizing a solid gas generating agent can have an enhanced efficiency in purifying and cooling a gas and the filter thereof will not obstruct the way to the discharged gas possibly. The gas generator for an airbag is provided with so simple a structure.
In order to achieve the stated object, the present invention provides the following gas generator for an airbag.
Specifically, it provides a gas generator for an airbag, comprising, in a cylindrical housing including at least one gas discharge port in its periphery and having at least one closed end portion, an inner cylindrical member in which the interior is defined to form an accommodating space for a gas generating agent, a filter for purifying the gas generated by the combustion of the gas generating agent, and an ignition means for igniting and burning the gas generating agent accommodated in the accommodating space,
wherein the inner cylindrical member comprises a first outside diameter portion and a second outside diameter portion formed to have a larger outside diameter than that of the first outside diameter portion and also to be in contact with the inner peripheral surface of the housing, with the tip end, in the first outside diameter portion side, in contact with the closed end portion (one end portion) of the housing,
the filter is provided radially on the outside of the first outside diameter portion in the inner cylinder, and
the ignition means is provided on the outside end portion (the other end portion) from the closed end portion of the housing.
In the above gas generator of the present invention, the filter is provided radially on the outside of only the first outside diameter portion in the inner cylinder disposed inside the housing. Therefore, in comparison with the case in which a filter is disposed along the entire axial length of the housing, the filter of the present invention, even in the same weight as the above filter, can be made thicker by an amount equal to the reduction in axial length. As a result, the gas travels a greater distance, which improves the cooling efficiency of the filter. Thus, the filter used in the gas generator of the present invention does not impede the passage of the gas, while providing a good cooling effect.
Also, since the ignition means is provided on the opposite end portion (the other end portion) from the closed end portion of the housing and is not located in the opening direction (that is, in the direction in which the gas is released) of the gas discharge port in the housing, the ignition means does not disturb the attachment of the airbag. The result of this configuration is that, when a gas flows through the combustion chamber (that is, the gas generating agent accommodating space) from the side where the ignition means is installed (in the other end portion side) toward the closed end portion (one end portion) side of the housing, ordinarily, the filter would be damaged by the compression force acting in the axial direction. In the airbag gas generator of the present invention, however, the filter is provided on the outside of the inner cylindrical member, and the tip end in the first outside diameter portion side of this inner cylindrical member abuts against the closed end portion side of the housing. The tip end in the first outside diameter portion side means the tip end of the portion (regardless of outside diameter), which exists in a much closer portion to the closed end portion (one end portion) of the housing than the portion where the first outside diameter portion is formed. Accordingly, the inner cylindrical member bears the action (compression force) during gas flow, so that the filter sustains no damage. Furthermore, since the second outside diameter portion formed in the inner cylindrical member abuts against the inner peripheral surface of the housing, the gas is prevented from making a short pass between the filter and the housing, and also the inner cylindrical member can be positioned properly.
The housing functions as the outer container of the gas generator, and more particularly is in the form of a cylinder that is closed at one end, and at least one gas discharge port is formed in the periphery thereof. One end portion of the housing is preferably closed by a closing portion formed integrally with the peripheral wall of the housing, but may also be closed with a closing member formed separately from the peripheral wall. The other open end portion of the housing can be closed with an igniter collar for supporting or fixing the ignition means as described later, or another member. For instance, it can be closed with a metal plate.
The housing accommodates at least an inner cylindrical member in which the interior is defined to form a space for storing a gas generating agent, a filter for purifying the gas generated by the combustion of the gas generating agent, and ignition means for igniting and combusting the gas generating agent stored in the accommodating space.
The inner cylindrical member is substantially cylindrical, and has at least two outside diameters (first outside diameter portion and second outside diameter portion) along its length. The portions formed to have different outside diameters (the first outside diameter portion and second outside diameter portion) can be adjacent to each other in the axial direction, or yet another portion having different outside diameter (third outside diameter portion) can be interposed between these first two outside diameter portions, so as to be adjacent to each in the axial direction. In other words, the inner cylindrical member includes at least two portions formed to have different outside diameters, a portion having one of these outside diameters (i.e. the second outside diameter portion) is formed in such a size (outside diameter) to abut against the inner surface of the housing, while the other portions having one or more outside diameters (the first outside diameter portion) are formed to have a smaller outside diameter than that of the second outside diameter portion. And the inner cylindrical member is disposed, with the tip end abutting against the closed end portion of the housing, to direct the first outside diameter portion at the closed end portion of the housing. A space for accommodating a gas generating agent is formed on the inside of this inner cylindrical member, and at least one opening is formed in the peripheral surface for releasing to the outside of the inner cylindrical member the gas produced by the combustion of the gas generating agent inside the gas generating agent accommodating space. The gas released from the opening needs to be subsequently purified with a filter, so it is preferable for the opening to be formed in a portion covered by the filter, such as all or part of the first outside diameter portion.
The filter has the function of purifying the gas produced by the combustion of the gas generating agent stored in the interior space of the inner cylindrical member, and the function of cooling this gas, and is provided on the outside of the inner cylindrical member in the radial direction, and preferably on the outside of the first outside diameter portion in the radial direction. In particular, when the filter is provided on the outside of the first outside diameter portion in the radial direction, the portion covered by the filter can be defined as the first outside diameter portion. When the first outside diameter portion of the inner cylindrical member is covered by the filter, the first outside diameter portion is formed to obtain enough space to accommodate the filter between the first outside diameter portion and the inner peripheral surface of the housing, and preferably is formed to obtain a space capable of functioning as a gas flow space between the outer peripheral surface of the filter provided on the first outside diameter portion, and the inner peripheral surface of the housing.
The function of the ignition means is to start the operation of the gas generator. The constitution of the ignition means can includes an igniter that produces a flame or heat mist for starting the operation of the gas generator upon receipt of an electrical actuation signal, or the constitution can includes an igniter that amplifies the flame or heat mist produced by the igniter. This igniter is installed on the opposite end portion (the other end portion) from the closed end portion (one end portion) of the housing.
The following aspects are preferred in the gas generator for an air bag according to the present invention.
The gas generating agent accommodating space comprises two combustion chambers which are adjacent to each other in the axial direction to be capable of communicating with each other, the first combustion chamber is provided to the closed end portion (one end portion) of the housing, and the second combustion chamber is provided to the opposite end portion (the other end portion) from the closed end portion of the housing, and the ignition means is provided inside the second combustion chamber, and the gas generating agents charged in the first combustion chamber and second combustion chamber differ from each other between the combustion chambers in at least one of a charged amount, composition, composition ratio, size, and shape. With this gas generator, the two combustion chambers axially adjacent to each other are formed to be capable of communicating with each other, and they can be arranged to communicate with each other from the outset (that is, always in communication), or alternatively they can be formed to communicate with each other when a blocking member (such as a rupture plate) disappears, deforms, moves, and/or burns in the operation of the gas generator. A partition member fixed by press-fitting inside the inner cylinder is an example of a partition between the first combustion chamber and second combustion chamber. This partition member can, for example, be provided with a communication hole that allows the first combustion chamber and second combustion chamber to communicate at all times, or be formed such that this communication hole is formed during the combustion of the second gas generating agent. The combustion performance of the second gas generating agent can be adjusted by adjusting the opening area of the communication hole.
Thus using different gas generating agents for the respective combustion chambers allows an amount of gas generated by the combustion of the gas generating agent to be varied in the operation of the gas generator, and as a result, it is possible to adjust the airbag inflation pattern as desired, such as inflating the airbag quickly at the initial stage and then increasingly slowly, or inflating the airbag in the opposite pattern.
In the present invention, the gas generating agent disposed in the first combustion chamber has the combustion temperature (the temperature generated during the combustion of the gas generating agent; the same applies hereinafter) of 1000 to 1700° C., and preferably 1000 to 1600° C., and even more preferably 1000 to 1500° C., while the gas generating agent disposed in the second combustion chamber has the combustion temperature of 1700 to 3000° C., and preferably 1700 to 2800° C., and even more preferably 1700 to 2500° C. This combustion temperature of the gas generating agent can be obtained by theoretical calculation. For instance, it can be computed from a NEW PEP (New Propellant Evaluation Program) produced on the basis of the basic program of the US Navel Weapons Center. When the combustion temperature of the gas generating agent is low, an amount of filter required for cooling purposes (that is, a filter that also functions as a coolant) will be smaller, and this is extremely favorable in terms of making the gas generator smaller and lighter. However, ignitability generally tends to decrease when the combustion temperature of a gas generating agent is low. Nevertheless, the problem with the ignitability of a gas generating agent can be solved as follows with the gas generator of the present invention. If the gas generating agent stored in the first combustion chamber (hereinafter referred to as the first gas generating agent) has a low combustion temperature (that is, has low ignitability), a gas generating agent having a higher combustion temperature (that is, better ignitability) than the first gas generating agent can be used as the gas generating agent disposed in the second combustion chamber (hereinafter referred to as the second gas generating agent), which promotes the ignition and combustion of the first gas generating agent.
An example of a combination of gas generating agents having such combustion temperatures is for the first gas generating agent to be a gas generating agent comprising guanidine nitrate and basic copper nitrate, and the second gas generating agent to be a gas generating agent comprising nitroguanidine and strontium nitrate. Specifically, the gas generating agent comprising guanidine nitrate and basic copper nitrate (the first gas generating agent) has a low combustion temperature and low ignitability, and when an attempt is made to ignite this agent using boron niter, which is commonly used as an igniter, the combustion finishes in an instant because of the boron niter in the form of a powder. Even if an amount of boron niter is increased, it is insufficient for burning the gas generating agent and sustaining the combustion. In view of this, it is preferable to use a gas generating agent comprising the above-mentioned nitroguanidine and strontium nitrate, for example, or a gas generating agent that can sustain combustion for a certain amount of time, as the second gas generating agent in order to ignite and combust the first gas generating agent with lower combustion temperature and ignitability. Since this causes the combustion of the second gas generating agent itself to be sustained for a certain amount of time, the first gas generating agent is exposed to the combustion flame of the second gas generating agent for a relatively long time, and as a result, combustion can be achieved even with the first gas generating agent with lower ignitability. In terms of this action and effect, the second gas generating agent can also be defined as one that is not directly ignited and burnt by a conventional igniter or transfer charge (or, even if it is ignited and burnt by them, one that can not obtain a sufficient combustion performance to give a gas generator including this agent an adequate occupant restraint performance), and a second gas generating agent defined such as this is not strictly confined to the range of combustion temperatures given above.
An amount of filter used (a filter functioning as a coolant) can be reduced by lowering the overall combustion temperature of the gas generating agent, and in this respect it is preferable for a charged amount of the first gas generating agent to be greater than a charged amount of the second gas generating agent. In view of this, in the gas generator of the present invention, charged amounts of the first gas generating agent and second gas generating agent can be set optionally to any ratio with a press-fitted partitioning plate. This provides an airbag gas generator in which the combustion temperature of the gas generating agent can be adjusted precisely as desired, and the operational output of the gas generator can be finely controlled.
Also, in the airbag gas generator of the present invention, the housing can be formed cylindrical and longer in the axial direction, and at least one opening, that allows communication between the gas generating agent accommodating space and the external environment of the inner cylindrical member, can be formed in the inner cylindrical member, the opening existing locally, only on part of the circumferential surface of the first outside diameter portion near the closed end portion of the housing. At least one opening formed in the inner cylindrical member functions as a gas outlet for releasing the gas produced indie the gas generating agent accommodating space to the outside of the inner cylindrical member (that is, to the external environment). The opening can be formed to allow communication from the outset (that is, open all the time), or it can be formed to allow communication (open) when a blocking member (such as a rupture plate) disappears in the operation of the gas generator. In a gas generator formed in this way, the ignition means is formed at one end and the opening at the other end of the gas generator that is formed longer in its axial direction. That is, when combustion of the gas generating agent begins from the side where the ignition means is installed, in the gas generating agent accommodating space (that is, the combustion chamber) formed on the inside of the inner cylindrical member, the flame or high-temperature gas flows toward the above-mentioned opening provided on the opposite side from the side where the ignition means is disposed. Therefore, even with a long housing, combustion that occurs at one end thereof (the end where the igniter is installed) proceeds to the opposite end, thereby affording effective ignition and combustion of all of the gas generating agent in the inner cylindrical member. Particularly, the combustibility of the first gas generating agent can be pronounced.
Also, in the airbag gas generator of the present invention, a third outside diameter portion that has a larger outside diameter than that of the first outside diameter portion and smaller than the second outside diameter portion can be further provided between the first outside diameter portion and the second outside diameter portion in the inner cylindrical member. Thus providing a third outside diameter portion ensures a constant gas generating agent accommodating space, ensures a first outside diameter portion for disposing the filter, and allows the range (or peripheral surface area) of the second outside diameter portion to be smaller, which results in a smaller contact area between the housing and the inner cylindrical member, and effectively prevents the transfer of heat from the inner cylindrical member to the housing, as well as the transfer of the heat of the filter to the housing via the inner cylindrical member. In other words, by providing the inner cylindrical member with a third outside diameter portion that does not touch the inner peripheral surface of the housing, the heat generated in the combustion chamber can hardly transfer to the peripheral walls of the housing.
Also, in the airbag gas generator of the present invention, the ignition means comprising an igniter to be actuated by an ignition current is used, this igniter is attached to a collar member that closes the opposite end portion to the closed end portion of the housing, and the second outside diameter portion-side end of the inner cylindrical member comes into contact with this collar member. This makes it easier to fix and position and the igniter, and the inner cylindrical member can also be fixed by fixing collar member. When fixed in this way, the inner cylindrical member is held tightly between the collar member and the closed end portion of the housing, which prevents the inner cylindrical member from moving. Also, since the filter is fixed to the inner cylindrical member that is held tightly and fixed, the entire structure housed in the housing can be fixed. In particular, in the fixing of the igniter collar, it is preferable to fix the igniter collar by crimping the open end portion of the housing (the opposite side to the closed end). This makes it easier to fix the collar, and furthermore the positioning of the collar is accomplished in the course of crimping the housing end portion.
In regard to the fixing of the collar member and the inner cylindrical member in particular, in the airbag gas generator of the present invention, a protrusion can be formed on the inner peripheral surface of the housing, and the collar member and the second outside diameter portion-side end of the inner cylindrical member can abut against this protrusion. In this case, the igniter collar provided with the igniter can be disposed after the inner cylindrical member first is fixed with this protrusion. This keeps the parts from falling out and so forth during conveyance along the gas generator manufacturing line, and therefore affords safe manufacture. Furthermore, the force of crimping the open end portion of the housing in the course of fixing the igniter collar can be prevented from acting directly on the inner cylindrical member.
Also, in the airbag gas generator of the present invention, a gas discharge port provided on the housing can be formed closer to the side where the ignition means is disposed, rather than to the axial center of the housing. If this is done, when two gas generators are linked and used together, that is, when creating gas generators in which the number of gas generators to be activated and the timing of activation can be adjusted according to the impact, by connecting end portions where the ignition means is not present, the ignition means of the linked gas generators are located away from the connected end portions. This facilitates the take-off of lead wires that are connected to the ignition means for the transmission of an activation signal, and does not interfere with the airbag. Also, the gas discharge ports in the connected gas generators are formed on the ignition means side of each gas generator, that is, on the side away from the connected portions. Because of this, when different air bags are connected to the respective gas generators to be used, the air bags can be connected more easily to gas discharge ports respectively. A configuration in which two gas generators are thus connected and a different airbag is connected to each gas generator is advantageous, for example, when one airbag designed to restrain the chest of an occupant, and a different airbag is designed to restrain the waist of the occupant. This gas generator can be used not only in a side airbag system, but also an air bag system for a driver side, an air bag system for passenger side, an air bag system for a curtain airbag and the like.
The present invention effectively solves the problems related to ensuring installation space and reducing weight in a gas generator for a side airbag and other such a small gas generator. In particular, when a filter is used in a pyrotechnic gas generator which uses a solid gas generating agent, such an airbag gas generator is provided that the purification and cooling efficiency of this filter in a smaller amount is enhanced, a filter is as little an obstacle as possible at the time of releasing a gas and a structure is simple.
Furthermore, in a gas generator in which a first combustion chamber and second combustion chamber are charged with different gas generating agents, even though a compound with low ignitability is used as the first gas generating agent, it can still be burnt effectively, and in a gas generator in which a third outside diameter portion is further formed in the inner cylindrical member, the transfer of the heat produced by the combustion of the gas generating agent to the housing can be kept to a minimum. Also, using an igniter collar not only facilitates the assembly of the gas generator, but also allows the constituent elements of the gas generator housed in the housing to be fixed easily and securely.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an axial cross section of an airbag gas generator;
FIG. 2 is a cross section of the main components in another embodiment of an airbag gas generator; and
FIG. 3 is a cross section of the main components in yet another embodiment of an airbag gas generator.
DETAILED DESCRIPTION OF THE INVENTION
Embodiments of the present invention will now be described with reference to the drawings. FIG. 1 is an axial cross section of an embodiment of the gas generator for an airbag according to the present invention. FIGS. 2 and 3 are cross sections of the main components in other embodiments.
With the gas generator shown in FIG. 1 , an inner cylindrical member 20 is disposed in a housing 10 that is closed at one end and open at the other end, a filter 3 is disposed on the outside of the inner cylindrical member 20 , and the inside of the inner cylindrical member 20 is charged with gas generating agents 41 and 42 . An igniter collar 6 having an igniter 5 , i.e. an ignition means, fixed thereto is provided to the open end portion 12 of the housing 10 , and the open end portion 12 of the housing 10 is crimped to fix this igniter collar 6 .
In the embodiment shown in FIG. 1 , the inner cylindrical member 20 comprises a first outside diameter portion 21 , a third outside diameter portion 23 , and a second outside diameter portion 22 , formed in that order starting from a closed end portion 11 of the housing 10 toward the open end portion 12 in which the igniter 5 is accommodated. The outside diameter of the respective outside diameter portions is formed to increase in that order. The second outside diameter portion 22 , which is formed in the largest outside diameter, is formed in a size such that its outer peripheral surface fits the inner peripheral surface of the housing 10 . In particular, with this embodiment, the axial length of each outside diameter portion is in inverse proportion to the outside diameter of each outside diameter portion. Specifically, the second outside diameter portion 22 , the third outside diameter portion 23 and the first outside diameter portion 21 are formed in that order of increasing length in the axial direction. The third outside diameter portion 23 of the inner cylindrical member 20 has a smaller outside diameter than that of the second outside diameter portion 22 , in other words, it is formed in such a size that is never in contact with the inner surface of the housing 10 . The third outside diameter portion 23 is thus formed to define a gap with the housing peripheral wall surface and also the contact surface area between the second outside diameter portion and the housing peripheral wall surface is small, and therefore, the transfer of heat from the inner cylindrical member 20 to the housing 10 is kept to an absolute minimum. Also, the filter 3 , which is formed by winding up a metal wire rod into multiple layers, is provided on the radial outside of the first outside diameter portion 21 , and the outside diameter of this first outside diameter portion 21 is set in view of the thickness of the filter 3 to be formed, and the width of a gap 7 to be formed on the outside of the filter 3 . And, the axial length of the first outside diameter portion 21 matches the axial length of the filter 3 to be formed. Plural openings 24 that allow communication between the external environment of the inner cylindrical member 20 and an accommodating space (combustion chambers) of the gas generating agent ( 41 and 42 ), and the flame produced by the combustion of the gas generating agent ( 41 and 42 ) stored inside the inner cylindrical member 20 is released from these openings 24 toward the filter 3 .
Since the axial length of the filter 3 is reduced in the present invention and the filter is made thicker by a corresponding amount, an effect of cooling and purifying the gas can be enhanced, and also an adequate gas passage surface area is ensured. The filter 3 is not limited to the embodiment shown in FIG. 1 , and it can be formed even thicker and shorter in the axial direction. The filter 3 can also be formed to cover just part of the first outside diameter portion 21 , rather than the entire portion. However, the openings 24 formed in the peripheral surface of the first outside diameter portion 21 have to exist in the range that is covered with the filter 3 .
Also, since the third outside diameter portion 23 is formed to have a larger outside diameter than that of the first outside diameter portion 21 , adequate space can be ensured in the interior thereof, which makes it possible for more gas generating agent to be stored therein.
A combustion chamber (i.e. gas generating agent accommodating space) is provided on the inside of the inner cylindrical member 20 . Particularly in this embodiment, two combustion chambers, that are adjacent to each other in the axial direction to communicate with each other, are provided in the inner cylindrical member 20 . A first combustion chamber 81 is provided to the closed end portion 11 of the housing 10 , and a second combustion chamber 82 is provided to the open end portion 12 of the housing 10 . The first combustion chamber 81 and the second combustion chamber 82 are partitioned by a partitioning wall 9 provided to separate the two chambers, and plural through holes are formed in this partitioning wall 9 , so that the two combustion chambers are kept in communication with each other. The first combustion chamber 81 is charged with the first gas generating agent 41 , and the second combustion chamber 82 is charged with the second gas generating agent 42 . When two combustion chambers are sectioned, the first combustion chamber 81 and second combustion chamber 82 can be charged with a different gas generating agent. For instance, the first combustion chamber 81 can be charged with a gas generating agent with low ignitability and a low combustion temperature (such sa a gas generating agent including guanidine nitrate and basic copper nitrate), while the second combustion chamber 82 can be charged with a gas generating agent that has good ignitability and can sustain combustion, so as to compensate for the low ignitability of the first gas generating agent 41 . Particularly, the combustion temperature of the first gas generating agent is preferably in the range of 1000 to 1700° C. Such a gas generating agent can be obtained, for example, by forming a composition comprising 41% by mass of guanidine nitrate, 49% by mass of basic copper nitrate, a binder and additives, and molding this composition into a single-perforated cylinder with the outside diameter of 1.8 mm, the thickness of 1.9 mm and the inside diameter of 0.7 mm. The combustion temperature of the second gas generating agent is preferably in the range of 1700 and 3000° C. Such a gas generating agent can be obtained, for example, by forming a composition including of 34% by mass of nitroguanidine and 56% by mass of strontium nitrate, and molding this composition into a pellet with the outside diameter of 1.5 mm, and the thickness of 1.5 mm. The combustion temperature of the gas generating agents can be suitably adjusted by varying the composition, the compositional ratio, the shape, size and so forth.
In this embodiment, the first combustion chamber 81 is provided on the inside of the first outside diameter portion 21 , and the second combustion chamber 82 is provided on the inside of the third outside diameter portion 23 and the second outside diameter portion 22 , and the volume of each combustion chamber can be adjusted by adjusting the position of the partitioning wall 9 .
Also, with this embodiment, a protrusion 14 is formed on the inner surface of the housing 10 , and this protrusion supports the end portion of the inner cylindrical member 20 in the second outside diameter portion 22 side, and fixes the inner cylindrical member 20 . Specifically, the end portion of the inner cylindrical member 20 in the first outside diameter portion 21 side (this does not necessarily have to be the end portion of the first outside diameter portion, and if there is a portion formed with an even smaller or larger inside diameter, this may be the end portion thereof) is in contact with the closed end portion 11 of the housing 10 , and the end portion on the other side (the end on the second outside diameter portion 22 side) is in contact with the protrusion 14 on the inner surface of the housing 10 , so the inner cylindrical member 20 is sandwiched and fixed at these two ends. The protrusion 14 on the inner surface of the housing 10 can be formed by crimping the corresponding location of the housing 10 .
The igniter 5 , which is fixed to the igniter collar 6 , is installed as the ignition means at the open end portion 12 of the housing 10 . This igniter collar 6 is fixed by crimping the open end portion 12 of the housing 10 and being held between the crimped end and the protrusion 14 on the inner surface of the housing 10 . The igniter collar 6 is also provided with a sealing member 61 such as an O-ring in order to prevent gas from passing between the peripheral surface of the collar and the inner surface of the housing 10 .
With a gas generator formed in this manner, when a flame is produced by an actuation of the igniter 5 by an actuation signal (current), the second gas generating agent 42 is ignited by this flame, and the combustion flame of the second gas generating agent 42 ignites and burns the first gas generating agent 41 . The gas produced by the combustion of the two gas generating agents is released from the openings 24 of the inner cylindrical member 20 toward the filter 3 , is purified and cooled while it passes through the filter 3 , and passes through the gap 7 to be ejected from a gas discharge port 13 .
In the embodiment shown in FIG. 1 , the gas discharge port 13 is formed away from the closed end portion 11 , that is, closer to the open end portion 12 (the side where the ignition means is provided), and therefore, when two gas generators are connected by connecting the respective closed end portions 11 of the housings 10 with each other, the ignition means and the gas discharge port 13 in one of the two connected gas generators is further apart from the other. This makes it easier for the gas discharge port 13 of each gas generator to be connected to a different airbag, and additionally it makes it easier to connect lead wires (cords for transmitting actuation signals) to the respective igniters 5 .
FIG. 2 illustrates an aspect in which the end portion of the inner cylindrical member 20 in the second outside diameter portion 22 side is in contact with the igniter collar 6 . Specifically, in the aspect shown in FIG. 1 , the protrusion 14 is provided inside the housing 10 to support the inner cylindrical member 20 , but the housing 10 ′ shown in this embodiment is not provided with such a protrusion, and the inner cylindrical member 20 can be also fixed by the end face of the igniter collar 6 at the time of fixing the igniter collar.
FIG. 3 illustrates an aspect in which the openings 24 formed in an inner cylindrical member 20 ′, particularly in a first outside diameter portion 21 ′, are provided locally in the periphery of the first outside diameter portion 21 ′ only in the closed end portion side of the housing 10 . With this configuration, the gas or flame of the second combustion chamber 82 and the first combustion chamber 81 flows toward the openings 24 , which improves the ignitability of the gas generating agent in the first combustion chamber 81 . Since the gas discharge port 13 is formed away from these openings 24 , the gas exhausted from the openings 24 passes through the filter 3 at an angle, which further promotes the purification and cooling of the gas. In addition, when the openings 24 are formed in the first outside diameter portion 21 of the inner cylindrical member 20 ′, they can be formed in a plurality of rows, such that the opening surface area is increased gradually toward the closed end portion 11 .
The filter shown in FIG. 1 is formed by winding a single wire rod into multiple layers. Such a filter can be obtained, for example, by winding a single wire rod into multiple layers around a core, after which the core is removed, and disposing the wound rod on the first outside diameter portion 21 of the inner cylindrical member 20 , or alternatively by winding the wire rod directly onto the first outside diameter portion of the inner cylindrical member 20 and disposing together with the inner cylindrical member 20 in the housing. Particularly in the latter case (when an inner cylindrical member wound with wire rod is disposed), the unraveling of the wire rod that can occur when the core is removed is prevented. If the winding end of the wire is fixed by spot welding or the like, there will be no unraveling.
In addition to a filter formed by winding a wire rod as described above, the filter shown in FIG. 1 can also be a filter obtained by winding a knitted wire into multiple layers and compression-molding the same in a mold, or alternatively, a plain woven wire mesh, plain-dutch wire mesh, punched metal, expanded metal, or the like is wound into multiple layers to be used as such a filter. | A gas generator, relating to a gas generator for a side air bag or the like, is provided. The gas generator has an inner cylindrical member stored in a housing, wherein the inner cylindrical member has a second outside diameter portion abutting against the inner peripheral surface of the housing, and a first outside diameter portion smaller in outside diameter than the second outside diameter portion, the tip end of the first outside diameter portion side abuts against the closed end portion (one end portion) of the housing, the filter is provided on the outside of the inner cylindrical member in the radial direction of the first outside diameter portion, and the ignition means is provided on the opposite end portion (the other end) from the closed end portion of the housing. | 41,988 |
CROSS-REFERENCE TO RELATED APPLICATIONS
This application is related to U.S. nonprovisional application Ser. No. 10/863,844, filed 3 Jun. 2004, hereby incorporated herein by reference, entitled “Electrical Current Transferring and Brush Pressure Exerting Interlocking Slip Ring Assembly,” joint inventors William A. Lynch, Wayne Marks, Jr. and Neal A. Sondergaard.
This application is related to U.S. nonprovisional application Ser. No. 10/985,074, filed 5 Nov. 2004, hereby incorporated herein by reference, entitled “Solid and Liquid Hybrid Current Transferring Brush,” joint inventors Neal A. Sondergaard and William A. Lynch.
This application is related to U.S. nonprovisional application Ser. No. 10/985,075, filed 5 Nov. 2004, hereby incorporated herein by reference, entitled “Folded Foil and Metal Fiber Braid Electrical Current Collector Brush,” joint inventors William A. Lynch, Neal A. Sondergaard and Wayne Marks, Jr.
This application is related to U.S. nonprovisional application Ser. No. 11/033,619, filed 13 Jan. 2005, hereby incorporated herein by reference, entitled “Quad Shaft Contrarotating Homopolar Motor,” joint inventors William A. Lynch and Neal A. Sondergaard.
This application is related to U.S. nonprovisional application Ser. No. 11/250,698, filed 8 Oct. 2005, hereby incorporated herein by reference, entitled “Ion Conducting Electrolyte Brush Additives,” joint inventors William A. Lynch and Neal A. Sondergaard.
STATEMENT OF GOVERNMENT INTEREST
The invention described herein may be manufactured and used by or for the Government of the United States of America for governmental purposes without payment of any royalties thereon or therefor.
BACKGROUND OF THE INVENTION
The present invention relates to machinery involving the conduction of electrical current between parts moving relative to each other, more particularly to methods and devices for effecting or facilitating such electrical conduction.
Various kinds of motors, generators and other electrical apparatus require the conduction of electricity between two relatively moving parts. Such mechanical arrangements usually involve the conduction of current between a stationary part (stator) and a rotating part (rotor). A device known as a “brush” or “current collector” is normally used for making sliding contact between stationary and rotating parts so as to conduct electrical current therebetween.
Depending on the particular machinery, a brush can be used to conduct current in either direction (i.e., either from the stationary part to the rotating part, or vice versa), and can be fixed with respect to either the rotating part or the stationary part. Among the desirable qualities of a brush are high current-carrying capacity (e.g., in terms of capability of carrying a high amount of current per unit area of the interface between the brush and the surface contacted thereby), low friction, and high wear resistance. Current collection brush technology has grown in interest with the advent and continued development of homopolar machine technology, particularly in the realm of homopolar motors (which operate on direct current) such as those that are currently envisioned for naval ship propulsion.
Conventional brushes include solid carbon brushes, copper fiber brushes and liquid metal brushes. The majority of brushes currently used are of the solid carbon variety. Solid carbon brushes provide limited power densities due to their characteristically small number of contact spots. In addition, solid carbon brushes tend to have a short life and to produce conductive wear debris, resulting in frequent brush replacement and frequent machinery cleaning and associated high maintenance costs. Generally speaking, as compared with solid carbon brushes, copper fiber brushes are considered to afford superior performance; however, copper fiber brushes are currently expensive to produce and can support only moderate current densities. It is generally believed that liquid metal brushes are capable of supporting very high current densities, but more research is needed in this area because of problems concerning stability and reactivity.
A conventional current collection assembly includes a brush and a “holder” (for the brush) as two separate components that are attached to each other. The holder is also attached to either the stationary part or the rotating part of the machinery. Soldering is normally implemented to achieve attachment between a brush and a holder. Small voltage drops are associated with solder joints, which can thus adversely affect performance. Moreover, solder joints are prone to mechanical failure.
SUMMARY OF THE INVENTION
In view of the foregoing, it is an object of the present invention to provide an improved current collection device.
As typically embodied, the present invention's device comprises two congruous elements, equal in length, each element having two ends. Each element includes a longitudinally straight section (which extends from the first end) and a longitudinally sinuous section (which extends from the second end). The elements are contrapositionally coupled so that: The straight sections (which are equal in length) adjoin; the first ends are even; the second ends adjoin; and, the sinuous sections (which are equal in length) are oppositely undulate. Each element includes an electrically conductive wire fabric (or a group of adjoining electrically conductive wire fabrics) and an elastomeric coating. According to typical inventive practice, each electrically conductive wire fabric is made of a suitable metal elemental material (such as copper, silver, or gold or another metal) or a suitable metal alloy material (such as including copper, silver, and/or gold and/or another metal). In each element: The electrically conductive wire fabric extends from the first end to the second end; the elastomeric material covers a portion of the outside surfaces (including both the inward facing and outward facing surfaces) of the electrically conductive wire fabric (or the group of adjoining electrically conductive wire fabrics), the elastomeric coating being predominately in the sinuous section; a solder material infuses a portion of the electrically conductive wire fabric (or the group of adjoining electrically conductive wire fabrics), the solder material-infused portion being in the sinuous section in the vicinity of the second end. The lower outside surface of the solder-infused portion is not covered by the elastomeric material, but instead is contactingly covered by an electrically conductive (e.g., metal) plate that facilitates electrical conductivity.
According to typical practice of the present invention, the two solder-infused portions of the respective sinuous sections of the two elements adjoin each other (e.g., are connected to or proximate to each other) so as to together form a solder-based electrical contact, which according to typical embodiments includes electrically conductive plating that covers the bottom surface of the two adjoining solder-infused portions. Further according to typical inventive practice, in each element a cement material infuses a portion of the electrically conductive wire fabric (or the group of adjoining electrically conductive wire fabrics), the cement-infused portion being in the sinuous section adjacent to the solder-infused portion. The two respective cement-infused portions thus barricade the solder-based electrical contact (which is formed by the two respective solder material-infused portions) so as to prevent infiltration of the solder material into other portions of the respective elements. The inventive device is securable at the solder-based electrical contact with respect to machinery so that: The straight sections together constitute a brush for contacting (at the first ends) a machinery part that moves relative to the inventive device; the electrically conductive plate that contiguously covers the solder-based electrical contact is in abutting physical contact with another machinery part, viz., a machinery part that is fixed with respect to the inventive device; and, the sinuous sections together constitute a spring for biasing the straight sections toward the contacted relatively moving machinery part.
The spring-like nature of the sinuous sections is associated with a reduction in the length of the elements (and hence of the inventive device) when the inventive device is secured at the solder-based electrical contact with respect to the machinery. According to many of the present invention's current collection applications, the two relatively moving machinery parts are a stationary part and a moving (e.g., rotating) machinery part; depending on the inventive embodiment, the contacted machinery part is either a stationary part or a moving (e.g., rotating) machinery part. The inventive device is securable at the solder-based electrical contact with respect to either a stationary machinery part (if the contacted machinery part is a moving part) or a moving machinery part (if the contacted machinery part is a stationary part) so that the elements together constitute an electrical conductor between the stationary machinery part and the moving machinery part. In accordance with some embodiments of the present invention, the two relatively moving machine parts are both moving (e.g., rotating) parts; for instance, the present invention can be practiced in association with contra-rotating machines in which both relatively moving parts rotate. The electrically conductive (e.g., gold, silver or other metal) plate (e.g., plating such as electroplating), which is attached to the solder-infused metal fabric and thereby made part of the solder-based electrical contact, serves to facilitate electrical conduction between the inventive device and the machine part with respect to which the inventive device is secured.
The present invention's device is normally practiced as a current collection device that serves as an electrically conductive bridge or conduit between two bodies in motion relative to each other, the inventive device effecting fixed electrical connection with respect to one of the bodies and effecting sliding electrical connection with respect to the other of the two bodies. The inventive current collection device represents a unitary combination that includes, in purpose and effect, both a brush and a bias-producing holder-analogue for the brush. The present invention is thus typically embodied as a combined, one-piece current collector that represents a kind of integrated “brush-plus-holder” device. The “spring” component of the inventive device is analogous to the holder of a conventional current collection assembly that includes a brush and a holder as two discrete parts, the holder being attached to an object as well as to the brush (thereby holding the brush in place). The inventive device's “brush” component represents a structurally continuous extension of the inventive device's spring component.
The inventive current collection device lacks a mechanical joint of any kind (e.g., a solder joint) for joining the inventive brush component with the inventive spring component, since they are intrinsically joined together as one. According to many inventive embodiments, no mechanical joint (e.g., solder joint) is required in the fabrication process of an inventive device. The inventive brush component and the inventive spring component are structurally continuous parts of the inventive unitary construction. Because of the present invention's obviation of attachment (e.g., solder-type attachment) between the present invention's brush component and the present invention's “spring” component, the present invention affords greater mechanical stability as well as greater electrical stability. The inventive device is less prone to mechanical failure associated with the utilization of one or more solder joints amidst a conventional current collection assembly. Furthermore, because of the relatively low mass of the inventive device as typically embodied, the inventive device is less prone to voltage fluctuation than is a conventional, more massive, brush-holder device.
The present invention can be used in practically any application involving relatively moving parts of a machine (e.g., an electrical machine or an electromechanical machine), including but not limited to applications involving motors (e.g., homopolar motors), generators (e.g., homopolar generators), commutators, etc. A typical brush component in accordance with the present invention is narrowly proportioned and thus, advantageously, may be characterized by low losses of magnetic circulating currents. Because the electrically conductive fibrous elements of a typical inventive device are less independent than are the electrically conductive fibrous elements in a conventional fiber brush, higher losses of electrical conduction (both in the electrically conductive elements and in the interface at which the brush makes sliding, frictional contact with a relatively moving object) may be associated with some embodiments of inventive practice than may be associated with some embodiments of conventional practice.
Other objects, advantages and features of the present invention will become apparent from the following detailed description of the present invention when considered in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
The present invention will now be described, by way of example, with reference to the accompanying drawings, wherein:
FIG. 1 is a longitudinally sectional front elevation view of a typical embodiment of an integral current collection device in accordance with the present invention, particularly illustrating the partially linear, partially curvilinear configuration of the inventive device.
FIG. 2 is a side elevation view of the inventive device shown in FIG. 1 .
FIG. 3 is a bottom plan view, oriented sideways, of the inventive device shown in FIG. 1 , with certain exterior layer portions peeled back to reveal corresponding interior layer portions.
FIG. 4 is a partial version of the bottom plan view shown in FIG. 3 of the inventive device shown in FIG. 1 , the solder-infused contact section being removed so as to reveal inward facing surfaces of the inventive device.
FIG. 5 is a top plan view, oriented sideways, of the inventive device shown in FIG. 1 .
FIG. 6 and FIG. 7 are each a view, similar to the view shown in FIG. 1 , illustrating use of the inventive device shown in FIG. 1 in machinery in association with machine parts including a rotor and a stator.
FIG. 8 is a plan view of a planar (unbent) rectangular piece of electrically conductive wire fabric suitable for inventive practice.
FIG. 9 , FIG. 10 and FIG. 11 are each a partial and enlarged view of the wire fabric shown in FIG. 5 . FIG. 9 depicts a biaxially braided wire fabric construction. FIG. 10 depicts a triaxially braided wire fabric construction. FIG. 11 depicts a wire fabric construction of plural (e.g., multiple) parallel bonded elongate members, each elongate member representing a braid-like grouping of plural individual wire strands, fibers or filaments.
FIG. 12 , FIG. 13 , FIG. 14 and FIG. 15 are each a schematic of an embodiment of an inventive method for fabricating an inventive device.
FIG. 16 is a perspective view (by way of photographic image) of an embodiment of a braid brush in accordance with the present invention.
DETAILED DESCRIPTION OF THE INVENTION
Reference is now made to FIG. 1 through FIG. 5 , which show a typical embodiment of an integral, dual-component, current collection device 100 in accordance with the present invention. The present invention's current collection device 100 includes two partially linear, partially sinuous elements representing equal and opposite halves of inventive device 100 , viz., an element 12 a (on the lefthand side as shown in FIG. 1 ) and an element 12 b (on the righthand side as shown in FIG. 1 ). Imaginary vertical geometric plane v bisects inventive device 100 into element 12 a and element 12 b , which are congruous and oppose each other so as to represent mirror images of each other when viewed as depicted in FIG. 1 . Inventive device 100 is thus characterized by a left-right symmetry, as illustrated in FIG. 1 , that is exhibited in complementary fashion by elements 12 a and 12 b with respect to vertical geometric plane v.
Each element 12 is characterized by the same overall vertical length L and two ends 13 . End 13 a 1 is the upper end of element 12 a ; end 13 a 2 is the lower end of element 12 a ; end 13 b 1 is the upper end of element 12 b ; end 13 b 2 is the lower end of element 12 b . Each element 12 includes a straight section 20 and a sinuous section 30 . In each element 12 , the overall vertical length L equals the sum of the straight section 20 's vertical length L STR plus the sinuous section 30 's vertical length L SIN . Not only overall length L, but also straight section length L STR and sinuous section length L SIN , are the same in each element 12 . Vertical length L effectively represents the axial length, taken along vertical plane v, of inventive device 100 . Straight section 20 a is longitudinally delimited by upper end 13 a 1 and horizontal geometric plane h. Straight section 20 b is longitudinally delimited by upper end 13 b , and horizontal geometric plane h. Sinuous section 30 a is longitudinally delimited by lower end 13 a 2 and horizontal geometric plane h. Sinuous section 30 b is longitudinally delimited by lower end 13 b 2 and horizontal geometric plane h. Sinuous sections 30 a and 30 b are largely separated from each other, but converge at lower ends 13 a 2 and 13 b 2 as well as in the vicinity of horizontal geometric plane h, which is shown in FIG. 1 to approximately intersect the bottom end of junction 23 . Lower ends 13 a 2 and 13 b 2 meet at vertical geometric plane v, and junction 23 coincides with vertical geometric plane v.
Each straight section 20 includes a flat or substantially flat surface 21 . The straight sections 20 a (of element 12 a ) and 20 b (of element 12 b ) adjoin each other, surface 21 a (of the core 14 a portion of straight section 20 a ) to surface 21 b (of the core 14 b portion of straight section 20 b ), so as to form a junction 23 . According to typical inventive practice, surfaces 21 a and 21 b are adhered to each other at junction 23 via a cement or other adhesive material 29 , such as shown in FIG. 5 . As shown in FIG. 1 , junction 23 is coincident with geometric plane v and is intermediate the corresponding surfaces 21 a (of straight section 20 a ) and 21 b (of straight section 20 b ). Straight sections 20 a and 20 b have the same length and adjoin so that upper ends 13 a 1 and 13 b 1 are even with each other, thus affording a continuous or substantially continuous upper edge face 25 that is suitable for contacting an object moving relative to inventive device 100 .
The “violin” shape of the inventive device 100 illustrated in FIG. 1 through FIG. 5 is but one of diverse shapes that are possible for practicing the present invention. As exemplified by the shown elements 12 a and 12 b , most inventive embodiments will be characterized by a plural number of undulations (waves) for each of two partially straight, partially undulating (wavy) elements 12 , wherein the elements' corresponding undulations are equivalent and opposite. Each undulation roughly describes a “U”-shape having its closed, bent end distanced from vertical geometric plane v and its open end proximate vertical geometric plane v. The undulating profile shown in FIG. 1 reveals two undulations, each having (at the closed, bent end of its “U”-shape) a crest 35 , wherein a trough 37 is situated between the crests 35 . Although each element 12 is shown in FIG. 1 to describe two undulations having congruently or approximately congruently curved shapes in terms of wavelength (measured, e.g., as the longitudinal distance between trough 37 and an end 13 ) and amplitude (measured, e.g., as the perpendicular distance between plane v and crest 35 ), such congruency between or among the undulations of each element 12 is not a requirement for inventive practice.
Each element 12 includes an electrically conductive core 14 and an electrically nonconductive covering or coating 16 . In each element 12 , the core 14 represents the main “structural” portion of element 12 . According to usual inventive practice, core 14 is composed of copper or silver or gold or another electrically conductive metal, or is composed of a metal alloy that includes copper and/or silver and/or gold and/or one or more other electrically conductive metals. Also according to usual inventive practice, covering 16 is composed of a natural rubber, or synthetic rubber (e.g., a silicone rubber), or other elastomer. Element 12 a includes metal core 14 a and elastomeric covering 16 a , and element 12 b includes metal core 14 b and elastomeric covering 16 b . To elaborate, in each element 12 the straight section 20 includes a portion of core 14 but excludes or substantially excludes elastomeric material; that is, the portion of core 14 that is in each straight section 20 is uncovered or substantially uncovered with elastomeric material 16 . The core 14 portion of each straight section 20 is thus exposed (or substantially exposed) to permit direct moving contact, frictional to some degree, with a machine part during operation of machinery with which inventive device 100 is associated. Further, in each element 12 , the sinuous section 30 includes a portion of core 14 and also includes elastomeric material 16 ; that is, a significant portion of core 14 that is in each sinuous section 30 is covered with elastomeric material 16 . FIG. 1 represents a longitudinal section of inventive device 100 because the elastomeric material 16 covers not only the outwardly and inwardly facing surfaces, but also the edges 27 , of sinuous sections 30 .
Each sinuous section 30 includes a solder material-infused portion 70 and a cement material-infused portion 80 . Solder-infused portion 70 is bounded on one end by vertical geometric plane v (where lower ends 13 a 2 and 13 b 2 meet) and on the other end by cement-infused portion 80 . In the solder-infused portions 70 a and 70 b , the corresponding portions of metal cores 14 a and 14 b are both impregnated with a solder material 71 (which is absorbed into the metal fabric core 14 material) in order to help establish an electrical contact region 700 , which is a continuum (or near-continuum) formed in part by the combined adjacency of solder-infused portions 70 a and 70 b . Solder-infused portions 70 a and 70 b combine, contiguously or nearly contiguously, to form an overall solder-infused portion of device 100 , viz., overall solder-infused portion 701 . Electrical contact region 700 includes not only the overall solder-infused portion 701 (which consists of the two adjacent solder-infused portions 70 a and 70 b ), but also includes, in abutting contact with the overall solder-infused portion 701 , an electrically conductive plating (e.g., electroplating) 90 . In the cement-infused portions 80 a and 80 b , the corresponding metal cores 14 a and 14 b are each impregnated with a cement material 81 (which is absorbed into the metal fabric core 14 material) in order to establish a barrier for preventing solder wicking into areas of inventive device 100 other than electrical contact region 700 . Each sinuous section 30 is covered with elastomeric material 16 , with the exception of the outward (downward) facing surface of solder-infused portion 70 . The bottom surface of electrical contact region 700 is provided not by an elastomeric material 16 but rather by the exposed electrically conductive plating 90 , which serves to improve the efficiency of the electrical contact and to prevent corrosion.
Still referring to FIG. 1 through FIG. 5 , and also referring to FIG. 6 and FIG. 7 , inventive device 100 can be considered to be divided into two structurally and functionally different components, viz., “brush” component 200 (the upper component as shown in FIG. 1 ) and “spring” component 300 (the lower component as shown in FIG. 1 ), which together form an integral whole, viz., inventive device 100 . Imaginary horizontal geometric plane h is drawn in FIG. 1 as an approximate demarcation between brush component 200 and spring component 300 . The spring component 300 shown in FIG. 1 bears some similarity, both structurally and functionally, to the “serpentine-shaped spring device” disclosed by William A. Lynch and Neal A. Sondergaard (the present inventors), et al., at U.S. Pat. No. 6,628,036 B1, issued 30 Sep. 2003, entitled “Electrical Current Transferring and Brush Pressure Exerting Spring Device,” said patent incorporated herein by reference.
Brush component 200 includes straight sections 20 a and 20 b , which are connected to each other in abutting fashion. Spring component 300 includes sinuous sections 30 a and 30 b , which are connected to each other end-to-end at respective lower ends 13 a 2 and 13 b 2 . Elements 12 a and 12 b together constitute a dual function unit 100 wherein the connected straight sections 20 a and 20 b together constitute a brush component 200 for making sliding, frictional contact (at upper ends 13 a 1 and 13 b 1 ) with a machine part that moves relative to inventive device 100 , and wherein the connected sinuous sections 30 a and 30 b together constitute a spring component 300 for biasing brush component 200 toward the machine part that is contacted by brush component 200 .
Brush component 200 includes a flat or substantially flat upper edge surface, viz., brush face 25 , which is formed by the combination of the corresponding upper edge surfaces of elements 12 a and 12 b at upper ends 13 a 1 and 13 b 1 . Brush face 25 represents the area of brush component 200 that makes contact with the moving part of a machine such as the “machinery” 50 shown in FIG. 6 and FIG. 7 . Brush face 25 is characterized by an “aspect ratio,” defined herein in relation to FIG. 5 as W/T, i.e., the ratio of the width W of brush face 25 to the thickness T of brush face 25 . The inventive practitioner may wish to change the aspect ratio of brush face 25 in order to suit particular applications; in this regard, the width W and/or the thickness T of brush face 25 can be varied, for instance in terms of numbers, thicknesses, and/or widths of electrically conductive sheets 40 .
The brush component 200 illustrated in FIG. 5 , which has four electrical conduction sub-layers (sheets) 40 , is rather narrow (i.e., has a relatively high aspect ratio) and should therefore afford very low magnetic circulating current losses. On the other hand, because the wires 41 (such as wires 41 shown in FIG. 9 through FIG. 11 ) of a typical inventive device 100 are less independent than are the electrically conductive fibers in a conventional fiber brush, inventive practice may be susceptible to higher electrical conduction losses in wires 41 as well as in interface 59 . Performance characteristics (such as power loss and wear rate) may need to be tested for given inventive devices 100 in order to establish their efficacy for given applications.
In FIG. 6 , inventive device 100 is mounted upon stator 54 , and stationary brush component 200 contacts rotor 52 at interface 59 ; in FIG. 7 , inventive device 100 is mounted upon rotor 52 , and rotating brush component 200 contacts stator 54 at interface 59 . In either arrangement, interface 59 is a surface portion that is constantly moving in accordance with the rotation of rotor 52 , which rotates in a rotational direction r about a rotational axis (such as rotational axis 55 shown in FIG. 6 ). Electrical contact region 700 represents an electrical contact area between inventive device 100 and the machine part with which inventive device 100 is fixedly coupled. The metal plate (e.g., plating) 90 of the inventive device 100 's electrical contact region 700 is in direct, fixed, physical contact with a surface region of the machine part with which inventive device 100 is fixedly coupled. According to some inventive embodiments, the machine part's fixedly contacted surface region (corresponding to electrical contact region 700 ) includes metal (e.g., gold or silver) plating, which abuts the inventive device 100 's metal (e.g., gold or silver) plate 90 . Such a plate-on-plate configuration may be particularly efficacious in terms of electrical contact efficiency and corrosion prevention.
Inventive device 100 is shown to be mechanically secured (to stator 54 in FIG. 6 ; to rotor 52 in FIG. 7 ) via one or more leaf springs 57 . A “leaf spring” is but one type of diverse mechanisms that can be used in inventive practice for mounting, clamping, or otherwise attaching or affixing the inventive device 100 with respect to the electrically conductive object (stator 54 in FIG. 6 ; rotor 52 in FIG. 7 ) that is to be fixedly joined with inventive device 100 . A typical leaf spring 57 is essentially a flat, rigid structure (made, e.g., of stainless steel or other material, which need not be electrically conductive) that in its natural state is moderately curved upward at its ends, which are not shown in FIG. 6 and FIG. 7 . At least one leaf spring 57 can be used for clamping an inventive device 100 to an object. The leaf spring 57 is positioned, concave upward, so as to adjoin the portion of the elastomeric layer 16 that is located on the upper side of the electrical contact region 700 . While the inventive device 100 is in place relative to the object, the two ends of the leaf spring 57 are pushed or bent downward (toward the object), thereby facilitating attachment at the two ends of the leaf spring 57 to the object. This attachment to the object at the two ends of the leaf spring 57 results in the application of firm, constant pressure by the leaf spring 57 onto the electrical contact region 700 and in the direction of the object, the electrical communication thereby being constantly maintained. For some embodiments, it may be preferable to provide plastic coating or tape on all or part of leaf spring 57 in order to protect the electrically conductive core material 14 and/or the elastomeric material 16 of the inventive device 100 from one or more sharp edges of the leaf spring 57 . Such coating or tape on leaf spring 57 may also serve to prevent any possible corrosion that may result from interaction of the core 14 's metal material with the leaf spring 57 's dissimilar metal material. In inventive embodiments in which structurally discrete elements are combined in the fabrication process, the solder material 71 (which infuses the fabric core 14 material of the electrical contact region 700 ) may serve to both mechanically and electrically connect electrically conductive core 14 a (at its lower end 13 a 2 ) and electrically conductive core 14 b (at its lower end 13 b 2 ) to each other, in addition to participating in the electrical connection with respect to the electrically conductive object (stator 54 in FIG. 6 ; rotor 52 in FIG. 7 ) that is fixedly joined with inventive device 100 . According to some inventive embodiments, the electric contact region 700 of inventive device 100 is press-fit into a complementary opening provided in the electrically conductive object to which inventive device 100 is fixedly joined.
Each sinuous section 30 , in the portion thereof other than the solder-infused portion 70 and the cement-infused portion 80 , represents a laminar material system that includes (i) an electrically conductive core layer 14 of uniform or approximately uniform thickness and (ii) two electrically nonconductive (e.g., elastomeric) exterior layers 16 of varying thicknesses. Each solder-infused portion 70 represents a laminar material system that includes elastomeric layer 16 on the upper side, a portion (e.g., half) of metal plate 90 on the lower side, and core layer 14 sandwiched therebetween. Electrical contact region 700 thus represents an overall laminar material system that combines the two laminar material systems corresponding to the two solder-infused portions 70 , wherein elastomeric material 16 is on the upper side, metal plate 90 is on the lower side, and solder-infused core material 14 is sandwiched therebetween. According to typical inventive practice, the metal plate (e.g., plating) 90 in electrical contact region 700 is at least substantially coextensive with the combined extent of the two end-to-end adjacent solder-infused portions 70 . The elastomeric layers 16 serve not only to protect much of inventive device 100 's core layers 14 from the elements, but also to enhance the spring-like attributes of inventive device 100 's spring component 300 . The core layers 14 are strategically covered with a thicker coating of elastomeric material 16 at individual bend locations 17 and joint bend location 19 (between elements 12 a and 12 b and directly below interface 23 ), these being locations where the maximum stresses occur when spring element 300 is compressed (and thereby rendered longitudinally shorter) during use of inventive device 100 , such as illustrated in FIG. 6 and FIG. 7 in the context of operating machinery 50 . Thickening of elastomeric material 16 at bend locations 17 and 19 can serve not only to structurally reinforce inventive device 100 but also to enhance the resilient quality of spring component 200 .
As illustrated in FIG. 6 and FIG. 7 , inventive device 100 is incorporated into machinery 50 , which additionally includes an electrically conductive rotor 52 (a rotating part of machinery 50 ) and an electrically conductive stator 54 (a stationary part of machinery 50 ). Inventive device 100 , as shown in FIG. 6 and FIG. 7 , is somewhat shorter and squatter than the same inventive device 100 is as shown in FIG. 1 . Inventive device 100 is shown in FIG. 6 and FIG. 7 to be situated between rotor 52 and stator 54 so that the distance along vertical geometric plane v and between interface 59 and the bottom surface of plate 90 of electrical connection region 700 is less than such distance is when inventive device 100 is freely situated as shown in FIG. 1 . Inventive device 100 is thus caused to be subjected to a longitudinal compressive force or stress that results in a shortening of length L SIN of spring component 300 and therefore a shortening of the overall length L of inventive device 100 . The bias-exerting attributes of spring component 300 are associated with this compression of spring component 300 . Spring component 300 exerts a bias (force, pressure, influence) with respect to brush component 200 so as to maintain brush component 200 , on a continuous basis, in a moderate pushing or pressing disposition at interface 59 against the slidingly, frictionally contacted object (rotor 52 in FIG. 6 ; stator 54 in FIG. 7 ).
As shown in FIG. 6 , inventive device 100 is attached at electrical contact region 700 to stator 54 . In contrast, as shown in FIG. 7 , inventive device 100 is attached at electrical contact region 700 to rotor 52 . In FIG. 6 the brush component 200 of stationary inventive device 100 is in sliding contact with rotor 52 at current collection interface 59 during rotation of rotor 52 , whereas in FIG. 7 the brush component 200 of moving (revolving) inventive device 100 is in sliding contact with stator 54 at current collection interface 59 during rotation of rotor 52 . Inventive device 100 is shown in both FIG. 6 and FIG. 7 to be perpendicular to rotor 52 ; otherwise expressed, vertical geometric plane v is shown to be perpendicular to the circular outline of rotor 52 . Nevertheless, brush component 200 can be disposed in either a perpendicular or oblique orientation with respect to rotor 52 , depending on the inventive application.
FIG. 6 and FIG. 7 are highly diagrammatic in nature. The terms “rotor” and “stator” are broadly used herein to refer to any rotating part and any stationary part, respectively, of any of diverse electrical or electromechanical machines (e.g., direct current motor-type machine, direct current generator-type machine, commutator-type machine, etc.) suitable for inventive practice, including but not limited to homopolar motors and homopolar generators. It is to be understood, however, that the rotor-stator arrangements of FIG. 6 and FIG. 7 are shown by way of example and are not intended to suggest any limitation regarding the present invention's potential applicability. For instance, the present invention can be practiced so as to use a solitary inventive device 100 (typically for instrumentation purposes) rather than paired inventive devices 100 (typically for power purposes). According to typical powering modes of inventive practice, the inventive device 100 shown in FIG. 6 and FIG. 7 would be one of a pair of inventive devices 100 . The present invention can be practiced in association with any machine having parts that move relative to each other, regardless of whether either part is characterized by rotative motion, linear motion, reciprocating motion, or any other kind of motion.
Regardless of whether machinery 50 is in the nature of a motor or a generator or another apparatus, according to typical inventive practice involving powering, inventive devices 100 are used in pairs. In each pair of inventive devices 100 , one inventive device 100 carries electrical current to (or into) the rotor 52 , while the other inventive device 100 carries electrical current from (or out of) the rotor 52 ; depending on the inventive application, either one of the pair of inventive devices 100 can be attached to either the rotor 52 or the stator 54 . FIG. 6 (which shows inventive device 100 attached to stator 54 ) and FIG. 7 (which shows inventive device 100 attached to rotor 52 ) can each be conceived as portraying part of machinery 50 either of a motor variety or a generator variety or some other variety. In general, known in the art are various types of machinery (including but not limited to motor and generator types) that implement current collection means.
Inventive device 100 represents, in large part, a composite laminate material system characterized by a nonconductive (e.g., elastomeric) exterior layer, viz., elastomeric covering 16 , and an electrically conductive (e.g., metal) interior layer, viz., core 14 . With the exception of electrical contact region 700 (where the elastomeric exterior layer 16 is placed on the inwardly-upwardly facing surface but not the outwardly-downwardly facing surface of each element 12 ), the elastomeric exterior layer 16 is placed on both the inwardly facing surface and the outwardly facing surface of each element 12 . According to some inventive embodiments, each core 14 includes a single sheet 40 , such as shown in FIG. 8 , of electrically conductive material, either a metal or metal alloy, such as consisting of or including copper, or silver, or gold or another electrically conductive metal. Although the present invention does not require that each core 14 itself have a layered construction, in furtherance of the strength and flexibility of the spring component 300 , many inventive embodiments provide for a plural-layered core 14 , each sub-layer of core 14 being constituted by an individual sheet 40 such as shown in FIG. 8 . According to typical inventive practice involving plural-layered cores 14 , the adjacent (abutting) sub-layers (sheets) 40 of a plural-layered core 14 are adhered to each other, surface-to-surface, using a cement or other adhesive material. The electrically conductive compositions of the respective sub-layer sheets 40 can be the same or can differ, depending on the inventive embodiment, the electrically conductive material of each sub-layer sheet 40 being either a metal or metal alloy, such as consisting of or including copper, or silver, or gold or another electrically conductive metal. The sheet sub-layers 40 are not necessarily adhered to each other throughout inventive device 100 , over entire expanses of surface-to-surface contact areas between adjacent sheets 40 of inventive device 100 . The amounts, scopes and locations of adhesive material 29 can differ, depending on the inventive embodiment. Generally speaking, the more adhesive 29 used, the greater the stiffness of inventive device 100 . For instance, adhesive material 29 can be used over all or substantially all of the surface-to-surface contact areas, if greater stiffness in inventive device 100 is desired. Alternatively, adhesive material 29 can be applied selectively in certain strategically located portions of the surface-to-surface contact areas (e.g., including at one or more points along junction 23 in brush component 200 ).
As illustrated in FIG. 1 and FIG. 5 through FIG. 7 , each core 14 has a plural-layered configuration formed, at least, by two rectangular sheets 40 of electrically conductive material (such as copper or another electrically conductive metal). As discussed hereinabove, adhesive 29 is typically applied, to some extent(s), in order to bond adjacent sheets 40 . Therefore, where adhesive material 29 is present, the plural-layered configuration of core 14 is formed by two adjacent sheets 40 and adhesive material 29 situated between the two sheets 40 . Where adhesive material 29 is absent, the plural-layered configuration of core 14 is formed by two adjacent sheets 40 , touching or nearly touching each other, with no adhesive 29 therebetween. Inventive device 100 is readily envisioned in FIG. 1 and FIG. 5 through FIG. 7 to include or exclude adhesive 29 in any arrangement or pattern. Let us assume, for instance, that adhesive 29 is used throughout or substantially throughout inventive device 100 . Core 14 a includes two adjoining electrically conductive sheets 40 a 1 and 40 a 2 and adhesive material 29 a therebetween; core 14 b includes two adjoining electrically conductive sheets 40 b 1 and 40 b 2 and adhesive material 29 b therebetween. Brush component 200 describes a laminar material system of four electrically conductive sheet layers 40 and three adhesive material layers 29 in alternation with each other. The four electrically conductive sheet layers 40 (viz., 40 a 1 , 40 a 2 , 40 b 2 , 40 b 1 ) are separated by the three adhesive layers 29 (viz., 29 a , 29 c , 29 b ). That is, proceeding sequentially downward in FIG. 5 , the adjacent layers of brush component 200 are 40 a 1 , 29 a , 40 a 2 , 29 c , 40 b 2 , 29 b , and 40 b 1 . Layers 40 a 1 , 29 a , and 40 a 2 are sub-layers of electrically conductive core 14 a ; layers 40 b 1 , 29 b , and 40 b 2 are sub-layers of electrically conductive core 14 b.
Regardless of whether cores 14 are layered (i.e., including at least two sheets 40 ) or unlayered (i.e., including one sheet 40 ), according to frequent inventive practice, each sheet 40 is an electrically conductive fabric member such as a “braided” electrically conductive fabric member, wherein the fabric member's “braided” configuration of electrically conductive wires lends desirable material qualities in terms of strength and flexibility for purposes of being made part of an integral current collection device 100 in accordance with the present invention. According to typical inventive practice, the electrically conductive wires are made of at least one electrically conductive metal that is selected from the group of electrically conductive metals including, but not limited to, copper, silver, and gold; alternatively, the electrically conductive wires are made of at least one electrically conductive metal alloy that alloys at least one electrically conductive metal that is selected from the group of electrically conductive metals including, but not limited to, copper, silver, and gold. The term “electrically conductive wire fabric” is broadly used herein to refer to any generally planar electrically conductive structure characterized by interlacing, intertwining, interweaving and/or binding of plural (e.g., multiple) electrical wires. An electrically conductive wire fabric can represent any of diverse combinations (e.g., woven, knitted, braided, meshed, knotted, felted and/or bonded) of electrically conductive wires oriented in two and/or three dimensions. The term “electrically conductive wire” is broadly used herein to refer to any elongate electrically conductive member (e.g., made of electrically conductive metal material). An electrically conductive wire can represent a single electrically conductive strand, fiber or filament, or a combination (e.g., bundled, twisted, braided) of electrically conductive strands, fibers or filaments.
FIG. 8 is diagrammatically representative of an electrically conductive sheet 40 , one or more of which constitutes a core 14 . In accordance with inventive practice, a sheet 40 need not be fabric. For instance, some inventive embodiments provide for a core 14 comprising at least one electrically conductive metal foil sheet 40 . Nevertheless, according to typical inventive embodiments, each sheet 40 is a piece of fabric, which is characterized by interlacing, intertwining, interweaving and/or binding of electrical wires. For instance, a fabric sheet 40 can exhibit a biaxially braided fabric pattern of wires 41 such as shown in FIG. 9 , or a triaxially braided fabric pattern of wires 41 such as shown in FIG. 10 , or a multi-braid pattern of parallelly bonded “braids” 43 . Each braid 43 is a strand, string, cord, etc. that is configured of wires 41 that are braided into such elongate form.
Elongate wire braids 43 such as shown in FIG. 11 , which are akin to the elongate hair braids adopted by some people in their hair style, are commercially available in the form of elongate items known as “solder wicks” (or “desolder wicks”) or “solder braids” (or “desolder braids”). A typical solder wick is manufactured as a metal (e.g., copper) structure coated with a flux such as a rosin material. A fabric sheet 40 can be assembled of individual wire braids 43 from commercial off-the-shelf (COTS) materials. A spindle of (e.g., 0.075 inch) solder wick can be obtained from any of various commercial entities (e.g., Radio Shack™). The solder wick is cut into strips (e.g., 7-inch strips). The solder wick strips are placed in acetone for being cleaned and are then removed from the acetone. The solder wick strips 43 are placed, even, parallel and contiguous, in the slot of a braided fabric fabrication plate (e.g., a 6-inch by 3.5-inch by 0.5-inch thick piece of aluminum having a ¾-inch wide, 1/16-inch deep slot across it for braided fabric assembly), and are secured (e.g., screwed down) at each end of each strip. An adhesive (e.g., Permatex™ automotive gasket cement thinned 50%) is applied to the adjoining solder wicks 43 inside the slot of the braid fabrication plate, and allowed to dry (e.g., about a half hour). The adjoining solder wicks 43 are removed and replaced in an inverted position in the slot of the fabrication plate. The adhesive is again applied to the adjoining solder wicks 43 and allowed to dry in a similar manner, whereupon the completed braided fabric 40 product is removed from the fabrication plate.
In the light of the instant disclosure, various methods and techniques for fabricating an inventive device such as shown in FIG. 1 through FIG. 7 will be appreciated by the ordinarily skilled artisan. The present invention lends itself to economical fabrication using relatively inexpensive commercial off-the-shelf (COTS) materials, as suitable, such as metal fabrics, solder braids, and silicone rubber from automotive gaskets. With reference to FIG. 12 through FIG. 15 , many embodiments for making an inventive device such as inventive device 100 provide initially for the assembly of electrically conductive core 12 material into an electrically conductive core framework 120 that essentially describes the “violin” shape of inventive device 100 . FIG. 12 and FIG. 13 illustrate an inventive methodology that takes a bilateral (with respect to vertical geometric plane v), dichotomized approach to fabrication, according to which each of the elements 12 a and 12 b is separately formed from one or more sheets 40 (including appropriately bent into sinuous shape), and the elements 12 a and 12 b are then joined together to form framework 120 . FIG. 14 and FIG. 15 illustrate an alternative, often preferred, inventive methodology that takes a more entire approach to fabrication, according to which one or more sufficiently long wire fabric sheets 400 are bent into a violin shape so as to extend therearound from upper end 13 a 1 to upper end 13 a 2 , thereby integrally forming framework 120 .
According to an example of a first inventive approach to making an inventive device, the inventive practitioner provides four planar (unbent) rectangular sheets 40 , practically identical, of electrically conductive wire fabric. The four wire fabric sheets 40 are separated into two pairs, each pair corresponding to an element 12 . For instance, as shown in FIG. 1 and FIG. 5 , sheets 40 a 1 and 40 a 2 are paired in element 12 a ; sheets 40 b 1 and 40 b 2 are paired in element 12 b . The two wire fabric sheets 40 in each pair are fixedly adjoined to each other using an adhesive material such as a cement material. According to some inventive embodiments, in addition to or as alternative to adhesive material 29 , cross-stitching is implemented with respect to the two adjoined sheets 40 in each pair in order to strengthen the inventive device and afford it a more stable shape. As depicted in FIG. 12 , each of the two adjoined pairs of wire fabric sheets 40 is bent together into an element 12 shape, characterized in part by linearity and in part by sinuosity, the two adjoined pairs being bent into practically identical partially linear, partially sinuous shapes. An alternative technique, depicted in FIG. 13 , is to bend each sheet 40 into an element 12 shape prior to adjoining two sheets 40 , the pairing being performed so as to nestle one bent sheet 40 inside the other; this technique may pose some degree of practical difficulty, however, as it would generally necessitate that the interior bent sheet 40 describe a slightly or moderately smaller element 12 shape than is described by the exterior bent sheet 40 . The two bent, adjoined pairs of wire fabric sheets 40 , each pair representing an element 12 , are coupled in opposition to each other, with the corresponding linear sections 20 a and 20 b of the two pairs being fixedly adjoined to each other using an adhesive material such as a cement material, and with the two lower element ends 13 a 2 and 13 b 2 adjoining each other (e.g., touching or nearly touching) end-to-end, thereby forming the violin-shaped electroconductive framework 120 . A lower portion 701 of device 100 (wherein portion 701 encompasses the junction between ends 13 a 2 and 13 b 2 ) is impregnated with the liquid solder material, which solidifies. The solder-infused portion 701 is then heated to re-melt the solder material (which is then allowed to re-solidify), thereby facilitating bonding between wire fabric sheets 40 and between ends 13 a 2 and 13 b 2 . Finally, the re-solidified solder-infused portion 701 is pressed to form a flat contact for attachment to the machinery.
According to an example of a second inventive approach to making an inventive device, the inventive practitioner provides two planar (unbent) rectangular sheets 400 , practically identical, of electrically conductive wire fabric. Each sheet 400 is present, in approximately fifty—fifty proportions, in both elements 12 a and 12 b . For instance, as shown in FIG. 1 and FIG. 5 , half of sheet 400 ′ is on the outwardly facing side of element 12 a , and half of sheet 400 ′ is on the outwardly facing side of element 12 b ; half of sheet 400 ″ is on the inwardly facing side of element 12 a , and half of sheet 400 ″ is on the inwardly facing side of element 12 b . The two wire fabric sheets 400 are fixedly adjoined to each other using an adhesive material such as a cement material. According to some inventive embodiments, in addition to or as alternative to adhesive material 29 , cross-stitching is implemented with respect to the two adjoined sheets 400 in order to strengthen the inventive device and afford it a more stable shape. As depicted in FIG. 14 , the two adjoined wire fabric sheets 400 are bent together into the electrically conductive violin-shaped framework 120 , with the corresponding linear sections 20 a and 20 b of the two elements 12 a and 12 b being fixedly adjoined to each other using an adhesive material such as a cement material. An alternative technique, depicted in FIG. 15 , is to bend each sheet 400 into framework 120 violin shape prior to adjoining the two sheets 400 , one bent sheet 400 being nestled inside the other; again, this technique may pose some degree of practical difficulty, as it would generally necessitate that the interior bent sheet 400 describe a slightly or moderately smaller framework 120 shape than is described by the exterior bent sheet 400 .
Once the violin-shaped electroconductive framework 120 is provided, the following steps are performed, in no particular order, at suitable locations and to suitable degrees: Inside and outside surfaces of framework 120 are covered with elastomeric material 16 ; two discrete portions of framework 120 are infused with cement material 81 (which is absorbed into the wire fabric 40 or 400 material), thereby forming two discrete cement-infused portions 80 ; an at least substantially continuous portion (extending between the two cement-infused portions 80 and encompassing the adjoining ends of elements 12 ) of framework 120 is infused with solder material 71 (which is absorbed into the wire fabric 40 or 400 material), thereby forming the overall solder-infused portion 701 of the inventive device; the solder-infused portion 701 is heated to re-melt the solder material 71 , which then re-soldifies, such re-melting and re-solidifying of solder material 71 serving to enhance bonding between wire fabric sheets 400 (or between wire fabric sheets 40 as well as between ends 13 a 2 and 13 b 2 ); the re-solidified solder-infused portion 701 is pressed; and, an electrically conductive plating 90 is attached, typically by electroplating, at the underside of the overall solder-infused portion 701 of the inventive device, thereby forming the overall electrical contact area 700 of the inventive device.
As described herein in preceding paragraphs with reference to FIG. 12 through FIG. 15 , some inventive techniques for making an inventive device 100 involve the assembly of a framework 120 prior to coating with elastomeric material 16 , infiltration with cement material 81 , and infiltration with solder material 71 . However, a variety of these and other inventive fabrication techniques can be practiced. Depending on the method for making an inventive device 100 , each of elastomeric material 16 , cement material 81 and solder material 71 can be applied at practically any stage in the fabrication process. For instance, inside and outside surfaces of individual or adjoined sheets 40 or 400 can be covered with elastomeric material 16 , prior to folding of individual or adjoined sheets 40 or 400 . Similarly, prior to folding of individual or adjoined sheets 40 or 400 , individual or adjoined sheets 40 or 400 can be infused with cement material 81 (which is absorbed into the wire fabric 40 or 400 material) and/or with solder material 71 . Some or all of the elastomeric material 16 , cement material 81 and/or solder material 71 can be applied to each sheet 40 or 400 prior to association with any other sheet 40 or 400 . According to some inventive approaches, elastomer 16 is administered prior to the folding of sheets 40 or 400 ; then, additional elastomer 16 is administered at strategic locations (e.g., at individual bend locations 17 and at joint bend location 19 ) subsequent to the folding of sheets 40 or 400 , or subsequent to the assembly of framework 120 , in order to enhance the “springiness” of the spring component 300 of inventive device 100 . If any elastomer 16 , cement 81 and/or solder 71 is applied prior to folding sheets 40 or 400 , it is important that the inventive practitioner correctly anticipate the locations of such material(s) upon assembly of device 100 .
Now referring to FIG. 16 , inventive braid brush 3000 represents a brush-inclusive, holder-exclusive embodiment of the present invention. Inventive braid brush 3000 corresponds to the brush component 200 of inventive embodiments such as described hereinabove with reference to FIG. 1 through FIG. 15 . The inventive prototype of braid brush 3000 pictured in FIG. 16 was made using COTS solder wicks and automotive gasket silicone rubber. The portrayed brush 3000 includes eight rows of individual solder wick braids 43 , an adhesive solder barrier, and a solder coating on its base. Each row of solder wicks 43 has about nine solder wicks 43 that are discretely arrayed, adjacent and edgewise. The numbers of “rows” and “columms” of solder wicks 43 can be varied in inventive practice in accordance with the desired aspect ratio.
Braid brush 3000 can be attached to a holder (e.g., the brush holder disclosed by Lynch et al. at the aforementioned U.S. Pat. No. 6,628,036 B1 issued 30 Sep. 2003, entitled “Electrical Current Transferring and Brush Pressure Exerting Spring Device”) using known soldering techniques for attaching fiber brushes to holders. The combination of a braid brush 3000 with the brush holder of Lynch et al. U.S. Pat. No. 6,628,036 B1 may afford a kind of synergy associated with the commonality of a braid-based construction. Braid brush 3000 may be suitable for any application for which a conventional fiber brush may be suitable, such as involving motors (e.g., homopolar motors), generators (e.g., homopolar generators), commutators, etc.
The present invention, which is disclosed herein, is not to be limited by the embodiments described or illustrated herein, which are given by way of example and not of limitation. Other embodiments of the present invention will be apparent to those skilled in the art from a consideration of the instant disclosure or from practice of the present invention. Various omissions, modifications and changes to the principles disclosed herein may be made by one skilled in the art without departing from the true scope and spirit of the present invention, which is indicated by the following claims. | A dual-nature, uni-constructed device, suitable for conducting electricity between two objects in relative motion, comprises two compatible elements each having a straight section and a sinuous section. The two elements are combined to form a unified whole whereby the two straight sections are mutually servable as a brush component and the two sinuous sections are mutually servable as a spring component. The inventive device is associable with an electrical or electromechanical machine so that, during machine operation, the brush component slidingly contacts a first machine part, the spring component is affixed to a second machine part and exerts a bias against the brush component, and the inventive device conducts electrical current from one machine part to the other machine part. Each element includes an electrically conductive main layer (including one or more wire fabric sheets) and two elastomeric outside layers (on opposite sides of the sinuous section). | 60,891 |
RELATED CASES
[0001] This is a continuation-in-part of co-pending Ser. No. 08/024,050, entitled “Collapsible Shade Structure”, filed Mar. 1, 1993, which is in turn a continuation-in-part of Ser. No. 07/764,784, entitled “Collapsible Shade Structure”, filed Sep. 24, 1991, now U.S. Pat. No. 5,301,705, the entire disclosures of which are incorporated by this reference as though set forth fully herein.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates to collapsible structures, and in particular, to collapsible play structures which may be provided in a variety of shapes and sizes. The collapsible play structures may be twisted and folded to reduce the overall size of the play structures to facilitate convenient storage and use.
[0004] 2. Description of the Prior Art
[0005] Two important considerations for all toys or play things targeted for children are convenience and variety. Relating to convenience, a toy must be easily transportable so that the child can move it around the home, or even to other places outside of the home. A toy must also be easily stored since a child is likely to have many other toys that compete for precious storage space in the home. As for variety, a toy must offer enough variety in play so that the child will be able to enjoy it for a long period of time without getting bored.
[0006] Larger toys often pose a greater problem with regards to convenience. The larger toys tend to be bulky, which makes it difficult to move them around the home, and sometimes makes it prohibitive to move them outside the house to other locations. Bulky toys also take up much storage space.
[0007] In the past, attempts have been made to provide play structures for the entertainment of children. Such play structures have been provided in many different shapes and sizes. For example, some have been shaped as playhouses to allow children to climb into and out of the structure. However, in order to provide a structure that can temporarily house a child, such a structure must be quite large and would be difficult to transport and store.
[0008] In response to this problem, attempts have been made to provide play structures that are assembled from generic rigid panels that may be disassembled after use. The generic panels are easily stored into a small container, which makes it convenient to transport and to store. These panels may also be assembled into structures having different shapes and sizes, thereby offering the child with variety. For example, U.S. Pat. No. 4,073,105 to Daugherty provides a fabrication device comprised of differently-shaped rigid panels 10 connected by superimposing the curled locking means 16 of adjacent panels 10 . Similarly, U.S. Pat. No. 3,987,580 to Ausnit provides a connective toy comprised of rigid bodies connected by interlocking ribs and grooves. Unfortunately, these play structures suffer from the drawback that it is very time-consuming to disassemble the structure after use for storage, and to re-assemble the structure before use. Since children tend to lack patience, such play structures will normally remain in their assembled state most of the time, which still results in the same problems discussed above.
[0009] Thus, there remains a need for a play structure which is convenient to use, to transport, and to store, and which offers play variety to the child.
SUMMARY OF THE DISCLOSURE
[0010] In order to accomplish the objects of the present invention, the collapsible play structure according to the present invention comprises a play module comprising at least three foldable frame members, each having a folded and an unfolded orientation. A fabric material substantially covers each frame member to form a side panel for each frame member when the frame member is in the unfolded orientation, with the fabric assuming the unfolded orientation of its associated frame member. Each side panel further comprises at least a left side, a bottom side and a right side. The left side of each side panel is connected and hinged to the right side of an adjacent side panel, and the right side of each side panel is connected and hinged to the left side of another adjacent side panel. The bottom side of each side panel is adapted to rest on a supporting surface to support the play module.
[0011] In one embodiment of the present invention, the play module comprises four side panels and four corresponding frame members, each having four sides, including a top side. A fabric is connected to the top sides of the four side panels and extends therebetween, and an opening may be provided in this fabric. Openings may also be provided in one or more of the side panels to allow a child to crawl therethrough.
[0012] Each side panel comprises a frame retaining sleeve for retaining one of the frame members. The frame retaining sleeves of adjacent side panels are stitched together to form a hinged connection. Alternatively, the frame retaining sleeves of adjacent side panels may converge to form a singular retaining sleeve which retains the adjacent sides of the adjacent frame members of the corresponding adjacent side panels. The stitchings which connect the frame retaining sleeves act as hinges for the corresponding side panels.
[0013] When the play module is to be folded and stored, the side panels and their corresponding frame members may be folded on top of each other about the hinges to have the side panels and frame members overlaying each other. The overlying side panels and frame members are then collapsed by twisting and folding to form a plurality of concentric frame members and side panels to substantially reduce the size of the play module in the folded orientation.
[0014] A plurality of the play modules may be connected to create play structures of different shapes and sizes. The play modules may be provided as separate play modules and connected by velcro, hooks, fasteners, or other attachment mechanisms which allow for convenient attachment and detachment. These separate play structures may be provided in identical or different shapes and sizes. Alternatively, a play structure may be provided that has a plurality of play modules integrally connected to form one unitary play structure which may be folded and collapsed according to the same principles as the separate play modules.
[0015] The collapsible play structures according to the present invention are convenient for use since they are easily and quickly folded and collapsed into a smaller size for transportation and storage. A plurality of these play modules may be easily transported and stored, and provide a child with much play variety since a large number of play structures having different shapes and sizes can be created therefrom.
BRIEF DESCRIPTION OF THE DRAWINGS
[0016] [0016]FIG. 1 is a perspective view of a collapsible play structure according to a first preferred embodiment of the present invention having one module;
[0017] [0017]FIG. 1A is a partial cut-away view of the section A of the play structure of FIG. 1 illustrating a frame member retained within a sleeve;
[0018] [0018]FIG. 2A is a cross-sectional view of a first preferred connection between two adjacent panels of the module of FIG. 1 taken along line 2 -- 2 thereof;
[0019] [0019]FIG. 2B is a cross-sectional view of a second preferred connection between two adjacent panels of the module of FIG. 1 taken along line 2 -- 2 thereof;
[0020] [0020]FIG. 3 is a perspective view of a collapsible play structure according to a second preferred embodiment of the present invention comprising three modules;
[0021] [0021]FIG. 4A is a cross-sectional view of a first preferred connection between the four adjacent panels of the modules of FIG. 3 taken along line 4 -- 4 thereof;
[0022] [0022]FIG. 4B is a cross-sectional view of a second preferred connection between the four adjacent panels of the modules of FIG. 3 taken along line 4 -- 4 thereof;
[0023] [0023]FIG. 4C is a cross-sectional view of a third preferred connection between the four adjacent panels of the modules of FIG. 3 taken along line 4 -- 4 thereof;
[0024] [0024]FIG. 4D is a cross-sectional view of a fourth preferred connection between the four adjacent panels of the modules of FIG. 3 taken along line 4 -- 4 thereof;
[0025] [0025]FIG. 5A is a cross-sectional view of a first preferred connection between the three adjacent panels of the modules of FIG. 3 taken along line 5 -- 5 thereof;
[0026] [0026]FIG. 5B is a cross-sectional view of a second preferred connection between the three adjacent panels of the modules of FIG. 3 taken along line 5 -- 5 thereof;
[0027] [0027]FIG. 6 is a perspective view of a collapsible play structure according to a third preferred embodiment of the present invention comprising four modules connected to the different side panels of one large module;
[0028] [0028]FIG. 7 is a perspective view of the collapsible play structure of FIG. 1 which may be sized to allow a child to wear the structure as part of a costume; and
[0029] FIGS. 8 (A) through 8 (E) illustrate how the collapsible play structure of FIG. 1 may be twisted and folded for compact storage.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0030] The following detailed description is of the best presently contemplated modes of carrying out the invention. This description is not to be taken in a limiting sense, but is made merely for the purpose of illustrating general principles of embodiments of the invention. The scope of the invention is best defined by the appended claims.
[0031] As shown in FIGS. 1 and 1A, the basic component for a collapsible play structure according to the present invention comprises a module 20 . As explained in greater detail hereinbelow, the collapsible play structures according to the present invention are each comprised of one or more of these modules 20 assembled to create a resulting play structure having the desired shape and size.
[0032] Referring to FIG. 1, according to a first preferred embodiment of the present invention, each module 20 comprises four side panels 22 a, 22 b, 22 c and 22 d connected to each other to encircle an enclosed space. Each side panel 22 a, 22 b, 22 c and 22 d has four sides, a left side 26 a, a bottom side 26 b, a right side 26 c and a top side 26 d. Each side panel 22 a, 22 b, 22 c and 22 d has a continuous frame retaining sleeve 24 a, 24 b, 24 c or 24 d provided along and traversing the four edges of its four sides 26 a, 26 b, 26 c and 26 d. A continuous frame member 28 a, 28 b, 28 c or 28 d is retained or held within each frame retaining sleeve 24 a, 24 b, 24 c or 24 d, respectively, to support each side panel 22 a, 22 b, 22 c and 22 d. Only the frame member 28 c is shown in FIG. 1A; the other frame members 28 a, 28 b and 28 d are not shown but are the same as frame member 28 c.
[0033] The continuous frame members 28 a, 28 b, 28 c and 28 d may be provided as one continuous loop, or may comprise a strip of material connected at both ends to form a continuous loop. The continuous frame members 28 a, 28 b, 28 c and 28 d are preferably formed of flexible coilable steel, although other materials such as plastics may also be used. The frame members should be made of a material which is relatively strong and yet is flexible to a sufficient degree to allow it to be coiled. Thus, each frame member 28 a, 28 b, 28 c and 28 d is capable of assuming two positions or orientations, an open or expanded position such as shown in FIG. 1, or a folded position in which the frame member is collapsed into a size which is much smaller than its open position (see FIG. 8(E)).
[0034] Fabric or sheet material 30 a, 30 b, 30 c and 30 d extends across each side panel 22 a, 22 b, 22 c and 22 d, respectively, and is held taut by the respective frame members 28 a, 28 b, 28 c and 28 d when in its open position. The term fabric is to be given its broadest meaning and should be made from strong, lightweight materials and may include woven fabrics, sheet fabrics or even films. The fabric should be water-resistant and durable to withstand the wear and tear associated with rough treatment by children. The frame members 28 a, 28 b, 28 c and 28 d may be merely retained within the respective frame retaining sleeves 24 a, 24 b, 24 c and 24 c without being connected thereto. Alternatively, the frame retaining sleeves 24 a, 24 b, 24 c and 24 d may be mechanically fastened, stitched, fused, or glued to the frame members 28 a, 28 b, 28 c and 28 d, respectively, to retain them in position.
[0035] [0035]FIG. 2A illustrates one preferred connection for connecting adjacent edges of two side panels 22 a and 22 d. The fabric pieces 30 a and 30 d are stitched at their edges by a stitching 34 to the respective sleeves 24 a and 24 d. Each sleeve 24 a and 24 d may be formed by folding a piece of fabric. The stitching 34 also acts as a hinge for the side panels 22 a and 22 d to be folded upon each other, as explained below. The connections for the three other pairs of adjacent edges may be identical. Thus, the connections on the left side 26 a and the right side 26 c of each side panel 22 a, 22 b, 22 c and 22 d act as hinge connections for connecting an adjacent side panel.
[0036] At the top side 26 d and the bottom side 26 b of each side panel 22 a, 22 b, 22 c and 22 d, where there is no hinge connection to an adjacent side panel, the frame retaining sleeve 24 a, 24 b, 24 c or 24 b may be formed by merely folding over the corresponding fabric piece and applying a stitching 35 (see FIG. 1A). The fabric piece for the corresponding side panel may then be stitched to the sleeve.
[0037] [0037]FIG. 2B illustrates a second preferred connection for connecting adjacent edges of two side panels 22 a and 22 d. As in the connection of FIG. 2A, the fabric pieces 30 a and 30 d are folded over at their edges at bottom side 26 b and top side 26 d to define the respective sleeves 24 a and 24 d. However, the frame retaining sleeves 24 a and 24 d converge at, or are connected to, one sleeve portion which interconnects side panels 22 a and 22 d to form a singular frame retaining sleeve 40 which retains the frame members 28 a and 28 d. Sleeve 40 may be formed by providing a tubular fabric, or by folding a piece of fabric, and applying a stitching 42 to its edges to connect the sleeve 40 to the fabric pieces 30 a and 30 d. Stitching 42 acts as a hinge for the side panels 22 a and 22 d. The connections for the three other pairs of adjacent edges may be identical.
[0038] An upper panel 32 comprised of fabric 30 e may also be connected to the upper edge 26 d of each side panel 22 a, 22 b, 22 c and 22 d. Likewise, a lower panel 36 comprised of fabric 30 f may also be connected to the bottom edge 26 b of each side panel 22 a, 22 b, 22 c and 22 d. The upper panel 32 and the lower panel 36 are preferably made of the same type of fabric as the side panels 22 a, 22 b, 22 c and 22 d. Each module 20 preferably comprises at least the four side panels 22 a, 22 b, 22 c and 22 d, with the upper and lower panels 32 and 36 being optional.
[0039] Openings 38 may be provided in some or all of the panels 22 a, 22 b, 22 c, 22 d, 32 and 36 . These openings 38 may be of any shape (e.g., triangular, circular, rectangular, square, diamond, etc.) and size and are designed to allow children to crawl through them to enter or to exit the module 20 .
[0040] While the module 20 of FIG. 1 is shown and described as having four side panels, each having four sides, it will be appreciated that a module may be made of any number of side panels, each having any number of sides, without departing from the spirit and scope of the present invention. For example, each module may have three or more side panels, and each side panel may have three or more sides. Thus, the module of the present invention may take a variety of external shapes. However, each side panel of the module, regardless of its shape, is supported by at least one continuous frame member.
[0041] FIGS. 8 (A) through 8 (E) describe the various steps for folding and collapsing the module 20 of FIG. 1 for storage. In FIG. 8(A), the first step consists of pushing in side panels 22 a and 22 d such that side panel 22 d collapses upon side panel 22 c and side panel 22 a collapses upon side panel 22 b. Then, in the second step shown in FIG. 8(B), the two side panels 22 a and 22 b are folded so as to be collapsed upon the two side panels 22 c and 22 d. The structure is then twisted and folded to collapse the frame members and side panels into a smaller shape. In the third step shown in FIG. 8(C), the opposite border 44 of the structure is folded in upon the previous fold to further collapse the frame members with the side panels. As shown in FIG. 8(D), the fourth step is to continue the collapsing so that the initial size of the structure is reduced. FIG. 8(E) shows the fifth step with the frame members and side panels collapsed on each other to provide for a small essentially compact configuration having a plurality of concentric frame members and layers of the side panels so that the collapsed structure has a size which is a fraction of the size of the initial structure.
[0042] A second preferred embodiment of the present invention is shown in FIG. 3. A play structure 50 comprises three modules 52 , 54 and 56 provided in an attached manner. Each module 52 , 54 and 56 is essentially of the same construction as module 20 , except that modules 52 and 56 share a common side panel 58 , and modules 54 and 56 share a common side panel 60 . The connections between adjacent side panels (i.e., the two side panel connections) may be the same as any of those illustrated in FIGS. 2A and 2B above.
[0043] [0043]FIG. 4A illustrates a preferred four side panel connection along line 4 -- 4 of FIG. 3, in which the four frame retaining sleeves 68 a, 68 b, 70 a and 70 b each retain a frame member 72 a, 72 b, 74 a and 74 b, respectively. Sleeves 68 a and 70 a, and side panels 62 a and 64 a, are connected by a stitching 75 and sleeves 68 b and 70 b, and side panels 58 and 60 , are connected by a stitching 76 . Each of the stitchings 75 and 76 also connect an interconnecting hinge fabric 77 which holds the two pairs of sleeves 68 a, 70 a and 68 b, 70 b together, and acts to hinge these two pairs of sleeves.
[0044] Alternatively, FIG. 4B illustrates a second preferred connection in which the four frame retaining sleeves 68 a, 68 b, 70 a and 70 b, each formed by a separate stitching, converge to form, or are connected to, one singular frame retaining sleeve 88 which retains the frame members 72 a, 72 b, 74 a and 74 b. The singular frame retaining sleeve 88 is created by folding a fabric material, or providing a tubular fabric, and applying a stitching 86 to connect the sleeve 88 to the side panels 58 , 60 , 62 a and 64 a. Stitching 86 acts as a hinge for the side panels 58 , 60 , 62 a and 64 a.
[0045] [0045]FIGS. 4C and 4D illustrate third and fourth preferred connections in which the four frame retaining sleeves 68 a, 68 b, 70 a and 70 b each retain a frame member 72 a, 72 b, 74 a and 74 b, respectively, and are stitched together with the fabric pieces of the side panels 62 a, 64 a, 58 and 60 by stitching 87 (FIG. 4C) and stitching 89 (FIG. 4D). The stitchings 87 and 89 also act to hinge the side panels 58 , 60 , 62 a and 64 a.
[0046] [0046]FIG. 5A illustrates a preferred connection for the three side panel connection 80 along line 5 -- 5 of FIG. 3, in which the three frame retaining sleeves 70 b, 70 c and 78 a each retain a frame member 74 b, 74 c and 84 a, respectively, and are held together by stitching 90 . The fabric pieces of side panels 60 , 64 c and 66 b are also stitched to the sleeves 70 b, 70 c and 78 a by the stitching 90 . Alternatively, FIG. 5B illustrates a second preferred connection in which the three frame retaining sleeves 70 b, 70 c and 78 a, each formed by a separate stitching, converge to form, or are connected to, one singular frame retaining sleeve 94 which retains the frame members 74 b, 74 c and 84 a. The singular frame retaining sleeve 94 is created by folding a fabric material and applying a stitching 92 to hold the sleeve 94 together with the side panels 60 , 64 c and 66 b. The stitchings 90 and 92 act as hinges for the side panels 60 , 64 c and 66 b. The three side panel connection 82 is identical to the three side panel connection 80 and is not further discussed herein.
[0047] To fold and collapse the play structure 50 , the side panels 62 a and 62 b of module 52 are pushed onto side panels 58 and 62 c, respectively, the side panels 64 a and 64 b of module 54 are pushed onto side panels 60 and 64 c, respectively, and the side panels 66 a and 66 b of module 56 are pushed onto side panels 58 and 60 , respectively. Thereafter, combined side panels 62 b and 62 c are folded over to be collapsed upon the combined side panels 62 a and 58 , and combined side panels 64 b and 64 c are folded over to be collapsed upon the combined side panels 64 a and 60 . The combined side panels 66 b, 60 , 64 a, 64 b and 64 c are then folded over and collapsed upon the combined side panels 66 a, 58 , 62 a, 62 b and 62 c, thereby creating a stack of ten side panels. The combined stack of ten side panels may then be twisted and folded in the manner described above in connection with FIGS. 8 (C)- 8 (E).
[0048] Alternatively, the three modules 52 , 54 and 56 of play structure 50 may be provided as three separate modules, each having four side panels. Each such module could be identical to module 20 of FIG. 1. The three separate modules may be connected by conventional attachment methods such as velcro, hooks, loops, fasteners or others, to create the play structure 50 , or another structure with a different shape. For example, a child may choose to create a play structure having three linear modules 52 , 54 and 56 . The attachment method allows for convenient attachment and detachment. Each module may be folded and collapsed in the manner described in FIGS. 8 (A)- 8 (E) for convenient storage.
[0049] Regardless of whether the modules 52 , 54 and 56 are provided separately or as an attached structure, the entire play structure 50 may be conveniently folded and collapsed, thereby making it convenient to move around the home, and requiring little storage space. If the modules 52 , 54 and 56 are provided separately, the child further derives an additional variety of play since he or she can create play structures of different shapes. Additionally, the child may derive amusement by attempting to align the openings 90 and 92 in the interfacing side panels so that he or she can crawl from one module into another.
[0050] Although the play structure 50 is shown as having three modules 52 , 54 and 56 , each being of the same size and shape, it will be appreciated that the present invention encompasses within its scope play structures having any number of modules, each having any number of different sizes and shapes and being made from side panels having any number of different sizes and shapes.
[0051] An example is illustrated in the third preferred embodiment of FIG. 6. The play structure 100 comprises a large module 102 , and four identical but smaller modules 104 , 106 , 108 and 110 , each connected to one of the four side panels of the large module 102 by a conventional attachment method, for example, velcro 112 . A mesh 114 may be provided to cover an opening in the large module 102 . The openings in the modules 102 , 104 , 106 , 108 and 110 may be provided in varying shapes and sizes. Although the play structure 100 is shown as having four identical modules 104 , 106 , 108 and 110 , these four modules may be provided in different shapes and sizes.
[0052] The separate modules according to the present invention may be provided or purchased on an individual basis, in different shapes and sizes, so that a child may be able to create a play structure of a desired shape and size. Alternatively, a specific number of differently shaped and sized modules may be packaged and sold together. In either case, the child will have the opportunity to create an endless variety of play structures at his or her disposal, thereby enhancing the amusement value of the modules, and stimulating creativity in the child by challenging the child to create as many different play structures as possible.
[0053] [0053]FIG. 7 illustrates an additional application for the module 20 . The module 20 may be sized such that it may be fitted around the body of a child, to act as part of a costume. The module 20 may then be able to support other bulky costumes, and would be especially useful for occasions such as halloween. For example, the child's head and arms could extend through opening 120 in the upper panel 32 and his legs could extend through an opening (not shown) in the lower panel 36 . Alternatively, the module 20 could be sized small enough so that the child's arms could extend through the openings 122 and 124 in the side panels 22 a and 22 c, respectively. Further, the lower panel 36 could be omitted if desired.
[0054] While the description above refers to particular embodiments of the present invention, it will be understood that many modifications may be made without departing from the spirit thereof. The accompanying claims are intended to cover such modifications as would fall within the true scope and spirit of the present invention. | A collapsible play structure comprises one or more play modules connected together, each play module comprising at least three foldable frame members, each having a folded and an unfolded orientation. A fabric material substantially covers each frame member to form a side panel for each frame member when the frame member is in the unfolded orientation. Each side panel further comprises at least three sides. The left side of each side panel is connected and hinged to the right side of an adjacent side panel, and the right side of each side panel is connected and hinged to the left side of another adjacent side panel. The bottom side of each side panel is adapted to rest on a supporting surface to support the play module. | 27,685 |
CROSS REFERENCE TO OTHER APPLICATIONS
This application is a continuation-in-part of patent application Ser. No. 210,197, filed on Nov. 26, 1980 and entitled "Control System for Sewing Machine", now pending, which is a continuation-in-part of patent application Ser. No. 168,525, filed July 4, 1980 and entitled "Control System For Sewing Machine", now U.S. Pat. No. 4,359,953.
TECHNICAL FIELD
The present invention relates generally to a control system to adapt a sewing machine for semi-automatic operation. More particularly, this invention is directed to an adaptive sewing machine control system incorporating a microprocessor controller in combination with a stitch counter, an edge sensor and stitch length control apparatus to achieve more precise seam lengths and end points.
BACKGROUND ART
In the sewn goods industry, where various sections of material are sewn together to fabricate products, reasonably precise seam lengths and/or end points are often necessary for proper appearance and function of the finished products. For example, the top stitch seam of a shirt collar must closely follow the contour of the collar and terminate at a precise point which matches with the opposite collar. In the construction of shoes, accurate seam lengths must be maintained when sewing together the vamps and quarter pieces to achieve strength as well as pleasing appearance. Seams with imprecise lengths and/or end points can result in unacceptable products or rejects, thus causing waste and further expense.
Achieving consistently accurate seam lengths and/or end points at high rates or production, however, has been a long standing problem in the industry. Sewing machines traditionally have been controlled by human operators. Rapid coordination of the operator's eyes, hands and feet is necessary to control a high speed industrial sewing machine. Considerable practice, skill and concentration are required to sew the same type of seam with consistent accuracy time and time again.
Since such sewing operations tend to be repetitive and, therefore, lend themselves to automation, systems have been developed heretofore for automatically controlling sewing machines. U.S. Pat. Nos. 4,108,090; 4,104,976; 4,100,865 and 4,092,937, assigned to the Singer Company, are representative of such devices. Each of these patents discloses a programmable sewing machine with three operational modes: manual, auto and learning. Control parameters are programmed into the system as the operator manually performs the initial sewing procedure for subsequent control of the sewing machine in the auto mode.
While these programmable sewing machines have several advantages over manually controlled machines, they are not without their disadvantages. The prior systems rely upon overall stitch counting to determine seam lengths and/or end points, variations in which can be caused by several factors. First, cloth or fabric is a relatively elastic material which can be stretched or contracted by the operator during the sewing procedure, thereby causing changes in average stitch lengths which can accumulate into a significant deviation over the length of a seam. Second, slippage can occur as the material is advanced between the presser foot and feed dog of the sewing machine, thereby causing further deviations in the length of the seam. Also, such slippage can vary in accordance with the speed of the sewing machine. Third, any deviations between the paths of the desired seams versus the paths of the seams as programmed can also contribute to inaccurate seam lengths. Variations in seam lengths become greatest with long seams and elastic material.
Thus, although the programmable sewing machines of the prior art offer higher speeds of operation, they have not been completely satisfactory in those applications where precise seam lengths and end points are required.
Another approach to the problem of stopping a sewing machine precisely and consistently at a given point was generally proposed in an article entitled "Fluidics for the Apparel Industry", Journal of the Apparel Research Foundation, Vol. 3, 1969. This article suggested that a sensor might be mounted in the presser foot of the sewing machine for sensing the edge of the material in order to initiate countdown of a preset number of stitches for stopping the machine at the desired point. This proposal, however, does not take into account the fact that edge conditions are dependent upon the seam and type of workpiece. No single preset number of stitches works well with pieces of different shapes or similar pieces of different sizes. As far as Applicants are aware, this proposal never has been embodied in a programmable sewing system.
U.S. patent application Ser. No. 168,525, filed July 14, 1980 and entitled "Control System for Sewing Machine" and Ser. No. 210,197, filed Nov. 26, 1980, and entitled "Control System for Sewing Machine", both assigned to assigner, disclose apparatus for improving the accuracy of seam lengths. However, even with the improved apparatus disclosed in these applications, the accuracy of the stitch length or seam end point is approximately ±1/2 stitch length. For many garments, this accuracy is not satisfactory and may result in unacceptable visual defects, as for example, shirt collars which have uneven seam end points.
A need therefore has arisen for an improved adaptive sewing machine control system utilizing a combination of stitch counting, edge detection techniques and stitch length control to obtain more accurate seam lengths and/or end points.
SUMMARY OF INVENTION
The present invention comprises a sewing machine control system which substantially improves the seam length accuracy to ±1/4 stitch length or better.
In accordance with the invention, there is provided a system including a microprocessor controller which can be programmed with a taught a sequence of sewing operations by the operator in one mode, while sewing the initial piece, for automatically controlling the machine during subsequent sewing of similar pieces of the same or different sizes in another mode. The semi-automatic system herein does not rely upon either pure stitch counting or material edge detection alone, but rather utilizes a combination of these techniques together with other features to achieve more accurate seam length and end point control. The present system further includes apparatus for varying the length of the last stitch sewn in order to improve the seam end point accuracy.
More specifically, this invention comprises a microprocessor-based control system for an industrial sewing machine. The system has manual, teach and auto modes of operation. In the preferred embodiment, one or more sensors are mounted in front of the presser foot for monitoring edge conditions of the material at the end of each seam. In the teach mode, operating parameters are programmed into the controller by the operator while manually sewing the first piece. For each seam, the number of stitches x sewn at the time of the last status change in the sensors, the sensor pattern after x stitches had been sewn, and the total number of stitches y sewn in the seam are recorded along with sewing machine and auxiliary control inputs. In the auto mode, the number of stitches sewn in each seam is monitored as the count passes a window set up around x until the characteristic sensor pattern including edge detection is seen, at which time y-x additional stitches are sewn to complete the seam. The amount of stitch completion at the time of detection of the material edge in monitored, and the reverse mechanism of the sewing machine is actuated in order to control the length of the last seam stitch to the desired length.
BRIEF DESCRIPTION OF DRAWINGS
A more complete understanding of the invention can be had by reference to the following Detailed Description taken in conjunction with the accompanying Drawing, wherein:
FIG. 1 is a perspective view of a programmable sewing system incorporating the invention;
FIG. 2 is a front view illustrating placement of the edge sensor relative to the sewing needle;
FIG. 3 is a sectional view taken along lines 3--3 of FIG. 2 in the direction of the arrows;
FIG. 4 is an end view of the sewing system illustrating the automatic control apparatus of the sewing machine reverse mechanism;
FIG. 5 is a graph illustrating the degrees of rotation of a sewing machine motor plotted against the length of a resulting stitch;
FIG. 6a illustrating the prior art sewing of a seam wherein the end of the last stitch ends exactly at the desired offset from the edge of the material;
FIG. 6b illustrates a graphical representation of the prior art sewing of a seam wherein the end of the last stitch passes the desired offset from the material edge by one-half stitch length;
FIG. 6c is a graphical illustration of the prior art sewing of the seam wherein the end of the last stitch terminates approximately one-half stitch length from the desired offset from the material edge;
FIG. 7a is a graphical illustration illustrating the sewing of a seam in accordance with the present invention in which the end of the last stitch terminates approximately one-fourth stitch length past the desired offset from the material edge;
FIG. 7b is a graphical illustration of the present invention wherein the end of a last stitch terminates approximately one-fourth stitch away from the desired offset from the material edge; and
FIG. 8 is a flow chart illustrating the operation of the present invention to provide plus and minus one-fourth stitch accuracy.
DETAILED DESCRIPTION
Referring now to the Drawings, wherein like reference numerals designate like or corresponding parts throughout the views, FIG. 1 illustrates a semi-automatic sewing system 10 incorporating the invention. System 10 is a microprocessor-based system adapted to extend the capabilities of a sewing machine by enabling the operator to perform sewing procedures on a manual or semi-automatic basis, as will be more fully explained hereinafter.
System 10 includes a conventional sewing machine 12 mounted on a work stand 14 consisting of a table top 16 supported by four legs 18. Sewing machine 12, which is of conventional construction, includes a spool 20 containing a supply of thread for stitching by a reciprocable needle 22 to form a seam in one or more pieces of material. Surrounding needle 22 is a vertically movable presser foot 24 for cooperation with movable feed dogs (not shown) positioned within table top 16 for feeding material past the needle.
A number of standard controls are associated with sewing machine 12 for use by the operator in controlling its functions. A handwheel 26 is attached to the drive shaft (not shown) of machine 12 for manually positioning needle 22 in the desired vertical position. Sewing speed is controlled by a speed sensor 15 which is actuated by a foot treadle 28, which functions like an accelerator. Vertical positioning of presser foot 24 can be controlled by heel pressure on foot treadle 28 which closes a switch 19 in speed sensor 15, which in turn causes the presser foot lift actuator 30 to operate. A leg switch 32 is provided for controlling the sewing direction of machine 12 by causing operation of reverse sew lever actuator 17. An important aspect of the present invention is the stop member 13 which prevents the reverse sew lever actuator 17 from being fully operated as will be subsequently described.
A toe switch 34 located adjacent to foot treadle 28 controls a conventional thread trimmer (not shown) disposed underneath the throat plate 36 of machine 12. Foot switch 38 on the other side of foot treadle 28 comprises a one-stitch switch for commanding machine 12 to sew a single stitch.
It will thus be understood that sewing machine 12 and its associated manual controls are of substantially conventional construction, and may be obtained from several commercial sources. For example, suitable sewing machines are available from Singer, Union Special, Pfaff, Consew, Juki, Columbia, Brother or Durkopp Companies.
In addition to the basic sewing machine 12 and its manual controls, system 10 includes several components for adapting the sewing machine for semi-automatic operation. One or more sensors 40 are mounted in laterally spaced-apart relationship in front of needle 22 and presser foot 24. A drive unit 42 comprising a variable speed direct drive motor, sensors for stitch counting and an electromagnetic brake for positioning of needle 22, is attached to the drive shaft of sewing machine 12. A main control panel 44 supported on a bracket 46 is provided above one corner of work stand 14.
On one side of work stand 14 there is a pneumatic control chassis 48 containing an air regulator, filter and lubricator for the sewing maching control sensors, pneumatic actuators and other elements of system 10. All of these components are of known construction and are similar to those shown in U.S. Pat. Nos. 4,108,090; 4,104,976; 4,100,865 and 4,092,937, the disclosures of which are incorporated herein by reference.
A controller chassis 50 is located on the opposite side of work stand 14 for housing the electronic components of system 10. Chassis 50 includes a microprocessor controller 51, appropriate circuitry for receiving signals from sensors and carrying control signals to actuators, and a power module for providing electrical power at the proper voltage levels to the various elements of system 10. The microprocessor controller 51 may comprise a Zilog Model Z-80 microprocessor or any suitable unit having a read only memory (ROM) and random access memory (RAM) of adequate storage capacities. An auxiliary control panel 52 is mounted for sliding movement in one end of chassis 50. Operation and function of the foregoing components will become more clear in the following paragraphs.
Referring now to FIGS. 2 and 3, further details of edge sensors 40 and their cooperation with needle 22 can be seen. If desired, only one edge sensor 40 can be used with sewing machine 12; however, complex shaped parts may require two or even three edge sensors located in laterally spaced-apart relationship in front of the needle. Sensors 40 can be mounted directly on the housing of sewing machine 12, or supported by other suitable means. As illustrated, each sensor 40 comprises a lamp/photosensor which projects a spot of light 40a onto a reflective tape strip 54 on throat plate 36. The status of each sensor 40 is either "on" or "off" depending upon whether the light beam thereof is interrupted, such as by passage of the trailing edge or discontinuity of the particular piece of material.
It will be appreciated that a significant feature of the present invention comprises usage of at least one and possibly a plurality of sensors 40 positioned in mutually spaced relationship ahead of needle 22 of sewing machine 12. Sensors 40 indicate whether or not the end of a particular seam is being approached. The condition of at least one sensor 40 changes as the trailing material edge passes thereunder to indicate approach of the seam end point. Sensors such as the Model 10-0672-02 available from Clinton Industries of Carlstadt, N.J., having been found satisfactory as sensors 40; however, infrared sensors and emitters, or pneumatic ports in combination with back pressure sensors could also be utilized, if desired. Any type of on/off sensor capable of detecting the pressure or absence of material a preset distance in front of needle 22 can be utilized with apparatus 10 since the exact mode of their operation is not critical to practice of the invention. Sensors 40 can be mounted directly on the housing of sewing machine 12 or on an adjustable mounting assembly.
Circuitry is provided in chassis 50 which detects the output of sensors 40 in order to generate electrical signals representative of the material edge. The controller 51 is responsive to such edge detection for allowing a selected number of stitches to be sewn after the edge detection. The controller 51 also determines the amount of the currently sewn stitch which has been completed at edge detection. The amount of the stitch is determined in response to the sewing machine motor rotation. In response to the amount of the stitch sewn at edge detection, the controller 51 controls the reverse mechanism of the machine in order to control the length of the last stitch sewn.
As described in the previously identified co-pending patent applications, the present system may first be operated in a teaching mode and thereafter operate in an automatic mode. The system may be taught in the teaching mode to sew x-y stitches after the material edge is detected. Thereafter, when the system is operated in the automatic mode, the edge of the material will be automatically detected by the sensor and the machine will then automatically sew x-y stitches and then terminate the seam. In this manner, automatic operation of the system may be provided in order to increase the speed and accuracy of the system without required human intervention. The present system operates is essentially the same manner as the systems described in the two co-pending patent applications, with additional improvements and accuracy being provided by the present invention as will be subsequently shown.
In operation of the system thus described, as a seam is sewn by the machine, the number of stitches from the starting point are counted by the encoder within drive unit 42. The reflective tape 54 will be covered by the material and the beams of the sensors 40 are blocked by the material. When the edge of the material moves past the reflective tape 54, the sensor beams are reflected from the reflective tape 54 and sensed. This provides the system with an indication of the location of the edge of the material. The system may then sew a predetermined number of stitches in order that the seam ends at a preselected location. In addition, auxiliary devices such as stackers, trimers, guides, and zig-zag lever actuators may be controlled in response to the material edge detection.
For a more detailed understanding and description of the operation of the system shown in FIGS. 1-3, reference is made to the co-pending patent applications Ser. Nos. 168,525 and 210,197, previously noted. The Specifications and Drawings of these applications are incorporated herein and may be referred to for a more detailed description of the operation of the system.
In the operation of the system described in copending patent applications Ser. Nos. 168,525 and 210,197, it was not possible to obtain accuracy better than plus or minus one-half stitch is determining the absolute end point of a seam. With the utilization of the present system to be described, accuracy in terminating a seam may be provided within plus or minus one-fourth stitch.
Referring to FIG. 4, an enlarged view of the reverse sew lever actuator assembly is illustrated. A pneumatic cylinder 1 is actuated in response to the leg switch 32 in order to pivot the reverse sew lever 17 about a pivot point 23. Alternatively, cylinder 21 may be actuated by a switch in chassis 48 as will be subsequently described. The lever 17 is illustrated in the solid line position in its normal operating position in the forward sew mode. When the cylinder 21 is actuated, the lever 17 is pivoted about pivot point 23 in order to place the machine in the reverse sew mode. Without the stop member 13, the lever 17 would normally be moved to the reverse sew mode as illustrated by the dotted line position 17'. However, because of the stop member 13, the lever 17 may only be moved to the dotted line position 17" adjacent the stop member 13. Consequently, according to the present invention, the reverse sew lever actuator is limited to approximately one-quarter its normal movement. This enables the sewing operation of the machine to be controlled to a greater accuracy then without the stop member 13.
FIG. 5 is a graph illustrating the length of a stitch displacement versus the rotation of the motor of the sewing machine. In an industrial sewing machine, the transport mechanism comprises a feed dog and presser foot. The amount by which the material being sewn is advanced for each stitch, termed stitch length, can be controlled by mechanical adjustments on the sewing machine. FIG. 5 illustrates the interval over 360° rotation of the sewing machine motor during which the stitch formation occurs. The interval over which the stitch formation occurs varies depending upon the machine type, such as drop feed, needle feed, top feed and the like. FIG. 5 illustrates material advancement over approximately 120° of the motor rotation of a typical sewing machine such as shown in FIG. 1. As shown in FIG. 5, the stitch is not begun until the motor has rotated approximately 60°. The stitch is then formed until it is completed after the sewing machine motor has completed approximately 180° rotation. The last 180° rotation of the sewing machine motor enables the machine to ready for the formation of the next stitch. The interval of the motor rotation is dynamically detected by the controller 51 over which stitch formation occurs, in order to determine the percentage of the stitch completed at edge detection.
FIGS. 6a-6c illustrate the operation of prior art devices such as are exemplified by the stitch controllers disclosed in Ser. Nos. 168,525 and 210,197, previously noted. FIG. 6a illustrates the sewing of a seam comprising a number of stitches utilizing a conventional sewing machine. In the example shown in FIG. 6a, the seam was started at the correct location relative to the material edge so that the end of the last stitch occurred exactly on the desired offset from the material edge. For example, if it were desired to end the seam one-quarter inch from the material edge, the operation shown in FIG. 6a was such that the seam ended exactly one-quarter inch from the material edge.
FIG. 6b illustrates the operation of a prior art device wherein the seam was started too close to the material edge, or wherein problems in material compaction or stretch occurred. Thus, the seam ended approximately one-half stitch past the desired offset from the material edge. If in the above example, the stitch length was 1/4 inch, the seam would end approximately one-eighth inch from the material edge, rather than the desired one-quarter inch from the material edge. It will be understood that it is not always possible to begin a seam at the exact desired position, and thus provisions must be made to end the seam as closely as possible to the desired offset from the material edge. With prior devices, it was not generally possible to obtain better than plus one-half stitch accuracy in case the exact starting point was not obtained during sewing. Even when the exact starting point is obtained, due to material stretching and the like, inaccuracies relative to the desired offset from the material edge often occur in actual sewing.
FIG. 6c illustrates the sewing of the seam wherein the seam ended approximately one-half stitch away from the desired offset from the material edge. In the previously noted example, the ending of the seam shown in FIG. 6c might be three-eighths inch away from the material edge rather than the desired one-fourth inch from the material edge.
It will be understood that the examples shown in FIGS. 6a-6c provided an accuracy of plus or minus one-half stitch length because it was not possible to vary the length of the stitch. In accordance with the present operation, the length of a stitch may be varied in order to provide greater accuracy. Such improved accuracy is required in certain sewing operations, such as top stitched collars, in order to provide the desired visual characteristics of the garment.
FIGS. 7a-7b illustrate operation of the present invention wherein accuracy of plus or minus one-fourth stitch may be provided. In accordance with the present invention, the edge detector described and shown in FIGS. 1-3 detects the edge of the material in order that the seam length can be stopped at a given distance from the material edge. The present system is originally taught by the operator to sew a given number of stitches y-x in a seam after the edge of the material is detected. When the operation is repeated in the automatic sewing mode, as described in the prior patent applications noted above, the system will sew until the edge is detected, and will then sew y-x stitches before terminating the seam. Depending upon the percentage of the stitch which has been sewn at the time of detection of the material edge, the last stitch sewn may be varied in order to provide increased accuracy to this seam termination.
The present system provides the capability to sew a specified number x of stitches, a specified number of stitches plus one additional stitch (x+1), or a specified number of stitches plus one-half additional stitch (x+1/2). An important aspect of the present invention is the ability to sew x+1/2 additional stitches by utilization of the reverse mechanism on the sewing machine as shown in FIG. 4.
The reverse mechanism operates in a linear fashion such that when then the mechanism is fully actuated as shown by position 17' in FIG. 4, a stitch is sewn in the reverse direction. The stitch length in the reverse direction will roughly correspond to the stitch length normally sewn in the forward direction when the lever is not depressed. If the reverse lever is approximately fifty percent depressed, the material is not advanced nor reversed during the stitch formation and a "condensed" stitch with zero length is formed. If the reverse lever 17 is moved only approximately twenty-five percent of its full range of movement, due to the positioning of the stop member 13, a forward stitch fifty percent of the normal stitch length is formed. Consequently, the addition of the stop member 13 causes a one-half length stitch to be sewn when the cylinder 21 actuates the reverse sew lever 17.
The controller 51 determines whether or not x, x+1/2 or x+1 additional stitches shall be taken after the sensor detects the material edge. The system periodically interrogates the edge sensor of the system during the formation of each stitch to determine if the sensor detects the material edge during the stitch. Sewing is continued until the sensor detects the edge. If the sensor detects the edge during the first twenty-five percent formation of the stitch being sewn, the system will sew x additional stitches after the current stitch is completed. If the sensor detects the edge of the material in the interval of twenty-five to seventy-five percent formation of the stitch length, the system will sew x+1/2 additional stitches. If the sensor detects the material edge during the last twenty-five percent of the stitch length, the system will sew x+1 additional stitch.
The x+1/2 and x+1 stitch cases are alike in that the system sews x+1 additional stitchs in both cases. However, in the x+1/2 case, the reverse mechanism 17 is actuated during the final stitch with the reverse mechanism constrained by the stop 13 such that the lever 17 cannot travel more than approximately twenty-five percent of its maximum travel. This causes the last stitch to be approximately one-half the normal stitch length.
FIGS. 7a and 7b illustrate how operation of the present system can improve the accuracy of the seam end point. In FIG. 7a, the seam was started at a point that the end of stitch 69 is slightly over 1/4 stitch away from the desired offset. Thus, the last stitch is varied in length by 1/2 such that the seam ends within 1/4 stitch of the desired offset. In FIG. 7b, the length of the last stitch is also reduced by one-half such that the seam ends approximately one-fourth stitch length away from the desired offset from the material edge.
FIG. 8 illustrates a flow diagram illustrating the operation of the present invention. The steps are implemented by suitable programming of the microprocessor controller 51. The program is suitable for adaptation to the Zylog Z-80 microprocessor and may be written into Z-80 assembly language in a manner known to the art.
At step 70, one stitch is taken. A determination is made at step 72 as to whether or not the edge sensor shown in FIGS. 2 and 3 has changed state during the last switch. If not, another stitch is taken at step 70. If it is determined that the sensor has changed during the last stitch, thereby indicating the detection of the material edge, D act is set in a register at step 74. D act is equal to the encoder count which represents the motor rotation angle when the sensor changed.
At step 76, a determination is made by the program as to whether or not D stop -D start is greater than or equal to zero. D start equals the encoder count value when the stitch movement begins. D stop equals the encoder count value when the stitch movement ends. If the decision at step 76 is no, the motor angle values D act , D stop and D start are adjusted at step 78 for numerical analysis reasons. Specifically, steps 76 and 78 are provided to enable the system to accommodate various machines having different feeding intervals during the rotation of the motor. At step 78, D start is set to zero, D stop is set to D stop +(360°-D start ) and D act is set to D act +360°-D start ).
If D stop -D start is greater than or equal to zero, the determination is made at step 79 as to whether or not D act is less than or equal to D T/4 +D start . In other words, the decision is made at step 79 as to whether or not the material edge was detected when the stitch was less than twenty-five percent completed. If the answer is yes, x additional stitches are taken by the system at step 80. If the edge of the material was not detected within the first one-quarter of the stitch length, a decision is made at step 82 as to whether or not D act is less than or equal to 3D/4T+D stop . In other words, a decision is made at step 82 as to whether or not the material edge was detected in the last twenty-five percent of the stitch. If so, x+1 additional stitches are taken at step 84 by the system.
If it is determined at steps 78 and 82 that the material edge was detected between twenty-five percent and seventy-five percent of the completion of the switch, x additional stitches are taken at step 86 and then the reverse mechanism is actuated at step 88 and one additional stitch is taken. This provides an additional one-half stitch to provide improved accuracy to the system.
It will be understood that the reverse mechanism could be actuated a greater or lesser amount than approximately twenty-five percent in order to decrease or increase the length of the stitch taken by the system. Moreover, it will be understood that instead of decreasing the last stitch length by one-half, the last two stitches could be reduced in length to three-fourths of their original length. Other variations involving reduction of the length of the stitch by movement of the reverse lever for predetermined amounts will be accomplished by the present invention.
It will thus be seen that the present system periodically interrogates the edge sensor as stitches are being formed in order to determine the state of formation of a stitch when the edge of the material is detected. Depending upon the amount of stitch formed at the time of edge detection, a predetermined number of additional stitches plus one stitch if necessary are taken by the system with the length of one or more of the stitches varied in order to provide improved accuracy.
Whereas the present invention has been described with respect to specific embodiments thereof, it will be understood that various changes and modifications will be suggested to one skilled in the art, and it is intended to encompass such changes and modifications as fall within the scope of the appended claims. | An adaptive semiautomatic sewing system (10) comprises a sewing machine (12), a drive unit (42) including a variable speed motor and encoder for counting stitches sewn and for sensing the rotation of the motor, at least one material edge sensor (40) mounted ahead of the needle (22) of the sewing machine, and a microprocessor controller (51) coupled to the sewing machine controls. The system (10) has manual, teach and auto modes of operation. In the teach mode, control parameters for each seam are stored as the operator sews the initial piece. Accurate control of seam lengths and end points is achieved by initiating countdown of a variable number of final stitches responsive to detection of the material edges by the sensors (40). In dependence upon the amount of the stitch which has been sewn upon edge detection, the reverse lever (17) is moved against stop member (13) in order to reduce the length of the last stitch sewn in order to improve the accuracy of the seam end point. | 32,477 |
RELATED APPLICATIONS
This disclosure is related to the following co-pending applications:
a. “Voltage/Current Regulator Improvements for an Implantable Medical Device” by inventor Goblish, et al., having U.S. patent application Ser. No. 10/133,702, and filed on Apr. 26, 2002; b. “Detection of Possible Failure of Capacitive Elements in an Implantable Medical Device” by inventors Heathershaw, et al., having U.S. patent application Ser. No. 10/133,925, and filed on Apr. 26, 2001; c. “Recharge Delay for an Implantable Medical Device” by inventors Goblish, et al., having U.S. patent application Ser. No. 10/133,703, and filed on Apr. 26, 2002; d. “Wave Shaping for an Implantable Medical Device” by inventors Jensen et al., having U.S. patent application Ser. No. 10/133,573, and filed on Apr. 26, 2002; e. “Automatic Waveform Output Adjustment for an Implantable Medical Device” by inventors Acosta et al., having U.S. patent application Ser. No. 10/133,961, and filed on Apr. 26, 2002; and f. “Programmable Waveform Pulses For An Implantable Medical Device” by inventors Goblish et al., having U.S. patent application Ser. No. 10/133,906, and filed on Apr. 26, 2002.
which are not admitted as prior art with respect to the present disclosure by their mention in this section.
FIELD OF THE INVENTION
This invention relates generally to implantable medical devices, and more particularly to techniques for providing a multiple independent stimulation channels in an implantable medical device.
BACKGROUND OF THE INVENTION
The medical device industry produces a wide variety of electronic and mechanical devices for treating patient medical conditions. Depending upon medical condition, medical devices can be surgically implanted or connected externally to the patient receiving treatment. Clinicians use medical devices alone or in combination with drug therapies and surgery to treat patient medical conditions. For some medical conditions, medical devices provide the best, and sometimes the only, therapy to restore an individual to a more healthful condition and a fuller life. One type of medical device that can be used is an Implantable Neuro Stimulator (INS).
An INS generates an electrical stimulation signal that is used to influence the human nervous system or organs. Electrical contacts carried on the distal end of a lead are placed at the desired stimulation site such as the spine and the proximal end of the lead is connected to the INS. The INS is then surgically implanted into an individual such as into a subcutaneous pocket in the abdomen. The INS can be powered by an internal source such as a battery or by an external source such as a radio frequency transmitter. A clinician programs the INS with a therapy using a programmer. The therapy configures parameters of the stimulation signal for the specific patient's therapy. An INS can be used to treat conditions such as pain, incontinence, movement disorders such as epilepsy and Parkinson's disease, and sleep apnea. Additional therapies appear promising to treat a variety of physiological, psychological, and emotional conditions. As the number of INS therapies has expanded, greater demands have been placed on the INS. Examples of some INSs and related components are shown and described in a brochure titled Implantable Neurostimulation Systems available from Medtronic, Inc., Minneapolis, Minn.
The effectiveness of the therapy as provided by the INS is dependent upon its capability of adjusting the electrical characteristics of the stimulation signal. For example, stimulation waveforms can be designed for selective electrical stimulation of the nervous system. Two types of selectivity may be considered. First, fiber diameter selectivity refers to the ability to activate one group of nerve fibers having a common diameter without activating nerve fibers having different diameters. Second, spatial selectivity refers to the ability to activate nerve fibers in a localized region without activating nerve fibers in neighboring regions.
The basic unit of therapy is a “therapy program” in which amplitude characteristics, pulse width, and electrode configuration are associated with a pulse train for treatment of a specific neurological conduction in a specific portion of the body. The pulse train may comprise a plurality of pulses (voltage or current amplitude) that are delivered essentially simultaneously to the electrode configuration. Typically, a pulse train is delivered to the patient using one or more electrode. The INS may be able to adjust the therapy program, for example, by steering the pulse train so that it affects desired portions of the neurological tissue to be affected. Alternatively, the INS may be able to adjust various parameters of the pulse train including, for example, the pulse width, frequency and pulse amplitude.
It is often desirable, however, for the INS to simultaneously provide multiple therapy programs to the patient. For example, it may be desirable to provide multiple therapy programs to treat the neurological condition being treated in various parts of the body. Alternatively, the patient may have more than one condition or symptom that needs to be treated. Moreover, multiple therapy programs could serve to provide sub-threshold measurements, patient notification, and measurement functions.
It is therefore desirable to provide an INS that is capable of delivering multiple independent therapy programs to the patient.
BRIEF SUMMARY OF THE INVENTION
The invention discloses techniques for delivering multiple independent therapy programs to the patient by an implantable medical device system. In accordance with an embodiment of the invention, the implantable medical device has a generator for generating necessary voltage signals for the therapy programs, one or more regulators configuring pulse trains from the voltage signals associated with the therapy programs, and a switching unit for dynamically selecting and configuring the electrodes that are to deliver each therapy program to the patient. A controller is also provided that configures the generator, the regulators, and the switching unit in accordance with the therapy programs. Once configured, the implantable medical device delivers the independent pulse trains associated with the therapy programs to a patient. The therapy programs may be simultaneous or overlapping in time.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows an environment of an exemplary Implantable Neuro Stimulator (INS);
FIG. 2 shows an INS block diagram;
FIG. 3 shows an INS basic operation flowchart;
FIG. 4 shows a telemetry module block diagram;
FIG. 5 shows a telemetry operation flowchart;
FIG. 6 shows a recharge module block diagram;
FIG. 7 shows a recharge module operation flowchart;
FIG. 8 shows a power module block diagram;
FIG. 9 shows power module operation flowchart;
FIG. 10 shows a therapy module block diagram;
FIG. 11 shows a therapy module operation flowchart;
FIG. 12 shows a therapy measurement module block diagram;
FIG. 13 shows a therapy measurement module operation flowchart;
FIG. 14 shows a stimulation engine system according to an embodiment of the present invention;
FIG. 15A shows a logic flow diagram for detecting an out-of-regulator condition according to an embodiment of the present invention;
FIG. 15B shows an electrical configuration corresponding to a regulator according to an embodiment of the present invention;
FIG. 16 shows a logic flow diagram for detecting a faulty coupling capacitor according to an embodiment of the present invention;
FIG. 17 shows a first configuration for a set of regulators according to an embodiment of the present invention;
FIG. 18 shows a second configuration for a set of regulators according to an embodiment of the present invention;
FIG. 19 shows a stimulation waveform according to an embodiment of the present invention;
FIG. 20 shows a state diagram for a finite state machine to form the stimulation waveform as shown in FIG. 19 according to an embodiment of the present invention;
FIG. 21 shows wave shaping of a stimulation pulse shown in FIG. 19 according to an embodiment of the present invention;
FIG. 22 shows a first apparatus that supports wave shaping as shown in FIG. 21 according to an embodiment of the present invention;
FIG. 23 shows a second apparatus that supports wave shaping as shown in FIG. 21 according to an embodiment of the present invention;
FIG. 24 shows a logic flow diagram representing a method for supporting wave shaping according to an embodiment of the present invention;
FIG. 25 shows a stimulation arrangement according to prior art; and
FIG. 26 shows a stimulation arrangement according to an embodiment of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
Overall Implantable Medical Device System.
FIG. 1 shows the general environment of an Implantable Neuro Stimulator (INS) medical device 14 in accordance with a preferred embodiment of the present invention. The neurostimulation system generally includes an INS 14 , a lead 12 , a lead extension 20 , an External Neuro Stimulator (ENS) 25 , a physician programmer 30 , and a patient programmer 35 . The INS 14 preferably is a implantable pulse generator that will be available from Medtronic, Inc. with provisions for multiple pulses occurring either simultaneously or with one pulse shifted in time with respect to the other, and having independently varying amplitudes and pulse widths. The INS 14 contains a power source and electronics to send precise, electrical pulses to the spinal cord, brain, or neural tissue to provide the desired treatment therapy. In the embodiment, INS 14 provides electrical stimulation by way of pulses although alternative embodiments may use other forms of stimulation such as continuous electrical stimulation.
The lead 12 is a small medical wire with special insulation. The lead 12 includes one or more insulated electrical conductors with a connector on the proximal end and electrical contacts on the distal end. Some leads are designed to be inserted into a patient percutaneously, such as the Model 3487A Pisces-Quad® lead available from Medtronic, Inc. of Minneapolis Minn., and some leads are designed to be surgically implanted, such as the Model 3998 Specify® lead also available from Medtronic. The lead 12 may also be a paddle having a plurality of electrodes including, for example, a Medtronic paddle having model number 3587A. Those skilled in the art will appreciate that any variety of leads may be used to practice the present invention.
The lead 12 is implanted and positioned to stimulate a specific site in the spinal cord or the brain. Alternatively, the lead 12 may be positioned along a peripheral nerve or adjacent neural tissue ganglia like the sympathetic chain or it may be positioned to stimulate muscle tissue. The lead 12 contains one or more electrodes (small electrical contacts) through which electrical stimulation is delivered from the INS 14 to the targeted neural tissue. If the spinal cord is to be stimulated, the lead 12 may have electrodes that are epidural, intrathecal or placed into the spinal cord itself. Effective spinal cord stimulation may be achieved by any of these lead placements.
Although the lead connector can be connected directly to the INS 14 , typically the lead connector is connected to a lead extension 20 which can be either temporary for use with an ENS 25 or permanent for use with an INS 14 . An example of the lead extension 20 is Model 7495 available from Medtronic.
The ENS 25 functions similarly to the INS 14 but is not designed for implantation. The ENS 25 is used to test the efficacy of stimulation therapy for the patient before the INS 14 is surgically implanted. An example of an ENS 25 is a Model 3625 Screener available from Medtronic.
The physician programmer 30 , also known as a console programmer, uses telemetry to communicate with the implanted INS 14 , so a physician can program and manage a patient's therapy stored in the INS 14 and troubleshoot the patient's INS system. An example of a physician programmer 30 is a Model 7432 Console Programmer available from Medtronic. The patient programmer 35 also uses telemetry to communicate with the INS 14 , so the patient can manage some aspects of her therapy as defined by the physician. An example of a patient programmer 35 is a Model 7434 Itrel® 3 EZ Patient Programmer available from Medtronic.
Those skilled in the art will appreciate that any number of external programmers, leads, lead extensions, and INSs may be used to practice the present invention.
Implantation of an Implantable Neuro Stimulator (INS) typically begins with implantation of at least one stimulation lead 12 usually while the patient is under a local anesthetic. The lead 12 can either be percutaneously or surgically implanted. Once the lead 12 has been implanted and positioned, the lead's distal end is typically anchored into position to minimize movement of the lead 12 after implantation. The lead's proximal end can be configured to connect to a lead extension 20 . If a trial screening period is desired, the temporary lead extension 20 can be connected to a percutaneous extension with a proximal end that is external to the body and configured to connect to an External Neuro Stimulator (ENS) 25 . During the screening period the ENS 25 is programmed with a therapy and the therapy is often modified to optimize the therapy for the patient. Once screening has been completed and efficacy has been established or if screening is not desired, the lead's proximal end or the lead extension proximal end is connected to the INS 14 . The INS 14 is programmed with a therapy and then implanted in the body typically in a subcutaneous pocket at a site selected after considering physician and patient preferences. The INS 14 is implanted subcutaneously in a human body and is typically implanted near the abdomen of the patient.
System Components and Component Operation.
FIG. 2 shows a block diagram of an exemplary INS 200 . INS 200 generates a programmable electrical stimulation signal. INS 200 comprises a processor 201 with an oscillator 203 , a calendar clock 205 , a memory 207 , a system reset module 209 , a telemetry module 211 , a recharge module 213 , a power source 215 , a power management module 217 , a therapy module 219 , and a therapy measurement module 221 . In non-rechargeable versions of INS 200 , recharge module 213 can be omitted. Other versions of INS 200 can include additional modules such as a diagnostics module. All components can be configured on one or more Application Specific Integrated Circuits (ASICs) except the power source. Also, all components are connected to bi-directional data bus that is non-multiplexed with separate address and data lines except oscillator 203 , calendar clock 205 , and power source 215 . Other embodiments may multiplex the address and data lines. Processor 201 is synchronous and operates on low power such as a Motorola 68HC11 synthesized core operating with a compatible instruction set. Oscillator 203 operates at a frequency compatible with processor 201 , associated components, and energy constraints such as in the range from 100 KHz to 1.0 MHz. Calendar clock 205 counts the number of seconds since a fixed date for date/time stamping of events and for therapy control such as circadian rhythm linked therapies. Memory 207 includes memory sufficient for operation of the INS such as volatile Random Access Memory (RAM) for example Static RAM, nonvolatile Read Only Memory (ROM), Electrically Eraseable Programmable Read Only Memory (EEPROM) for example Flash EEPROM, and register arrays configured on ASICs. Direct Memory Access (DMA) is available to selected modules such as telemetry module 211 , so telemetry module 211 can request control of the data bus and write data directly to memory bypassing processor 201 . System reset module 209 controls operation of ASICs and modules during power-up of INS 200 , so ASICs and modules registers can be loaded and brought on-line in a stable condition. INS 200 can be configured in a variety of versions by removing modules not necessary for the particular configuration and by adding additional components or modules. Primary cell, non-rechargeable versions of INS 200 will not include some or all of the components in the recharge module. All components of INS 200 are contained within or carried on a housing that is hermetically sealed and manufactured from a biocompatible material such as titanium. Feedthroughs provide electrical connectivity through the housing while maintaining a hermetic seal, and the feedthroughs can be filtered to reduce incoming noise from sources such as cell phones.
FIG. 3 illustrates an example of a basic INS operation flowchart 300 . Operation begins with when processor 201 receives data from either telemetry 301 or from an internal source 303 in INS 200 . At receiving data step 305 , received date is then stored in a memory location 307 . The data 307 is processed by processor 201 in step 309 to identify the type of data and can include further processing such as validating the integrity of the data. After data 307 is processed, a decision is made whether to take an action in step 311 . If no action is required, INS 201 stands by to receive data. If an action is required, the action will involve one or more of the following modules or components: calendar clock 205 , memory 207 , telemetry 211 , recharge 213 , power management 217 , therapy 219 , and therapy measurement 221 . An example of an action would be to modify a programmed therapy. After the action is taken, a decision is made whether to prepare the action to be communicated in step 313 , known as uplinked, to patient programmer 35 or console programmer 30 through telemetry module 211 . If the action is uplinked, the action is recorded in patient programmer 35 or console programmer 30 . If the action is not uplinked, the action is recorded internally within INS 200 .
FIG. 4 shows a block diagram of various components that may be found within telemetry module 211 . Telemetry module 211 provides bi-directional communications between INS 200 and the programmers. Telemetry module 211 comprises a telemetry coil 401 , a receiver 403 , a transmitter 405 , and a telemetry processor 407 . Telemetry is conduced at a frequency in the range from about 150 KHz to 200 KHz using a medical device protocol such as described in U.S. Pat. No. 5,752,977 entitled “Efficient High Data Rate Telemetry Format For Implanted Medical Device” issued on May 19, 1998 and having named inventors Grevious et al.. Telemetry coil 401 can be located inside the housing or attached to the outside of the housing, and telemetry coil 401 can also function as the recharge coil if operation of the coil is shared or multiplexed. Receiver 403 processes a digital pulse representing the Radio Frequency (RF) modulated signal, knows as a downlink, from a programmer. Transmitter 405 generates an RF modulated uplink signal from the digital signal generated by telemetry processor 407 . Telemetry processor 407 may be a state machine configured on an ASIC with the logic necessary to decode telemetry signal during reception, store data into RAM, and notify processor 201 that data was received. Telemetry processor 407 also provides the logic necessary during transmission to request processor 201 to read data from RAM, encode the data for transmission, and notify the process that the data was transmitted. Telemetry processor 407 reduces some demands on processor 201 in order to save energy and enable processor 201 to be available for other functions.
FIG. 5 illustrates an example of a telemetry operation flowchart 500 . To begin telemetry, either the patient or the clinician uses patient programmer 35 or console programmer 30 and places the telemetry head containing telemetry coil 401 near INS 200 or the ENS. In step 501 , the RF telemetry signal is received through telemetry coil 401 and includes a wake-up burst that signals telemetry processor 407 to prepare telemetry processor 407 to receive incoming telemetry signals. Telemetry processor 407 is configured to receive a particular telemetry protocol that includes the type of telemetry modulation and the transmission rate of the incoming telemetry signal in step 503 . Telemetry receiver 403 demodulates the time base signal into digital pulses in step 505 . Telemetry processor 407 converts the digital pulses into binary data that is stored into memory. In step 509 , processor 201 will then take whatever action is directed by the received telemetry such as adjusting the therapy. Telemetry signal transmission is initiated by processor 201 requesting telemetry processor 407 to transmit data in step 551 . Telemetry processor 407 is configured for the desired telemetry protocol that includes the type of modulation and the speed for transmission in step 553 . Telemetry processor 407 converts the binary data into a time based digital pulses in step 555 . Transmitter 405 modulates the digital signal into an RF signal that is then transmitted through telemetry coil 401 to programmer 30 or 35 in step 559 .
FIG. 6 shows a block diagram of various components that may be found within recharge module 213 . Recharge module 213 provides controlled power to the battery (contained in power source 215 ) for recharging the battery and provides information to INS 200 about recharging status. Recharge module 213 regulates the charging rate of power source 215 according to power source parameters and keeps the temperature rise of INS 200 within acceptable limits so that the temperature rise does not create an unsafe condition for the patient. INS 200 communicates charging status to the patient's charger ( 213 ), so the patient charges at a level that prevents INS 200 from overheating while charges power source 215 rapidly. Recharge module 213 comprises a recharge coil, an Alternating Current (AC) over-voltage protection unit 601 , an AC to DC converter 603 , a recharge regulator 605 , a recharge measurement unit 607 , and a recharge regulator control 609 . Recharge module 213 charges the battery by receiving a power transfer signal with a frequency of about 5.0 KHz to 10.0 KHz and converting the power transfer signal into a regulated DC power that is used to charge the battery. The recharge coil can be the same coil as telemetry coil 401 if shared or multiplexed or the recharge coil can be a separate coil. AC over-voltage protection unit 601 can be a Zener diode that shunts high voltage to ground. AC to DC converter 603 can be a standard rectifier circuit.
Recharge regulator 605 regulates the voltage received from AC to DC converter 603 to a level appropriate for charging the battery. The recharge regulator control adjusts recharge regulator 605 in response to recharge measurements and a recharge program. The recharge program can vary based upon the type of device, type of battery, and condition of the battery. The recharge measurement block 607 measures current and voltage at regulator 605 . Based upon the recharge measurement, the regulation control can increase or decrease the power reaching power source 215 .
FIG. 7 illustrates an example of recharge module operation flowchart corresponding to recharge module 213 . Recharging INS 200 begins in the same manner as telemetry with either the patient or the clinician using patient programmer 35 or console programmer 30 and placing the telemetry head containing the recharge coil near INS 200 or the ENS. After the recharge signal is received in step 701 , it is converted to from AC to DC in step 703 . The DC signal is regulated in step 707 . Regulator output power is measured in step 707 and then fed back in step 705 in order to assist in controlling the regulator output power to an appropriate power level. Power source 215 is charged in step 709 , and the power source charge level is measured in step 711 . The measured power source charge level also is fed back in step 705 , so regulator 605 can control the regulator output to a level that is appropriate for power source 215 . Once recharge module 213 fully charges power source 215 , recharge module 213 can be configured to function as a power source for INS 200 while power is still received.
FIG. 8 shows a block diagram of various components that may be found within power management module 217 , and FIG. 9 illustrates an example of a flowchart of power management module 217 . Power management module 217 provides a stable DC power source to INS 200 with voltages sufficient to operate INS 200 such as between about 1.5 VDC and 2.0 VDC. Power management module 217 includes a first DC to DC converter 801 , a second DC to DC converter 803 , and power source measurement component 805 . One or more additional DC to DC converters can be added to the power management module to provide additional voltage values for INS 200 . First DC to DC converter 801 and second DC to DC converter 803 can be operational amplifiers configured for a gain necessary for the desired output voltage. Power source measurement component 805 measures the power source and reports this measurement to processor 201 , so processor 201 can determine information about power source 215 . If processor 201 determines that power source 215 is inadequate for normal operation, processor 201 can instruct power management module 217 to initiate a controlled shutdown of INS 200 .
INS power source 215 typically provides a voltage sufficient for power management module 217 to supply power to INS 200 such as above 2.0 VDC at a current in the range from about 5.0 mA to 30.0 mA for a time period adequate for the intended therapy. INS power source 215 can be a physical storage source such as a capacitor or super capacitor, or power source 215 can be a chemical storage source such as a battery. The INS battery can be a hermetically sealed rechargeable battery such as a lithium ion (Li+) battery or a non-rechargeable battery such as a lithium thionyl chloride battery. The ENS battery can be a non-hermetically sealed rechargeable battery such as nickel cadmium or a non-rechargeable battery such as an alkaline.
FIG. 10 shows a block diagram of various components that may be found within therapy module 219 . Therapy module 219 generates a programmable stimulation signal that is transmitted through one or more leads to electrical contacts implanted in the patient. Therapy module 219 comprises a therapy controller (waveform controller) 1001 , a generator 1003 , a regulator module 1005 , and an electrical contact switches unit 1007 . Therapy controller 1001 can be a state machine having registers and a timer. Other embodiments of the invention may utilize other types of processors such as an ASIC, a microprocessor, a gate array, and discrete circuitry. Therapy controller 1001 controls generator 1003 and regulator module 1005 to create a stimulation signal. (A waveform generator that forms the stimulation signal may comprise generator 1003 and regulator module 1005 .) Generator 1003 assembles capacitors that have been charged by power source 215 to generate a wide variety of voltages or currents. Regulator module 1005 includes current/voltage regulators that receive a therapy current or voltage from generator 1003 and shape the stimulation signal according to therapy controller 1001 . Regulator module 1005 may include any number of devices or software components (active or passive) that maintains an output within a range of predetermined parameters such as current, voltage, etc. Electrical contact switches unit comprises solid state switches with low impedance such as Field Effect Transistor (FET) switches. The electrical contacts are carried on the distal end of a lead and deliver the stimulation signal to the body through an electrode. Additional switches can be added to provide a stimulation signal to additional electrical contacts. In the embodiment, therapy module 219 can deliver individual output pulses in the range from 0.0 Volts to 15.0 Volts into a range from about 1.0 Ohm to 10.0 K Ohms impedance throughout its operating parameter range to any combination of anodes and cathodes of up to eighteen electrical contacts for any given stimulation signal. Other embodiments can support a different voltage range, a different impedance range, or a different electrode arrangement.
FIG. 11 illustrates and example of operation with a flowchart of therapy module 219 . The therapy begins with the therapy controller 1001 configuring the generator 1003 according to the therapy program to provide appropriate voltage to regulator module 1005 in step 1101 . Therapy controller 1001 also configures regulator module 1005 to produce the stimulation signal according to the therapy program in step 1103 . Therapy controller 1001 also configures electrical contacts unit 1007 to so the stimulation signal is delivered to the electrical contacts specified by the therapy program in step 1105 . The stimulation signal is delivered to the patient through electrodes in step 1107 . After the stimulation signal is delivered to the patient, most therapies include a time delay in step 1109 before the next stimulation signal is delivered.
FIG. 12 shows a block diagram of various components that may be found within therapy measurement module 221 . Therapy measurement module 221 measures one or more therapy parameters at therapy module 219 to determine whether the therapy is appropriate. Therapy measurement module 221 includes a therapy voltage measurement component 1201 , a therapy current measurement component 1203 , and a therapy output measurement component 1205 . The therapy voltage measurements and therapy current measurements are taken periodically to perform therapy calculations. The therapy output measurement is a measurement of the delivered therapy that is used for safety and other purposes.
FIG. 13 illustrates an example of an operation flowchart of therapy measurement module 221 . In step 1301 , the therapy measurement operation begins by processor 201 setting up parameters of the therapy measurement to be taken (e.g. the specific stimulation signal to measure) and at which electrical contacts to perform the measurement. Before a therapy measurement is taken, a threshold determination is made whether a therapy measurement is needed in step 1303 . For some therapies, a therapy measurement may not be taken. When a therapy measurement is not taken, often a patient physiological measurement will be performed and reported to processor 201 for action or storage in memory in step 1305 . When a therapy measurement is desired, the therapy is delivered in step 1307 and then the therapy measurement is performed in step 1309 . The therapy measurement is reported to processor 201 for action or storage in memory in step 1311 . Examples of some actions that might be taken when the therapy measurement is reported include an adjustment to the therapy and a diary entry in memory that can be evaluated by the clinician at a later time.
Those skilled in the art will appreciate that the above discussion relating to the operation and components of the INS 14 serve as an example and that other embodiments may be utilized and still be considered to be within the scope of the present invention. For example, an ENS 25 may be utilized with the present invention.
Stimulation Engine.
FIG. 14 shows a stimulation engine system 1400 according to an embodiment of the present invention. Stimulation engine 1400 comprises therapy module 219 and therapy measurement block 221 . Therapy module 219 comprises generator control module 1003 , waveform controller (therapy controller) 1001 , regulators 1401 , 1403 , 1405 , and 1407 , and electrode controller (electrical contact switches unit) 1007 . Regulators 1401 - 1407 receive an input voltage from a capacitor bank comprising capacitors 1451 - 1465 . In the embodiment, capacitors 1451 - 1465 are associated as capacitor pairs such as described in U.S. Pat. No. 5,948,004 entitled “Implantable Stimulation Having An Efficient Output Generator” issued on Sep. 7, 1999 having named inventors Weijand et al. Capacitors 1451 - 1465 are charged by a battery 1467 during a recharging interval (during which a capacitor arrangement forms a charge configuration). If a capacitor pair is charged across battery 1467 in parallel and subsequently discharged across a load in series, the corresponding voltage (as provided to a regulator) is double of the voltage of battery 1467 . If a capacitor pair is charged across battery 1467 in series and subsequently discharged across the load in parallel, the corresponding voltage is one half the voltage of battery 1467 . The embodiment may utilize capacitor pairs both with a parallel configuration and with a series configuration in order to obtain a desired voltage level to a regulator. Moreover, other embodiments of the invention can utilize other types of capacitor configurations (e.g. capacitor triplets to obtain one third of the battery voltage and capacitor octets to obtain one eighth of the battery voltage) in order to achieve a desired level of voltage granularity to a regulator. Thus, any fraction of the battery voltage can be obtained by a corresponding capacitor configuration
In the embodiment, waveform controller 1001 (as instructed by processor 201 ) configures the capacitor bank through generator control 1003 in order to provide the required voltage inputs (corresponding to 1417 - 1423 ) to regulators 1401 - 1407 , respectively (during which the capacitor arrangement forms a stack configuration). Regulators 1401 - 1407 are instructed to generate stimulation pulses (as illustrated in FIG. 19 ) at time instances by waveform controller 1001 through control leads 1409 - 1415 , respectively. In the embodiment, a voltage drop across a regulator (e.g. 1401 - 1407 ) is determined by a digital to analog converter (DAC) that is associated with the regulator and that is controlled by waveform controller 1001 . In the embodiment, waveform controller 1001 can independently control as many as four regulators ( 1401 - 1407 ) in order to form four independent simulation channels, although other embodiments may support a different number of regulators. Each stimulation channel is coupled to electrode controller 1007 through a coupling capacitor ( 1471 - 1477 ). Each stimulation channel can be coupled to at least one of sixteen electrodes (E 0 -E 15 ). Once again, variations of the embodiment may support different numbers of electrodes. An electrode may be either an anode or a cathode.
Therapy measurement block 221 monitors various components of the stimulation engine system 1400 for performance and diagnostic checks. To assist with its monitoring function, therapy measurement block 221 has associated holding capacitors 1491 and 1493 . Once again, variations of the embodiment may support different number of holding capacitors. At least one of the holding capacitors may be redundant in case the first capacitor has failed. As one example, therapy measurement block 221 monitors the voltage across a regulator in order to detect whether there is sufficient “headroom” (which is the voltage difference between the regulator's voltage input and voltage output). Some factors that may alter the “headroom” include a change of the voltage of battery 1467 and changing electrical characteristics of surrounding tissues (for example, caused by a movement in the placement of a lead). If a regulator does not have sufficient headroom, the regulator may not be able to regulate a stimulation pulse that has a constant amplitude over the duration of the pulse. Rather, the amplitude of the stimulation pulse may “droop.” In the embodiment, therapy measurement block 221 monitors input 1481 and input 1485 to determine the input voltage and the output voltage of regulator 1401 . (In the embodiment, regulators 1403 , 1405 , and 1407 can be similarly monitored.) Typically the voltage drop across regulator should be 0.3 volts or greater in order to achieve adequate regulation. For example, if therapy measurement block 221 determines that the voltage drop across regulator 1401 is less than a minimum value, then therapy measurement block 221 may notify processor 201 about regulator 1401 experiencing an out-of-regulator condition. In such a case, processor 201 may instruct generator 1003 to associate another capacitor pair to the voltage input of regulator 1401 in order to increase the input voltage. (It is assumed that redundant capacitor pairs are available.) Also, processor 201 may store the occurrence of the out-of-regulator and report the occurrence over a telemetry channel through telemetry module 211 . The clinician may wish to recharge battery 1467 in such a case.
If battery 1467 has been recharged after additional capacitor pairs have been configured to compensate for a previous out-of-regulator condition of regulator 1401 , the voltage drop across a regulator may be greater than what is necessary to maintain adequate regulation. In such a case, therapy measurement block 221 may remove a capacitor pair that is associated with the voltage input of regulator 1401 .
In another embodiment of the invention, therapy measurement block 221 monitors the voltage of battery 1467 . If the voltage of battery 1467 is below a threshold value, therapy measurement block 221 reports the low battery condition to processor 201 . Consequently, processor 201 may instruct generator 1003 to configure capacitor pairs for the active regulators (e.g. regulators 1401 , 1403 , 1405 , and 1407 ). (It is assumed that there are a sufficient number of capacitor pairs.). As discussed below, in yet another embodiment of the invention, therapy measurement block 221 monitors various capacitive elements of the stimulation engine system 1400 for possible failure (e.g., holding capacitors 1491 and 1493 and coupling capacitors 1471 - 1477 ).
Automatic Waveform Output Adjustment.
FIG. 15A shows a logic flow diagram 1500 for detecting an out-of-regulator condition. In step 1501 , therapy measurement block 221 measures the voltage drop across a regulator (e.g. regulator 1401 ). In step 1503 , therapy measurement block 221 determines whether the voltage drop is less that a threshold value. If not, therapy measurement block monitors another regulator (e.g. regulator 1403 ) in step 1505 . If so, then therapy measurement block 221 informs INS processor 201 about the out-of-regulator condition in step 1507 . In step 1509 , it is determined if a capacitor pair is available so that the capacitor pair may be added to the associated capacitor configuration. If so, a capacitor pair is added and another regulator is monitored.
Variations of the embodiment may detect a faulty capacitor of a capacitor pair. For example, if capacitor 1451 (C 1 ) is shorted, the associated voltage across capacitor 1451 is essentially zero. Consequently, the associated input voltage to a regulator is reduced, causing the voltage drop across the regulator to be reduced. With the logic shown in FIG. 15A , another capacitor pair is configured in order to compensate for capacitor 1451 shorting. Moreover, additional logic steps can be included to detect a faulty capacitor and removing the faulty capacitor from service. In a variation of the embodiment, a capacitor pair is removed from the capacitor arrangement and another capacitor pair is added. If the voltage drop across the regulator is consequently within limits, the capacitor pair that was removed from the configuration is assumed to have a faulty capacitor. If a spare capacitor pair is not available, processor 201 may be notified so that programmer 30 or 35 can be alerted over the telemetry channel. In another embodiment, processor 201 may instruct the INS to shutdown in order to deactivate the generation of a stimulation waveform that is not with an acceptable range.
The embodiment may be used to detect other failure mechanisms. For example, rather than reconfiguring the capacitor configuration, an original regulator can be replaced with a spare regulator. If a voltage drop across the spare regulator is within an acceptable range, then the original regulator is determined to be faulty. However, if it is determined that the original regulator is not faulty, the capacitor arrangement (comprising C 1451 - 1465 ) can be tested. In one embodiment, the capacitors of the capacitor arrangement can be charged to a known voltage, such as the measured battery voltage, and the voltages across the capacitors can be measured by therapy measurement block 221 . If a voltage is low across a capacitor, the capacitor may be determined to be faulty. In such a case the capacitor may be replaced with a redundant capacitor.
FIG. 15B shows an electrical configuration corresponding to regulators 1401 , 1403 , 1405 , and 1407 . The electrical configuration comprises an amplifier 1553 in which an output 1557 feeds into a negative input and a programmed input voltage 1555 feeds into a positive input of amplifier 1553 . Thus, amplifier 1553 is configured as a voltage follower amplifier (i.e. output 1557 should approximately equal programmed input voltage 1555 if the circuitry is operating properly). Amplifier 1553 receives a power supply voltage from a capacitor arrangement 1551 through a reg top 1559 and a reg bottom 1561 .
The embodiment corresponding to FIG. 15A measures a voltage drop across a regulator (e.g. 1401 , 1403 , 1405 , or 1407 ). In FIG. 15B , the voltage drop across the regulator corresponds to a voltage difference between reg top 1559 and output 1557 . Moreover, other embodiments of the invention may utilize other electrical measurements in order to determine an out-of-regulator condition. In one embodiment, if output 1557 does not approximately equal programmed input voltage 1555 , therapy measurement block 221 may determine the occurrence of an out-of-regulator condition. In another embodiment, output 1557 (as measured by therapy measurement block 221 ) is compared with an expected output voltage. In the embodiment, processor 201 is cognizant of the configuration of capacitor arrangement 1551 and the battery voltage. Processor 201 may use electrical formulae that correspond to the known configuration in order to determine the expected output voltage. A sufficiently large difference between output 1557 and the expected output voltage is indicative of an out-of-regulator condition. In another embodiment, an out-of-regulator condition is detected when the voltage difference between reg top 1559 and reg bottom 1561 (corresponding to an input signal to regulator 1401 , 1403 , 1405 , or 1407 ) is less than programmed input voltage 1555 .
Detection and Correction of Possible Failure of Coupling Capacitor.
In the embodiment, a coupling capacitor (e.g. 1471 , 1473 , 1475 , and 1477 ) is used to transfer charge to an electrode. The accumulated voltage across the coupling capacitor is a measure of the charge that is transferred to the electrode. Moreover, the value of the coupling capacitor determines the maximum charge that can be transferred to the electrode for a given stimulation voltage. However, the coupling capacitor may fail in which the coupling capacitor becomes shorted. In such a case, the coupling capacitor becomes unable to limit excess charge. In order to detect a shorted condition, therapy measurement block 221 monitors the voltage drop across the coupling capacitor (e.g. capacitor 1471 which corresponds to regulator 1401 ). Inputs 1481 and 1483 enable therapy measurement block 221 to monitor the voltage drop across coupling capacitor 1471 . Similar inputs are provided for each other coupling capacitor ( 1473 , 1475 , and 1477 ) in circuit. A voltage drop greater than or less than a prescribed range may be indicative of a possible failure in the coupling capacitor 1471 .
Once the system detects a failed coupling capacitor, it may take any number of corrective actions including, but not limited to, perform a corrective recharge to compensate for the failure, replacing the failed capacitor with another capacitor, notifying the implantable medical device or the physician programmer, and/or shutting down the implantable medical device. FIG. 16 shows a logic flow diagram 1600 of one embodiment for detecting a faulty coupling capacitor and taking corrective action. In step 1601 , therapy measurement block 221 measures the voltage across the coupling capacitor (e.g. coupling capacitor 1471 ). Although a voltage drop measurement across the coupling capacitor is made, any measurement providing charge information would suffice to determine whether the capacitor has failed including, but not limited to, energy information going in and out of the capacitive element, and current information going in and out of the capacitive element. In step 1603 , if it is determined that the voltage drop is less than a predefined threshold, it is assumed that the coupling capacitor has malfunctioned and corrective action should be taken. Otherwise, step 1605 is executed and another coupling capacitor is monitored by therapy measurement block 221 .
In step 1607 , corrective action is taken by removing from service the coupling capacitor (e.g. coupling capacitor 1471 ) and its associated regulator (e.g. 1401 ) and notifying the INS processor 201 . In step 1609 , logic 1600 determines if a spare capacitor/regulator pair can be configured in order to assume the functionality of the faulty capacitor. In either case, the INS processor 201 may be notified. The INS processor 201 may then notify the clinician (i.e., the physician programmer 30 ) about the condition through the telemetry channel. If a spare regulator is available, the spare regulator is configured in step 1613 to assume the functionality of the regulator that was removed. INS processor 201 is informed in step 1615 . Step 1617 is executed, and another coupling capacitor is monitored. In other embodiments, other forms of corrective action may be taken. For example, the system can provide a charge balance pulse in an amount to compensate for the capacitive element being outside the predefined threshold. The charge balance pulse can be calculated by determining charge going in and going out of the coupling capacitor. For example, if the stimulation pulse is at a constant current, the system can determine the current amount and duration. The charge balance pulse can then be in an amount that zeros out the difference in the charges going in and going out of the coupling capacitor. In another example, the system can just notify the INS processor 201 and physician programmer 30 or it can just simply shut itself down from operation.
Other embodiments of the invention may monitor the coupling capacitor (e.g. coupling capacitor 1471 ) in order to detect whether the coupling capacitor becomes open. In such a case, the voltage drop across the coupling capacitor may exceed a predefined threshold. In this case, even the associated regulator/capacitor pair may become ineffective in the treatment of the patient. Therapy measurement block 221 may therefore remove the regulator/capacitor pair and configure a spare regulator.
In yet other embodiments, therapy measurement block 221 may measure other elements other than capacitive elements including, but not limited to, holding capacitors 1491 and 1493 . In one exemplary embodiment, therapy measurement block 221 measures the voltage of the battery using one of the holding capacitors 1491 or 1493 . After a certain time period (e.g., several seconds or several minutes), therapy measurement block 221 re-measures the voltage of the battery using the same holding capacitor 1491 or 1493 . Under proper operation of the holding capacitor 1491 , the two voltage measurements should be roughly the same. If the two voltage measurements vary by more than a predetermined threshold, however, there is likely a failure in the holding capacitor. Alternatively, if the original voltage measurement of battery is outside a predefined range, it may be indicative of a failed capacitor. For example, if the original voltage measurement of battery is be less than 2V, then it is likely that the holding capacitor has failed. This is the case since if the battery voltage had reached 2V, the circuitry would have already been shut down for purposes of conserving battery resources. In another alternative, if the holding capacitor is open circuited, the therapy measurement block 221 would have been unable to take the initial battery voltage measurement. Once the system determines a possible failure of the holding capacitor, it may then take appropriate action as discussed above (e.g., replacing holding capacitor with redundant capacitor, notifying the implantable medical device or physician programmer of capacitor failure, etc.).
Regulator Improvements.
FIG. 17 shows a first configuration for a set of regulators comprising regulators 1401 , 1403 , 1405 , and 1407 according to an embodiment of the present invention. The configuration shown in FIG. 17 may be used to generate a Pulse Width “A” pulse (pwa) 1923 that is shown in FIG. 19 . Other embodiments may support a different number of regulators in order to generate a different numbers of corresponding waveforms. Capacitors 1451 , 1453 , 1455 , 1457 , 1459 , 1461 , 1463 , and 1465 have been charged by battery 1467 so that capacitors 1459 and 1461 have a 1.5 volt potential and capacitors 1451 , 1453 , 1455 , 1457 , 1463 , and 1465 have a 3.0 volt potential. In order to provide a 3.0 volt input to regulator 1403 , a 4.5 volt input to regulator 1407 , a 7.5 volt input to regulator 1405 , and a 13.5 volt input to regulator 1401 , a voltage reference 1711 is configured with respect to BPLUS of battery 1467 . Waveform controller 1101 configures the capacitors 1451 - 1465 and the voltage reference through generator control 1003 . The output of regulator 1403 is connected to anode 1703 ; the output of regulator 1407 is connected to anode 1707 ; the output of regulator 1405 is connected to anode 1705 ; the output of regulator 1401 is connected to anode 1701 ; and voltage reference 1711 is connected to cathode 1709 .
FIG. 18 shows a second configuration for a set of regulators comprising regulators 1401 , 1403 , 1405 , and 1407 according to an embodiment of the present invention. The configuration shown in FIG. 18 may be used to generate a pulse width “B” pulse (pwb) 1915 that is shown in FIG. 19 . Capacitors 1451 - 1465 have the same voltage potential as shown in FIG. 17 . However, waveform controller 1001 configures a voltage reference 1811 to be the negative side of capacitor 1451 so that the input voltage to each regulator ( 1407 , 1403 , 1405 , and 1401 ) has a negative polarity rather than a positive polarity. As in the configuration shown in FIG. 17 , cathode 1709 is connected to the voltage reference. Consequently, the voltage outputs of regulators 1407 , 1403 , 1405 , and 1401 have a negative polarity. Waveform controller 1001 also configures capacitors 1451 - 1465 so that capacitors 1451 and 1453 are between voltage reference 1811 and the input of regulators 1407 and 1403 , capacitors 1451 , 1453 , 1455 , 1457 are between voltage reference 1811 and the input of regulator 1405 , and capacitors 1451 , 1453 , 1455 , 1457 , 1459 , 1461 , 1463 , and 1465 are between voltage reference 1811 and the input of regulator 1401 .
Table 1 compares the voltage outputs of regulators 1401 , 1403 , 1405 , and 1407 in FIGS. 17 and 18 .
TABLE 1
Comparison of Regulator Output Voltages for pwa and pwb
Configurations
Pulse Width A
Pulse Width B
Configuration
Configuration
Anode 1701
12 volts
−11 volts
Anode 1703
2 volts
−5 volts
Anode 1705
6 volts
−6 volts
Anode 1707
3 volts
−1.5 volts
With regulators 1401 , 1403 , 1405 , and 1407 having a capability of generating negative voltage, the risk of a charge accumulation that may damage surrounding tissue around stimulated electrodes is reduced. The required amplitude of a stimulation pulse pwa 1923 (as shown in FIG. 19 ) varies with the type of therapy.
With a therapy pulse (e.g. pwa 1923 ) that is delivered to the tissue, it may be necessary to retract an equal amount of charge from the same tissue after the therapy pulse is completed. This retraction of charge is typically done in the form of a secondary pulse, or recharge pulse, which causes an equal amount of charge to flow in the opposite direction of the original therapy pulse. If the amount of charge in the secondary pulse does not equal the amount of charge in the therapy pulse, charge will accumulate on the electrode surface, and the chemical reactions at the electrode-tissue interface will not remain balanced, which can cause tissue and electrode damage. For example, the accumulated charge may be accompanied by electrolysis, thus causing hydrogen, oxygen and hydroxyl ions to form. As a result, the pH level of the immediate layer of fluid in the proximity of the electrode may deviate from its norm. PH variations may oscillate between pH 4 and pH 10 within a few microns of the electrode. Also, charge accumulation may cause dissolution of the electrode (e.g. platinum), resulting in lead corrosion and possible damage to tissue that encounters the resulting chemical migration. Thus, the reduction of the net charge that accumulates in the region of the treatment reduces the possibility of accompanying tissue damage and electrode damage.
As will be discussed in the context of FIG. 19 , pwb pulse 1925 may have a negative polarity (as supported by the regulator configuration in FIG. 18 ). The negative charge that accumulates in the surrounding tissue during pwb pulse 1925 counterpoises the positive charge that accumulates during pwa pulse 1923 .
If the electrical characteristics between a stimulated electrode pair can be modeled as an equivalent circuit having a capacitor, the charge accumulated during pwa interval 1909 may be counterpoised by the charge accumulated during pwb interval 1915 if the product (amplitude of pwa 1923 )*(interval of pwa 1909 ) approximately equals the product (amplitude of pwb 1925 )*(interval of pwb 1915 ) when the polarities of pwa pulse 1923 and pwb pulse 1925 are opposite of each other.
Other embodiments of the invention may generate positive and negative current waveforms by converting a voltage pulse to a current pulse, in which the output from the regulator is driven through a resistance in the regulator.
Recharge Delay and Second Pulse Generation.
FIG. 19 shows stimulation waveform 1901 according to an embodiment of the present invention. FIG. 19 shows waveform 1901 spanning a rate period interval 1902 . Waveform 1901 may repeat or may change waveform characteristics (corresponding to changing a waveform parameter) during a next rate period interval. Stimulation waveform 1901 may be programmed in order to customize a therapeutical treatment to the needs of the patient. An initial delay (delay_ 1 ) interval 1905 commences with a rate trigger event. The rate trigger event occurs at the beginning of each rate period interval. During a pulse width A (pwa) setup interval 1907 , capacitors 1451 - 1465 are moved from a charge configuration to a stack configuration. A pulse width pwa interval 1909 commences upon the completion of interval 1907 . During interval 1909 , regulators 1401 - 1407 apply voltage or current outputs to a set of electrodes (e.g. anodes) while corresponding electrodes (e.g. cathodes) are connected to a stimulation voltage reference. In the embodiment, pwa interval 1909 is programmable from 0 to 655 msec with increments of 10 microseconds, in which an associated timer is a 16-bit timer.
A second delay (delay_ 2 ) interval 1911 may begin upon the completion of pwa interval 1909 . During interval 1911 , all electrode connections remain open. In the embodiment, second delay interval 1911 is programmable from 0 to 655 msec with increments of 10 microseconds.
A pwb setup interval 1913 may begin upon the completion of second delay interval 1911 . During interval 1913 , capacitors 1451 - 1465 are moved from a charge configuration to a stack configuration. A pwb interval 1915 follows interval 1913 . During pwb interval 1915 , regulators 1401 - 1407 apply voltage or current outputs to the set of electrodes (e.g. anodes) while corresponding electrodes (e.g. cathodes) are connected to a stimulation voltage reference. In the embodiment, pwb interval 1915 is programmable from 0 to 655 with increments of 10 microseconds.
While the embodiment configures the stimulation pulse during pwa interval 1909 with a positive polarity and the stimulation pulse during pwb interval 1915 with a negative polarity, other embodiments may reverse the polarities. Moreover, other embodiments may configure both pulses during intervals 1909 and 1915 to have the same polarity.
A third delay (delay_ 3 ) interval 1917 begins upon completion of pwb interval 1915 . During interval 1917 , all electrodes connections remain open. In the embodiment, the third delay interval 1917 is programmable from 0 to 655 msec with increments of 10 microseconds.
A passive recharge interval 1919 is triggered by the completion third delay interval 1917 . During interval 1919 , electrodes may be connected to a system ground. In the embodiment, waveform controller 1001 (through passive recharge control 1491 ) passively recharges the connected electrodes in order to provide a charge balance in tissues that are adjacent to the connected electrodes. Passive recharging during interval 1919 may function to complete the recharging process that may be associated with pwb interval 1915 . In the embodiment, passive recharge interval 1919 is programmable from 0 to 655 msec with increments of 10 microseconds. A wait interval 1921 follows interval 1919 in order to complete rate period interval 1902 . In the embodiment, the rate period interval is programmable from 0 to 655 msec. In the embodiment, if the sum of the component intervals ( 1905 , 1907 , 1909 , 1911 , 1913 , 1915 , 1917 , 1919 , and 1921 ) exceed the rate period interval, the rate period interval takes precedence over all components intervals in the event of a conflict. For example, all waveform timers are reloaded and a new waveform may commence with the occurrence of rate trigger event.
Pulses generated during pwa pulse interval 1909 and pwb interval 1915 may be used to stimulate surrounding tissues or may be used to assist in charge balancing. The effects of charge balancing during a pulse may be combined with charge balancing during passive recharge interval 1919 in order to obtain a desired charge balancing. (Recharging may provide charge balancing with active components or with passive components or both.)
Other embodiments of the invention may initiate rate period interval 1902 with a different interval than delay_ 1 interval 1905 . For example, other embodiments may define the beginning of rate period interval 1902 with passive recharge interval 1919 . Moreover, with the embodiment or with other embodiments, any of the delay intervals (delay_ 1 interval 1905 , delay_ 2 interval 1911 , delay_ 3 interval 1917 , wait interval 1921 ), pulse intervals (pwa interval 1909 , pwb interval 1915 ), setup intervals (pwa setup interval 1907 , pwb setup interval 1913 ), or passive recharge interval 1919 may be effectively deleted by setting the corresponding value to approximately zero. Also, other embodiments may utilize different time increments other than 10 microseconds.
FIG. 19 also shows a second waveform 1903 that is formed during the formation of 1901 . (In the embodiment, regulators 1401 and 1407 may be utilized to form four waveforms.) Waveform 1903 is phased with waveform 1901 (with each waveform having the same rate period interval). A pwa pulse 1927 (that is associated with waveform 1903 ) occurs after the completion of pwa pulse 1923 (that is associated with waveform 1901 ). The clinician may stimulate a set of electrodes with waveform 1901 . The subsequent stimulation of the set of electrodes by waveform 1903 may cause the firing of the neurons that may not be possible only with waveform 1901 or 1903 alone. In the embodiment, waveforms 1901 (corresponding to regulator 1401 ) and 1903 (corresponding to regulator 1403 ) may be applied to the same electrode or to two electrodes in close proximity. In the embodiment, if regulators 1401 and 1405 are configured to the same electrode, regulators 1401 and 1405 are configured in series for voltage amplitude waveforms and in parallel for current amplitude waveforms.
In the embodiment, the rate period interval of waveforms 1901 and 1903 are the same. However, other embodiments of the invention may utilize different rates periods for different waveforms.
FIG. 20 shows a state diagram that a finite state machine 2000 utilizes to form the waveforms as shown in FIG. 19 according to an embodiment of the present invention. A finite state machine may be associated with each waveform that is generated by INS 200 . In the embodiment, state machine 2000 is implemented with waveform controller 1001 . Waveform controller 1001 , in accordance with state machine 2000 , controls generator 1003 , regulators 1401 - 1407 , passive recharge control 1491 , and electrode control 1007 in order to generate stimulation pulses in accordance with state machine 2000 . Moreover, waveform controller 1001 may obtain waveform parameters from processor 201 . The clinician may alter a waveform parameter (e.g. pwa pulse duration 1909 ) by sending an instruction over the telemetry channel through telemetry unit 211 to processor 201 in order to modify the waveform parameter. In the discussion of FIG. 19 , it is assumed that wave shaping (as will be discussed in the context of FIG. 21 ) is not activated. In FIG. 20 , a state delay_ 1 2001 corresponds to first delay interval 1905 . A transition 2051 initiates a state pwa setup 2003 upon the expiration of interval 1905 . State 2003 corresponds to pwa setup interval 1913 . If wave shaping is activated, states ws_ 1 2005 , ws_ 2 2007 , and ws_ 3 2009 may be executed. (However, discussion of states 2005 , 2007 , and 2009 are deferred until the discussion of FIG. 21. ) A delay_ 2 state 2013 may be accessed directly from state delay_ 1 2001 through transition 2050 if pwa pulse is not generated during pwa interval 1909 .
Assuming that wave shaping is not activated, a state pwa 2011 is executed upon the completion of pwa setup interval 1907 through a transition 2053 . State pwa 2011 corresponds to interval pwa 1909 during which pwa pulse 1923 is generated. Upon the completion of interval 1909 , state delay_ 2 2013 is entered through a transition 2073 . State 2013 corresponds to delay_ 2 interval 1911 . If pwb pulse is generated, a pwb setup state 2015 is entered through transition 2077 upon the completion of delay_ 2 interval 1911 . If pwb pulse 1925 is not generated, a delay_ 3 state 2019 is entered through transition 2075 upon the completion of delay_ 2 interval 1911 . State pwb setup 2015 corresponds to pwb setup interval 1913 and state delay_ 3 state 2019 corresponds to delay_ 3 interval 1917 .
With the completion of pwb setup interval 1913 , if pwb pulse 1925 is to be generated, a pwb state 2017 is entered through transition 2079 . The pwb state 2017 corresponds to pwb interval 1915 during which the pwb pulse 1925 is generated. Upon the completion of pwb interval 1915 , delay_ 3 state 2019 is entered through transition 2081 . Upon the completion of delay_ 3 interval 1917 , finite state machine enters a passive recharge (pr) state 2021 through transition 2085 or a wait state 2023 through transition 2083 . The pr state 2021 may be circumvented if recharging during pwb 2017 state adequately eliminates a charge accumulation that occurs during pwa state 2003 . The pr state 2001 corresponds to passive charge interval 1919 . Upon the completion of passive recharge interval 1919 , state machine 2000 enters wait state 2023 , and remains in state 2023 until the completion of the rate period interval. State machine 2000 consequently repeats the execution of states 2001 - 2023 .
Other embodiments of the invention may support a different number of stimulation pulses (e.g. three, four, and so forth) during rate period interval 1902 .
Wave Shaping.
FIG. 21 shows a waveform 2101 in which stimulation pulse pwa 1923 is generated by wave shaping according to an embodiment of the present invention. Waveform 2101 , as shown in FIG. 21 , spans a rate period interval 2102 . Wave shaping of pwa 1923 corresponds to a state ws_ 1 2005 , a state ws_ 2 2007 , and a state ws_ 3 2009 (as shown in finite state machine 2000 in FIG. 20 ) and corresponds to a ws_ 1 duration 2109 , a ws_ 2 duration 2111 , and a ws_ 3 duration 2113 in FIG. 21 . Durations 2109 , 2111 , and 2113 correspond to phases 1 , 2 , and 3 of pwa pulse 1923 . In the embodiment, pwa pulse 1923 is synthesized in order to adjust the therapeutical effectiveness of pwa pulse 1923 . In the embodiment, without wave shaping, pwa pulse 1923 is essentially a rectangular pulse (flat-topped) as illustrated in FIG. 19 .
In the embodiment, pwa interval 1909 is subdivided into three phase intervals 2109 , 2111 , and 2113 . During phase intervals 2109 , 2111 , or 2113 , at least one parameter is associated with the stimulation waveform. In the embodiment, a parameter may correspond to characteristics of the stimulation waveform (e.g. a desired amount of rise during the phase) or may correspond to an electrode configuration in which the stimulation waveform is applied. In the embodiment, all other time intervals remain the same and all time intervals maintain the same order of succession (e.g. pwb 1925 follows pwa 1923 ) as in the case without wave shaping. During each of the three phases (ws_ 1 2150 , ws_ 2 2160 , and ws_ 3 2170 ) of pwa pulse 1923 , the output amplitude may be rising, falling, or constant across a phase. (Other embodiments may utilize a different number of phases. Typically, with a greater number of phases, one can achieve a better approximation of a desired waveform. The desired waveform may correspond to any mathematical function, including a ramp, a sinusoidal wave, and so forth.) Each of the three phases is defined by a register containing an initial output amplitude, a register containing a final output amplitude, and a register containing a number of clock periods in which the amplitude output remains constant across an incremental step. In the embodiment, a phase duration (e.g. 2109 , 2111 , and 2113 ) is determined by:
(|final amplitude count−initial amplitude|+1)*(number of clock periods per step)
The output amplitude changes by one amplitude step after remaining at the previous amplitude for a clock count equal to the value of the clock periods per step as contained in a register. The output amplitude range setting in a register determines a size of an amplitude step. (In the embodiment, the step size may equal 10, 50, or 200 millivolts.)
An example of wave shaping illustrates the embodiment as shown in FIG. 21 . The step size is 500 millivolts for phases 2150 and 2160 and 1 volt for phase 2170 . The master waveform generator clock is 10 microseconds. Durations 2109 , 2111 , and 2113 are each 400 microseconds. During duration 2109 , the initial amplitude register contains 70 ( 46 16 ) and the final amplitude register contains 40 ( 28 16 ). The clock periods per step is 10 or 100 microseconds (10*10 microseconds). During duration 2109 , waveform 2103 starts at 3.5 volts and descends 0.5 volts every 100 microseconds until the amplitude value is 2.0 volts.
During duration 2111 , the initial amplitude register contains 0 and the final amplitude register contains 70 ( 46 16 ). The clock periods per step is 10. During duration 2111 , waveform 2105 starts at 0 volts and ascends 0.5 volts every 100 microseconds until the amplitude value is 3.5 volts. During duration 2113 , the initial amplitude register contains 30 ( 1 E 16 ). The clock periods per step is 20 (corresponding to 200 microseconds). During duration 2113 , waveform 2107 starts at 1.5 volts and ascends to 2.5 volts in one step.
Finite state machine 2000 (as shown in FIG. 20 ) supports wave shaping with ws_ 1 state 2005 , ws_ 2 state 2007 , and ws_ 3 state 2009 . With wave shaping enabled, state 2005 , 2007 , or 2009 is entered from pwa setup state 2003 through transitions 2057 , 2055 , and 2059 , respectively. The pwa state is not executed when wave shaping is enabled. In the embodiment, the synthesis associated with any phase ( 2150 , 2160 , 2170 ) may be circumvented. For example, ws_ 1 state 2005 may enter ws_ 2 state 2007 through transition 2061 , may enter ws_ 3 state 2009 through transition 2063 , or may enter delay_ 2 state 2013 through transition 2065 .
Other embodiments of the invention may support a different number of phases than is utilized in the exemplary embodiment. Also, other embodiments may utilize wave shaping for other portions of waveform 2101 (e.g. a pwb pulse 2129 ).
FIG. 22 shows a first apparatus that supports wave shaping as shown in FIG. 19 according to an embodiment of the present invention. Output voltage V out 2203 corresponds to phase 2150 , 2160 , or 2170 . A digital to analog converter (DAC) 2201 generates V out 2203 in accordance to a digital input 2209 . Input 2209 is obtained from register 2205 . Register 2205 receives a digital input 2211 from waveform controller 1001 . Input 2211 is stored in register 2205 when clocked by clk_step 2207 , which occurs at a rate of updating phases 2150 , 2160 , or 2170 (corresponding to a “step”). Waveform controller 1001 updates digital input 2211 in order to cause V out 2203 to equal a desired value during phases 2150 , 2160 , or 2170 in accordance with an initial output amplitude, a final output amplitude, an amplitude step size, and a step time duration parameters.
In a variation of the embodiment, DAC 2201 determines a voltage drop across a regulator (e.g. 1401 , 1403 , 1405 , or 1407 ). The value of the stimulation waveform (with a voltage amplitude) is approximately a voltage input to the regulator minus the voltage drop (as determined by DAC 2201 ). Consequently, digital input 2211 is determined by subtracting an approximate value of the stimulation waveform from the input voltage to the regulator.
FIG. 23 shows a second apparatus that supports wave shaping as shown in FIG. 19 according to an embodiment of the present invention. An output V out 2301 corresponds to phases 2150 , 2160 , and 2170 in FIG. 21. V out 2301 is the output of an analog adder 2303 having inputs 2305 and 2307 . Input 2305 is obtained from a gate 2309 in which a step voltage V 1 2311 is gated by a gate control 2313 in accordance with a step time duration. With apparatus 2300 ,
V out= V out+ V in
FIG. 24 shows a logic flow diagram 2400 representing a method for supporting wave shaping according to an embodiment of the present invention. Step 2401 determines whether wave shaping is activated. If not, process 2400 is exited in step 2403 . In such a case, pwa stimulation pulse 1923 is generated as an essentially flat pulse over time duration 1909 . If wave shaping for an i th phase of the pwa pulse is activated, step 2405 is executed.
In step 2405 , an initial output voltage V start , a final output voltage V final , a step size V i , a step duration t 1 and a phase time duration T 1 are determined. In step 2407 , V out is equal to V start . Step 2409 determines if the step time duration t 1 has expired. If so, V out is incremented by the step size V 1 in step 2411 . If V out equals the final output voltage V final in step 2413 , the output voltage V out remains constant until the end of the phase duration T 1 in step 2415 . If V out is not equal to the final output voltage V final and the phase time duration T 1 has not expired (as determined in step 2417 ), step 2409 is repeated in order to update V out for another step time duration t 1 .
Other embodiments of the invention may support wave shaping of a current amplitude of waveform 2101 . In such cases, a voltage amplitude may be converted into a current amplitude by driving a resistor that is associated with a regulator (e.g. 1401 , 1403 , 1405 , and 1407 ).
Simultaneous Delivery of a Plurality of Independent Therapy Programs.
FIG. 25 shows a stimulation arrangement that is associated with an implantable neuro stimulator according with prior art such as that disclosed in U.S. Pat. No. 5,895,416. Lead 2501 comprises a plurality of electrodes including cathode 2503 , cathode 2505 , and anode 2507 . Anode 2507 provides a common reference for either a voltage amplitude pulse or a current amplitude pulse through cathodes 2503 and 2505 . Waveforms 2511 and 2513 are applied to cathodes 2503 and 2505 , respectively. Waveform 2511 differs from waveform 2513 by amplitude scaling; however, component time durations are the same for waveform 2511 and waveform 2513 . Moreover, the waveforms serve to treat the same neurological condition in a specific portion of the body.
FIG. 26 shows a stimulation electrode arrangement that is associated with INS 200 according to an embodiment of the present invention. INS 200 stimulates leads 2601 and 2603 . Lead 2601 comprises electrodes 2605 - 2619 , and lead 2603 comprises electrodes 2621 - 2635 . The basic “unit” of therapy is a “therapy program” in which amplitude characteristics, pulse width, and electrode configuration are associated with a pulse train for treatment of a specific neurological conduction in a specific portion of the body. Multiple therapy programs may therefore be used to either treat distinct neurological conditions or treat the same neurological condition but in distinct areas of the body. The pulse train may comprise a plurality of pulses (voltage or current amplitude) that are delivered essentially simultaneously to the electrode configuration.
In FIG. 26 , four therapy programs (program 2637 , program 2639 , program 2641 , and program 2643 ) are configured and activated. In the embodiment, thirty two therapy programs may be defined in which one to four therapy programs may be activated to form a therapy program set. (Other embodiments may support a different number of therapy programs and a different size of the therapy program set.)
Additional therapy programs (not directly accessible by the patient) may be provided for any number of reasons including, for example and without limitation, to treat neurological conditions in distinct parts of the body, to treat distinct neurological conditions, to support sub-threshold measurements, patient notification, and measurement functions. For example, a patient notification program is used to define an output pulse train for patient notification such as some type of patterned stimulation that can be discernable by the patient. The patient notification program may be activated by a low battery (battery 1467 ) condition. A lead integrity measurement program defines a pulse train to executing lead (e.g. 2601 and 2603 ) integrity measurements.
In FIG. 26 , the therapy program set comprises therapy programs 2637 (program 1 ), 2639 (program 2 ), 2641 (program 3 ), and 2643 (program 4 ). Each therapy program comprises four waveforms C 1 , C 2 , C 3 , and C 4 that are generated by regulators 1401 , 1403 , 1405 , and 1407 , respectively. Table 2 illustrates the configuration of the program set as shown in FIG. 26 . Stimulation pulses are applied to cathodes 2607 - 2617 of lead 2601 and to cathodes 2623 - 2633 of lead 2603 , while anodes 2605 , 2619 , 2621 , and 2635 serve as common references.
TABLE 2
EXAMPLE OF THERAPY PROGRAM SET
Lead 1 (2601)
Lead 2 (2603)
Electrode
1
2
3
4
5
6
1
2
3
4
5
6
program
C1
C2
C3
C4
1 (2637)
program
C1
C2
C3
C4
2 (2639)
program
C1
C2
C3
C4
3 (2641)
program
C1
C2
C3
C4
4 (2643)
With therapy program 2637 (program 1 ), stimulation pulses 2655 , 2657 , 2651 , and 2653 are applied to cathodes 2611 , 2613 , 2627 , and 2629 , respectively. With therapy program 2639 (program 2 ), stimulation pulses 2665 , 2667 , 2661 , and 2663 are applied to cathodes 2611 , 2613 , 2627 , and 2629 , respectively. The pulse characteristics of a regulator (e.g. 1401 , 1403 , 1405 , 1407 ) may vary from one therapy program to another. For example, pulse 2655 and pulse 2665 are generated by regulator 1401 ; however, pulse 2655 and pulse 2665 may have different characteristics in order to obtain a desired therapeutical effect.
With therapy program 2641 (program 3 ), stimulation pulses 2675 , 2677 , 2671 , and 2673 are applied to cathodes 2615 , 2617 , 2631 , and 2633 , respectively. With therapy program 2643 (program 4 ), stimulation pulses 2685 , 2687 , 2681 , and 2683 are applied to cathodes 2607 , 2609 , 2623 , and 2625 , respectively.
Thus, embodiments of the INDEPENDENT THERAPY PROGRAMS IN AN IMPLANTABLE MEDICAL DEVICE are disclosed. One skilled in the art will appreciate that the present invention can be practiced with embodiments other than those disclosed. The disclosed embodiments are presented for purposes of illustration and not limitation, and the present invention is limited only by the claims that follow. | Apparatus and method for independently delivering a plurality of therapy programs in an implantable medical device. A therapy controller configures the device to generate independent pulse trains associated with a plurality of therapy programs and dynamically configures the electrodes to deliver the independent pulse trains to the patient. Once configured, the implantable medical device delivers the plurality of therapy programs to the patient wherein the therapy programs may overlap in time. | 83,044 |
RELATED APPLICATIONS
[0001] This application is a continuation in part of U.S. application Ser. No. 12/119,228 filed on May 12, 2008 entitled “Methods For Analyzing Job Functions And Job Candidates And For Determining Their Co-Suitability”.
FIELD OF THE INVENTION
[0002] The present invention relates to a computerized injury management process and system. More particularly, to an adaptive system that provides physicians with treatment recommendations based on the injury data inputted wherein the computer database provides a selection of diagnoses from which the physician can select from which also includes recommended treatment protocol for a particular diagnosis and more particularly a feedback data entry to constantly increase the knowledge base of the program.
BACKGROUND OF THE INVENTION
[0003] Historically, a physician would rely on his own experience and judgment to identify what type of injury a patient had based on what he or she was seeing during an initial patient examination which would often include imaging of the injured area using x-ray or MRI scans. The severity of the injury would be determined and based on that determination; the physician would select what treatment he would give based on the options he knew and his history of success in treating similar injuries.
[0004] Another trend is to use a review of the literature to determine which treatments have shown the most promise in treating a particular injury. Repositories of outcome research, such as provided by the Cochrane Library (http://www.thecochranelibrary.com/view/0/index.html), offer an online searchable database of outcome research, categorized by injury type. Other services, such as BMJ (http://www.us.bestpractice.bmj.com/best-practice/marketing/bp-app.html) offer a subscription based service allowing the user online access to diagnosis guidelines and treatment protocols considered to be “Best Practices” for a particular diagnosis.
[0005] This access to other treatments that are available provides a resource beyond those limited to the physician's own experience and training
[0006] One of the limitations of this type of research is the physician's initial diagnosis itself may be flawed or incomplete and as a result the research may advise a treatment or repair procedure more invasive or less invasive than required due to initial misinterpretation of the injury.
[0007] Preferably, the physician could be aided in the entire procedure of evaluation diagnosis and treatment if the research tools available to him were more interactive.
[0008] In U.S. Pat. No. 7,705,727 issued Apr. 27, 2010 by Stanley L Pestotnik, et al entitled “System, Method And Computer Program For Interfacing An Expert System To A Clinical Information System” which proposed a flow of information and actions between the expert and system and clinical system and allows maintenance of audit logs in both systems. The patent allows a physician to use an expert system while specifically maintaining separate patient data. This reduces the data entry burden on the physician while maintaining patient privacy.
[0009] In U.S. Pat. No. 7,490,085 issued on Feb. 10, 2009, Matthew J. Walker, et al received a patent entitled “Computer-Assisted Data Processing System And Method Incorporating Automated Learning”. In that patent, a technique is provided for enhancing performance of computer-assisted data operating algorithms in a medical context. Datasets are compiled and accessed, which may include data from a wide range of resources, including controllable and prescribable resources, such as imaging systems. The datasets are analyzed by a human expert or medical professional, and the algorithms are modified based upon feedback from the human expert or professional. Modifications may be made to a wide range of algorithms and based upon a wide range of data, such as available from an integrated knowledge base. Modifications may be made in sub-modules of the algorithms providing enhanced functionality. Modifications may also be made on various bases, including patient-specific changes, population-specific changes, feature-specific changes, and so forth.
[0010] In U.S. Pat. No. 8,041,749 issued Oct. 18, 2011, entitled “Systems And Methods Of Managing Specification, Enforcement, Or Auditing Of Electronic Health Information Access Or use” Michael E. Beck teaches a way to allow access and user rights to health information. Methods and apparatus, including computer program products, related to managing specification, enforcement, or auditing of electronic health information use. In general, data characterizing a request to modify access rights to health information is received and the access rights are modified in accordance with the request, where the modifying includes modifying a property characterizing access rights of a relationship between a first user and second users, or an organization of the second users. The access rights may be independent of the health information and modification of access rights may be independent of a security of the health information.
[0011] In general, the medical professional is using computer aided systems to better address his patient's treatments and improve their quality of life.
[0012] The inventor of the present invention has received several patents on computer aided systems. In U.S. Pat. No. 6,865,581 Pandya, et al provides for analyzing jobs in terms of their tasks and physical requirements and a physician assessing a patient. Pandya most recently received an allowance dated Mar. 14, 2012 on U.S. application Ser. No. 12/119,228, Publication No. 2009-0281879 entitled, “Methods For Analyzing Job Functions And Job Candidates And For Determining Their Co-Suitability”; the subject matter of that application being incorporated by reference herein in its entirety.
[0013] In the context of making recommendations of content, this latest patent employed the combination of (1) breaking a job down into elemental tasks and the physical and mental requirements of each task; (2) a doctor, diagnosing the injured worker by inputting the injury into the medical diagnosing utility and the medical diagnosis utility then makes recommendations regarding the worker's ability to handle certain tasks and the doctor prescribes the computer generated recommendations as maximum allowable physical and mental requirements and movements; and (3) a risk assessment utility for parsing the computer database of past worker injuries to determine what elements of a job are more prone to causing injuries and the risk assessment utility being used to also adapt a job or job elements to compensate or reduce the risks. This application of the computer and associated software is a valuable tool to accelerate an injured worker's return to work (RTW) in a faster and safer fashion which minimizes re-injury.
[0014] A goal of the present invention is to provide the attending physician an interactive knowledge based system that starts at the examination of the injured patient and provides the physician examination, diagnosis and treatment protocols based on the doctor's input and preferably incorporates the treatment outcomes of every treated patient to provide a constantly updated knowledge base. Each entry adds to the statistical significance of the diagnostic and treatment databases to improve a “best practices” situation for the physicians or those persons responsible for treatment supervision such as physical therapists and trainers. Preferably, the computer software incorporates the latest version of ICD, International Classification of Disease, into the diagnosis protocol.
[0015] International Classification of Disease, 9 th edition, Clinical Modification is a standardized classification of disease, injuries, and causes of death, by etiology and anatomic localization and codified into a 6-digit number, which allows clinicians, statisticians, politicians, health planners and others to speak a common language, both US and internationally. ICD-10 CM, introduced in 2002, replaces ICD-9 CM with a final adoption deadline of Oct. 1, 2013, mandated by Health and Human Services (HHS). ICD-10 CM includes 68,000 diagnostic codes, five times more than ICD-9 CM. It expanded the code from five to seven characters, allowing alpha, except for U, in position four through seven (from ANN.NN to ANN.AAA A).
SUMMARY OF THE INVENTION
[0016] In a first embodiment of the invention, a method for aiding a physician in examining, diagnosing and treating an injured patient has the steps of creating a computer database that converts a selected injured body part to a ICD code; conducting an initial examination of an injured patient to identify the injury location or body part or multiple injury locations or body parts and inputting those locations or body parts into the computer database to identify an ICD code or codes; creating an ICD examination diagnosis computer database to automatically convert an ICD code to a sorted group of one or more preliminary diagnoses with examination protocols for each preliminary diagnosis; conducting recommended examination protocols and inputting examination results to the computer database to narrow diagnosis to most likely diagnosis; selecting a recommended diagnosis; creating a computer database of treatment protocols for every computer generated injury diagnosis, the treatment protocols having usage data and outcome data; selecting a treatment protocol; initiating treatment; and inputting treatment outcome results back into the computer database for statistical inclusion into the computer database.
[0017] In a second embodiment, the use of the ICD code can be eliminated and can be substituted with or optionally embedded in a computer test database that provides a list of tests suggested by the injured body part identified and sorted diagnosis database that offers diagnosis based on tested results. The tests narrow the diagnosis to most likely diagnosis. Wherein the physician selects a recommended diagnosis initiates treatment and inputs treatment outcome results for statistical inclusion into the database.
[0018] A preferred embodiment is a method and computer system for executing the method for determining whether an injured player/athlete can return to play in their current position, a different existing position, the current position but altered in some form, or a different existing position but altered in some form to result in lost time reduction, having the steps of (a) creating a computer database by conducting an elemental analysis of a player's position's functions and requirements for a particular sport by breaking a position down into elemental tasks and the physical and mental requirements of each task; creating a parsable database of the positions, tasks and elements to establish specific maximum physical requirements and required movements; and storing this elemental analysis on the computer database; (b) conducting an initial medical diagnosis of the injured player by a physician examination of the player and inputting the computer database with the initial injury report to determine the physical capabilities and limitations of the player wherein the medical diagnosis has the steps of a doctor seeing the injured player patient; the doctor, inputting the data from the examination into the computer database based on the injury; the computer database automatically diagnosing the player based on the inputted data: the computer database making recommendations regarding the player's ability to handle certain tasks; the doctor reviewing the computer database recommendations and prescribing the computer database recommendations as maximum allowable restrictions on activities of the player wherein the recommendations include specific maximum allowable physical and mental requirements and movements; and the physician's office inputting the maximum allowable restriction data into the computer database; and (c) using a risk assessment utility that is used to parse the computer database of past injuries to determine what elements of a position are more prone to causing injuries, wherein said risk assessment utility is used to also adapt a position or position elements to compensate or reduce the risks; (d) comparing by computer the elemental analysis and the medical diagnosis computer generated data to determine whether the player can function in a new assignment of a particular position, wherein the particular position is either the current position, the different existing position, the current position but altered in some form, or the different existing position but altered in some form, by performing the step of comparing the injured player's inputted computer generated medical diagnosis of allowable physical and mental requirements and movements with each position's elemental analysis requirements to either allow the injured player to safely return to play by first determining if the injured player's allowable capability exceeds each possible new assignment of elemental position requirements and then using the risk assessment utility to assess the risk for each position and altered position to assign a position for the injured player that minimizes the risk of injury for the injured player based on the computer database of past injuries; or prevent the injured player from performing any position with tasks in the computer database exceeding the injured player's allowable restrictions on activities.
[0019] The method wherein (e) the computer database has information selected from the group consisting of the team's positions, the team's players, injuries to a team's players, position candidates, required skills, required education; (f) the computer database is searched by computer according to predetermined search criteria so as to result in a match between a player and a position, between a diagnosis and a position, a possibility for adapting a player or a position to fit the criteria, or to assess the risk inherent in a position; and (g) determining whether the player can do the position.
DEFINITIONS
[0020] As used herein and in the claims:
[0021] “Patient” as used herein a patient is any person with an injury or limited functionality that is being diagnosed and treated by a physician using the computer based system of the present invention.
[0022] “Physician” is the expert medical professional who is making the initial examination and using the computerized system to arrive at a diagnosis and treatment protocol.
[0023] “Physician's Staff” are those personnel tasked to assist the physician in the treatment of a patient and whose work affects the examination, diagnosis and treatment and data entry. These include clerical, radiologist, nurses, trainers, therapists and anyone tasked to assist in treating the patient.
[0024] “Player or Athlete” as used herein a player or athlete can be any person who on an amateur basis or professional plays a sport or as a result of the activity has a range of physical requirements needed to perform the activity. By way of example these activities can include field and track, gymnastics, swimming, dance, ballet, golf, bowling, race car driving, tennis, wrestling, boxing, hunting, cycling, as well as team sports like football, basketball, hockey, soccer, baseball, volleyball, lacrosse, etc. In addition, these functional requirements are not limited to those in high school, college or professional organized sports, but further includes workers or retirees whose ability to play or practice their desired activity is dependent on their physical health. This expanded definition is particularly important to those senior citizens desirous of maintaining physical performance and functional capabilities which can degenerate with age. This is true of amateur athletes as well as professionals in any sport or activity. As for many patients, their quality of life is dependent on the ability to participate in their favorite sport or physical activity.
BRIEF DESCRIPTION OF THE DRAWINGS
[0025] The invention will be described by way of example and with reference to the accompanying drawings in which:
[0026] FIG. 1 is a flow chart of a first embodiment of the present invention.
[0027] FIG. 2 is a flow chart of a second embodiment of the present invention.
[0028] FIG. 3 is a flow chart of a third embodiment of the present invention.
[0029] FIG. 4 is a screen shot showing that each user will have a secure login with password protection.
[0030] FIG. 5 is a screen shot of a dashboard listing each case showing the status and other case specific information.
[0031] FIG. 6 is a screen shot showing by selecting an injured player, the screen of FIG. 6 will open which shows the history and physical particulars i.e. mechanism, location, etc driven by the injured body part selected.
[0032] FIG. 7 is a screen shot showing detail for mechanism component screen provides the user with definitions and criteria.
[0033] FIG. 8 is a screen shot of an additional page for history and physical information still driven by body part. Selections on history and physical drive the next screen which narrows down diagnosis.
[0034] FIG. 9 screen shot is research that shows the data summary for the tests conducted during the physical. It is a compilation of the different research with sensitivity and specificity—how accurate the tests are in differentiating a diagnosis.
[0035] FIG. 10 screen shot is the summary of the diagnostic research as well as the testing completed by the physician during the exam.
[0036] FIG. 11 screen shot shows the treatment regimen selected based on ASMI (Andrews Sports Medicine Institute) by level of research—were they controlled studies, anecdotal, etc.
[0037] FIG. 12 screen shot is where the actual treatment is selected based on the criteria selected in the previous screen. It is diagnosis specific, and based on the scoring of outcome research.
[0038] FIG. 13 screen shot is return to play (RTP) criteria, again driven by the choices selected in the previous screens.
[0039] FIG. 14 screen shot is the reporting screen where reports can be viewed or submitted for scoring and review.
DETAILED DESCRIPTION OF THE INVENTION
[0040] In one embodiment of the invention, using a large computer based medical program can greatly facilitate treatment of athletes. Athletes in a particular sport are required to function depending on the position played and as a result certain injuries can be more or less damaging to a players performance depending on the position played. As a result of this a computer facilitated medical diagnosis program can greatly facilitate the treatment and performance of athletes. When a player is injured, a physician can examine the athlete, identify the body part injured and enter that information into the database. The ICD database will provide a plurality of sorted diagnoses from which the user can select the desired diagnosis based on his initial examination. This initial examination can be enhanced by the computer program with preferred or recommended examination test procedures to be conducted should the physician have failed to do so or if the physician has more than one possible diagnosis that looks likely. By conducting computer recommended further examinations and testing, this diagnosis can be narrowed and optimized to increase the probability that the selected diagnosis is the most appropriate for the injury to this particular athlete. Once the diagnosis is selected, the physician needs to identify and input the player's position in the particular sport, be it basketball, soccer or football or any other sport. From the selected position there will be a computer database that has position requirements, the position requirements for a particular player's position requirements will be known. These requirements are fed into a computer database. Within the subset of requirements are the maximum allowable and possibly minimum allowable performance conditions, these are also loaded into the computer database. Once the physician knows the player's position, he can establish based on the diagnosis the injury's severity. Based on the injury's severity he can use the computer database to compare the maximum allowable conditions and adjust the maximum allowable conditions in such a fashion that he can compare the player's injury severity to the player's ability to perform. At this point, a review of functional deficits is made, once the functional deficits is established, the physician can look at the injury and the player's inability to perform at maximum allowable performance and review the functional deficits to allow a review of treatment options. In order for this to happen, the computer based program will evaluate the player based on the diagnosis and his playing position. The system then will return a list of proprietary and non-proprietary functional testing to be performed. The physician will measure the athlete's current functional capabilities and enter those into the system. The system returns a list of functional deficits and suggested treatments to remedy those deficits. Functional testing is completed at the conclusion of treatment to determine treatment success. New diagnostic, treatment and return to play outcomes are reported back to a holding database where they are peer reviewed and scored prior to release and inclusion into a master database. This entire system is shown in the flow diagram illustrated in FIG. 1 . As shown in FIGS. 1A and 2 , alternative embodiment flow charts are illustrated wherein the ICD code can be assimilated into and incorporated into a test database or substituted for by a more comprehensive test database or one enhanced for specialties such as orthopedic injuries or neurological injuries etc. This injury and disease management database allows for an interactive constantly updated computer program system to facilitate physicians and their ability to diagnose and treat injured people and in this particular use for players or athletes. The basis of this process involves the creation of the database which allows for input, follow-up and determination of outcomes all entered into the database. The program then searches and provides reporting as requested by the user based on a search parameter. This would include: 1) the ability to determine how many providers recommend a particular treatment and what the results of it were. 2) The development of best practices based on outcomes. 3) The initial development of suggested recommendations of treatment based on a current review of best practices, which then becomes supplemented and updated based on the learning system in the database. 4) A measure of validity and strength of recommendations is further included.
[0041] A couple of examples of such a program would be: 1) NFL database and search engine: input best practices for management of a particular injury which can be assessed by the subscriber. The provider then inputs his or her own management into the system as well as follow-ups. The system then adds this to the database, and this becomes compiled into the learning system. As the database grows, the system can deliver information that is learned to subsequent users in various formats. a) A trainer sees a player with a Grade 2 MCL sprain. He accesses the database, which provides information about the condition. The provider then adds his or her own experience. This then helps the database grow and refine the experiences for subsequent users. 2) Medical Conditions: A physician treats a patient with lung cancer using radiation. As physicians access the database to determine best practices, they enter their own experience, which helps the database grow.
[0042] An example of reporting as the living database captures information would be 9000 physicians treated sarcoidosis with high dose steroids with these outcomes. The system would also help determine the strength of the recommendations based on the number of inputs and outcomes.
[0043] The computer will integrate a series of relational databases that will allow a subscriber to use the computer to: input a diagnosis, review typical functional limitations with that diagnosis, access requirements of the athlete's playing position (return-to-play criteria), measure the deficit between those requirements and current physical capabilities, search for the best treatment to remediate that deficit, and filter, score, and report results of treatment back to the database, thereby modifying the database with those new outcome results.
[0044] Using a series of relational databases integrated into the exemplary UnicoreSports platform, subscribers are able to enter predetermined criteria into the computer, and the computer will match those criteria with relevant guidelines for diagnosis, treatment, and return to play criteria. The computer sorts and filters any new guidelines and adjusts the database accordingly. Subscribers are able to use the computer program to review, choose, and evaluate treatment practices based on an athlete's or player's injury and position on the field of play. The attached flow charts of FIGS. 1 , 2 and 3 depict the process as it is currently envisioned.
[0045] One embodiment of the present invention can comprise conducting an elemental analysis of a position's functions and requirements, conducting a medical diagnosis of a player to determine the physical limitations or physical abilities the player is capable of, and comparing the elemental analysis and the medical diagnosis to determine whether the player can function in a particular position. For example, a position can be divided up into individual tasks, with each task being broken down into elemental parts. Such elemental parts can be objectively described by the physical and/or mental functions associated with each task, such as for example physical movements, weights, and repetitions involved. These elemental parts can be collected into an integrated parsable database and computerized for ease and speed of searching and comparing. In this same example, a player can undergo a medical diagnosis (a medical check-up) to determine what the player is capable of For example, in conducting a medical diagnosis of an injured player, a doctor can recommend that the player limit his activities and actions to certain maximum allowable units, such as maximum weight lifted, maximum repetitions per hour, maximum time standing or sitting, and maximum body motions such as twisting or bending. These maximum allowables also can be collected into an integrated parsable database and computerized for ease and speed of searching and comparing. The maximum allowables determined in the medical diagnosis that can be compared to the elemental analysis to determine a fit between a player and a position.
[0046] Another embodiment of the present invention can compare the elemental analysis of a database of positions to the medical diagnosis of an injured player to determine whether the player can return to play in a particular position, such as the player's pre-injury position, or in any position within a team or play location. In this embodiment, the maximum allowables resulting from the medical diagnosis initially can be compared with the elemental analysis of the player's original position to determine whether the player can return to play at his or her original position. If not, the player's maximum allowables can be compared to the elemental analyses of a portion or of all of the positions within a team or group of teams to determine whether the player can return to play in any position within the team or group of teams. This could be beneficial to organizations and players organizations alike.
[0047] A further more general embodiment of the present invention can comprise use of the elemental analysis to provide for specific needs of a team. In this embodiment, the maximum allowables can be compared to the elemental analyses of various positions and if no appropriate positions are available, or if a desired position is not appropriate, the elemental analyses can be reviewed to determine if the position can be altered to accommodate the players available. This is a valuable tool in establishing team needs in drafting or acquiring new players.
[0048] Additionally, another general embodiment of the present invention can comprise use of the elemental analysis and the specifics of injuries reported by players to create a clinically relevant risk assessment for determining the specific risks of a position, and use of the risk assessment for modifying a position's functions and requirements to suit the player or other players. For example, the various injuries occurring in connection with a specific position can be tagged to the elemental analysis. The various injuries can be assessed using standard statistical techniques to result in a determination of the likelihood of such injuries occurring in the future by players on this position. This type of determining could identify injury trends very early on and help teams and organizations to adjust rules and implement proactive measures to lower risk. Concussions and head and neck injuries in NFL football and NHL hockey are examples of problems that could easily have been discovered and addressed much earlier with the present invention. Such uncovering of these issues could have saved players and avoided litigation against the organizations.
[0049] The elemental analysis, in summary, comprises breaking a position down into its component tasks. Additionally, the specific position tasks also can be further broken down into whether the task involves repetitions tasks, and into how the tasks can be accomplished. The elemental task information is entered into a database, preferably a parsable database, and more preferably a computerized parsable database.
[0050] The medical diagnosis, in summary, comprises diagnosing a player. A typical medical or clinical diagnosis can include, for example but not limited to, providing descriptions of the player's injury, providing limitations on physical and/or mental activities, and providing a timeline for recovering from such injury and limitations. The physical and/or mental activities can be broken down into specific activities and the limitations attached to such activities. For example, but not limited to, the medical diagnosis can provide that a player can lift no more than a prescribed amount and can only twist the torso no more than 90 degrees. In other words, the medical diagnosis can provide maximum allowable actions in weight and movement. The maximum allowables can be entered into the same database as the elemental analysis, but preferably either is entered into a separate database or is maintained as separate data pertaining to a particular player. For example, while the elemental analysis data can be pertinent to all medical diagnoses and therefore preferably should be parsable relative to all players, the medical diagnoses can be and generally are specific to each individual player and their respective positions.
[0051] The comparison between the elemental analysis and the medical diagnosis, in summary, can be initiated after converting the medical diagnosis into the maximum allowables and then comparing the maximum allowables to the elemental analysis to determine whether the player's limitations or functional deficits will allow the player to do the position, whether the position has acceptable task criteria to accommodate a player, and whether the task criteria can be altered to accommodate an injured player. Medical and clinical criteria are used when creating the restrictions and maximum allowable actions from the medical diagnosis. In other words, the maximum allowable actions link the elemental analysis with the medical diagnosis.
[0052] The present invention comprises several utilities that can be carried out individually or in various combinations, or all together, to increase the chance of successfully determining whether a player, such as an injured player, can return to a previous position, or more generally matching a player to a position, and vice versa. The present invention preferably comprises (a) an elemental analysis utility for creating and using an integrated database of positions, position functions, position tasks, and position requirements; (b) a medical diagnosis utility for creating and using an integrated database of player injuries, and of injuries to a particular player; and (c) a return to play utility for more effectively allowing an injured or disabled player with functional deficits to return to play and to match position candidates with positions by comparing the medical diagnosis with the elemental analysis. Additional utilities can include (d) a risk assessment utility for parsing the integrated databases to determine the risk of a player being injured or re-injured when performing at a specific position, and (e) a modification utility for allowing the modification of a position to suit a particular player, preferably based on a comparison of the medical diagnosis with the elemental analysis. Amazingly, almost all of this work is done by teams manually without any organized way to measure a player's ability after injury or aging to move to an alternate position gaining additional productive play.
[0053] Each utility can have the ability to query the elemental analysis database to provide information relevant to the utility so as to be able, for example (a) to pair a player with the most suitable position or a position with the most suitable player, (b) to allow the adaptation of a position to a player or to address recurring injuries resulting from the position, (c) to allow the modification of a player's tasks in performing a position to address an injury or recurring injuries resulting from the position, (d) to determine whether a position candidate is suitable for a particular or any position and vice versa, (e) to use a medical or physical diagnosis of a player to determine whether a position is available for the player or whether a position can be adapted to such a player, and (f) to assess the risk of future injuries resulting from a position.
[0054] Throughout this specification, various terms will be used in a general sense and are meant to encompass or include a range of subsets. The term player includes players, disabled players, injured players, and position candidates, depending on the situation. The term team includes all types of teams at schools, universities, amateur or professional. The term position includes all positions, professional, paraprofessional, amateur, skilled or unskilled. The terms tasks or elements include the various specific activities and actions that make up a position. Although the methods and systems of this invention can be used by many different types of teams, for ease of this disclosure, the invention will be disclosed in conjunction with teams having multiple player positions.
II. General Features
[0055] The invention can be used to implement a team-wide, play location-specific method and system for analyzing players and positions for determining, for example, whether an injured player can return to the player's position, whether a particular player is suitable for a particular position, and vice versa, and how a particular player can alter his or her play mechanics or how a particular position can be adapted to a particular player. In short, an integrated parsable database comprising elemental analysis information on the team's positions, the team's players, injuries to a team's players, position candidates, required skills, required education, and combinations of these, is created. This database is parsed according to predetermined search criteria based on the utilities disclosed above so as to result in a match between a player and a position, between a diagnosis and a position, a possibility for adapting a player or a position to fit the criteria, and/or to assess the risk inherent in a position.
[0056] A feature of the invention is the creation of a standard, objective parsable database of at least the requirements for specific positions within a specific team or organization of teams. Additional information can be included in the database such as, but not limited to, on-the-position injuries to players and how these injuries occurred, and establishing regulations and requirements for players and positions. Another feature of the invention is a means for parsing the database so as to allow the comparison of a player to a position, and vice versa, so as to determine the co-suitability of the player to the position, and vice versa. This parsing function allows the user, such as the team, to determine the best position for a player, whether a position can be adapted to a player, and the risks associated with a position relative to a player. In a simple form, the present invention can provide the team, as well as physicians, other health practitioners, trainers, coaches, human resource persons, and risk management persons, the knowledge of the tasks, elements of tasks and qualifications required of specific positions within a team, thus allowing a more objective determination of whether a person is suitable for a position, such as whether a potential player is capable of performing a specific position, whether a position can be modified for a potential or existing player, and/or whether an player can return to play, either in the original position or, if not, in another position within the team or in related or other teams.
[0057] The database can be created in many ways by inputting the desired information. For example, a task-specific position analysis can be conducted of the physical requirements for each position. For another example, a physical demands analysis can be completed giving a written and/or a pictorial description of the various functions involved in carrying out the position. In the position analysis and physical demands analysis, the various restrictions and maximum allowable physical requirements of a player, through the medical diagnosis, is compared with the restrictions or maximum allowable actions and requirements of each specific task of a position, can be quantified and included in the database. In other words, an elemental analysis of each position is conducted and the elemental restrictions and requirements are included in the database. Then the database can be parsed in connection with the various utilities of the invention.
[0058] Additionally, regulations and rules can be inputted and cross-referenced to specific positions; educational, certification, and credentialing analyses if implemented by the organization can be completed for each position; and playplace injuries, how the injuries occurred, and what effect the injuries had on the player can be compiled. All of this information can be inputted into the database, cross-referenced, and made available in a parsable format by one of ordinary skill in the database creation field. By parsing this type of database, the suitability of a player for a position or a position for a player, the risk assessment of a position or a position task, and the ergonomics of a position can be determined for an injured player in a return to play situation or for the acquiring of a new player be it through a draft or trade.
[0059] In an alternative embodiment, the present invention can help teams and players find suitable matches between the player and the team's position bank. Use of the parsable database can find alternative positions that a player can do. For example, in use, the database can be parsed by maximum weight the player is able to lift, maximum frequencies of motion or movement a player is able to do, and/or the physical activities the player is able to do. Similarly, the database can be parsed in the contracting process by allowing the player to input his or her physical limitations and positions that the team has available then will be returned, and the player and the team can decide if the player is right for the position. This is advantageous in both the return to play and selection processes.
[0060] In another alternative embodiment, the present invention can help teams use medical and physical diagnoses of players to find suitable positions for players and to adapt current positions to particular players or a particular organization. For an example in use, a medical diagnosis, which could include tasks the player can and cannot perform, can be compared with the team's positions. Positions that the team has available that satisfy the diagnosis criteria then will be returned, and the player and the team can decide if the player is right for the position. This also is advantageous in both the return to play and selection processes.
[0061] In another alternative embodiment, the present invention can help teams use player injury data to adapt positions and to assess the risk of future injuries by players carrying out positions. When injury data is cross-referenced to positions, it can more easily be determined whether a position has a higher risk of injury, and what that injury might be. Additionally, this injury information can be used to adapt the position so as to possibly reduce or eliminate the risk in the future. This is advantageous in the return to play and rules creation and adaptation processes.
[0062] A. Elemental Analysis Utility.
[0063] As already disclosed, position elemental analysis includes breaking a position down into elemental tasks and the physical and mental requirements of each task. A database of the positions and elemental tasks is created for parsing in other utilities.
[0064] B. Medical or Clinical Diagnosis.
[0065] As already disclosed, diagnosis includes using a medical or physical diagnosis of a player to determine the suitability of a player for the player's original position, a different existing position, the same position but altered in some form, or a different existing position but altered in some form, or whether a position candidate can satisfy the criteria for existing positions or for existing positions altered in some form. For example, the post-injury player may have different physical abilities than the pre-injury player, and one player may have different physical abilities and needs than another player. The medical or physical diagnosis utility can be used to determine whether a player can return to play in the same position, a different existing position, the same position but altered in some form, or a different existing position but altered in some form, or whether a position candidate can satisfy the criteria for existing positions or for existing positions altered in some form. This utility can include:
[0066] (1) Utilizing a medical or physical diagnosis that leads to restriction of a player to match that player with a particular or any position within a team;
[0067] (2) Utilizing a medical or physical diagnosis of a person to determine the restrictions for a player to take a position, based on the maximum allowable tasks for the position;
[0068] (3) Utilizing this diagnosis-based assessment of a person to translate the restrictions for a player into the maximum allowable tasks for the player so as to be able to match the player to a position and vice versa;
[0069] (4) Allowing searching of the database for a listing of possibly appropriate positions for the player, determining why or why not a position can or cannot be done by the player, and then matching the restrictions with all position elements in a team; and/or
[0070] (5) Applying the diagnosis-based assessment to qualifications or essential functions required to allow searching of the database for a listing of possibly appropriate positions for the player.
[0071] In a simple playing example, the medical diagnosis can operate as follows. The doctor sees patient, namely, the player. The doctor, based on the injury, makes a diagnosis of the player using his examination and the computer database. As part of this diagnosis, the doctor further makes recommendations regarding the player's ability to handle certain tasks. For example, as already disclosed, the recommendations may include that the player cannot do certain tasks at all for two weeks, that the player cannot lift more than a certain amount, that the player cannot twist more than 90 degrees, that the player can perform no more than a prescribed amount of repetitions per minute, et cetera. The doctor then prescribes these restrictions as the maximum allowables. Alternatively, the system, based on historical data, can use known artificial intelligence methods to prescribe restrictions.
[0072] C. Return to Play Utility.
[0073] This utility can be defined as determining whether a player can return to play in the same position, a different existing position, the same position but altered in some form, or a different existing position but altered in some form. The medical diagnosis for a particular player can be used to parse the elemental analysis database for making this determination. Similarly, this utility can be used in the acquisition or hiring of new players. That is, a new player's physical and educational skills and training can be used to determine whether the new player satisfies the criteria for existing positions or for existing positions altered in some form. The return to play utility can be used in determining whether a player can return to play in the same position, a different existing position, the same position but altered in some form, or a different existing position but altered in some form. This utility can include:
[0074] (1) More effectively allowing a player to return to play in a particular position or any position within a team;
[0075] (2) Allowing training and coaching personnel and advisors to contemporaneously communicate to determine whether a particular player can function in a particular position or in a different position within a team;
[0076] (3) More effectively getting an injured player back to play;
[0077] (4) Determining whether a player has the appropriate faculties for a specific position or for any position in the database both during the pre-employment process and post injury; and/or
[0078] (5) Allowing a ranking of positions suitable for the physical capabilities of a player and basing the ranking on positions with the most suitable elements and/or positions within or proximal to the player's pre-injury position. The graphic representation of this ranking accomplishes another important objective in that it translates the clinical terms used by the physician into the terms of the specific tasks and elements used by the team.
[0079] This utility also can comprise an acquiring or hiring utility that can be used in determining whether a player's physical and educational skills and training satisfy the criteria for existing positions or for existing positions altered in some form. This utility can include:
[0080] (1) Determining whether a player has the abilities and faculties necessary for a particular or any position within a team;
[0081] (2) Determining whether a particular position within a team is suitable for a particular or any player;
[0082] (3) Increasing the ability for a team to retain and place players in positions within the team;
[0083] (4) Creating and using a database listing maximum allowable tasks for positions, including searching the database to find a position suitable for an individual;
[0084] (5) Determining whether a player has the appropriate faculties for a specific position or for any position in the database both during the pre-hiring process and post injury;
[0085] (6) Allow a ranking of positions suitable for the physical capabilities of a player and basing the ranking on positions with the most suitable elements and/or positions within or proximal to the player's pre-injury position; and/or
[0086] (7) Allowing a matching of a player's certifications, training, and/or credentialing with the positions in a database.
[0087] D. Risk Assessment Utility.
[0088] This utility can be used to determine what elements of a position are more prone to causing injuries and to adapting positions or position elements to compensate or reduce such risks. Similar to a position elemental analysis, an elemental risk assessment can be made of each position by taking past injuries that occurred for the position and creating a database of such injuries. The risk assessment utility can be used to parse a database of past injuries to determine what elements of a position are more prone to causing injuries and to adapting positions or position elements to compensate or reduce such risks. This utility can include:
[0089] (1) Utilizing a physical demands analysis (elemental analysis) and scalability to create and use a database to help show which task of a position is associated with a specific risk of injury;
[0090] (2) Allowing a comparison of position elements for creating a risk assessment of whether a specific position or a specific task will or does have a higher risk of causing injury to a player or causing a repeat injury to a previously player; and/or
[0091] (3) Allowing the creation of risk management reports based on position tasks.
[0092] E. Modification Utility.
[0093] This utility can be used to create and modify positions based on player abilities, skills, and training For example, the player diagnosis and the risk assessment can be used to create the criteria, tasks, and elements for new positions or to adapt the criteria, tasks, and elements of existing positions to more fully employ players. The position creation and adaptation utility allows the use of player abilities, skills, and training to create the criteria, tasks, and elements for new positions or to adapt the criteria, tasks, and elements of existing positions to more fully employ players. This utility can include:
[0094] (1) Using a database of playplace injuries or other player information to assist in determining the necessary criteria for a position;
[0095] (2) Allowing a searching of positions at other related teams to allow players at one related team to be transferred to other related teams, or to allow players at one lower division or farm league team to move up to a parent team or vice versa; and/or
[0096] (3) Allowing a categorization of the positions based on various hierarchies, such as department, facility, physical requirements, essential or non-essential functions, et cetera.
III. Database
[0097] The database can include information about positions, players, injuries, regulations, rules, et cetera. Generally, the database preferably comprises the elemental tasks of each position and allows a parsing of the database based on criteria for allowing a player to perform the tasks of a position. In this manner, players can be matched to positions that the players can physically handle. Specifically, the innovation of creating the database, matching the database up with clinical data of physical restrictions and requirements, and applying the database to players to determine player suitability for a specific position is a preferred feature of this invention. The innovation of breaking a position down into playstation, tasks and elements, matching up injury data with each playstation, task and element, and determining whether an individual playstation, task or element is more likely to cause an injury or whether an injury is more likely to occur when performing an individual playstation, task or element is another feature of this invention.
[0098] Positions are analyzed in terms of elements and tasks. An element is the smallest step into which it is practical to subdivide any play activity without analyzing separate motions, movements and mental processes involved. A task is one or more elements and is one of the distinct activities that constitute logical and necessary steps in the performance of play by the player. Further, positions may be broken down in terms of positions. A position is a collection of tasks constituting the total play assignment of a single player. Finally, team positions are a group of positions within a team setting, which are identical with respect to their major or significant tasks and sufficiently alike to justify their being covered by a single analysis.
[0099] Each element is analyzed in terms of its physical demands. Strength requirements are obtained using standard position analysis equipment. Definitions for physical requirements are taken from, for example, commonly available sources such as The Revised Handbook for Analyzing Positions published by the United States Department of Labor, Employment and Training Administration in 1991. For example, play can be categorized as sedentary play, light play, medium play, heavy play, and very heavy play. Elements can include such activities as running, standing, walking, sitting, lifting, carrying, pushing, pulling, climbing, balancing, stooping, jumping, kneeling, crouching, crawling, and reaching.
[0100] Essential functions are any element of the task that must be completed by the player without assistance and without modification. If a player is unable to perform an essential function he is unable to complete his required position duties. Thus, for example, when creating the position portion of the database, one must take into account whether removing the function fundamentally changes the position and if the function is critical to overall performance of the position, as well as other questions.
[0101] The parsable database is created to allow for more effective return to play and retention of positions. By breaking a position down into playstations, specific tasks, and inputting this elemental analysis (for example, physical position restrictions and requirements) into the parsable database, a position can be matched up a player according to essential and non-essential functions as determined by the team and weighted by the team. Similarly, a medical professional can provide clinical restrictions (maximum allowables) for a position (for example, physical restrictions based on a hypothetical ordinary or average player could or should be able to accomplish), which can be inputted into the parsable database. In this manner, the various restrictions and requirements of a position are available for parsing and matching to a player.
IV. Parsing
[0102] The present invention has been specifically and uniquely designed to address and expedite early and appropriate return to play options. The primary component of this system is a parsable database that allows the user to view specific tasks associated with each position, including all physical demands of the position. The invention can graphically show (1) a list of the specific elements of the player's position that fall inside and outside of the parameters of the restrictions, (2) a list of other positions available with the team that are within the restrictions or are closest to the restrictions, and (3) specific injuries that occur during individual position tasks. By identifying the specific elements with their physical requirements, the user can isolate the elements that the player is unable to perform and assist in identifying alternative positions, tasks or methods that are within the imposed physical restrictions, and create a risk assessment for a particular position or position task. This accomplishes another important objective in that it translates the clinical terms used by the physician into the terms of the specific tasks and elements used by the team.
[0103] The present invention enables the teams to evaluate return-to-play issues from the beginning of care. Using the present invention, the team is able to make a more accurate disposition of the player's case, hopefully resulting in an early and safe return to play in the same position, the same position adapted based on the injury or diagnosis, a different position, or a different adapted position. Further, the team can utilize the search engine to determine if there are any other positions on the team that the player can currently perform within the restrictions set out by the physician or in the medical diagnosis. This allows a determination to be made to see if these tasks can be reasonably modified to allow the player to return to his original, albeit, modified position.
[0104] When examining the player and developing a medical diagnosis, the physician can view still photos, video and metrics regarding the player's position and thus more accurately determine the restrictions or allowable actions. The present invention will compare these restrictions with the information player's position and other positions in the database, and the system will provide a listing of positions in descending order of positions (if any) that satisfy the physician's criteria, to positions that satisfy most of the physician's criteria, to positions that satisfy only some of the physician's criteria, and so on. The team is now able to make a reasonable recommendation for the player's ability to perform the player's position and, if not, whether there are other positions in the team that the player can do in the injured and recovered state. Alternatively, the team can review the listing of positions and determine whether any of the positions can be modified to accommodate the player.
[0105] Contemporaneously, the injury data is attached in the database to the specific position and position task during which the injury occurred. As the injury data is compiled, that is when additional injury data is inputted into the database, an injury profile is created for a specific position and position task. Using this data, a risk assessment for the position and position task can be created, and the occurrence of a future injury can be predicted. Additionally, the injury data can be used to modify the position. Thus, the database can be parsed both for determining whether a current position and position task has a risk of injury or a high predictability of an injury occurring, and for positions and position tasks that could or should be modify to reduce the risk of future injury. Thus, the present invention provides a clinical model of the risk of injury due to a position or position task, what the injury is likely to be, and why the injury occurred.
[0106] A parsing of the database can generate a listing of the types of injuries occurring and the frequency of the injuries in elemental detail, that is, which position element is prone to injury. Thus, the position element can be modified (e.g., lowering a maximum lifting weight), or a different player or assistant can be assigned to the position (e.g., a stronger player to carry out the specific task), or in the case of return to play assigning the injured player to a different position. Thus, a risk prediction database can be developed for each position task, each position, or each team. This results in a very powerful tool for predicting risk based on position tasks, namely, the ability to identify which players with particular medical diagnoses can or cannot perform a position or a position task. If the position task is an essential element of the position, the diagnosed player can be assigned to a different position, the position can be modified, or an assistant can be assigned to carry out the position task.
[0107] One aspect of the parsing ability is predicting risk based on previously reported and inputted position injuries. The present invention comprises a very powerful tool for predicting injury risk because each injury is attached to a specific position task and therefore the injury risk assessment is based on elemental analysis. The database can be parsed for a particular type of restriction or a particular type of injury and, based on the injury, the invention can identify positions for players who have medical restrictions either from previous lifting injuries or a medical diagnosis. With the present invention, a team can parse players with a particular diagnosis and break down how many elemental (or position task) injuries occurred and what the elemental injuries were, and use the position elemental analysis to determine and evaluate player risk relative to a position or position task. In other words, the present invention matches a position elemental analysis with a player diagnosis to allow the team to determine whether the player is suitable for the position and vice versa. Comparing a position at the elemental analysis level with a player medical diagnosis can allow the team to determine which positions or position task is an injury risk. Thus, by capturing a medical diagnosis (injury) associated with a particular position task element and capturing that data, a team is able to determine or predict, based on particular position task elements and historical injuries throughout the entire team or entire organization, the risk of injury.
V. Illustrative Embodiment
[0108] Referring now to the figures, an illustrative embodiment of various features of the invention is disclosed. Some of the figures are flowcharts illustrating the information gathered for input into the parsable database and how the database can be used to carry out the various utilities of the invention. Some of the figures are screen shots of a software application developed for carrying out the invention illustrating the information that can be parsed in the database and typical results that are returned. Overall, a disclosure of how the inventive database is created, updated, and used is provided by these figures and the connected disclosure.
[0109] FIG. 1 is a flow chart using the computer based system wherein based on an examination, the body part injured is fed into the ICD database which provides a code from which a database of sorted diagnoses is fed back to the examining physician a number of possible diagnoses which are pared down by prompting additional tests until a recommended diagnosis or a group of ranked diagnoses are provided from which the physician arrives at a selected diagnosis. As shown in the flow charts of FIG. 2 or 3 , the flow chart of FIG. 1 can be modified simply to have a test or injury database in the place of the ICD information or embedded with the ICD information.
[0110] The ten screen shot FIGS. 4-14 show an exemplary use of the computer database. FIG. 4 shows that each user will have a secure login with password protection. Once logged in, the user sees FIG. 5 which is a dashboard listing each case showing the status and other case specific information. By selecting an injured player, the screen of FIG. 6 will open which shows the history and physical particulars i.e. mechanism, location, etc driven by the injured body part selected. By continuing on, more information is shown in FIG. 6 . Continuing the program, FIG. 7 shows detail for mechanism component screen provides the user with definitions and criteria. FIG. 8 is an additional page for history and physical information still driven by body part. Selections on history and physical drive the next screen which narrows down diagnosis. FIG. 9 screen is research that shows the data summary for the tests conducted during the physical. It is a compilation of the different research with sensitivity and specificity—how accurate the tests are in differentiating a diagnosis. FIG. 10 is the summary of the diagnostic research as well as the testing completed by the physician during the exam. FIG. 11 shows the treatment regimen selected based on ASMI (Andrews Sports Medicine Institute) by level of research—were they controlled studies, anecdotal, etc. FIG. 12 is where the actual treatment is selected based on the criteria selected in the previous screen. It is diagnosis specific, and based on the scoring of outcome research. FIG. 13 is return to play (RTP) criteria, again driven by the choices selected in the previous screens. FIG. 14 is the reporting screen where reports can be viewed or submitted for scoring and review.
[0111] Additionally, after parsing the database, if no appropriate position is returned, then one option would be to change the medical treatment of the player to allow the player to be able to perform a different position. Using the alternative positions obtained from the database as a starting point, the physician can revise the player's treatment plan to allow the player to perform the alternative position. This new information can be inputted into the database for use in later situations, such as if a similar situation occurs, and the alternative position and treatment plan can be returned in the results of parsing the database.
[0112] The information gleaned and created during each of the above processes can be used by other utilities in determining whether the player can return to play in the same position, a different position, or not at all, as disclosed herein. This information also can be used by the physician and/or the team in prescribing whether a particular player can carry out a particular position or position task, or in modifying a particular position or position task, in that a particular player may no longer be able to carry out the position or a position task based on the medical diagnosis of the injury. Similarly, this information can be parsed when determining whether a particular position can be carried out by a particular player and in determining the risk of injury assessment of a particular position or position task, for current players, injured players, or new hires.
[0113] Thus it can be seen that the inventive database, utilities, and processes allow for a constant and continuous updating of a parsable database of criteria that are useful for various situations in determining whether a position is appropriate for a player and vice versa. This integrated parsable database comprises information on the team's positions, the team's players, injuries to a team's players, position candidates, required skills, required education, required certifications or credentials, governmental and legal requirements, and combinations of these. This database can be parsed according to predetermined criteria based on the utilities disclosed above so as to result in a match between a player and a position, between a diagnosis and a position, a possibility for adapting a player or a position to fit the criteria, and/or to assess the risk inherent in a position. As a result, this invention can facilitate return to play after an injury, can decrease lost player time and productivity by allowing a position to be modified or a player to return to play in a different, suitable position, and can provide for an elemental analysis of each position task and injuries related to each position task so as to assess the risk of injury of a position or individual position task.
[0114] Variations in the present invention are possible in light of the description of it provided herein. While certain representative embodiments and details have been shown for the purpose of illustrating the subject invention, it will be apparent to those skilled in this art that various changes and modifications can be made therein without departing from the scope of the subject invention. It is, therefore, to be understood that changes can be made in the particular embodiments described which will be within the full intended scope of the invention as defined by the following appended claims. | A method for aiding a physician in examining, diagnosing and treating an injured patient has the steps of creating a computer database that converts a selected injured body part to a sorted group of one or more preliminary diagnoses with examination protocols for each preliminary diagnosis; conducting recommended examination protocols and inputting examination results to the computer database to narrow diagnosis to most likely diagnosis; selecting a recommended diagnosis; creating a computer database of treatment protocols for every computer generated injury diagnosis, the treatment protocols having usage data and outcome data; selecting a treatment protocol; initiating treatment; and inputting treatment outcome results back into the computer database for statistical inclusion into the computer database. | 69,575 |
TECHNICAL FIELD OF THE INVENTION
[0001] This invention is related to construction of an adhesive tape with a composition that enables it to resist high temperature treatments and maintain a low electrostatic level when removed from a polymer or metal surface, through a combination of a polyetherimide polymer film and an adhesive of an acrylic or silicone type, which may be added to conductive materials of an organic polymer nature, organic or inorganic metallic salts, organic salts of organic compounds such as aniline, activated carbon or micronized carbon black.
[0002] This invention also involves a system whereby the aforementioned additives are added to the adhesive, as well as the equipment systems for applying the former to the polyetherimide polymer film.
BACKGROUND OF THE INVENTION
[0003] Several alternatives have been described for building adhesive or non-adhesive tapes that maintain their stability in high temperature conditions; and which also contribute to maintaining a low electrostatic level when being supplied from a roll or dispatcher and applied to a specific surface. One of the main applications of these alternatives is to protect electric or electronic circuits when they are subject to high temperatures in a furnace or soldering machine; and only specific sections must be exposed. The stability of the adhesive tape must be ensured in such a way that the caloric energy has a greater impact, particularly in the section subject to change or processing. This type of procedure is known as masking or temporary protection, which is the most common procedure recommended for electric circuits, as insulating masking films; or in electronic circuits as gold fingers.
[0004] Bearing in mind the surfaces on which the masking adhesive films are placed, it is frequently important that the electrostatics formed by the friction of the adhesive surface and the backing film be reduced in order to prevent damage to the electric or electronic circuit through conduction when they come into contact with each other. There are products on the market that have been used for many years to protect electronic or electric circuits, against high temperature as well as the high electrostatic levels generated during handling. These products include those manufactured with a polyimide backing made by companies such as Dupont or ChengDu New HuaWei International Trade Limited, and which use a silicone-base adhesive based on the chemical structure of a siloxane polymer. These products include tapes 5419 and 5433 made by 3M Company, or the tapes manufactured by Qtek or Saint-Gobain.
[0005] There are also products such as tape 5563 made by 3M Company, which uses an acrylic adhesive that remains stable at temperature of up to 220° C. and has a polyimide film. This tape also has the ability to reduce the electrostatic charge when unwound from a master roll or when friction is produced against a metal surface during removal.
[0006] Within the current status of the technique, systems such as that of Takeuchi and Nakao in patent JP7176842 are described. They consist of a panel in which a polyimide film is placed, maintaining properties when subject to high temperatures. This system is dependant upon a reaction of components, which makes it more suitable for use as a whole plate that subsequently adjusts itself through mechanical means such as adhesives or screws. A system of polymers resistant to high temperatures is described in WO02092654 on polyimides that release a small amount of heat in low widths, are stable under ultraviolet light as well as at high temperatures, as alternatives to the Kapton commercial film produced by Dupont. This invention provides an alternative for high temperature heat-resistant films, even though it does not take into account an adhesive or mechanism to reduce the electrostatic charge generated by the friction caused by the film itself, or with a different material. There is a version of an adhesive tape resistant to organic solvents and to high temperatures, which is formed from a base solution that is placed on semiconductor materials as a thin film. This film is mentioned in Patent JP6340847 belonging to Ikeda et al., which also indicates the use of treatment prior to placement and represents additional energy consumption.
[0007] Another item described within current techniques is a tape that prevents a conductor material from being covered by the adhesive during sealing with a resin. The tape described in Patent JP6212134 belonging to Inagaki and Hara has a polyimide resin adhesive, an epoxy resin and an inorganic additive. This type of construction offers good resistance to chemicals and high temperatures, but construction is highly complex, which has limitations in temporary applications, in which the tape must be removed after a few minutes.
[0008] An invention such as that described in Patent EP0369408 belonging to Eguchi and Kuroda shows a polyimide film on which a very thin metal film, such as copper for example, is placed in such a way that the result is a flexible circuit that may be printed. This invention takes advantage of the high resistance of the polyimide polymer to manufacture circuits, but it does not have properties to reduce electrostatics. A application is described in Patent BE801115 belonging to Dupont, which consists of a polyimide film used to make laminates with an acrylic adhesive that makes it suitable for permanent fixture on metal surfaces.
[0009] One application generally found for high temperature heat resistant polymers and the chemical attack is described in Patent GB1383985 belonging to Rhone Polenc SA. In this application it is also indicated that the polyimide films may be used to join electronic circuit panels and to cover electric conductors. In this case the initial polyimide film must be covered with an additional polymer, which makes its production process complex and its cost very high.
[0010] Patent WO9620983 belonging to Gutman and Yau describes a tape focused more specifically toward use in electronics. It is comprised of a silicone adhesive tape that has conductive material resting on a polyimide film in the form of a thin coat. This construction makes the tape heat resistant and, in addition, reduces the electrostatics caused by friction against itself or against a surface made of a different material. This construction is used as a base for manufacturing tapes that are applied to electronic or electric circuits by taking advantage of the properties of the polyimide polymer, even when the later represents a material with limited supplies. A product is described in Patent JP2004136625, in which a tape is built based on a combination of conductive materials and resins that is able to act as a means of transport for electronic chips, transport of electronic circuits or bedding for printed electronic circuits. Likewise, in Patent JP20022069395 belonging to Miyako and Taima, there is an adhesive tape through placement of a coating of a conducting material over any material acting as a substrate, which might be a polyolefin. This application is especially important in cases where reduction of electrostatics is such that the tape must become a semiconductor. Patent JP2001152105 belonging to Ito and Kawada describes a conductive adhesive tape, but this time one that has three coats of material, including a melamine, a polyolefin and a fluoroalkylsilane, which makes it a product specifically for conducting electricity and limits it to non-temporary uses.
[0011] Work has been conducted on silicone adhesives to provide them with increased conductivity in such a way as to reduce the electrostatic discharge level generated during their use in electronic systems industries. Patent JP10120904 belonging to Hirano et al. describes an adhesive with a silicone base to which a boron compound is added. This type of adhesive eliminates the need to use a polyolefin or polyimide film or one of any other compound to reduce electrostatics. Nonetheless, its design does not allow it to maintain resistance to physical deformations or damages from direct blows. One version of a tape reduces electrostatics using a conduction system through small conductive strands on the very thin coat of adhesive protected by a paper or polyolefin film containing a low surface energy or anti-adherent agent. Although it is highly effective for conducting static electricity, this tape has limitations when a low-cost solution is required for protecting surfaces for a short period of time.
OBJECTIVES OF THE INVENTION
[0012] Based on a review of the status of the technique consulted, an objective of certain embodiments of this invention is to build an adhesive tape that uses different adhesive compositions and a polyetherimide polymer film providing protection and insulation in electronic and electric applications, as well as in applications in which protection is needed for surfaces at the time they are subjected to high temperatures.
[0013] Another objective of certain embodiments of this invention is to offer various alternatives for designing construction of a protective adhesive tape that also reduces electrostatics.
[0014] Another goal of certain embodiments of the invention is to present manufacturing systems for producing the high temperature heat resistant adhesive tape.
BRIEF DESCRIPTION OF THE INVENTION
[0015] The new invention can prevent mechanical damages to the adhesive and the covered surface due to the fact that the polyetherimide polymer film offers a barrier that is highly resistant to tension and the mechanical stress from the cut-die. At the same time, it provides a silicone or acrylic adhesive tape with the advantage that conducting materials may be added as transition metals, micronized carbon black or boron salts, which may easily be blended with a silicone-base adhesive to achieve a very thin coat on a polyetherimide polymer film. The micronized carbon refers to one carbon black used as powder and having a particle distribution between 1 and 50 microns, while the transition metals or boron salts present a particle size of 150 to 200 microns.
[0016] The polyetherimide is resistant to the mechanical stress encountered during its use as temporary protection for electronic and electric circuits; in addition to insulating the surface covered by the adhesive tape, thereby limiting contact with the outside environment, preventing propagation of static electricity and/or limiting contact with materials conducting electricity that might cause a short circuit.
[0017] This invention also includes the method for manufacturing the new adhesive tape in a simpler way, which shortens production time and ensures uniformity in the final characteristics. Thus a tape is obtained that uses a polyetherimide polymer, eliminating the use of polyimide and its derivatives; and an adhesive containing dispersed particles that contribute to reducing the electrostatic charge generated by friction between surfaces. In addition, its measurements and chemical structure remain stable under high temperature conditions.
[0018] In one aspect, the present invention comprises a film or backing, an adhesive, a low adhesion or anti-adherent agent (also known as LAB for Low-Adhesion-Backing), and agents that can modify electrostatic build-up.
[0019] In other aspects, the invention may include a primer or Corona treatment of the film or backing. In other aspects, the invention may include a system for applying the adhesive on the film or backing.
[0020] In all cases, the chemical composition may be altered, depending on the final application in which the product is to be used. In the case of the film or backing, the composition includes a polyetherimide polymer. Another option is to place a polyolefin or die-cut sheet of paper coated with a low adhesion compound over the adhesive in such as way that the adhesive takes on the geometrical shape of the die-cut or raised portions when the film or sheet is removed. This ensures that only a minimum of air remains between the adhesive and substrate material, and makes the adhesion contact more effective.
[0021] There have presented products to be used as protection for electronic or electric circuits, as well as products that can be used for conduction and dispersion of the electrostatics formed by friction of the adhesive tape or adhesive itself, with itself or with a different surface.
[0022] Several of these products are already being marketed by companies such as Nitto (Japan), 3M Company (U.S.A.), Q-tek Company (U.S.A.), Parmacel Company (U.S.A.) and Saint Gobain SA (France). These products are based on a polyimide polymer film; the preferred product is that offered by Dupont in the United States. The adhesive used in these cases is preferably a silicone derivative that is modified so that it constitutes a pressure-sensitive adhesive. Some of the aforementioned products also add electricity conduction materials to the adhesive, in the form of fine particles such as metallic salts that include silver, gold, copper, tin, zinc, iron or vanadium.
[0023] Although the aforementioned products are effective with regard to their resistance to heat and reduction of electrostatics, they do have the disadvantage that they are very expensive, they are limited to maximum temperatures of up to 180° C. and their use is restricted to permanent applications or more controlled environments in order to prevent the adhesive on the backing film from slipping off the tape.
[0024] This invention also involves construction of an adhesive tape using the new polyetherimide polymer and a silicone or acrylic base adhesive. It is processed through a simple pumping manufacturing system and the fact that it lowers production costs makes it feasible for use in simple, temporary applications, with resistance to temperatures up to 180° C., with the ability to reduce electrostatics.
[0025] Sometimes a primer or Corona treatment is needed to keep the adhesive on the film or backing, in order to improve the interaction between the film or backing itself and the adhesive. The theory regarding operation of the Corona treatment and primer has been widely analyzed and is well known among persons with an understanding of the art. Many different pieces of equipment and formulas are used to manufacture products such as labels, adhesive tapes, protective folios, medical tapes, etc.
[0026] The product of this invention also includes a low adhesion agent or LAB (low-adhesion-backing) on the other side of the film or backing, which prevents the adhesive from sticking or losing its adhesive quality. This agent has many different compositions but for this invention silicone or silicone and urea compounds are satisfactory.
[0027] Processes for manufacturing adhesive tapes or folios may be used to place the adhesive over the film or backing. The processes include those that use systems for melting an adhesive without organic solvent and those with systems for applying adhesives dissolved in organic solvents (toluene, heptane, ethyl acetate, etc.) or water. In all cases operating conditions for placing the adhesive will make it necessary to consider the nature of the film or backing and that of the adhesive. It is important to mention that for those with a knowledge of the art, the use of any current system or any created in the future that involves the elementary principle of placing a thin coat on a die-cut, raised portion section constitutes a derivation of this invention.
[0028] Manufacture of the product of this invention includes, but is not limited in its description or sequence to, the following:
[0000] 1. Application of a Corona treatment or primer on at least one of the sides of the film or backing;
2. Application of a low adhesion agent on the side of the film or backing where the adhesive will be provided;
3. Drying the primer and the low adhesion agent in ovens or other drying equipment;
4. Placement of a thin coating of adhesive on the film or backing surface, following the contour of the die-cut or raised portions;
5. Substantial elimination of any solvent present in the adhesive or cooling of the melted adhesive;
6. Winding up of the tape in a master roll.
[0029] At present there are versions of adhesive tapes on the market that use polyimide polymers as a first choice. This invention uses polyetherimide polymer, which has sufficient properties to work as an alternative to polyimide and presents an equally competitive price. Thus a product is constructed that is functional in defined applications and yet does not have the problems pertaining to polyimide supplies.
[0030] Formation of small sphere-shaped or semi sphere-shaped capsules or particles, which contain the adhesive, constitutes one derivation of construction of the invention. Components marketed under the brand name Scotch Grip, manufactured by 3M Company, are found within this type, and they include products made with the technology presented by Scotch Grip 2353, Scotch Grip 2510, Precote 85, Precote 80 and Precote 30.
[0031] In addition, existence of a micro-replicated profile in the adhesive, through reproduction of the surface of the type of Scotch Cal® products manufactured by 3M Company makes it possible to offer an alternative that reduces flaws caused by a lack of contact between the adhesive and the substrate material, due to the presence of air.
BRIEF DESCRIPTION OF THE DRAWINGS
[0032] FIG. 1 shows the different geometrical shapes and distributions of the cut-die or raised portions on the film or backing of this invention. These examples in shapes 1 a , 1 b , 1 c , 1 d , 1 e , 1 f and 1 g are not the only ones possible; and they may include other geometrical shapes that construct a final product of the invention.
[0033] FIG. 2 shows the main thicknesses in the film or backing used: the total thickness of the film or backing on the raised portions (H) and the thickness of the base of same (h).
[0034] FIG. 3 shows the angle (i) that the die-cut or raised portions might have in the film or backing.
[0035] FIG. 4 shows a diagram of the finished protective adhesive film, comprised of an upper coat of adhesive (ii), a lower coat of adhesive (iii) and a film or backing with a die-cut or raised portions (iv).
[0036] FIG. 5 shows an example of the geometrical shapes in a film or backing with a die-cut or raised portions, and the span (v) that exists between them in order to obtain channels.
[0037] FIG. 6 shows a graph with the levels of electrostatics formed under conditions with 25° C. and 50% relative humidity when micronized carbon black and copper salts are added to the adhesive.
[0038] FIG. 7 shows the effect on the adhesion to steel, of additives to reduce electrostatics.
[0039] FIG. 8 shows a graph with the levels of electrostatics formed when micronized carbon and regular carbon black are added, in the extrusion of the polyetherimide film.
[0040] The following conditions were used for FIGS. 6 through 8 : 25° C., 50% relative humidity, a conditioning time of 24 hours, detachment speed of 12 inches per minute and the Hewlett Packard static energy reader Mod. 2639, as gauging equipment for electrostatics.
DETAILED DESCRIPTION OF THE INVENTION
[0041] This invention consists of a film or backing composed of polyetherimide, which may or may not have a die-cut or raised portions of different size or shape and maintains a thin coat of adhesive on its surface.
[0042] The film or backing may have various geometrical shapes on its cut-die or raised portions, as shown in FIGS. 1 a , 1 b , 1 c , 1 d , 1 e , 1 f and 1 g . Likewise, the measurements of this die-cut may vary; although the ideal sizes, though not the only ones, are those shown in table 1:
[0000]
TABLE 1
Measurements of the die-cut or raised proportion on the film or backing
Length
Geometrical shape on the
Depth
(or diameter)
Width
die-cut or raised proportion
(millimeters)
(millimeters)
(millimeters)
Polygon
0.127-2.0
1.5-7.0
1.5-7.0
Circle
0.127-2.0
1.0-5.0
—
[0043] The die-cut or raised portions have dimensions that make it possible to place the adhesive on its surface, in various thicknesses that include a size similar to that of the die-cut or raised proportion itself. It is preferable for the dry adhesive to have the dimensions shown in Table 2 below, the objective of which is to show examples of recommended sizes although they are not the only ones applicable to the invention:
[0000]
TABLE 2
Thickness of the dry adhesive on the die-cut or the flat
surface of the film backing
Geometrical shape of the die-cut
Depth (mm)
Polygon
0.127-1.2
Circle
0.127-1.2
Flat surface
0.05-2.0
[0044] It is important to point out that, as illustrated in FIG. 2 , the measurements in H and h, pinpointed as the total thickness of the raised portions and the thickness of the film base, respectively, may vary depending on the requirements of the final application of the product of this invention. In any event, the existence of a thinner or thicker film or backing will be determined by the properties of the material of which it is composed, as well as by the ease with which it may be used in the final application sought.
[0045] It is preferable to use a pressure-sensitive adhesive (PSA), thereby making it possible to determine the thickness of the adhesive over the film or backing. Any person familiar with adhesives of any composition is able to understand that the amount of solids, adhesive power, removal power and other properties of an adhesive film are influenced by the chemical composition of the thickness of the adhesive chosen. Therefore, the thickness of the adhesive may range between about 0.0002 and about 0.002 inches (0.00508 and 0.0508 millimeters) for the product of this invention. Presently, the preferable amount is about 0.001 inches (0.0254 millimeters), or an amount equal to between about 3 and 35 grams per square meter based on the contents of the solids in the adhesive itself.
[0046] The adhesive compound in the product of this invention is a pressure-sensitive adhesive (PSA), a composition that is comprised mainly of a silicone-based polymer, preferably a solution containing polydimethylsiloxane and polysiloxane resin rubbers. Adhesives of an acrylic type may also be used, including blends with isooctylacrylate or 2-ethylhexylacrylate with acrylamide or acrylic acid, butyl acrylate and methacrylates, essentially.
[0047] In the event the tape use requires that the electrostatics be reduced, a conductive material may be added to the polyetherimide film forming extrusion process. The film with the properties shown in Table 3 in particular is an option for reducing electrostatics and maintaining good resistance to temperatures of up to 220° C.
[0000]
TABLE 3
Properties of a polyetherimide film with a thickness
of 0.001 to 0.002 inches.
Property
Testing method
Tensile modulus
ASTM-D-882
2768 MPa
Resistance to breakage (machine direction)
ASTM-D-882
121.1 Mpa
Maximum elongation (machine direction)
ASTM-D-882
130.3%
Resistance to breakage (crossweb
ASTM-D-882
112.1 Mpa
direction)
Maximum elongation (crossweb
ASTM-D-882
1198.2%
machinery direction)
Shrinkage at 200° C.
GE
0.4%
International
Method
[0048] The features shown above illustrate what can be used but are not the only possibilities.
[0049] One important characteristic of the film die-cut or raised proportion is the angle at which the geometrical form may be constructed on the surface. This angle may range between 0° and 70° compared to the perpendicular of the film or backing base. This is shown in FIG. 3 and it demonstrates in a way that is easy to understand for persons familiar with the technique that the angle (i) may be altered in combinations with the depth of the die-cut or raised proportion shown in the different FIGS. 1 a , 1 b , 1 c , 1 d , 1 e , 1 f and 1 g . The presence of the angle also makes the adhesive slide toward the bottom of the die-cut or raised proportion, depending on the slope. A steeper slope causes an increased amount of adhesive to slide to the bottom of the die-cut or raised proportion. Nonetheless, it is possible to control the flow capacity of the adhesive by altering the composition and formula of the adhesive used. In constructing the product of this invention, it is best to have most of the adhesive sustained on the upper surfaces of the die-cut or raised proportion (ii), leaving the smallest portion along the sides and bottom of the geometrical shape (iii) on the film or backing (iv), as shown in FIG. 4 .
[0050] The adhesion properties of the final product are affected by the type of adhesive, the contact surface and the geometrical shape selected for the backing or film. A larger contact surface with an adhesive with a high instantaneous adhesive power can keep the product on glass, ceramic or steel surfaces. The contact surface of the film or backing that comes into contact with the adhesive and, in turn, the surface that is positioned over the protected surface also determines the power with which the product of the invention will stay firmly in place. In addition, the compositions of the adhesives used will help to reinforce the affinity and adhesion of the product on the reinforced surface. It is also important to point out that the type of adhesive must be selected according to the manufacturing process in which the film acting as reinforcement will be used. In cases in which the material to be reinforced drifts at high speeds, an adhesive with a high instant adhesive power will make it possible to rapidly join the surface in movement. Any combination of adhesive with an application process is valid, in accordance with the specific needs of the user.
[0051] Different combinations may be used between the type of film or backing and the adhesive. Any person with knowledge of the subject will be able to deduce that variations in the adhesive power on a given surface may be selected from a variety of combinations arising from this invention. Some examples that describe the adhesive powers stemming from combinations of an adhesive and film or backing are shown in Table 4. They are only some examples to illustrate possibilities, but are not the only options:
[0000]
TABLE 4
Peel force (ASTM-D-3303) obtained with different adhesives
and die-cuts or raised portions in the film or backing.
Adhesive power
Geometrical shape
Adhesive
(ounces/24 inch 2 )
Diamond
Pressure-sensitive acrylic
20-35
Square
Pressure-sensitive acrylic
15-20
Hexagon
Silicone-based adhesive
5-10
Flat surface
Silicone-based adhesive
10-15
[0052] When the film or adhesive has a die-cut or raised proportion, the span between the geometrical shapes must be such that even after placing the adhesive, the gases, vapors or liquids can escape through the channels or ducts. As shown in FIG. 5 , as long as there is enough space (v) for the adhesive to be placed without the space being flooded, the impurities that are also mixed with the gases) vapors or liquids will have an escape route. Based on the nature of the adhesive placed on the backing or film, with regard to its composition, amount of solids and viscosity, the span between the geometrical shapes of the film or backing will vary in order to keep flaws to a minimum in the protection application chosen.
[0053] For cases in which the adhesive or film backing has a die-cut or raised proportion, it is important to keep the spaces formed by the combination of the adhesive and the protected surface. An adhesive thickness that equals the depth of the die-cut or raised proportion in the film or backing will eliminate the channels or ducts through which the gases, vapors or liquids can escape. Likewise, a geometrical shape in which the space of the channels or ducts of the film borders are reduced, will also have a significant impact on the effectiveness of eliminating gases, vapors or liquids in the section formed by the adhesive and the substrate material. In all cases, the speed with which the gases, vapors or liquids are eliminated must determine the size of the channels or ducts used in the finished product. It is best to use a ratio of one half of the depth of the die-cut or raised proportion, and/or the distance between the geometrical shapes in the die-cut as the thickness of the adhesive placed to manufacture the product. Other ratios are valid for originating this invention based on the desired results.
[0054] It is also possible to add materials with the capacity to reduce electrostatics directly to the adhesive. These materials include silver, boron, gold, copper, tin, zinc, iron and vanadium salts and activated carbon with particle sizes ranging from about 150 and 200 microns in a concentration of 1 to 5% w/w, or micronized carbon black with particle size of about 1 to 50 microns in a concentration of 1 to 5% w/w. The name ‘micronized carbon black’ refers to carbon particles having a particle size of about 1 to 50 microns, and it is maintained for all references in this document. The latter materials are able to conduct electricity and distribute it throughout an area of the adhesive film, reducing its concentration in the surface treated. Conventional methods may be used to disperse the material, such as a propeller mixer, disk mixer, ribbon blender, blade mixer or any other method that facilitates dispersion of the particles. Mixing at between 3000 and 5000 revolutions per minute is good for dispersing these particles. Any person with knowledge of the technique will recognize that any other mixing system used to disperse the particles constitutes an extension of this invention. An agent to assist suspension may be also be used, such as surfacing agents, agents that form viscosity such as xanthate gum or dried silica, as well as polyurethane or acrylic thickeners.
[0055] FIG. 6 shows how electrostatics is reduced when copper salts are added to a silicone adhesive; it is possible to reduce electrostatics to an acceptable level for applications in electronics. It may also be seen that the electrostatic reduction level becomes nearly constant with the increase in the micronized carbon black. This phenomenon is observed when concentrations of materials exceed 1.5% w/w. The amount of additives to reduce electrostatics, have to take into consideration the reduction in the adhesion of the adhesive solution that is prepared to make the tape. As seen in FIG. 7 , raising the amount of additive causes a reduction in adhesion seen on stainless steel panel. The proper combination of electrostatic reduction and adhesion on a surface will have to select the amount of additives that will provide a convenient low electrostatic level and a sufficient adhesion performance.
[0056] It is also possible to review effect of electrostatics reduction when micronized carbon black or materials such as copper, silver, tin or gold salts are used directly in production of the polyetherimide film when cast or calendered. This effect is shown in FIG. 8 , where it may be seen that the electrostatic reduction level becomes constant at nearly the same level as that seen in the adhesive (1.5% w/w).
[0057] A material such as vanadium pentoxide can reduce the electrostatics to an even greater extent, even though it shows the same tendency to reach a constant level at levels of approximately 1.5% w/w. It is possible to add this material to the adhesive or to the low adhesion agent; thus it is an alternative for reducing the electrostatics to values of 200 volts or below.
[0058] It is also possible to reduce the electrostatics formed by friction of the adhesive when it is unfastened from a section of the polyetherimide film surface, by adding the same materials as those used for the adhesive, but now placed through the low adhesion agent. The low adhesion agent is placed in order to be able to peel several layers of the adhesive film, one over the other, to make it easier to unfasten them. The components used to reduce the electrostatics are mixed in with the low adhesion agent in such a way that they are deposited in a very thin coat over the outside of the polyetherimide polymer film, so that they distribute the electrostatics formed by friction of the adhesive when it is unfastened from the film. The ingredients are blended in the same way as that described for the adhesive of this invention. Conductive acrylic adhesives, made up of molecules with carboxyl groups that permit electron conduction, such as acrylate, ethylhexyl and acrilamide derivatives, constitute another alternative. Yet another option is to add particles of the conductive materials listed above directly to the reaction of the formation of the polyetherimide polymer, in a concentration of between 0.5 and 1% w/w.
[0059] In order to place the adhesive, it is necessary to know the amount of solids of the formula, as well as the temperatures at which they will be placed. The tensions of the film or backing during placement of the adhesive will depend on the type of system in which it is applied. Thus the systems preferred for placing the adhesive do not limit the use of others known in the current status of the technique as shown in Table 5.
[0000]
TABLE 5
Systems for placing the adhesive on the film or backing
System
Some features
Extrusor and drop die
Medium speed for solvent-based adhesives
(30-80 m/min)
Pumping and application
Organic solvent-based adhesives (toluene,
by roll coating
heptane, etc.) or water-based; medium-low
speeds (up to 80 m/min)
Pumping and font die
Organic solvent-based adhesives (toluene,
heptane, etc.) or water-based; medium-low
speeds (up to 50 m/min)
[0060] Roll coating systems with a gravure roll, 95 QCH stainless steel and diameter of 20-30 centimeters, at a speed of 20 meters per minute, may also be used to apply the adhesive.
[0061] The polyetherimide film with die-cut or raised proportion used in this invention can be manufactured with different mechanisms. It is also feasible to find them on the market, such as those offered by General Electric Polymers, Bloomer Plastics Company, 3M Company, Mitsubishi Polymers and Dupont Company, among others. The various compositions and physical properties make it possible to construct a wide range of protective films. The thickness and type of the film used to reinforce the materials are a very important factor in this invention. Likewise, the chemical nature of the film will be defined by the environmental conditions under which it will be used during reinforcement. A regular polyolefin film may be made more resistant to shearing or tearing when polyolefin, carbon or fiberglass fibers are placed in its structure. These fibers may be added through the same systems used to generate the polyolefin film, such as extrusion or lamination, or through application with the adhesive that has an affinity with the film and the fibers. The thickness of a film backing for this invention may range between 0.001 and 0.01 inches (0.0254 to 0.254 mm, but preferably 0.0254 mm) in order to achieve the protection, resistance and electrostatic reduction performance described. Its use will depend on the conditions under which it will be operating and the customer's needs with regard to cost and effectiveness. Any person familiar with the technique knows that an increase in the thickness of the film backing will depend on the resistance level and type of application sought. Thus, thickness of the polyetherimide film will permit to have better resistance to high temperatures by the adhesive tape made out if it, as seen in Table 6.
[0000]
TABLE 6
Temperature resistance of the adhesive masking tape made with
polyetherimide film.
Polyetherimide film
Type of adhesive (coated at
thickness (inches)
10 grams per square meter)
Heating conditions
0.001
Acrylic
180° C., 6 hours
0.002
Silicone
250° C., 3 hours
0.002
Silicone
300° C., 3 minutes
[0062] The data in Table 6 are only some examples demonstrating the temperature resistance and are not limitative of the combination of adhesive, thickness and conditions that derivate from them.
[0063] Current methods to promote an improved interaction to prevent the adhesive from being detached from the final product may be used to improve retention o adhesive on film or backing when constructing this invention. Some examples include the Corona treatment and application of a primer to the side on which the adhesive is to be placed. Both methods are well known within the current status of the technique. Their inclusion in this description is to serve as an example of the preferred methods for constructing this invention, but they should not be considered the only alternatives and any other method that makes it possible for the adhesive to stay on the film or backing of the product may also be used. Selection of the Corona treatment may vary up to 60 kilowatts on a width of 1.2 meters, or the equivalent in order to achieve a surface energy equal to 35 dynes; while the primer may be chosen from among a group of compounds that include acrylic products, ureas and natural or synthetic rubber derivatives (available from a number of companies, such as Dupont Company and 3M Company, among others).
[0064] Specific examples demonstrating construction of a high temperature heat resistant film are shown as follows.
EXAMPLE 1
High Temperature Heat Resistant Acrylic Adhesive Tape
[0065] An adhesive made of isooctyl acrylate and acrylamide compounds in a proportion of 90%/10% was placed on a polyetherimide polymer film that had a 1 millimeter circular raised portion, and a span of 0.5 millimeters between each circle. The amount of acrylic adhesive placed was sufficient to keep the adhesive at a thickness of approximately 0.25-0.3 millimeters. The adhesive was coated with a font die, which was fed with a peristaltic pump at a rate of 10-15 kilograms per minute. The adhesive solution had a viscosity of 3000 to 5000 centipoises and total solids of 40%. Construction was completed with placement of a low adhesion agent, RD1530 at 2% total solids from 3M Company, on the other side of the backing or film.
EXAMPLE 2
Reinforcement Tape for Welding of Electronic Plates
[0066] An adhesive composed of a silicone polymer made of siloxane polydimethyl and polysiloxane such as adhesive silicone 7925 from Dow Chemical, was placed in a weight of 20 g/m2 over a polyetherimide polymer film that has a flat surface 0.001 inch (0.0254 mm) thick. The adhesive was coated with a drop die with a lips gap of 0.02 to 0.03 inches, made of stainless steel and fed with a peristaltic pump at a rate of 20-25 kilograms per minute, to provide a continuous flow of adhesive in a gap of 0.01 to 0.015 inches from the surface of the polyetherimide film. Construction was completed with placement of a low adhesion agent, RD1530 at 2% total solids from 3M Company, on the other side of the backing or film, as in example 1.
EXAMPLE 3
High Temperature Heat Resistant Tape with High Static Reduction (<200 Volts)
[0067] An adhesive composed of a silicone polymer made of siloxane polydimethyl and polysiloxane as in Example 2, was placed in a weight of 20 g/m2 over a polyetherimide polymer film that had a 0.001 inches thick (0.0254 mm) flat surface. The adhesive was added to a vanadium pentoxide solution using a surfacing or thixotropic agent such as xanthate gum in a concentration of 2% w/w, and mixing it with a marine propeller at 3000 rpm for one hour. The adhesive was coated with a drop die with a lips gap of 0.03 to 0.045 inches, made of stainless steel and fed with a peristaltic pump at a rate of 20-25 Kg per minute, to provide a continuous flow of adhesive in a gap of 0.008 to 0.01 inches from the surface of the polyetherimide film. Construction was completed with placement of a low adhesion agent, RD1530 at 2% total solids from 3M Company, on the other side of the backing or film, as in Example 1.
EXAMPLE 4
High Temperature Heat Resistant Tape with Medium Static Reduction (>200 Volts)
[0068] An adhesive composed of a silicone polymer made of siloxane polydimethyl and polysiloxane as in example 2, was placed in a weight of 20 grams per square meter, over a polyetherimide polymer film that had a flat surface 0.001 inches thick (0.0254 mm). The adhesive was added with micronized carbon black, which was made by adding these latter components and a thixotropic agent such as xanthate gum in a concentration of 2% w/w in toluene, and mixing with a marine propeller at 3000 rpm for one hour. The adhesive solution was coated with a font die, which was fed with a peristaltic pump at a rate of 15-20 kilograms per minute. The adhesive solution had a viscosity of 3000-5000 centipoises and total solids of 50%. Construction was completed with placement of a low adhesion agent, RD1530 at 2% total solids from 3M Company, on the other side of the backing or film, as in Example 1.
EXAMPLE 5
High Temperature Heat Resistant Tape with Micro-Replicated Acrylic Adhesive
[0069] An adhesive composed of a silicone polymer made of isooctyl acrylic and acrylamide compounds in a proportion of 95%/5%, was placed in a weight of 20 grams per square meter over a polyetherimide polymer film that had a flat surface 0.003 inches thick (0.0762 mm). The adhesive was diluted with ethyl acetate to place it on a piece of 0.05 mm by 0.05 mm release paper that had a micro-replicated net pattern in such a way that the net was created by squares of 0.05 mm in length and 0.05 mm in width. The pattern was then replicated throughout the adhesive surface including the 0.001 mm deep channels separating the squares in the net. The adhesive was coated on the release paper with a font die, which was fed with a peristaltic pump at a rate of 10 to 15 kilograms per minute. The adhesive solution had a viscosity of 3000-5000 centipoises and total solids of 40%. The coated paper was then placed onto the surface of the polyetherimide film using a winder machine running at 20 to 25 meters per minute, and which has two cylinders of 60 to 70 centimeters in diameter and 162 centimeters in length, rotating at the same speed and pressing the paper on the polyetherimide film. The resultant product was a tape where the micro-replicated adhesive was transferred from the release paper to the polyetherimide film. The release paper is obtained from the line of products Scotch Cal®, manufactured by 3M Company, St. Paul, Minn., USA.
[0070] Various modifications and changes in this invention will be apparent to persons familiar with the technique, even though they may not explicitly arise from all of its objectives and principles. It must also be understood that this invention is not restricted to the examples shown herein.
SUMMARY OF THE INVENTION
[0071] In this invention a description is provided of a high temperature heat resistant adhesive tape made from a polyetherimide polymer film, with or without a die-cut or raised proportion surface in various geometrical shapes and sizes, which makes it possible to release the fluids retained between the protected surface and the adhesive. The adhesive film acts as a backing for one adhesive that facilitates connection to the substrate and maintains its stability, along with that of the film, under temperatures up to 220° C. This makes the adhesive tape an alternative for protecting or insulating surfaces such as electronic or electrical circuits. Compounds such as derivatives of organometallic derivatives, boron, carbon or micronized carbon black may be added to the adhesive in order to reduce the electrostatics caused by friction between the adhesive and the polyetherimide coating, either alone or with a different surface. These compounds may also be added to the film during the production process or when the low adhesion agent is placed on the film when the adhesive tape is manufactured. | Provided is a heat-resistant masking tape suitable for electronics applications comprising a polyetherimide polymer film having a first surface and a second surface, an adhesive on the first surface, and a low adhesion agent on the second surface, wherein at least one of the polyetherimide film, the low adhesion agent and the adhesive includes micronized carbon black. Also provided is a process for making this tape and electronic circuits using this tape. | 51,649 |
TECHNICAL FIELD
[0001] The present invention relates to a transport device that transports non-self-propelled transport vehicles carrying articles along a transport path including a curved path and forms a continuous floor on the transport vehicles in the entire or partial transport path.
BACKGROUND ART
[0002] According to one transport device that can form a continuous work floor (work plane) on which a worker rides to perform work while transporting transport vehicles carrying articles along a transport path, front and back transport vehicles (1 and 1) are coupled together by vehicle coupling units (vehicle coupling means (9), coupling start means (10), and decoupling means (11)) and are transported at a constant speed by a pushing drive means (5A) in a straight work line (pushing run section (3)) where the ends of the transport vehicles (1) are in abutment with each other to form a continuous work floor, and the transport vehicle (1) having exited out of the work line is decoupled and transported at a higher speed by a high-speed drive means (5C) in a return line (high speed run section (4)) for returning the transport vehicle (1) having exited out of the work line to the entrance of the work line (for example, refer to Patent Document 1).
[0003] According to another transport device, the transport vehicles (movable bodies (10)) are coupled together by a coupling unit (30) at the front and back parts opposed to each other so as to be capable of relative rotation in the lateral direction, a train-like endless continuous body (90) is formed from a transport vehicle group (moving body (10) group) and a coupling unit (30) group, and the endless continuous body (90) is driven by a feed unit (50) (for example, refer to Patent Document 2).
[0004] According to still another transport device, transport vehicles (pallets (2)) are divided into a plurality of sections relative to the transport direction, the divided transport vehicles (divided pallets (2A, 2B, and 2C)) are movably coupled together in a horizontal plane, and the transport vehicles are transported in a free flow system in which, when the following transport vehicle abuts with the preceding transport vehicle, the following transport vehicle pushes the preceding transport vehicle (for example, refer to Patent Document 3).
[0005] According to still another transport device, each of the transport vehicles (1) is composed of one or more vehicle bodies (1A and 1B) and coupled vehicle bodies (2A and 2B) that are positioned at the front or back side of the vehicle bodies (1A and 1B) in the transport direction and are coupled to the vehicle bodies (1A and 1B) so as to be capable of relative rotation around a vertical axis, the upper surfaces of the vehicle bodies (1A and 1B) and the upper surfaces of the coupled vehicle bodies (2A and 2B) are flush with each other, a coupling means (C) is provided to couple the transport vehicles (1 and 1) positioned at the front and back sides in the transport direction, the plurality of transport vehicles (1, 1, . . . ) is coupled by the coupling means (C) and is arranged as a transport vehicle group (A) in a transport path including a curved path (C1), a work line (L1) for performing parts assembly work while transporting the transport vehicle group (A) at a constant speed is formed with a work floor (B) composed of the upper surfaces of the vehicle bodies (1A and 1B) and the coupled vehicle bodies (2A and 2B), a return line (L2) is provided such that the transport vehicle (1) at the front end of the transport vehicle group (A) in the transport direction is separated and transported at a high speed and is coupled to the back end of the transport vehicle group (A), and an article (W) is unloaded from the single transport vehicle (1) separated from the transport vehicle group (A) and a new article (W) is loaded onto the same on the return line (L2) (for example, refer to Patent Document 4.).
[0006] According to one wafer transport device that transports silicon wafers on a semiconductor production line, a liquid drive source (6) induces a flow of pure water (4) in a constant direction in a fluid path (5) as a circulation flow path, a float (3) carrying a wafer carrier (2) storing silicon wafers (1, 1, . . . ) and floating on the pure water (4) is moved by the flow along the fluid path (5), the float (3) is stopped by float stoppers (7a and 7b) in the vicinity of manufacturing devices (9a and 9b), and the wafer carrier (2) is transferred from the float (3) to the manufacturing devices (9a and 9b) and is transferred from the manufacturing devices (9a and 9b) to the float (3) by manipulators (8a and 8b) (for example, refer to Patent Document 5).
CITATION LIST
Patent Literatures
[0007] Patent Document 1: JP-A No. 2006-117079
[0008] Patent Document 2: JP-A No. H08-282481
[0009] Patent Document 3: JP-A No. 2007-112605
[0010] Patent Document 4: JP-A No. 2013-107731
[0011] Patent Document 5: JP-A No. 863-102238
SUMMARY OF INVENTION
Technical Problem
[0012] The transport device as described in Patent Document 1 is configured to decouple the transport vehicle and transport the same at a high speed by the high-speed drive means on the line other than the straight work line (return line), and no work floor (work plane) on which the worker rides to perform work can be formed on the line other than the straight work line, thereby leading to degradation in work efficiency and space efficiency.
[0013] The transport device as described in Patent Document 2 is configured to drive the entire train-like endless continuous body by the feed unit, and it is thus necessary to stop the entire endless continuous body to load and unload the articles on and from the transport vehicles with degradation in work efficiency.
[0014] The transport device as described in Patent Document 3 is configured in the free flow system in which the preceding and following transport vehicles are not coupled but the following transport vehicle pushes the preceding transport vehicle, and a gap may be produced between the preceding and following transport vehicles. Accordingly, it is hard to form reliably the continuous work floor (work plane) on which the worker rides.
[0015] In contrast to the foregoing devices, according to the transport device as described in Patent Document 4, each of the transport vehicles is composed of one or more vehicle bodies and coupled vehicle bodies that are positioned at the front or back side of the vehicle bodies in the transport direction and are coupled to the vehicle bodies so as to be capable of relative rotation around the vertical axis, and the upper surfaces of the vehicle bodies and the upper surfaces of the coupled vehicle bodies are approximately flush with each other. This makes it possible to form the continuous work floor on which the worker rides to perform parts assembly work, from the upper surfaces of the vehicle body composed of the transport vehicle group by coupling the plurality of transport vehicles via the coupling means and the upper surfaces of the coupled vehicle bodies, and it is also possible to arrange the transport vehicle group in the transport path including the curved path.
[0016] Therefore, the worker is allowed to perform the parts assembly work even in the curved path with improvement in work efficiency and space efficiency.
[0017] Further, the articles are unloaded from and loaded onto the single transport vehicle separated from the transport vehicle group on the return line. This eliminates the need to stop the transport vehicle group on the work line at the time of loading and unloading of the articles, and allows the worker to perform work while the transport vehicle group is transported at a constant speed on the work line with further improvement in work efficiency.
[0018] Moreover, the preceding and following transport vehicles in the transport vehicle group are coupled by the coupling means on the work line and no gap is produced between the preceding and following transport vehicles even with fluctuation in the transport speed. This makes it possible to form reliably the continuous work floor (work plane) on which the worker rides.
[0019] The transport device as described in Patent Document 4 has the foregoing features. However, the transport device is configured to include the transport vehicle group formed by coupling the plurality of transport vehicles via the coupling means and the large work floor on the transport vehicle group. Accordingly, the weight of the transport vehicle group becomes heavier to increase running resistance, and it is necessary to add large thrust at the time of driving by the drive unit.
[0020] Therefore, the drive unit needs to be large in capacity, which causes the problem of increased energy consumption.
[0021] Further, to drive the transport vehicle group by a friction-type drive unit, for example, it is necessary to press a friction roller strongly against the friction surface of the transport vehicle. Accordingly, the frame of the transport vehicle needs to be enhanced in strength with increase in manufacturing costs and the rubber of the friction roller surface may be deteriorated at earlier stages by breakage, deformation, or separation.
[0022] The foregoing problems also exist in the transport devices as described in Patent Documents 1 to 3.
[0023] The transport device as described in Patent Document 5 is configured to transport the float by the flow of pure water in the water way induced by the liquid drive source in the constant direction. Accordingly, the drive system includes a few sliding parts, and therefore dust is unlikely generated at the drive system and the wafer is not contaminated even if the pure water is scattered. This improves the yield of the semiconductor production line.
[0024] However, when the float is transported by the water flow, it is difficult to keep constant the transport speed. Accordingly, this configuration cannot be applied to the work line on which the worker performs work while the transport vehicle group constituting the work floor is transported at a constant speed.
[0025] Further, to transport an article long in the transport direction (travelling direction), it is necessary to lengthen the float in the transport direction and increase the curvature radius of the curved path (corner) with limitation on the layout of the water way.
[0026] In view of the foregoing circumstances, an object of the present invention is to provide a transport device that transports non-self-propelled transport vehicles carrying articles along a transport path including a curved path and forms a continuous floor on the transport vehicles in the entire or partial transport path. The transport device can suppress increase in running resistance due to rise in weight of the transport vehicle group and suppress increase in energy consumption and manufacturing costs, thereby to prevent earlier-stage degradation of the rubber of the friction roller surface due to breakage, deformation, or separation at the time of driving by the friction-type drive unit.
Solution to Problem
[0027] To solve the foregoing problems, a transport device according to the present invention transports a non-self-propelled transport vehicle carrying an article along a transport path including a curved path and forms a continuous floor on the transport vehicle in the entire or partial transport path. The transport device includes: running rails that are laid along the transport path to support running wheels of the transport vehicle; guide rails that guide the transport vehicle along the transport path; a drive unit that drives the transport vehicle; and a water way that is formed along the transport path to reserve water, wherein the transport vehicle is formed such that a plurality of frame bodies with upper surfaces approximately flush with each other is coupled together so as to be bendable relatively in the horizontal direction, and a float body partially or entirely immersed in the water reserved in the water way is fixed to a lower part of each or any of the frame bodies (Claim 1 ).
[0028] According to this configuration, the transport vehicle is formed by coupling the plurality of frame bodies so as to be bendable relatively in the horizontal direction and the float body is fixed to the lower part of each or any of the frame bodies. The plurality of frame bodies bend in the horizontal direction along the curved path and the float body fixed to the lower part of the frame body moves in the water way along the curved path.
[0029] Therefore, even when an article longer in the transport direction is to be transported, it is not necessary to increase the curvature radius of the curved path, without limitation on the layout of the transport path (water way) including the curved path.
[0030] Further, the transport vehicle is formed by coupling the plurality of frame bodies with the upper surfaces approximately flush with each other so as to be bendable relatively in the horizontal direction. Accordingly, the worker can ride on the upper surface of the vehicle to perform work even in the curved path, with improvement in work efficiency and space efficiency.
[0031] Furthermore, the transport vehicle is driven by the drive unit, which allows the transport vehicle to be transported at a constant speed. This achieves formation of the work line on which the worker can perform work while the transport vehicle forming the continuous floor is transported at a constant speed.
[0032] Moreover, although the formation of the continuous floor leads to increase in the weight of the vehicle, the float body is fixed to the lower part of each or any of the frame bodies and is immersed in the water reserved in the water way. Accordingly, the load of the vehicle on the running rails becomes smaller due to the buoyancy of the float body.
[0033] Therefore, the running resistance between the running wheels of the vehicle and the running rails is reduced to decrease thrust necessary for driving the vehicle. This results in reduction of energy consumption.
[0034] It is preferred that the transport vehicle include a friction surface, and the drive unit driving the transport vehicle is a friction-type drive unit including a friction roller to be in abutment with the friction surface (Claim 2 ).
[0035] According to this configuration, it is possible to reduce the load of the vehicle acting on the running rails due to the buoyancy of the float body and decrease thrust necessary for driving the vehicle as described above. Thus, even though the transport vehicle includes the friction surfaces and the drive unit driving the transport vehicle is a friction-type drive unit including a friction roller to be in abutment with the friction surfaces, it is possible to make the pressing force of the friction roller relatively small. This causes no increase in manufacturing costs for improving the strength of the frame bodies for the transport vehicle or no earlier-stage degradation of the rubber of the friction roller surface due to breakage, deformation, or separation during driving by the friction-type drive unit.
[0036] It is preferred that a guided member drooping from an article support base supporting the article is supported in an ascendible and descendible manner by a guiding member provided at one of the frame bodies, and the float body partially or entirely immersed in the water reserved in the water way is fixed to the guided member positioned under the guiding member (Claim 3 ).
[0037] According to this configuration, the guided member drooping from the article support base is supported in an ascendible and descendible manner by the guiding member and the float body is fixed to the guided member. Thus, in the state in which the article support base does not support the article, the guided member and the article support base ascend due to the buoyancy of the float body, and the load of the article support base does not act on the transport vehicle.
[0038] Further, in the state in which the article support base supports the article, the article support base, the guided member, and the float body descend due to the load of the article, the float body is more immersed in the water with increased buoyancy, and thus the force acting on the transport vehicle due to the load of the article, the article support base, and the guided member becomes smaller.
[0039] Therefore, it is possible to lessen the strength of the vehicle and decrease the running resistance between the running wheels of the vehicle and the running rails, thereby reducing thrust necessary for driving the vehicle with lower energy consumption.
[0040] It is preferred that the transport device includes a height holding means that, in the state in which the article support base supports the article, holds the height of the article support base relative to the frame bodies at a constant value (Claim 4 ).
[0041] According to this configuration, in the state in which the article support base supports the article, the article support base, the guided member, and the float body descend due to the load of the article, and the float body is more immersed in the water with increased buoyancy. The height holding means holds the height of the article support base relative to the frame bodies at a constant value while the buoyancy is about to match with the load of the article, the article support base, the guided member, and the float body.
[0042] Therefore, it is possible to suppress the load of the article, the article support base, the guided member, and the float body acting on the transport vehicle and reduce the running resistance between the running wheels of the vehicle and the running rails. In addition, when the worker rides on the continuous floor to perform work, the height of the article is uniform relative to the floor. Accordingly, there is no deterioration in workability even if the water in the water way ruffles and shakes the float body in the vertical direction.
[0043] It is preferred that a work line is configured such that a plurality of the transport vehicles is coupled together by a coupling means to form a transport vehicle group and the transport vehicle group is arranged in the transport path including the curved path, and the worker rides on an upper surface of the transport vehicle group as a work floor to perform work while the transport vehicle group is transported at a constant speed, a return line is provided such that the transport vehicle at the front end of the transport vehicle group in the transport direction is separated and transported at a high speed and is coupled to the back end of the transport vehicle group, and, on the return line, the article is unloaded from the single transport vehicle separated from the transport vehicle group and a new article is loaded onto the same (Claim 5 ).
[0044] According to this configuration, the plurality of transport vehicles can be coupled together by the coupling means to form the transport vehicle group, and the worker can perform work on the upper surface of the transport vehicle group as the work floor, and the worker can unload and load the articles from and onto the transport vehicle separated from the front end of the transport vehicle group in the transport direction. This eliminates the need to stop the transport vehicle group on the work line for unloading and loading the articles with increased work efficiency.
[0045] It is preferred that a section between the pair of frame bodies adjacent to each other at the front and back sides of the transport direction is formed in an arc-shaped convex portion at one side and in an arc-shaped concave portion at the other side in a plane view, the curvature radiuses of the arc-shaped convex portion and the arc-shaped concave portion are approximately identical, and the center of rotation around which the pair of frame bodies bends relatively in the horizontal direction is approximately identical to the centers of curvatures of the arc-shaped convex portion and the arc-shaped concave portion (Claim 6 ).
[0046] According to this configuration, the space between the pair of frame bodies adjacent to each other at the front and back sides of the transport direction is formed in the arc-shaped convex portion at one side and in the arc-shaped concave portion at the other side in a plane view, the curvature radiuses of the arc-shaped convex portion and the arc-shaped concave portion are approximately identical, and the center of rotation around which the pair of frame bodies bends relatively in the horizontal direction is approximately identical to the centers of curvatures of the arc-shaped convex portion and the arc-shaped concave portion. Accordingly, the gap between the pair of frame bodies adjacent to each other at the front and back sides of the transport direction is smaller and is not widened even when the pair of frame bodies bends relatively in the horizontal direction.
[0047] It is preferred that one of the front end and the back end of the transport vehicle is set as the arc-shaped convex portion and the other is set as the arc-shaped concave portion, the coupling means coupling the transport vehicles positioned at the front and back sides of the transport direction is composed of an arc-shaped guide groove formed in the arc-shaped convex portion at the coupling side of the transport vehicle positioned at the front and back sides of the transport direction and an engagement body for engagement with the arc-shaped guide groove provided at the arc-shaped concave portion at the coupling side of the same such that they are engageable with each other into a coupled state and are disengageable from each other into a decoupled state, and the center of curvature of the arc-shaped guide groove is approximately identical to the center of curvature of the arc-shaped convex portion (Claim 7 ).
[0048] It is also preferred that one of the front end and the back end of the transport vehicle is set as the arc-shaped convex portion and the other is set as the arc-shaped concave portion, the coupling means coupling the transport vehicles positioned at the front and back sides of the transport direction is composed of an arc-shaped guide groove formed in the arc-shaped concave portion at the coupling side of the transport vehicle positioned at the front and back sides of the transport direction and an engagement body for engagement with the arc-shaped guide groove provided at the arc-shaped convex portion at the coupling side of the same such that they are engageable with each other into a coupled state and are disengageable from each other into a decoupled state, and the center of curvature of the arc-shaped guide groove is approximately identical to the center of curvature of the arc-shaped concave portion (Claim 8 ).
[0049] According to these configurations, one of the front end and the back end of the transport vehicle is set as the arc-shaped convex portion and the other is set as the arc-shaped concave portion, a coupling means coupling the transport vehicles positioned at the front and back sides of the transport direction is composed of an arc-shaped guide groove formed in the arc-shaped convex portion (concave portion) at the coupling side of the transport vehicle positioned at the front and back sides of the transport direction and an engagement body for engagement with the arc-shaped guide groove provided at the arc-shaped concave portion (convex portion) at the coupling side of the same such that they are engageable with each other into a coupled state and are disengageable from each other into a decoupled state, and the center of curvature of the arc-shaped guide groove is approximately identical to the center of curvature of the arc-shaped convex portion (concave portion). Accordingly, in the coupled state in which the transport vehicles positioned at the front and back sides of the transport direction are coupled together by the coupling means, the gap between the transport vehicles is small and is not widened even when the front and back transport vehicles bend relatively in the horizontal direction.
[0050] Therefore, the continuous floor can be obtained with little gap even in the curved path, which improves workability and causes no risk that the worker has their legs caught in the gap.
[0051] In addition, the front and back transport vehicles are coupled together by the coupling means, and no gap is produced between the front and back transport vehicles even with variations in the transport speed and the like. Accordingly, it is possible to form reliably the continuous work floor on which the worker rides.
[0052] Further, the coupling means is composed of the arc-shaped guide groove and the engagement body, and the center of curvature of the arc-shaped guide groove and the center of curvature of the arc-shaped convex portion (concave portion) are approximately identical. Accordingly, the coupling means is easy to fabricate, and the simply-structured coupling means can bring the transport vehicles into the coupled state and the decoupled state in a stable and reliable manner.
[0053] It is preferred that the transport device includes a water flow generation unit that generates a forward water flow in the transport direction in the water reserved in the water way to apply thrust to the transport vehicle via the float body in the transport direction (Claim 9 ).
[0054] According to this configuration, the water flow generation unit applies thrust to the transport vehicles via the float bodies and the transport vehicles are driven by the thrust, which reduces the drive force of the drive unit necessary for driving the transport vehicles.
Advantageous Effects of Invention
[0055] As described above, according to the transport device in the present invention, the following significant advantages can be produced:
[0056] (A) Even when an article long in the transport direction is to be transported, it is not necessary to increase the curvature radius of the curved path, and there is no limitation on the layout of the transport path (water way) including the curved path.
[0057] (B) The worker can ride on the upper surface of the vehicle to perform work even in the curved path with improvement in work efficiency and space efficiency.
[0058] (C) The transport vehicles can be transported at a constant speed, and it is possible to form a work line such that the worker performs work while the transport vehicles constituting the continuous floor are transported at a constant speed.
[0059] (D) The running resistance between the running wheels of the vehicle and the running rails can be reduced to decrease thrust necessary for driving the vehicle and cut energy consumption. In addition, even though the drive unit driving the transport vehicle is a friction-type drive unit, there is no increase in manufacturing costs for improving the strength of the frame bodies for the transport vehicle or no earlier-stage degradation of the rubber of the friction roller surface due to breakage, deformation, or separation.
[0060] (E) The continuous work floor with little gap can be obtained even in the curved path to improve workability and cause no risk that the worker has their legs caught in the gap.
BRIEF DESCRIPTION OF THE DRAWINGS
[0061] FIG. 1 is a diagram schematically illustrating a layout of a transport device according to an embodiment of the present invention;
[0062] FIG. 2 is a front view of a transport vehicle according to the embodiment of the present invention;
[0063] FIG. 3 is a vertical cross-sectional view of the transport vehicle as seen from the back side;
[0064] FIG. 4 is a plane view of the transport vehicle in a curved path on a work line;
[0065] FIG. 5 is a plane view of the transport vehicle in a straight path on a return line;
[0066] FIG. 6 is a bottom view of the transport vehicle;
[0067] FIG. 7 include vertical front views describing operations of a coupling means that couples a transport vehicle (following vehicle) approaching from the back side to a transport vehicle (preceding vehicle) at the back end of a transport vehicle group, FIG. 7( a ) illustrates the state in which the following vehicle approaches the preceding vehicle and an inclined surface of a coupling frame of the following vehicle is in abutment with a lift roller of the preceding vehicle, FIG. 7( b ) illustrates the state in which the following vehicle further approaches the preceding vehicle and the coupling frame is lifted and swung upward by the lift roller, FIG. 7( c ) illustrates the state in which the following vehicle further approaches the preceding vehicle and the coupling frame is swung more upward, and FIG. 7( d ) illustrates the coupling complete state in which the following vehicle further approaches the preceding vehicle, the coupling frame is swung downward, and the lift roller enters in an arc-shaped guide groove;
[0068] FIG. 8 is a vertical front view describing the operation of decoupling by the coupling means;
[0069] FIG. 9 is a front view of a configuration example of a height holding means;
[0070] FIG. 10 is a bottom view of a modification example of the transport vehicle;
[0071] FIG. 11 includes vertical front views for describing operations of a coupling means that couples a transport vehicle (following vehicle) approaching from the back side to a transport vehicle (preceding vehicle) at the back end of a transport vehicle group composed of a modification example of the transport vehicles, FIG. 11( a ) illustrates the state in which the following vehicle approaches the preceding vehicle, FIG. 11( b ) illustrates the state in which the following vehicle further approaches the preceding vehicle and a coupling frame is lifted and swung upward by a lift roller, and FIG. 11( c ) illustrates the coupling complete state in which the following vehicle further approaches the preceding vehicle, the coupling frame is swung downward, and the lift roller enters in an arc-shaped guide groove; and
[0072] FIG. 12 is a vertical front view describing the operation of decoupling by the coupling means.
DESCRIPTION OF EMBODIMENTS
[0073] Next, embodiments of the present invention will be described in detail with reference to the accompanying drawings. However, the present invention is not limited to the embodiments illustrated in the accompanying drawings and includes all of embodiments satisfying the requirements described in the claims.
[0074] The side in the direction of transporting articles (see arrow F in the drawings) will be designated as front side, and the side in the reverse direction as a back side. Views seen from the left side will be designated as front views.
[0075] As illustrated in the schematic layout diagram of FIG. 1 , a transport device according to an embodiment of the present invention transports non-self-propelled transport vehicles 1 , 1 , . . . carrying articles E by feed units T 1 , T 2 , and T 3 as friction roller-type drive units along an endless transport path composed of straight paths S 1 and S 2 and curved paths C 1 and C 2 .
[0076] The transport device arranges a transport vehicle group A formed by coupling front and back transport vehicles 1 and 1 by a coupling means C (see the vertical front view of FIG. 7 ) described later in the transport path including the curved path C 1 , and has a work line L 1 such that a continuous work floor (work plane) B (see the front views of FIGS. 2 and 9 ) on which the worker rides to perform work is formed on the transport vehicles 1 , 1 , . . . in part of the transport path. As illustrated in the vertical cross-sectional view as seen from the back side of FIG. 3 , the work floor B is flush with a floor surface G.
[0077] In addition, a return line L 2 is formed by part of the straight path S 2 , the curved path C 2 , and part of the straight path S 1 such that the transport vehicle 1 at the front end of the transport vehicle group A is separated from the transport vehicle group A, and the separated transport vehicle 1 is transported at a high speed and coupled to the back end of the transport vehicle group A.
[0078] Further, the return line L 2 includes a loading station ST 1 where the articles E are loaded and an unloading station ST 2 where the articles E are unloaded. At the unloading station ST 2 , the articles E are unloaded from the single transport vehicle 1 separated from the transport vehicle group A, and at the loading station ST 1 , new articles E are loaded onto the empty single transport vehicle 1 .
[0079] Furthermore, a water way WW reserving water W is provided under the transport vehicles 1 along the transport path. Float bodies F 1 to F 4 illustrated in the front view of FIG. 2 are immersed in the water W to generate buoyancy acting on the transport vehicles 1 .
[0080] The transport vehicle group A is transported by a constant-speed transport feed unit T 1 . Specifically, the transport vehicle 1 at the front end is driven by press-fitting friction rollers 21 , . . . of the constant-speed transport feed unit T 1 to the side surface of the transport vehicle 1 at the front end (see a driven surface H in FIGS. 3 to 6 ) while receiving reaction force by backup rollers 22 , . . . of the constant-speed transport feed unit T 1 , thereby to tow the following transport vehicles 1 , 1 , . . . and transport the transport vehicle group A in an integrated manner at a constant speed.
[0081] By bringing a friction roller 21 of the brake feed unit T 3 slightly lower in speed than the constant-speed transport feed unit T 1 into press-fit with the side surface (driven surface H) of the transport vehicle 1 at the back end of the transport vehicle group A, it is possible to produce the effect that tension force acts on the entire transport vehicle group A to prevent occurrence of rattle among the transport vehicles 1 in the vehicle group A.
[0082] Alternatively, the constant-speed transport feed unit T 1 may be provided at the back end of the transport vehicle group A to drive the vehicle group A forward, and the brake feed unit T 3 may be provided at the front end of the transport vehicle group A.
[0083] Further, as described above, the single transport vehicle 1 separated from the transport vehicle group A is transported by the high-speed transport feed unit T 2 bringing the friction roller 21 into press-fit with the side surface (driven surface H) of the transport vehicle 1 . At the loading station ST 1 and the unloading station ST 2 , the transport vehicle 1 is stopped at a predetermined position to load and unload the articles E.
[0084] Furthermore, when the transport vehicle 1 loaded with the new article E at the loading station ST 1 is to be transported at a high speed and coupled to the back end of the transport vehicle group A by the high-speed transport feed unit T 2 , the high-speed transport feed unit T 2 is shifted to low-speed operation to decelerate the transport vehicle 1 having been transported at a high speed and couple the same to the back end of the transport vehicle group A by the coupling means C.
[0085] In this example, a water flow generation unit as an underwater pump with a discharge port may be provided at an appropriate position in the schematic layout illustrated in FIG. 1 (for example, in the vicinity of the high-speed transport feed unit T 2 on the return line L 2 ) so that the water flow generation unit generates a forward water flow to assist the feed units T 1 , T 2 , and T 3 as drive units.
[0086] In the case where the layout of the transport device does not constitute a closed circuit (endless path) as illustrated in FIG. 1 , a water flow generation unit generating a water flow by a difference in height may be used instead of the water flow generation unit as an underwater pump.
[0087] As illustrated in the front view of FIG. 2 , the vertical cross-sectional view as seen from the back side of FIG. 3 , the plane views of FIGS. 4 and 5 , and the bottom view of FIG. 6 , the transport vehicle 1 according to the embodiment of the present invention is composed of a vehicle body 2 with an article support base D supporting the article E, a front coupled vehicle body 3 A that is positioned at the front side of the vehicle body 2 and is coupled to the vehicle body 2 around a vertical axis so as to be capable of relative rotation, a back coupled vehicle body 3 B that is positioned at the back side of the vehicle body 2 and is coupled to the vehicle body 2 around the vertical axis so as to be capable of relative rotation, and others. The upper surface of the vehicle body 2 and the upper surfaces of the front coupled vehicle body 3 A and the back coupled vehicle body 3 B are approximately flush with each other.
[0088] The vehicle body 2 is formed by fixing a frame member to the lower surface of a plate member with straight right and left sides and arc-shaped convex front and back sides (front and back end portions) and attaching running wheels 4 , 4 , . . . to the front, back, right, and left of the frame body with the horizontal upper surface, such that the running wheels 4 , 4 , . . . roll on right and left running rails R and R laid along the transport path.
[0089] The front coupled vehicle body 3 A is formed by fixing a frame member to the lower surface of a plate member with straight right and left sides, an arc-shaped convex front side (front end portion), and an arc-shaped concave back side (back end portion), and attaching running wheels 5 , 5 , . . . to the front, back, right, and left of the frame body with the horizontal upper surface, such that the running wheels 5 , 5 , . . . roll on the running rails R and R.
[0090] The back coupled vehicle body 3 B is formed by fixing a frame member to the lower surface of a plate member with straight right and left sides and arc-shaped concave front and back sides, and attaching running wheels 6 , 6 , . . . to the front, back, right, and left of the frame body with the horizontal upper surface, such that the running wheels 6 , 6 , . . . roll on the running rails R and R.
[0091] The curvature radiuses of the arc-shaped convex portions and the arc-shaped concave portions are approximately identical.
[0092] As illustrated in the plane views of FIGS. 4 and 5 and the bottom view of FIG. 6 , coupling rods 7 and 8 long in the front-back direction are fixed to the right and left at the back side of the lower surface of the frame member of the front coupled vehicle body 3 A, and they are protruded backward. Coupling rollers (horizontal rollers rotatable around the vertical axis) 7 A and 8 A as engagement bodies are attached to the upper sides of the back end portions of the coupling rods 7 and 8 .
[0093] In addition, coupling rods 9 and 10 long in the front-back direction are fixed to the right and left of the lower surface of the frame member of the back coupled vehicle body 3 B, and they are protruded forward and backward. Coupling rollers (horizontal rollers rotatable around the vertical axis) 9 A and 10 A as engagement bodies are attached to the upper sides of the front end portions of the coupling rods 9 and 10 . Coupling rollers (horizontal rollers rotatable around the vertical axis) 9 B and 10 B as engagement bodies are attached to the upper side of the back portion of the coupling rod 9 and the upper side of the back end portion of the coupling rod 10 .
[0094] The coupling rod 9 is protruded more backward than the coupling rod 10 . Guide rollers (horizontal rollers rotatable around the vertical axis) 13 A and 13 B along a guide rail G 2 described later are attached to the lower side of the back end portion of the coupling rod 9 .
[0095] Arc-shaped guide grooves 14 A and 14 B are formed on the insides (inner-diameter sides) of the arc-shaped convex portions at the front and back sides of the vehicle body 2 , and an arc-shaped guide groove 15 is formed on the inside (inner-diameter side) of the arc-shaped convex portion at the front side of the front coupled vehicle body 3 A. The centers of curvatures of the arc-shaped guide grooves 14 A, 14 B, and 15 are approximately identical to the centers of curvatures of the arc-shaped convex portions.
[0096] The coupling rollers 7 A and 8 A at the back end portions of the coupling rods 7 and 8 of the front coupled vehicle body 3 A engage with the arc-shaped guide groove 14 A, and the coupling rollers 9 A and 10 A at the front end portions of the coupling rods 9 and 10 of the back coupled vehicle body 3 B engage with the arc-shaped guide groove 14 B. In this engagement state, the center of rotation around which the vehicle body 2 and the front coupled vehicle body 3 A bend relatively in the horizontal direction becomes approximately identical to the centers of curvatures of the arc-shaped convex portion at the front side of the vehicle body 2 and the arc-shaped concave portion at the back side of the front coupled vehicle body 3 A, and the center of rotation around which the vehicle body 2 and the back coupled vehicle body 3 B bend relatively in the horizontal direction becomes approximately identical to the centers of curvatures of the arc-shaped convex portion at the back side of the vehicle body 2 and the arc-shaped concave portion at the front side of the back coupled vehicle body 3 B.
[0097] Therefore, the gap between the vehicle body 2 and the front coupled vehicle body 3 A and the gap between the vehicle body 2 and the back coupled vehicle body 3 B are small, and the gaps will not be widened even when the vehicle body 2 and the front coupled vehicle body 3 A and the vehicle body 2 and the back coupled vehicle body 3 B bend relatively in the horizontal direction.
[0098] In the state in which the front and back transport vehicles 1 , 1 , . . . are coupled together as illustrated in FIG. 4 , the coupling rollers 9 B and 10 B at the back portions of the coupling rods 9 and 10 of the back coupled vehicle body 3 B of the preceding vehicle engage with the arc-shaped guide groove 15 of the front coupled vehicle body 3 A of the following vehicle. In this engagement state, the center of rotation around which the back coupled vehicle body 3 B of the preceding vehicle and the front coupled vehicle body 3 A of the following vehicle bend relatively in the horizontal direction is approximately identical to the centers of curvatures of the arc-shaped concave portion at the back side of the back coupled vehicle body 3 B of the preceding vehicle and the arc-shaped convex portion at the front side of the front coupled vehicle body 3 A of the following vehicle.
[0099] Therefore, in the state in which the transport vehicles 1 and 1 positioned at the front and back of the transport direction are coupled together by the coupling means C, the gap between the vehicles 1 and 1 is small and will not be widened even when the front and back transport vehicles 1 and 1 bend relatively in the horizontal direction.
[0100] Accordingly, the continuous work floor B with little gap can be obtained even in the curved path C 1 to improve workability and eliminate the risk that the worker has their legs caught in the gap.
[0101] In the foregoing description, the transport vehicle 1 is composed of the vehicle body 2 , the front coupled vehicle body 3 A, and the back coupled vehicle body 3 B, that is, the transport vehicle 1 is formed by coupling the three frame bodies capable of bending relatively in the horizontal direction. However, the transport vehicle 1 in the present invention is merely required to be formed such that a plurality of frame bodies with the upper surfaces approximately flush with each other is coupled together so as to be capable of bending relatively in the horizontal direction.
[0102] In the foregoing description, the front side (front end portion) of the transport vehicle 1 is an arc-shaped convex portion and the back side (back end portion) of the same is an arc-shaped concave portion. Alternatively, the front side may be an arc-shaped concave portion and the back side may be an arc-shaped convex portion.
[0103] As illustrated in the vertical cross-sectional view as seen from the back side of FIG. 3 and the plane view of FIG. 4 , in the transport vehicle group A with the front and back transport vehicles 1 and 1 coupled on the work line L 1 , guide rollers 11 A and 11 B provided at the front and back of the right side of the lower surface of the vehicle body 2 and guide rollers 12 A and 12 B provided at the front of the right side of the lower surface of the front coupled vehicle body 3 A sandwich a guide rail G 1 laid at the right side of the transport path, and the transport vehicles 1 , 1 , . . . (transport vehicle group A) are guided by the guide rail G 1 .
[0104] In addition, as illustrated in the plane view of FIG. 5 , the guide rollers 11 A and 11 B provided at the front and back of the right side of the lower surface of the vehicle body 2 and the guide rollers 12 A and 12 B provided at the front of the right side of the lower surface of the front coupled vehicle body 3 A sandwich the guide rail G 1 , and guide rollers 13 A and 13 B at the back end portion of the coupling rod 9 of the back coupled vehicle body 3 B sandwich the guide rail G 2 laid at the left side of the transport path, and therefore the single transport vehicle 1 separated from the transport vehicle group A on the return line L 2 is guided by the guide rails G 1 and G 2 .
[0105] As illustrated in the front view of FIG. 2 and the plane views of FIGS. 4 and 5 , the float body F 1 is fixed to the lower part of the frame body of the vehicle body 2 , the float body F 2 is fixed to the lower part of the frame body of the front coupled vehicle body 3 A, and the float body F 3 is fixed to the lower part of the frame body of the back coupled vehicle body 3 B. The float bodies F 1 , F 2 , and F 3 are partially or entirely immersed in the water reserved in the water way WW, and the load of the vehicle 1 acting on the running rails R and R becomes smaller due to the buoyancy of the float bodies F 1 , F 2 , and F 3 .
[0106] Therefore, the running resistance between the running wheels 4 , . . . , 5 , . . . , 6 , . . . of the vehicles 1 and the running rails R and R is reduced to decrease thrust necessary for driving the vehicle 1 and cut energy consumption.
[0107] In this example, the immersed volumes of the float bodies F 1 , F 2 , and F 3 are changed according to the weights of the frame body of the vehicle body 2 , the frame body of the front coupled vehicle body 3 A, and the frame body of the back coupled vehicle body 3 B to allow the appropriate buoyancy to act according to the weights of the frame bodies. Specifically, the immersed volume of the float body F 1 of the heaviest vehicle body 2 is made largest, the immersed volume of the float body F 3 of the lightest back coupled vehicle body 3 B is made smallest, and the immersed volume of the float body F 2 of the front coupled vehicle body 3 A heavier than the back coupled vehicle body 3 B and lighter than the vehicle body 2 is made larger than the immersed volume of the float body F 3 and smaller than the immersed volume of the float body F 1 .
[0108] By adjusting the immersed volumes of the float bodies F 1 , F 2 , and F 3 , the loads of the frame body of the vehicle body 2 , the frame body of the front coupled vehicle body 3 A, and the frame body of the back coupled vehicle body 3 B acting on the running rails R and R can be uniformed. This minimizes the frictional resistance during running of the transport vehicle 1 .
[0109] As illustrated in the front view of FIG. 2 , the vertical cross-sectional view as seen from the back side of FIG. 3 , the plane views of FIGS. 4 and 5 , and the front view of FIG. 9 , front and back rods 19 and 19 as guided members drooping from the article support base D supporting the article E are supported in an ascendible and descendible manner by front and back guiding members 20 and 20 provided at the frame body of the vehicle body 2 . Float bodies F 4 and F 4 partially or entirely immersed in the water W reserved in the water way WW are fixed to the rods 19 and 19 under the guiding members 20 and 20 .
[0110] Therefore, in the state in which the article support base D does not support the article E (shown by virtual lines in FIG. 9 ), the rods 19 and 19 and the article support base D are raised by the buoyancy of the float bodies F 4 and F 4 and the load of the article support base D does not act on the vehicle body 2 (transport vehicle 1 ).
[0111] In the state in which the article support base D supports the article E (shown by solid lines in FIG. 9 ), the article support base D, the rods 19 and 19 , and the float bodies F 4 and F 4 are lowered under the load of the article E and the immersed amounts of the float bodies F 4 and F 4 increase to enhance the buoyancy and decrease the force acting on the vehicle body 2 (transport vehicle 1 ) under the loads of the article E, the article support base D, and the rods 19 and 19 .
[0112] Therefore, it is possible to lessen the strength of the vehicle 1 and decrease the running resistance between the running wheels 4 , . . . , 5 , . . . , 6 , . . . of the vehicle 1 and the running rails R and R, thereby reducing thrust necessary for driving the vehicle 1 with lower energy consumption.
[0113] Further, in the state in which the article support base D supports the article E (shown by the solid lines in FIG. 9 ), the lower surface of the article support base D is in abutment with upper surfaces 20 A and 20 A of the guiding members 20 and 20 and the height of the article support base D (article E) is held at a constant value relative to the transport vehicle 1 while the buoyancy of the float bodies F 4 and F 4 is about to match the loads of the article E, the article support base D, the rods 19 and 19 , and the float bodies F 4 and F 4 .
[0114] By providing the height holding means that, in the state in which the article support base D supports the article E, holds the height of the article support base D (article E) at a constant value relative to the transport vehicle 1 (the frame bodies), the height of the article E is made constant relative to the work floor B on which the worker rides to perform work. Accordingly, there is no degradation in workability even when the water W in the water way WW ripples to shake the float bodies F 4 and F 4 in the vertical direction.
[0115] The height holding means is not limited to the configuration in which the upper surfaces 20 A and 20 A of the guiding members 20 and 20 illustrated in FIG. 9 bring into abutment with the lower surface of the article support base D to determine the lowest position of the article support base D. Alternatively, the article support base D may be provided with guide rollers such that the guide rollers are brought into contact with the guide rails laid on the ground to hold the height of the article support base D (article E) at a constant value.
[0116] Next, a configuration example of the coupling means C will be described mainly with reference to the vertical front views for describing operation of FIG. 7 .
[0117] As illustrated in FIGS. 2, 5, and 7 , a coupling frame 16 is attached to the front end portion of the front coupled vehicle body 3 A so as to be capable of swinging upward around a swinging shaft 16 B, and an inclined plane 16 A is formed on the lower surface at the front end edge of the coupling frame 16 .
[0118] In addition, as illustrated in FIGS. 5 and 7 , a lift roller 17 is attached to the tip of an arm protruding backward at the center of the back coupled vehicle body 3 B in the horizontal direction so as to be capable of rotation around a horizontal axis.
[0119] Therefore, as illustrated in FIG. 7( a ) , in the state in which the following vehicle 1 B is close to the preceding vehicle 1 A and the inclined plane 16 A of the coupling frame 16 of the following vehicle 1 B is in abutment with the lift roller 17 of the preceding vehicle 1 A, when the following vehicle 1 B further approaches the preceding vehicle 1 A as illustrated in FIGS. 7( b ) and 7( c ) , the lift roller 17 of the preceding vehicle 1 A swings the coupling frame 16 of the following vehicle 1 B upward around the swinging shaft 16 B.
[0120] Then, when the following vehicle 1 B further approaches the preceding vehicle 1 A as illustrated in FIG. 7( d ) , the coupling frame 16 of the following vehicle 1 B swings downward and the lift roller 17 of the preceding vehicle 1 A enters into the arc-shaped guide groove 15 . In this state, the coupling rollers 9 B and 10 B of the preceding vehicle 1 A (for example, see FIGS. 4 and 5 ) engage with the arc-shaped guide groove 15 of the following vehicle 1 B (for example, see FIG. 5 ), and the following vehicle 1 B is coupled to the preceding vehicle 1 A.
[0121] Next, a configuration example for decoupling the front and back vehicles by the coupling means C will be described.
[0122] As illustrated in the vertical front view of FIG. 8 , decoupling cam rails 18 and 18 (also see FIG. 3 ) provided at predetermined positions lift operated rollers 16 C and 16 C of the coupling frame 16 of the following vehicle 1 B to open the front side of the lift roller 17 and the coupling rollers 9 B and 10 B of the preceding vehicle 1 A (at the front end of the transport vehicle group A in the transport direction), whereby the preceding vehicle 1 A is decoupled from the following vehicle 1 B.
[0123] Accordingly, the preceding vehicle 1 A (at the front end of the transport vehicle group A in the transport direction) is driven by the high-speed transport feed unit T 2 to transport the preceding vehicle 1 A alone.
[0124] When the front and back transport vehicles 1 and 1 are coupled by the coupling means C, no gap is produced between the front and back transport vehicles 1 and 1 even with variations in the transport speed and the like, thereby forming reliably the continuous work floor B on which the worker rides.
[0125] In addition, the coupling means C is composed of the arc-shaped guide groove 15 and the engagement bodies (coupling rollers 9 B and 10 B), and the center of curvature of the arc-shaped guide groove 15 is approximately identical to the center of curvature of the arc-shaped convex portion. Accordingly, the coupling means C is easy to fabricate, and the simply-structured coupling means C can bring the transport vehicles into the coupled state and the decoupled state in a stable and reliable manner.
[0126] Next, modification examples of the transport vehicle 1 and the coupling means C will be described.
[0127] In the bottom view of a modification example of the transport vehicle 1 of FIG. 10 , the vertical front view for describing the operation of the coupling means of FIG. 11 , and the vertical front view for describing the operation of decoupling by the coupling means of FIG. 12 , the components with the same reference signs as those in FIGS. 1 to 11 are identical or equivalent to the components illustrated in FIGS. 1 to 11 .
[0128] The modification example of the transport vehicle 1 illustrated in the bottom view of FIG. 10 will be described below as compared to the transport vehicle 1 illustrated in the bottom view of FIG. 6 .
[0129] In the transport vehicle 1 of FIG. 6 , the arc-shaped guide groove 15 is formed at the arc-shaped convex portion at the coupling side (front end portion) of the transport vehicle 1 .
[0130] In contrast to this, in the transport vehicle 1 of FIG. 10 , the arc-shaped guide groove 15 is formed at the arc-shaped concave portion at the coupling side (back end portion) of the transport vehicle 1 . In addition, in the transport vehicle 1 of FIG. 10 , the center of curvature of the arc-shaped guide groove 15 is approximately identical to the center of curvature of the arc-shaped concave portion at the back end portion.
[0131] In the transport vehicle 1 of FIG. 6 , the coupling frame 16 , the inclined plane 16 A, the swinging shaft 16 B, and the operated rollers 16 C are provided at the front coupled vehicle body 3 A, and the lift roller 17 is attached to the tip of the arm protruding backward from the back coupled vehicle body 3 B.
[0132] In contrast to this, in the transport vehicle 1 of FIG. 10 , the coupling frame 16 , the inclined plane 16 A, the swinging shaft 16 B, and the operated rollers 16 C are provided at the back coupled vehicle body 3 B, and the lift roller 17 is attached to the tip of the arm protruding forward from the front coupled vehicle body 3 A.
[0133] Further, in the transport vehicle 1 of FIG. 6 , the coupling rods 9 and 10 long in the front-back direction are fixed to the back coupled vehicle body 3 B and are protruded forward and backward, the coupling rollers 9 A and 10 A as engagement bodies are attached to the upper sides of the front end portions of the coupling rods 9 and 10 , and the coupling rollers 9 B and 10 B as engagement bodies are attached to the upper side of the back portion of the coupling rod 9 and the upper side of the back end portion of the coupling rod 10 .
[0134] In contrast to this, in the transport vehicle 1 of FIG. 10 , the coupling rods 9 and 10 are fixed to the back coupled vehicle body 3 B and are protruded forward, and the coupling rollers 9 A and 10 A as engagement bodies are attached to the upper sides of the front end portions of the coupling rods 9 and 10 , the coupling rods 23 and 24 fixed to the front coupled vehicle body 3 A are protruded forward, and the coupling rollers 23 A and 24 A as engagement bodies are attached to the upper sides of the front end portions of the coupling rods 23 and 24 .
[0135] Furthermore, in the transport vehicle 1 of FIG. 6 , the guide rollers 13 A and 13 B along the guide rail G 2 are attached to the lower side of the back end portion of the coupling rod 9 protruding more backward than the coupling rod 10 .
[0136] In contrast to this, in the transport vehicle 1 of FIG. 10 , the guide rollers 13 A and 13 B along the guide rail G 2 are attached to the lower side of the back end portion of the coupling rod 9 protruding backward, as in the transport vehicle 1 of FIG. 6 .
[0137] According to the configuration of the transport device as described above, the vehicle body 2 , the front coupled vehicle body 3 A, and the back coupled vehicle body 3 B are coupled together so as to be capable of bending relatively in the horizontal direction to form the transport vehicle 1 , and the float bodies F 1 , F 2 , and F 3 are fixed to the lower parts of the frame bodies of the vehicle body 2 , the front coupled vehicle body 3 A, and the back coupled vehicle body 3 B. Accordingly, the vehicle body 2 , the front coupled vehicle body 3 A, and the back coupled vehicle body 3 B bend in the horizontal direction along the curved paths C 1 and C 2 , and the float bodies F 1 , F 2 , and F 3 fixed to the lower parts of the vehicle body 2 , the front coupled vehicle body 3 A, and the back coupled vehicle body 3 B move in the water way WW along the curved paths C 1 and C 2 .
[0138] Therefore, even in the case of transporting the article E long in the transport direction, it is not necessary to increase the curvature radiuses of the curved paths C 1 and C 2 with no limitation on the layout of the transport path (water way WW) including the curved paths C 1 and C 2 .
[0139] In addition, the vehicle body 2 , the front coupled vehicle body 3 A, and the back coupled vehicle body 3 B with the upper surfaces flush with one another are coupled together so as to be capable of bending relatively in the horizontal direction to form the transport vehicle 1 , and the worker can ride on the upper surface of the vehicle to perform work even in the curved path C 1 with improved work efficiency and space efficiency.
[0140] Further, the load of the vehicle 1 acting on the running rails R and R is lessened by use of the buoyancy of the float bodies F 1 , F 2 , F 3 , and F 4 to reduce thrust necessary for driving of the vehicle 1 . Accordingly, even when the side surface (or any other surface) of the transport vehicle 1 includes a friction surface H and the drive unit for driving the transport vehicle 1 is a friction-type drive unit including a friction roller 21 to be in abutment with the friction surface H, the pressing force of the friction roller 21 can be made relatively small. Accordingly, there is no increase in manufacturing costs for enhancing the strength of the frame bodies of the transport vehicle 1 or no earlier-stage deterioration of the rubber of the surface of the friction roller 21 due to breakage, deformation, separation, or the like when being driven by the friction-type drive unit.
[0141] Furthermore, in the configuration in which the water flow generation unit is provided to generate a forward water flow in the water W reserved in the water way WW and apply thrust to the transport vehicle 1 via the float bodies F 1 , F 2 , F 3 , and F 4 , the transport vehicle 1 can be driven by the thrust generated from the water flow to reduce the driving force of the feed units T 1 , T 2 , and T 3 as drive units for driving the transport vehicle 1 .
[0142] In the foregoing description, the continuous work floor (work plane) B on which the worker rides to perform work is formed on the transport vehicles 1 , 1 , . . . . However, the transport device in the present invention is also applicable to the transport path dedicated for transport without work processes. In the case of using the transport device in the present invention for the transport path dedicated for transport, not the continuous work floor on which the worker rides to perform work but a continuous floor is formed on the transport vehicles 1 , 1 , . . . so that the worker or others rides on the continuous floor to traverse the transport path, for example.
[0143] In the foregoing description, the work floor B is formed in some parts of the straight paths S 1 and S 2 and the curved path C 1 . Alternatively, the work floor B may be formed only in some parts of the straight paths S 1 and S 2 or may be formed only in some parts of the curved paths C 1 and C 2 .
[0144] Further, in the foregoing description, the work floor B is formed in part of the transport path including the curved path C 1 . Alternatively, the work floor B may be formed in the entire transport path. This case produces the advantage that the worker can ride on the work floor B to perform work in the entire region (entire length) of the transport path. In this case, however, it is not possible to stop the individual vehicle 1 to load and unload the articles E (see the loading station ST 1 and the unloading station ST 2 illustrated in FIG. 1 ). Accordingly, the articles E are loaded and unloaded in synchronization with the vehicle 1 moving at a constant speed or the articles E are loaded and unloaded while all the coupled vehicles 1 , 1 , . . . are stopped concurrently.
REFERENCE SIGNS LIST
[0000]
A Transport vehicle group
B Continuous work floor
C Coupling means
C 1 ,C 2 Curved path
D Article support base
E Article
F Transport direction
F 1 , F 2 , F 3 , and F 4 Float body
G Floor surface
G 1 and G 2 Guide rail
H Driven surface
L 1 Work line
L 2 Return line
R Running rail
S 1 ,S 2 Straight path
ST 1 Loading station
ST 2 Unloading station
T 1 Constant-speed transport feed unit (friction-type drive unit)
T 2 High-speed transport feed unit (friction-type drive unit)
T 3 Brake feed unit (friction-type drive unit)
W Water
WW Water way
1 Transport vehicle
1 A Preceding vehicle
1 B Following vehicle
2 Vehicle body (frame body)
3 A Front coupled vehicle body (frame body)
3 B Back coupled vehicle body (frame body)
4 , 5 , and 6 Running wheel
7 , 8 , 9 , and 10 Coupling rod
7 A, 8 A, 9 A, 9 B, 10 A, and 10 B Coupling roller (engagement body)
11 A, 11 B, 12 A, 12 B, 13 A, and 13 B Guide roller
14 A, 14 B, and 15 Arc-shaped guide groove
16 Coupling frame
16 A Inclined plane
16 B Swinging shaft
16 C Operated roller
17 Lift roller
18 Decoupling cam rail
19 Rod (guided member)
20 Guiding member
20 A Upper surface (height holding means)
21 Friction roller
22 Backup roller
23 and 24 Coupling rod
23 A and 24 A Coupling roller | An object of the present invention is to suppress rise in running resistance with increases in weight of a transport vehicle group, and prevent higher energy consumption and manufacturing cost. A transport device transports a transport vehicle ( 1 ) carrying an article (E) along a transport path including a curved path and forms a continuous floor (B) on the transport vehicle ( 1 ) in the entire or partial transport path. The transport device includes: running rails (R) that are laid along the transport path to support running wheels ( 4, 5 , and 6 ) of the transport vehicle ( 1 ); guide rails that guide the transport vehicle ( 1 ) along the transport path; a drive unit that drives the transport vehicle ( 1 ); and a water way (WW) that is formed along the transport path to reserve water (W). | 67,604 |
CROSS-REFERENCES TO RELATED APPLICATIONS
This is a utility patent application, taking priority from provisional patent application Ser. No. 60/993,760, filed Sep. 14, 2007.
BRIEF DESCRIPTION OF THE INVENTION
The present invention is directed to power generation systems and methods for converting naturally occurring moist air into power and water, enabling generation of power without carbon combustion and without the release of green-house gasses which usually accompany thermodynamic power generation.
STATEMENT AS TO THE RIGHTS TO INVENTIONS MADE UNDER FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
Not Applicable.
REFERENCE TO A “SEQUENCE LISTING,” A TABLE, OR A COMPUTER PROGRAM LISTING APPENDIX SUBMITTED ON A COMPACT DISK
Not Applicable.
BACKGROUND OF THE INVENTION
Water vapor exists at significant levels in most geographic locations on earth. This water vapor takes the form of moist air. Processing this moist air into dry air and water results in a net surplus of energy for the process. This energy can be captured and converted to commercially transmittable energy, electrical power, through a thermodynamic cycle process coupled to a water vapor separation module which extracts enriched water vapor from naturally occurring moist air.
Direct solar energy generation systems can only convert a small percentage of the energy that reaches earth from the sun. A large amount of the sun's energy works to evaporate water from large and small bodies of water. The sun evaporates water everywhere on earth and the process expends 2.26 MJ/kg (429.9 Btu/lbm) for each kg (2.204 lbm) of water evaporated. A mass of 1 kg (2.204 lbm) of water with a mixing ratio of 0.3% in dry air represents 2.26 MJ (199 Btu) of water vapor enthalpy distributed in a volume of approximately 333 cubic meters (11,759 cubic feet). The herein described methods, and system for carrying out the disclosed methods, involve enriching ambient water vapor and then releasing the water vapor enthalpy in a heat-exchange boiler, which vaporizes a working fluid used in a Rankine-cycle turbine generator system.
The Rankine-cycle is frequently used in power generation plants. Usually, some sort of carbon combustion creates the heat used to vaporize the working fluid used in the Rankine-cycle. While this method of generating power via carbon combustion is used worldwide, because of its relative inexpensiveness, there are many drawbacks to carbon combustion-based Rankine-cycle plants. For example, the discharge from the combustion of fossil fuels is released into the air. This discharge contains carbon dioxide and water vapor, as well as other substances such as nitrogen, nitrous oxides, sulfur oxides, and (in the case of coal-fired plants) fly ash and mercury. These hazardous substances are obviously a threat to human health and animal life. And the released carbon dioxide is widely believed to be at least a major contributor, if not a cause, of global warming and climate change. Development of a non-carbon-combustion Rankine-cycle power generation plants would be highly advantageous.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING
FIG. 1 a illustrates an exemplary Rankine-cycle power generation plant utilizing carbon combustion in accordance with the prior art;
FIG. 1 b illustrates an exemplary system and method for converting moist air into water and power, in accordance with the present invention;
FIG. 2 illustrates two possible arrangements for barrier panels within a standard 40-ft shipping container, in accordance with the present invention;
FIG. 3 illustrates a barrier panel, in accordance with the present invention;
FIG. 4 illustrates an exemplary two-stage compression plus Rankine-cycle system for converting moist air into water and power, in accordance with the present invention;
FIG. 5 illustrates an exemplary three-stage compression plus Rankine-cycle system for converting moist air into water and power, in accordance with the present invention; and
FIG. 6 illustrates an alternative exemplary three-stage compression plus Rankine-cycle system for converting moist air into water and power wherein evaporative coolers and utilized in place of intercoolers, in accordance with the present invention.
DETAILED DESCRIPTION OF THE INVENTION
Although the present invention may be described in terms of various systems, the present invention also relates to methods for performing the operations herein. Accordingly, the following discussion applies equally to systems for converting moist air into water and power, and to methods for converting moist air into water and power.
The herein disclosed system for converting moist air into power and water utilizes a modified Rankin-cycle in most embodiments, and may utilize related thermodynamic cycles (such as the Stirling-cycle and the Ericsson-cycle) in some alternative embodiments. A Rankin-cycle is a thermodynamic cycle in which heat is converted to work. Power plants use the Rankin-cycle to generate about 80% of all electrical power used in the United States, and most of the electrical power used worldwide. FIG. 1 a illustrates a traditional prior art Rankin cycle system with a condenser, as is used to generate electrical power throughout much of the world.
In FIG. 1 a , heat is added to boiler 01 . This heat is created by a combustion process, which usually involves burning some sort of carbon-based fuel, such as biomass, petroleum, or natural gas. At boiler 01 , the heat from the combustion interacts with a working fluid which is pumped through working fluid feed 10 by feed pump 05 . The interaction of the heat with the working fluid at boiler 01 causes some transfer of heat into the working fluid, increasing the temperature and pressure of the working fluid. After leaving boiler 01 , the working fluid is carried by working fluid feed 10 to turbine 02 . The working fluid enters turbine 02 at a relatively high pressure and temperature, makes its way through turbine 02 , and then exists turbine 02 at a lower pressure and temperature. Turbine 02 is generally a rotary engine whose blades are turned by the high pressure and high temperature working fluid entering turbine 02 from boiler 01 . When turbine 02 's blades are turned, shaft 07 also turns, causing generator 04 to generate electricity.
The working fluid then exits turbine 02 at a lower pressure and temperature, and is then fed through condenser 03 , which changes the working fluid back to a liquid state, and can also further lower the temperature or pressure, before the working fluid is fed by feed pump 05 back to boiler 01 to complete the cycle. Condenser 03 causes the working fluid to interact with a fluid (controlled by cold fluid feed 11 ) at a much lower temperature relative to the working fluid exiting turbine 02 . Condenser 03 usually utilizes a large body of cool water, such as a nearby river or lake, to interact with the working fluid. The end result of the Rankine-cycle is a relatively efficient system for continuously converting combustion heat (obtained from burning carbon-based fuels) into electricity.
FIG. 1 b illustrates a preferred embodiment of the herein disclosed invention, which is an alternative Rankine-cycle (or in some embodiments another thermodynamic-cycle) electrical power generation system that is able to utilize greatly compressed water vapor (extracted from naturally moist air) in place of combustion heat to produce electricity. In FIG. 1 b , moist air is drawn into the system through vapor separation module 151 . A vapor separation module may alternatively be referred to as a vapor separator. Vapor separation module 151 can perform one or more of several functions. The main function of vapor separation module 151 is to enrich the level of water vapor in the air being drawn through the system. Vapor separation module 151 can contain a permeable barrier, which may be formed of cellulose acetate or another material with similar characteristics, through which water vapor is drawn.
Other possible functions which may be performed by vapor separation module 151 are to remove noncondensable gasses and/or to generate relatively small amounts of electrical power through incorporation of wind-turbines 151 A in the air stream of the vapor separation module 151 . These additional optional functionalities of vapor separation module 151 will be discussed in greater detail below.
The enriched water vapor is extracted from the moist air by the vapor separation module 151 and travels through water vapor feed 153 to compressor module 152 , where the water vapor is compressed. Compression of the water vapor at compressor module 152 increases the pressure and temperature of the water vapor. Compressor module 152 may be one compressor, or may instead be a subsystem of two or more compressors which perform a staged compression of the water vapor. Staged compression, which alternatively may be referred to as a multi-step compression process, greatly increases the water vapor pressure over several steps of compression, and is able to achieve higher compression ratios (leading to higher overall system efficiencies) than a single compressor system. Multi-stage compression embodiments will be explained in greater detail below.
The compressed water vapor then leaves compressor module 152 , traveling through water vapor feed 153 to heat exchanger module 101 , where the compressed water vapor interacts with a turbine working fluid. Heat exchanger module 154 may be one heat exchanger boiler or may, when staged compression is utilized, be a subsystem of two or more heat exchanger boilers. Multi-stage exchanger boiler systems will be explained in greater detail below.
Heat exchanger module 154 facilitates the compressed water vapor moving in close proximity past a working fluid being fed in the opposite direction by working fluid feed 05 . The close proximity of the two fluids causes the water vapor to condense, creating output water (a useful by-product of the herein disclosed systems), and causes the working fluid to heat up greatly. The working fluid, at a high temperature, is then fed by working fluid feed 05 through turbine 02 . Turbine 02 , condenser 03 , generator 04 , shaft 07 , cold fluid feed 11 and cold fluid reservoir 106 can be the same components utilized in traditional combustion heat Rankine-cycle power generation systems. Many variations of the working fluid thermodynamic-cycle are possible and may be used to convert the heat released from the condensing water vapor (such as Rankine-cycle, Stirling-cycle, Ericsson-cycle, and variations of them). Such practical variations will be appreciated by those skilled in the art and are intended to be covered by this specification.
The following conference papers cover the same material disclosed herein and additionally provide standard thermodynamic analysis of the disclosed systems. They have been archived by ASME: American Society of Mechanical Engineers & AIAA: American Institute of Aeronautics and Astronautics, respectively, and are hereby incorporated by reference:
Vidmar, R., “Converting Moist Air into Water and Power,” ASME Power 2008, 22-24 Jul. 2008, Orlando, Fla., POWER2008-60032, pp 12, 2008. Vidmar, R., “Site Location Considerations Associated with Conversion of Moist Air into Water and Power,” International Energy Conversion Engineering Conference IECEC, 28-30 July, Cleveland, Ohio, AIAA-2008-5778, pp 22, 2008.
Vapor separation module 151 may contain a barrier which is used to separate enriched water vapor from the input moist air. Moist air enters vapor separation module 151 and is drawn across a barrier material at approximately 0.1 m/s before exiting the opposite side of vapor separation module 151 . A fan, in place of wind-turbine 151 A, may be utilized to draw the moist air through vapor separation module 151 , or if the wind conditions are appropriate no fan may be needed. In situations where the surrounding wind conditions negate the need for a fan to draw the moist air through, wind-turbine(s) 151 A may be placed within the vapor separation module structure to capture a portion of the wind energy that is naturally expended carrying the moist air through the vapor separation module. Alternatively, dual-purpose fans may be incorporated which can be used to actively draw moist air through when wind conditions are poor, but which can also convert natural wind-driven movement of moist air into electrical power when wind conditions are more favorable and the fan is not needed for actively drawing moist air through.
The barrier used to extract water vapor from the moist air traveling through vapor separation module 151 is a thin film that may be formed of cellulose-acetate, or another type of plastic or other material with similar characteristics. An optimum barrier is highly permeable to water vapor and much less permeable to N 2 and O 2 . The film forming the barrier may be relatively thin and consistent; for example, one mil (0.001 inch, 25.4 micrometers) thick with no pinholes or other leaks. A pressure gradient is created across the barrier from the atmospheric side (from which the naturally moist air is drawn) to the vacuum side (which is created by the pull of compressor module 152 ), resulting in the net transport of water vapor across the barrier to the vacuum side and into water vapor feed 153 . The barrier surface area is proportional to the barrier thickness and inversely proportional to the pressure difference across the barrier. Cellulose acetate is favorable because it facilitates the transmission of water vapor across the barrier; but some N 2 and O 2 may also cross the barrier. The magnitude of the permeability and small pressure gradient across the barrier requires that the overall barrier surface area be relatively large.
The fundamental component in a large barrier system is a single barrier panel that can be joined in parallel to form a larger system. An example large-scale system for converting moist air into water and power may utilize standard 40-ft shipping containers. Shipping containers of this size are abundantly available in the United States and relatively inexpensive because many more goods are imported to the United States in such containers than are typically exported in such containers. Each shipping container may be fitted with approximately 3,500 m 2 of barrier surface area. A shipping container may be fitted with approximately 76 sealed barrier panels, each with a 2.3 m height and a 10.0 m width mounted vertically along the long axis of the container for a total area of 3,496 m 2 . A preferred embodiment, however, fits each shipping container with approximately 450 sealed barrier panels, each with a 2.3 m height and a 1.7 m width, mounted vertically within the container, across the width of the container for an area of 3,519 m 2 .
FIG. 2 illustrates two example arrangements of barrier panels, in accordance with the present invention, within standard 40-ft shipping containers. Shipping container 201 is arranged with one intake aperture 211 so that moist air travels the entire length of the 40-ft shipping container. Such an arrangement allows the moist air to travel along a large number of barrier panels. Shipping container 202 is arranged with five intake apertures 212 along the long side of the shipping container. Such an arrangement allows more volume of moist air to be drawn through the container, utilizing the five intake apertures 212 , but the moist air does not travel along as large a number of barrier panels. Fans, filters, and/or louvers 220 may be incorporated into or adjacent to the intake apertures. Fans, as discussed above, may be used to draw moist air through and/or as wind-turbines to generate electrical power. Filters may be used to remove particulate matter from ambient air. Louvers 220 may be used to regulate air flow through the vapor separation module in surrounding high wind conditions and could be placed at just the intake aperture 211 or apertures 212 or at both the intake(s) and exit(s) of each shipping container 201 .
FIG. 3 illustrates two views of a barrier panel 301 which may be used individually or in parallel with multiple additional barrier panels, to extract or enrich water vapor from the moist air drawn through the vapor separation module. Each panel 301 may be formed of two sheets of barrier material 302 . A layer of mesh 303 can be used to separate the barrier sheets and to provide a relatively high conductance path for water-vapor extraction. The panel is sealed on all edges 304 , and one end may have a hypodermic tube 305 for water vapor extraction, and may have an excess flow valve 306 to seal a panel off from the compressor if a large leak develops. The entire barrier panel may be quite thin (possibly as thin as 2 mm, as is shown in FIG. 3 as an example) including both sheets of barrier material 302 and the layer of mesh 303 . Dimensions, however, are only provided as examples because barrier panel 301 will function properly at varying thicknesses.
The presence of N 2 and/or O 2 in the water vapor moving through the compressor module and the heat exchanger module is not ideal. These gasses will not be compressed properly by the compressor module nor condensed properly by the heat exchanger module, therefore causing less than ideal heat to be transferred to the working fluid in the heat exchanger module, resulting in less electrical power generation, and lowering overall system efficiency. The N 2 and O 2 , and any other noncondensable gasses present after being drawn through the barriers, may be removed by a noncondensable gas removal subsystem incorporated into the vapor separation module.
A noncondensable gas removal subsystem may be simply another barrier-type system whereby water vapor containing a small fraction of noncondensible gasses is drawn past another set of barriers which are highly impermeable to water vapor but highly permeable to the unwanted gasses, which are thereby separated from the water vapor. Alternatively, the noncondensable gas removal subsystem may utilize barriers which are permeable to N 2 and/or O 2 while being impermeable to water, thus pulling the unwanted noncondensable gases from the water vapor while allowing the enriched water vapor to pass alongside the barrier unimpeded. Those skilled in the art will recognize that there are many possible methods to remove unwanted noncondensable gasses from the water vapor and any such method may be appropriately incorporated into the herein disclosed system for converting moist air into water and power.
FIG. 4 and FIG. 5 illustrate multi-stage compression embodiments of the herein disclosed system for converting moist air into water and power.
FIG. 4 shows a two stage compression system 401 utilizing two compressors (C 1 and C 2 ) and a working fluid moving through a Rankine-cycle. Compressor module 452 includes the two compressors, enabling increased compression of the water vapor over what would be possible using only one compressor. As seen in FIG. 4 , a heat exchanger intercooler 462 (HX INT) may be used between the two compressors. A system designed for two-stage compression may utilize three heat exchangers 411 (HX 1 ), 421 (HX 2 ), and 431 (HX 3 ). A working fluid is heated by intercooler 462 at heat exchanger 411 and by condensation of the water vapor leaving the second compressor and flowing through heat exchangers 421 and 431 . A person skilled in the art will recognize that such a two-stage compression plus Rankine-cycle system may be designed in any number of arrangements, with a varying number of heat exchangers and other components, depending on a number of considerations. For example, the intercooler 462 could be replaced by an equivalent evaporative cooler with water injection, which would eliminate the need for one of the heat exchangers, 411 , and would eliminate the need for a split flow of the Rankine-cycle working fluid. This specification intends to cover all such permutations of a two-stage, or multi-stage compression system for converting moist air into water and power.
The two-stage compression system 401 for converting moist air into water and power, as shown in FIG. 4 , is modeled below using thermodynamic properties evaluated as is known in the art. The laws of thermodynamic conditions are imposed on each of the components of the system. The following calculations, temperatures, pressures, etc., are provided only as examples.
As illustrated in FIG. 4 , a series of numbers are utilized to illustrate different conditions (such as temperature, pressure, energy) at different points in the process of the two-stage compression system of the present invention. This series of numbers only illustrate the calculated conditions within FIG. 4 and are distinguished from similar numbers utilized to illustrate components of the systems illustrated in FIGS. 1 a and 1 b , as well as other numbers utilized to illustrate calculated conditions within FIGS. 5 and 6 . Looking to FIG. 4 , water vapor circulates along the path from the vapor separation module 451 to discharge point 490 . In contrast, the intercooler 462 between the compressors of the compressor module 452 uses water in a continuous circulation circuit. The turbine also uses water as the continuous circuit working fluid in the Rankine-cycle loop. Because the net output of the Rankine-cycle depends on the working-fluid properties, other fluids besides water could be used to possibly increase Rankine-cycle efficiency, as is known in the art. The condenser (HX 4 ) for the Rankine-cycle is also water cooled from a cold liquid reservoir, although other alternatives are possible as further discussed below.
Intercooler 462 is liquid cooled, with the water-vapor discharge temperature, T 7 , set to be 20 C (36 F) above the saturation temperature at the discharge pressure, P 7 , i.e. T 7 =T sat (P 7 )+20. This maintains a high quality steam for the input to the second compressor of the module 452 . Increasing T 7 further results in a slight decrease in output power, but a rather large increase in power required by the second compressor of module 452 and is disadvantageous. The outlet temperature, T 27 , of intercooler 462 was set 10 C (18 F) below the output temperature, T 6 , of the first compressor of module 452 , i.e., T 27 =T 6 −10. The outlet temperature, T 19 , of heat exchanger 411 is 10 C (18 F) lower than the outlet temperature, T 27 , of intercooler 462 , which is also the high temperature input to the heat exchanger 411 , i.e., T 19 =T 27 −10. The outlet temperature, T 18 , for the Rankine working fluid is 10 C (18 F) lower than the high-temperature output, T 9 , of the third heat exchanger 431 , T 18 =T 9 −10. The temperature of the Rankine working fluid into condenser (HX 4 ), was set to 32 C (89.60 F) to maintain the steam quality leaving the turbine. A common value for the liquid cooling reservoir temperature, T 23 , is 15 C (59 F) or 288 K (518.40 R).
The overall optimization for maximum work output from the turbine has numerous inputs. Optimization in these calculations uses reasonable choices for operating temperatures. The thermal properties of intercooler 462 and Rankine-cycle working fluids were adjusted to minimize entropy in the heat exchangers by varying the pressure. While testing different conditions, a systematic trend emerged in the optimization of the Rankine cycle pressure: the input pressure to the turbine, P 21 , is slightly greater than the output pressure of the second compressor, P 8 .
The net output power (P out ) is the sum of power generation less the expenditure from the turbine (P turbine ), compressors (P C1 , and P C2 ), pumps (P P1 , P P2 , P P3 , and P P4 ), and fan (P in,fan ) used in the system:
P out =P turbine −P C1 −P C2 −P P1 −P P2 −P P3 −P P4 −P in,fan
This power, which can be converted to electricity by a generator, is the net output power for the two stage compression system for converting moist air into water and power as shown in FIG. 4 .
The herein disclosed systems may alternatively utilize a series of compressors. FIG. 5 shows a three stage compression system 501 utilizing three compressors (C 1 , C 2 and C 3 ) and a working fluid moving through a Rankine-cycle. Compressor module 552 includes the three compressors, enabling increased compression of the water vapor over what would be possible using only one compressor or using two compressors. As seen in FIG. 5 , a first intercooler 562 may be used between the first two compressors of module 552 , and a second intercooler 563 may be used between the second and the third compressors of module 552 . Three-stage compression may require that the first compressor of module 552 be significantly larger than the second and third compressors, because of the large volume of low-pressure water vapor drawn through vapor separation module 551 . It is, however, possible to arrange several smaller compressors in parallel to achieve the same effect as using a very large first compressor.
A system designed for three-stage compression may utilize four Rankine-cycle heat exchangers 511 (HX 4 ), 521 (HX 5 ), 531 (HX 6 ), and 541 (HX 7 ). The Rankine-cycle working fluid is heated by intercooler 562 at heat exchanger 511 , by intercooler 563 at heat exchanger 521 , and by condensation of the water vapor leaving the third compressor at heat exchangers 531 and 541 . A person skilled in the art will recognize that such a three-stage compression plus Rankine-cycle system may be designed in any number of arrangements, with a varying number of heat exchangers and other components, depending on a number of considerations. For example, the intercoolers 562 and 563 could be replaced by equivalent evaporative coolers with water injection, which would eliminate the need for two of the heat exchangers, 511 and 521 , and would eliminate the need for a split flow of the Rankine cycle working fluid. Such a three-stage compression system with evaporative coolers is shown in FIG. 6 as an example. This specification intends to cover all such permutations of a three-stage or multi-stage compression system for converting moist air into water and power.
Traditionally, Rankine-cycle and other power generation plants utilize a nearby body of relatively cool water to condense and/or cool the working fluid exiting the turbine, as shown in FIGS. 1 a , 1 b , 4 - 6 . The herein disclosed systems may be alternatively designed to utilize air-cooled rock-bed heat exchangers in place of, or in combination with, a body of relatively cool water. In arid geographic locations the moisture in the ambient air may be enough to supply water vapor for a herein disclosed system, but such cooling water may not be readily available. Luckily in such arid locations daytime and nighttime temperatures vary significantly. When night air is 10 C (18 F) to 15 C (27 F) cooler than the daytime high temperature, it can be used at night to cool a rock-bed. A thermal reservoir made of rock that forms a porous structure may be used to cool the working fluid exiting the turbine. Such a rock-bed heat exchanger is shown in FIG. 4 at 491 , in FIG. 5 at 591 , and in FIG. 6 at 691 . The vaporized and/or high temperature working fluid may be fed through a relatively cool bed of rock to condense and/or cool the working fluid in a liquid-to-gas heat exchanger which may use a fan to circulate air through the cool rock-bed. The rock is kept cool by fanning relatively cold air through the rock bed at night.
Hornfels, or hornfellic rock, have desirable properties for use as an air-cooled rock-bed heat exchanger. Hornfels have a density of 2,600 kg/m3 (173.62 lbm/ft3), a specific heat of 1.470 kJ/kg-C (351.09 Btu/lbm-F), a thermal conductivity of 4 W/m-C (2.311 Btu/hr-ft-F), and a thermal diffusion constant of 1.046 m2/s (11.25 ft2/s). Other rock with similar properties may also function as an air-cooled rock-bed heat exchanger.
As stated throughout this specification, a by-product of the transfer of heat from the compressed water vapor to the thermodynamic-cycle working fluid is output water. In other words, the herein disclosed system inputs moist air and outputs water and electrical power. The output water can, of course, be used for any desirable purpose. One such purpose is to utilize a hydrodynamic elevation drop to generate electrical power. FIG. 5 at 590 , and FIG. 6 at 690 , illustrate such a use of the output water. The output water may be directed to flow through a hydroelectric turbine (which may alternatively be referred to as a water turbine) to generate electrical power. For example, the system for converting moist air into water and power may be located at a relatively high elevation. The output water may be collected in some sort of basin, and then allowed to flow down from the relatively high elevation through a hydroelectric turbine, generation electrical power.
The output water may be used in other practical ways as well. If the output water is used to irrigate crops, trees, or other plants that otherwise may struggle in the local climate, such a use may bring the herein disclosed system from being merely carbon neutral (i.e., this system does not burn carbon in its operation) to carbon negative and O 2 positive. The plants which otherwise would not grow can use the output water to thrive, thereby absorbing CO 2 and producing O 2 .
Finally, the herein disclosed systems for converting moist air into water and power can also be described as related methods for converting moist air into water and power. All the preceding discussion of the various embodiments of the system applies equally to methods for converting moist air into water and power. For example, a method for converting moist air into water and power includes: drawing moist air through a vapor separation module, separating enriched water vapor from the moist air, compressing the enriched water vapor in a compressor module, transferring heat from the enriched water vapor to a working fluid, and then moving that working fluid through a thermodynamic cycle such as the Rankine-cycle (or alternatively the Stirling-cycle, the Ericsson-cycle, and other similar thermodynamic-cycles).
The herein disclosed systems and methods may be advantageously utilized at a wide spectrum of locations throughout the United States and worldwide. Relatively humid climates, such as Miami, Fla., provide high moisture content in the local air, and so such a location may be ideal for the present invention. A high moisture level means that relatively less volume of air needs to be drawn through the vapor separation module to obtain an equal volume of water vapor. For the same reason, less compressor power, or less compression, may be needed in such a high moisture location. Arid climates such as Reno, Nev., however, provide significantly less natural moisture in the air, and so a relatively larger volume of air must be drawn through the vapor separation module. For similar reasons, arid locations require relatively greater compressor power, or relatively more compression. Consequently, two-stage compression systems and methods may be more appropriate for humid locations while three-stage compression systems and methods may be more appropriate for arid locations. Similarly, humid locations may require less overall barrier surface area for the vapor separation module than do arid locations.
As described above for the various embodiments of the systems, the methods of converting moist air into water and power involve general steps that may be carried out in numerous possible ways. For example, the step of compressing in a compressor module may involve only one compressor and no intercooling, it may involve a three-stage compression using three compressors and two intercooling steps in between each compression, or it may involve an alternative or hybrid compression process. Those skilled in the art will recognize that all permutations of the herein described embodiments of the systems and methods for converting moist air into water and power are possible.
While the present invention has been illustrated and described herein in terms of a preferred embodiment and several alternatives associated with systems and methods for converting moist air into water and power, it is to be understood that the various components of the combination and the combination itself can have a multitude of additional uses and applications. Accordingly, the invention should not be limited to just the particular descriptions and various drawing figures contained in this specification that merely illustrate one or more preferred embodiments and applications of the principles of the invention. Furthermore, all dimensions and calculations are provided only as examples and are not meant to limit this disclosure solely to those conditions. | The present invention is directed to power generation systems and methods for converting naturally occurring moist air into power and water, enabling generation of power without carbon combustion and without the release of green-house gasses which usually accompany thermodynamic power generation. According to one embodiment, a compressor module is used to greatly compress enriched water vapor drawn from the surrounding moist air. The compressed water vapor is then condensed into output water by a working fluid, while the heated working fluid is used in a Rankine-cycle power generation loop to turn a turbine and thereby create transmittable electrical power. | 33,694 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] This invention relates generally to integrated circuits comprising power MOSFETs in parallel with Schottky rectifiers. More particularly, this invention relates to a novel and improved structure and improved process of fabricating an integrated trench MOSFET and Schottky rectifier with low charge between gate and drain (Qgd).
[0003] 2. The Prior Arts
[0004] The Schottky barrier rectifiers have been used in DC-DC converters. In parallel with the parasitic PN body diode, the Schottky barrier rectifier acts as clamping diode to prevent the body diode from turning on for the reason of higher speed and efficiency, so the recent interests have been focused on the technology to integrate the MOSFET and the Schottky barrier rectifier on a single substrate. In U.S. patent application publication No. 6,351,018 and No. 6,593,620, methods of forming the Schottky rectifier on the same substrate with MOSFET are disclosed, as shown in FIG. 1 and FIG. 2 , respectively.
[0005] In FIG. 1 , an integrated trench MOSFET-Schottky rectifier structure is fabricated on an N substrate 102 , into which a plurality of trenches 100 are etched. A thin layer of insulator 104 lines the sidewalls of the trenches 100 which are refilled with conductive material 106 to act as gate material. Well regions 108 of a second doping type, e.g., P dopant, are formed by diffusion between every two trenches except those where Schottky rectifier will be formed (trench 100 - 3 and 100 - 4 , as illustrated). Near the top surface of every well region, source regions 112 are introduced followed by the formation of P+ body region 114 between every two adjacent source regions within each well region. In order to distinguish the conductive layers player different roles, 116 is marked to figure those layers connecting to source regions while 118 figures the anode of Schottky rectifier 110 as shown. And metal layer 120 is deposited to short the source regions 212 and the anode of Schottky rectifier 110 .
[0006] In FIG. 2 , another combination structure is illustrated, which has DMOS transistor devices within DMOS transistor region 220 and has Schottky barrier rectifier devices within rectifier region 222 . The combination structure further comprises: a substrate 200 heavily doped with a first semiconductor type dopant, e.g., N+ dopant, on which an epitaxial layer 202 lightly doped with the same semiconductor type dopant as substrate is grown, serving as drain for the DMOS transistor devices and cathode region for the Schottky rectifier devices; metal layer 218 coated on the rear side of the substrate to act as a common drain contact for DMOS transistors and a common cathode electrode for the Schottky rectifiers; metal layer 216 deposited on the front side of the substrate to act as a common source contact for the DMOS transistor devices and as common anode electrode for the Schottky rectifier devices; trench regions lined with oxide layer 206 and filled with polysilicon 210 to serve as trench gates; BPSG layer 214 covering each trench gate to insulate the polysilicon 210 from conductive layer 216 for the DMOS transistors; body regions 204 of a second semiconductor doping type, e.g., P dopant, are formed between every two trench gates in DMOS transistors portion; source region 212 heavily doped with said first semiconductor doping type adjacent the sidewalls of trench gates near the top surface of said body region. It should be noticed that, the Schottky barrier rectifiers and the DMOS transistors in this structure have separated trench gates in contrast to the structure mentioned in FIG. 1 .
[0007] Though both structures in prior arts introduced can achieve the integration of MOSFET devices and Schottky barrier rectifiers on a single substrate, there are still some disadvantages affecting the performances of whole device.
[0008] First of all, in order to further increase the switching speed of a semiconductor power device, it is desirable to reduce the coupling charges between the gates and drain Qgd such that a reduction of a gate to drain capacitance Crss can be achieved. However, conventional devices shown in FIG. 1 and FIG. 2 each has a large amount of coupling charges Qgd between gates and drain due to the direct coupling between the trench bottoms and portion of trench sidewalls and the drift region.
[0009] Another disadvantage of the prior art is that, the planar contact employed occupies a large area, almost one time of MOSFET. As the size of devices is developed to be smaller and smaller, this planar contact structure is obviously should replaced by another configuration which will meet the need for size requirement. On the other hand, this kind of planar structure will lead to a device shrinkage limitation since the contacts occupy a large area, resulting in high specific on-resistance according to the length dependence of resistance.
[0010] Another disadvantage of prior art is that, during fabricating process, an additional P+mask or contact mask for opening of Schottky rectifier anode contact is required, therefore increases the fabrication cost.
[0011] Accordingly, it would be desirable to provide an integrated trench MOSFET-Schottky rectifier structure having lower Qgd, lower on-resistance, and, at the same time, having smaller device area with lower fabrication cost.
SUMMARY OF THE INVENTION
[0012] It is therefore an object of the present invention to provide new and improved integrated trench MOSFET-Schottky rectifier device and manufacture process solving the problems mentioned above.
[0013] One advantage of the present invention is that, doping regions of a second semiconductor doping type, e.g., P dopant, marked by p* regions as shown in FIGS. 3 to 6 , are formed surrounding the lower portions of trench gate sidewalls to decouple trench gates from the drain such that the coupling charges between trench gates and the drain can be reduced. Furthermore, doping regions of a first semiconductor doping type, e.g., N dopant, marked by n* regions as shown in FIGS. 3 to 6 , are formed right below the trench bottoms to provide a current path between the drain to the source such that the decoupling p* regions will not inadvertently increase the resistance between the drain and source but Crss can be significantly reduced to a value that is about half or even lower when compared with the capacitance of the conventional devices because the Crss (Capacitance between gate and drain) or Qgd will be mainly determined by trench width in the present invention when compared with the conventional devices as shown in FIG. 1 and FIG. 2 .
[0014] Another advantage of the present invention is that, the planar contact for both MOSFET devices and Schottky rectifier are replaced by trench contact structure. By employing this trench contact, the devices are able to be shrunk to achieve low specific on-resistance for trench MOSFET, and, at the same time, achieve low Vf (forward voltage) and low Ir (reverse leakage current) for Schottky rectifier.
[0015] Another advantage of the present invention is that, there's no need to use additional mask to open the anode of Schottky rectifier in fabricating process according to this invention, therefore cost saving is achieved.
[0016] Briefly, in a preferred embodiment, as shown in FIG. 3 , the present invention disclosed an integrated device cell formed on a heavily doped substrate of a first semiconductor doping type comprising: a trench MOSFET and a trench Schottky rectifier. Said trench MOSFET further comprises: trench gates filled with doped poly above a layer of gate oxide and surrounded by a source region of first semiconductor doping type encompassed in a body region of second semiconductor doping type above a drain region disposed on the bottom surface of said substrate; tilt-angle implanted regions of the opposite dopant type to substrate surrounding the lower portions of trench gates sidewalls to further reduce Qgd; doping regions of the same dopant type as the substrate right below trench gate bottoms for functioning as a current path between the drain to the source for preventing a resistance increase caused by the doping regions surrounding the lower portions of the trench gates sidewalls; trench contacts penetrating a thick oxide layer and filled with tungsten plugs padded with barrier layer of Ti/TiN or Co/TiN to connect all the source regions to source metal of Al alloys or Copper deposited onto a resistance-reduction layer of Ti or Ti/TiN; P+ regions at the bottom of each contact trench to further reduce contact resistance;. The trench Schottky rectifier further comprises: trench gates filled with doped poly and penetrating into epitaxial layer built on said substrate; tilt-angle doping regions of the opposite dopant type to the substrate surrounding the sidewalls of trench gates; doping regions of the same dopant type as the substrate right below trench gate bottoms; contact trenches with a layer of Ti/TiN or Co/TiN lining the inner surface; P+regions at the bottom of each contact trench except trenches penetrating into trench gates introduced in the same step with those of trench MOSFET; tungsten plug filled into each the contact trench as anode material for trench Schottky and connected to metal layer of Al alloys or Copper which is the same metal layer as source metal for trench MOSFET. What should be noticed is that, according to this preferred embodiment, the integrated structure has single gate oxide and the trench gates in Schottky rectifier is not connected with trench gates in trench MOSFET but shorted with anode of Schottky rectifier.
[0017] Briefly, in another preferred embodiment, as shown in FIG. 4 , the structure disclosed is similar to that shown in FIG. 3 except that, there is no P+ region underneath each contact trench in trench Schottky rectifier by using additional P+ mask to block P+ Ion Implantation during fabricating process. [ 00016 ] Briefly, in another embodiment, the present invention disclosed an integrated structure formed on a heavily doped substrate of a first semiconductor doping type comprising a trench MOSFET and a trench Schottky rectifier and in parallel with a trench gate portion. Said trench MOSFET further comprises: trench gates filled with doped poly above a layer of gate oxide and surrounded by a source region of the first semiconductor doping type encompassed in a body region of the second semiconductor doping type above a drain region disposed on bottom surface of said substrate; tilt-angle implanted regions of the opposite dopant type to substrate surrounding the lower portions of trench gate sidewalls to further reduce Qgd; doping regions of the same dopant type as the substrate right below trench gate bottoms for functioning as a current path between the drain to the source for preventing a resistance increase caused by the doping regions surrounding the lower portions of the trench gates sidewalls; trench contacts penetrating a thick oxide layer and filled with tungsten plugs padded with layer of Ti/TiN or Co/TiN to connect all the source regions to source metal of Al alloys or Copper deposited onto a resistance-reduction layer of Ti or Ti/TiN; P+ regions at the bottom of each contact trench to further reduce contact resistance. The trench Schottky rectifier further comprises: trench gates filled with doped poly and penetrating epitaxial layer built on said substrate; doping regions of the opposite dopant type to the substrate surrounding the sidewalls of trench gates; doping regions of the same dopant type as the substrate right below trench gate bottoms; contact trenches with a layer of Ti/TiN or Co/TiN lining the inner surface; P+ regions at the bottom of each contact trench introduced in the same step as those of trench MOSFET; tungsten plug filled into each the contact trench as anode material for trench Schottky and connected to metal layer of Al alloys or Copper which is the same metal layer as source metal for trench MOSFET. What should be noticed is that, according to this preferred embodiment, the trench gate in Schottky rectifier introduced in not shorted with anode via trench contact like the first embodiment, and trench MOSFET and trench Schottky rectifier have common trench gate.
[0018] Briefly, in another preferred embodiment, as shown in FIG. 6 , the structure disclosed is similar to that shown in FIG. 5 except that, there is no P+ region underneath each contact trench in trench Schottky rectifier by using additional P+ mask to block P+ Ion Implantation during fabricating process.
[0019] These and other objects and advantages of the present invention will no doubt become obvious to those of ordinary skill in the art after having read the following detailed description of the preferred embodiment, which is illustrated in the various drawing figures.
BRIEF DESCRIPTION OF THE DRAWINGS
[0020] The present invention can be more fully understood by reading the following detailed description of the preferred embodiments, with reference made to the accompanying drawings, wherein:
[0021] FIG. 1 is a side cross-sectional view of an integrated trench MOSFET and Schottky rectifier of prior art.
[0022] FIG. 2 is a side cross-sectional view of another integrated trench MOSFET and Schottky rectifier of prior art.
[0023] FIG. 3 is a side cross-sectional view of a preferred embodiment in accordance with the present invention.
[0024] FIG. 4 is a side cross-sectional view of another preferred embodiment in accordance with the present invention.
[0025] FIG. 5 is a side cross-sectional view of another preferred embodiment in accordance with the present invention.
[0026] FIG. 6 is a side cross-sectional view of another preferred embodiment in accordance with the present invention.
[0027] FIGS. 7A to 7E are a serial of side cross-sectional views for showing the processing steps for fabricating integrated trench MOSFET and Schottky rectifier in FIG. 4 .
DETAILED DESCRIPTION OF THE EMBODIMENTS
[0028] Please refer to FIG. 3 for a preferred embodiment of the present invention where an integrated trench MOSFET and Schottky rectifier is formed on a heavily N+ doped substrate 300 with back metal 322 on rear side as drain. Onto said substrate, an epitaxial layer 302 of the same doping type as substrate and lighter concentration is grown. The disclosed structure further comprises a plurality of trench gates 310 for trench MOSFET and a plurality of wider trench gates 310 ′ for Schottky rectifier, where trench gates 310 and 310 ′ all filled with doped poly padded by a single gate oxide layer 314 along the inner surface of gate trenches. A plurality of P body regions 304 extend between trench gates on the upper portion of the epitaxial layer 302 except between those for Schottky rectifier. The body regions 304 further encompassed source regions 312 formed near the top surface of the epitaxial layer 302 . A thick oxide insulation layer 308 covering the top surface of epitaxial layer with contact trench opened and filled with tungsten plug 322 over a barrier layer 306 of Ti/TiN or Co/TiN for trench MOSFET and Schottky rectifier, respectively. Right below each trench contact except those for Schottky rectifier gate connection, a P+ region 340 is formed to reduce the resistance between metal plug 322 and body region 304 to allow a low-resistance contact for trench MOSFET portion. In Schottky rectifier portion, trench contacts are used to form Schottky diodes along trench contact sidewalls after the formation of layer 306 along each trench. Above the thick oxide layer 308 , metal layer 330 composed of Al alloys or Copper coated with a resistance reduction layer 318 composed of Ti or Ti/TiN is deposited to be electrically connected to source regions 312 and body regions 304 of trench MOSFET while functioning as anode metal for Schottky rectifier. Especially, the trench gates in Schottky rectifier is not connected with then trench gates in trench MOSFET but shorted with anode of Schottky rectifier.
[0029] For the purpose of reducing the Qgd, the sidewalls of trench gates for Schottky rectifier and bottom portion of the sidewalls of trench gates for trench MOSFET are surrounded by P-dopant regions 315 , as marked by p* in FIG. 3 . Furthermore, the central portions underneath the bottom of all trench gates are formed with N doped regions 320 , as marked by n* in FIG. 3 below each trench gate. The Qgd is reduced with the p* dopant regions 315 while the n* dopant regions 320 under the trench bottom provide a current path of drain to source thus prevent the inadvertent increase of the resistance. Furthermore, by reducing the Qgd, the capacitance Crss may be reduced to half of the original capacitance or even lower compared to the capacitance of the conventional devices.
[0030] FIG. 4 shows a side cross sectional view of another preferred embodiment of the present invention with a similar configuration to that of structure shown in FIG. 3 . The only difference is that, there is no P+ area underneath trench contacts for Schottky rectifier, which implemented by using additional P+ mask to block P+ Ion Implantation during fabricating process.
[0031] Please refer to FIG. 5 for another preferred embodiment of the present invention which is built in an N doped epitaxial layer 502 onto an N+ doped substrate 500 . A plurality of trenches and at least a wider trench for gate connection are etched into said epitaxial layer and are filled with doped poly padded with a layer of gate oxide 514 to form trench gates 510 and at least a common trench gate 510 ′ for both trench MOSFET and Schottky rectifier. P body regions 504 are extending between two adjacent trench gates 510 with source regions 512 near its upper surface. Source-body contact trenches and at least a gate contact trench with P+ contact area 540 whereunder are opened through thick oxide interlayer 508 and into P-body regions and trench gate for gate connection, respectively. Above a barrier layer 506 composed of Ti/TiN or Co/TiN, tungsten plugs 522 are filled into contact trenches to form source-body contact and gate contact, respectively. Metal layer composed of Al alloys or Copper coated with a resistance reduction layer 518 composed of Ti or Ti/TiN is deposited and patterned by metal mask to form metal layer 530 and 530 ′. Specifically, metal layer 530 contacts the source and body regions of Trench MOSFET with the anode of Schottky rectifier, while metal 530 ′ is connected to the common trench gate, which means the trench gate in Schottky rectifier is not shorted with anode via trench contact like the first embodiment. For the purpose of reducing the Qgd, the sidewalls of trench gates for Schottky rectifier and bottom portion of the sidewalls of trench gates for trench MOSFET are surrounded by P-dopant regions 515 and the central portions underneath the bottom of all trench gates are formed with N doped regions 520 .
[0032] FIG. 6 shows a side cross sectional view of another preferred embodiment of the present invention with a similar configuration to that of structure shown in FIG. 5 . The only difference is that, there is no P+ area underneath trench contacts for Schottky rectifier, which implemented by using additional P+ mask to block P+ Ion Implantation during fabricating process.
[0033] In FIG. 7A , an N doped epitaxial layer 402 is grown on an N+ substrate 400 , then, after a thick oxide deposition along top surface of the epitaxial layer 402 , a trench mask (not shown) is applied, which is then conventional exposed and patterned to leave mask portions. The patterned mask portions define the gate trenches 410 a for trench MOSFET and 410 ′ for Schottky rectifier, which are dry oxide etched and dry silicon etched through mask opening to a certain depth. Next, a sacrificial oxide (not shown) is grown and then removed to eliminate the plasma damage may introduced during trenches etching process. After that, a screen oxide is grown for the followed Boron angle Ion Implantation to form p* areas 415 wrapping the sidewalls and bottoms of gate trenches 410 a and 410 a′.
[0034] In FIG. 7B , another vertical Arsenic or Phosphorus Ion Implantation is carried out to form n* area 420 right below the gate trenches 410 a and 410 a ′. In FIG. 7C , screen oxide is first removed and gate oxide layer 414 is formed on the front surface of epitaxial layer 402 and the inner surface of gate trenches 410 a and 410 a ′. Next, all gate trenches are filled with doped poly to form trench gates 410 for trench MOSFET and trench gates 410 ′ for Schottky rectifier. Then, the filling-in conductive material such as doped poly is etched back or CMP (Chemical Mechanical Polishing) to expose the portion of gate oxide layer that extends over the surface of epitaxial layer. Next, by employing a P-body mask, an Ion Implantation is applied to form P-body regions 404 , followed by a P-body diffusion step for P-body region drive in. After removing the P-body mask, another Ion Implantation is applied to form N+ source regions 412 using a source mask followed by an n+ diffusion step for source regions drive in. Then, in FIG. 7D , a thick oxide interlayer 408 is formed over whole top surface, through which contact trenches 422 a are etched by forming a contact mask (not shown) by successive dry oxide etching and dry silicon etching. Next, the BF2 Ion Implantation is applied over contact area mask to form the P+ area wrapping the bottom of contact trenches in trench MOSFET portion to further reduce contact resistance. In FIG. 7E , after the deposition of Ti/TiN or Co/TiN layer 406 , a step of RTA (Rapid Thermal Annealing) under 730˜900° C. for 30 seconds is carried out for the formation of TiSi 2 or CoSi 2 . Then, all contact trenches are filled with W metal 422 to form trench contacts for trench MOSFET and Schottky rectifier. After the Ti/TiN/W or Co/TiN/W etching back, Al Alloys or copper metal layer is deposited over a resistance reduction layer 418 composed of a low resistance metal layer such as a Ti or Ti/TiN layer to serve as front metal 430 . Last, Drain metal 422 composed of Ti/Ni/Ag is then deposited on rear surface after backside grinding.
[0035] Although the present invention has been described in terms of the presently preferred embodiments, it is to be understood that such disclosure is not to be interpreted as limiting. Various alternations and modifications will no doubt become apparent to those skilled in the art after reading the above disclosure. Accordingly, it is intended that the appended claims be interpreted as covering all alternations and modifications as fall within the true spirit and scope of the invention. | An integrated circuit includes a plurality of trench MOSFET and a plurality of trench Schottky rectifier. The integrated circuit further comprises: tilt-angle implanted body dopant regions surrounding a lower portion of all trench gates sidewalls for reducing Qgd; a source dopant region disposed below a bottom surface of all trench gates for functioning as a current path for preventing a resistance increased caused by the body dopant regions. | 23,548 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority to and the benefit of the filing of U.S. Provisional Patent Application Ser. No. 61/681,566, entitled “Probe Fabrication Using Combined Laser and Micro-Fabrication Technology”, filed on Aug. 9, 2012, and the specification and claims thereof are incorporated herein by reference.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0002] Not Applicable.
INCORPORATION BY REFERENCE OF MATERIAL SUBMITTED ON A COMPACT DISC
[0003] Not Applicable.
COPYRIGHTED MATERIAL
[0004] Not Applicable.
BACKGROUND OF THE INVENTION
[0005] 1. Field of the Invention (Technical Field)
[0006] The present invention relates to probe fabrication methods and probe products thus manufactured.
[0007] 2. Description of Related Art
[0008] Laser machining has been employed to fabricate vertical probes for probing integrated circuits. However, it has been found that this fabrication approach may not provide sufficient control over fine details of probe shape. In one example, probe designs where the probe tip has a reduced-width section (which can be referred to as a skate) were laser fabricated. The resulting variability of skate width was about 3 μm, which leads to a significant reduction of probe yield.
BRIEF SUMMARY OF THE INVENTION
[0009] The present invention is of a method of making a probe (and the resulting probe), comprising: providing a metal foil; creating a tip on an edge of the foil; and laser cutting a body of the probe from the foil with one or more tips at an end of the body. In the preferred embodiment, creating comprises one or more of laser cutting, plating, depositing, and sputtering material. For plating, depositing, or sputtering, the material can be layered, and preferably comprises Rhodium or Palladium. Etching spring material may be done prior to the plating, depositing, and/or sputtering, and preferably the spring material comprises BeCu. Laser cutting is preferably performed by one or more picosecond lasers. The method can additionally comprise creating a distal end of the probe proximate an edge of the metal foil opposite the edge having the tip, preferably by one or more of laser cutting, plating, depositing, and sputtering material. The distal end can be etched with spring material prior to the plating, depositing, and/or sputtering of material.
[0010] Further scope of applicability of the present invention will be set forth in part in the detailed description to follow, taken in conjunction with the accompanying drawings, and in part will become apparent to those skilled in the art upon examination of the following, or may be learned by practice of the invention. The objects and advantages of the invention may be realized and attained by means of the instrumentalities and combinations particularly pointed out in the appended claims.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
[0011] The accompanying drawings, which are incorporated into and form a part of the specification, illustrate one or more embodiments of the present invention and, together with the description, serve to explain the principles of the invention. The drawings are only for the purpose of illustrating one or more preferred embodiments of the invention and are not to be construed as limiting the invention. In the drawings:
[0012] FIG. 1 is a perspective view of metal foil the beginning of the method of the invention;
[0013] FIG. 2 is a perspective view of same after creation of a tip by etching/plating;
[0014] FIG. 3 is a top detail view of the tip; and
[0015] FIG. 4 is a perspective view of the foil after laser cutting of the probe body.
DETAILED DESCRIPTION OF THE INVENTION
[0016] With the present invention, the problems cited above are addressed by employing micro-fabrication technology (e.g., as used in microelectronics fabrication, micro-electro-mechanical systems (MEMS) fabrication, etc.) to fabricate critical parts of the probes (e.g., probe tips and/or probe distal ends). Here distal refers to the end of the probe that is opposite the tip. Such micro-fabrication technology includes, but is not limited to etching (single or dual sided), and layer build up (e.g., by deposition, plating, sputtering etc.). For example, the probe tip can be coating with a contact material (e.g., rhodium, palladium etc.) after its mechanical features (e.g., the skate) are defined. After the fine features of probes have been formed with micro-fabrication technology, the remaining parts of the probe shape can be defined via laser machining. This approach provides the advantages of both micro-fabrication (good control of small feature sizes) and laser machining (flexibility, ability to handle larger structures than micro-fabrication).
[0017] The preferred method of the present invention starts with a metal foil that has alignment features for future processing. The tip feature can be created using two-sided etching of spring material (e.g., BeCu) followed by plating the tip with desirable contactor material (e.g., Rh, Pd, etc.). Another option is to start with the tip feature and the foil created through MEMS/Multi-layer metal plating/deposition (including sputtering). This allows for accurate tip feature creation coated with such metals as Rhodium, Palladium. etc. The same can be applied to creation of the distal end of the probe. The body of the probe is preferably laser cut after the tip/distal end are made. Picosecond laser cutting is preferred.
[0018] Referring to the figures, FIG. 1 illustrates the starting metal foil 12 . FIG. 2 shows the foil after tip 14 creation by etching/plating. FIG. 3 shows detail of the tip and a preferred shape thereof. FIG. 4 shows the foil after laser cutting of the probe body 16 , with the tip intact thereon. FIG. 4 shows a probe body with an extended portion comprising multiple discrete probe sections that are then joined at the tip, although a traditional single-section extended portion can also be made according to the invention. Furthermore, the probe can be made such that more than one tip is created at the end of the probe. Additionally, the tip or tips (as well as the distal end) may also be formed by laser cutting.
[0019] Note that in the specification and claims, “about” or “approximately” means within twenty percent (20%) of the numerical amount cited.
[0020] Although the invention has been described in detail with particular reference to these preferred embodiments, other embodiments can achieve the same results. Variations and modifications of the present invention will be obvious to those skilled in the art and it is intended to cover in the appended claims all such modifications and equivalents. The entire disclosures of all references, applications, patents, and publications cited above are hereby incorporated by reference. | A method of making a probe (and the resulting probe) comprising providing a metal foil, creating a tip on an edge of the foil, and laser cutting a body of the probe from the foil with one or more tips at an end of the body. | 7,227 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] Not Applicable
FEDERALLY SPONSORED RESEARCH
[0002] Not Applicable
SEQUENCE LISTING OR PROGRAM
[0003] Not Applicable
BACKGROUND OF THE INVENTION—FIELD OF INVENTION
[0004] The field of invention is in information technology based systems that manage core business activities specifically those business activities that are complex in nature.
BACKGROUND OF THE INVENTION
[0005] Most e-commerce transactions are simple in nature. For example, the retailer to consumer business process is a direct sequence of events; browse a catalog, make a selection, make a payment using a credit card and deliver the purchased product. The entire transaction is completed with a single interaction between the seller and the buyer. This type of transaction does not reflect the complex nested transactions of many of today's commercial transactions. Transactions in the business world are often long lived propositions, involving: negotiations, commitments, contracts, floating exchange rates or other complex financial derivatives, shipping and logistics, tracking, varied payment instruments, exception handling and termination or satisfaction. Each of these stages may cycle multiple times with prior transactions impacting present transactions and present transactions creating additional commitments for future transactions.
[0006] In a joint white paper of the Object Management Group and CommerceNet, Gabriel Gross, President of Centre Internet European, summarized the current state of electronic commerce applications as
[0007] Mainly limited to two functionalities: cataloging on one side and payment facilities on the other side. The current electronic commerce world is in practice a lot less sophisticated than real world commerce where several levels of interaction can take place between potential client and vendor, and several levels of intermediaries can act or interfere.
[0008] At a basic level, commercial transactions have two phases:
1) Construction
a) Information collection involving catalogues and brokerage systems to locate sources; b) Agreement leading to terms and conditions through negotiation mechanisms; and, c) Engagement resulting in the “signed contract”.
2) Execution
a) Configuration involving deployment across the group of participants in the transaction; b) Service execution in context of the higher level contract and management of exceptions; and, c) Termination involving validation and closing the contract across all participants. Termination may be long lived as contracts may include ongoing service agreements with the customer and other aspects of overall customer relationship management.
[0017] Ideally an information technology system will integrate other aspects of a business into the transaction process. This integration will allow for optimization of business processes. The integration of physical capabilities will allow for maximum resource utilization. Integration of financial data will allow for maximization of revenue. The greatest potential gain comes from the combined integration of contracting, physical capabilities and financials to allow optimization according to marginal costs. Through a marginal costing approach a business can maximize net income.
[0018] Enterprise systems must also address the world of multi-seller, multi-buyer commerce. This requires building information systems capable of handling/processing simultaneous requests from multiple users. Inherent to this disclosed system is a request scheduling process, which prioritizes, queues and processes the requests of multiple users.
[0019] In addition, a complex transaction or business process requires management of many dynamic roles: customer (the one who pays), consumer (the one who receives), merchant (the one who gets paid) and provider (the one who delivers). Additional sub-roles also exist, including: brokers, aggregators, referral services and other forms of intermediation. Additional supporting roles exist, including: bankers, credit providers, shippers, insurers and other third parties. Each of these roles imposes requirements on the Enterprise System.
[0020] The underlying data sources must be accessible to meet the different information needs of each role and procedure. This disclosed system maintains data at the minimal level of granularity required by any system, subsystem or role. This level of granularity ensures that no data are lost by a roll-up process. While stored at a granular level the data must possess the structural information needed to reassemble the data into any required format. Again this disclosed system allows for the summation and efficient handling of the granular data.
[0021] Enterprise systems require the inter-operation of computer applications, which depend upon consistent protocols and formats for information exchange. The complexity of building such virtual marketplaces mandates a computing paradigm based on standards. Otherwise inter-operability is impossible. The ultimate purpose of these standards is to develop consistent business semantics used by all participants—a common language of digital commerce. The extent of today's solution is to provide commonality to the names and relationships of processes, workflows, and data across all value and supply chains. This commonality is often provided through direct mapping of fields and/or translation tables.
[0022] An example is the new standard for defining and naming data on a Web page adopted by the World Wide Web Consortium (W3C) in 1997. The Extensible Markup Language (XML) allows structured data—with standard names and consistent semantics—to be moved around the Web in a simple, straightforward manner. XML is, however, little more than the reintroduction of the “unit record concept” introduced with the punch card in the 1950s. These cards stored chunks of data (fields) that were tagged with names giving them attribute/value pairs bound together as a standalone document (record). In other words, XML is simple text data (ASCII) and must be linked to an underlying infrastructure in order to handle the adaptive business processes and workflows needed for e-commerce. The most difficult aspect of inter-operability is to gain global agreement and definition of the underlying processes and procedures—an effort that has eluded information systems designers since the introduction of centralized databases. Thus, XML enables the use of the consistent business semantics but does not provide for the complex processes or functions. The disclosed system goes beyond simply creating a uniform naming structure. This system provides a structure for defining the entire process that lies on top of the data structure.
[0023] Without consistent business semantics, the business processes and workflows cannot be shared between multiple organizations or even inter-company departments. However, even with consistent semantics the task knowledge needed for such activity, adaptive business processes and workflows, overwhelms current software paradigms. A proposed solution is the use of intelligent agent technology, which is based on task level knowledge and knowledge sharing standards [such as a simplified version of the Knowledge Interchange Format (KIF)]. Today's intelligent agent technology is still in its infancy and, therefore, cannot approach the knowledge base required to prepare transactions. This disclosed system provides for a basic transaction language to describe the complex transactions and processes. The language focuses on supporting human decision makers not replacing them.
[0024] Enterprise computing seeks to consolidate and harmonize the many disparate information systems and data sources scattered throughout an enterprise into a unified whole. The goal is to streamline business processes and enable outward-facing information systems. The attention given to enterprise computing in recent years is a result of the business process re-engineering revolution, which was enabled by information technologies such as client/server computing. Through some hard learned lessons, corporations now know that it is insufficient to wire together machines through a network using a client/server architecture. A coherent information model and technology architecture was missing from this structure.
[0025] The disclosed system provides the much needed solution. Rights and engines define the core of this system. The Rights maintain subsystems and roles, at the most granular level required by any business system. The engines are responsible for the exercise of these Rights. Maintaining sufficient granularity ensures the integrity and availability of all system data. In other words, the core of this system prevents the loss of data by storing all data centrally in one usable format. These core Rights are subsequently developed into hierarchical structures. The hierarchical structures may involve tiering relationships within and between the Rights. These tiered hierarchical structures allow the creation of complex transactions and processes.
[0026] Object oriented computing is touted as the solution for managing the ever-growing complexity inherent in computing solutions. Objects are chunks of software that reflect real things in the real world: customers, employees, orders, shipments, and so on. Objects combine their processes and their data into a single entity in such a way that the integrity of the object is ensured by the object itself. This is in contrast to the relational database model typical of client/server architectures, where data is isolated from the processes that manipulate it. Such processes may be scattered across an organization resulting in integrity and complexity problems when they are integrated. Companies that tried to link the relational databases with the processes that use them created incomprehensible spaghetti architectures. These spaghetti architectures failed to create a unified enterprise information infrastructure. The structured products approach maintains the data in its most granular form. Therefore, data is exposed to all systems and the web of interconnected data sources is avoided. Each organization or business area is subsequently responsible for the reconstruction of the data to produce their required view of the business.
[0027] The next evolution in object oriented design, distributed object computing, is recognized as the future for building enterprise information architectures. Objects communicate to one another, to users and other systems by presenting interfaces with their services. To ask an object to perform a task, the object is sent a message requesting a service. In essence, using objects to build information systems is like building a simulation that includes the representation of people, places, things and events, which are found in the business setting or domain. Four key advantages result:
1) Objects reflect the real world and, thus, greatly enhance understanding and communication among systems developers and business people; 2) Objects are stable, allowing the object's internals and interfaces to be changed without affecting other parts; 3) Objects help achieve software reuse as they are extended through mechanisms, such as inheritance, without rewriting the entire object; and, 4) Objects reduce complexity as programmers do not have to understand the internals of the object. They do not need to know how an object works internally, only what the object is and to what messages it responds (i.e. how to communicate to the object).
[0032] Distributed object computing has evolved rapidly over the past five years. Early uses of this computing paradigm dealt with system or “technology” objects. A printer is a simple technology object. A programmer no longer needs to “program” a printer. Instead the programmer sends the printer object a message to request the object take care of printing the current document. Traditional procedural programming required that programmers know all about programming printers, carefully writing each instruction to handle line feeds, tabbing and so on.
[0033] While technology objects simplify coding, they do not address the business applications or business semantics. The object-oriented solution created of a higher level of abstraction allowing information system developers to work with objects representing business entities and processes. At this level of abstraction, powerful business information models were designed with object-oriented concepts. These business objects handled the tasks of business processes and activities while suppressing the details of the underlying objects. The details were needed, of course, but the internals of the business object managed theses matters by sending appropriate messages to the underlying objects. While at an abstract level the use of objects to manage business processes is both appealing and practical, implementation problems exist. In an enterprise system the underlying data and the corresponding processes are frequently used across the entire system. This requires the exposure of the process and underlying data which is exactly what true object oriented design attempts to prevent. The disclosed system presents a unique combination of business objects with exercise engines and data structures. While the exercise engines control the processes, the granular data structure ensures data availability across business units. The business objects are built upon these shared structures.
[0034] The “Holy Grail” of enterprise systems is to allow the business user to define, manage and maintain the business functions. Thus, control of the implemented business processes is returned from the realm of the corporate information technology department to the domain of the business user. In this regard, Common Object Request Broker Architecture (CORBA) made system and technology inter-operations available, and many mission critical business systems and applications have been developed. The interface definition language (IDL) specification allows programmers to write and publish interfaces that are used by objects anywhere. To date, however, developers must still master a mix of business object semantics and the underlying technology objects, which require low-level plumbing, in order to build complete business solutions. A business object component model that suppresses the complexity of the underlying systems technology is needed to provide a clear separation of concerns. With such a system, business solution developers can assemble and tailor pre-built business components into complete solutions.
[0035] Technologists are component assemblers and deal with the complexity of the underlying information systems and technology infrastructure. Computer specialists are the tool-smiths for building reusable components. Because business objects provide the abstractions needed for building high-level components that inter-operate, business solution developers are able to assemble applications using business constructs and semantics that insulate them from the underlying complexity. The ultimate language of application development will be the “language of business,” not “the language of computers”, and eventually business users will develop their own information systems solutions to business problems. Only when the business user can accomplish the tasks originally in the domain of the computer specialist, can the goal of a truly agile business be realized. The disclosed system creates the structures necessary to minimize the services of a computer specialist. Business strategies identified by the business users can be implemented on an enterprise wide scale using this disclosed system.
[0036] The component paradigm has changed “programming.” Application programmers who made up the bulk of commercial information technology shops are being replaced by technologists assembling components. The components are not delivered to corporations as a big pile of parts and pieces. Instead the components arrive pre-assembled into industry specific application frameworks. These frameworks represent applications that are nearly complete. The task of solutions developers will be to customize the components of the frameworks to meet the unique needs of the specific company.
[0037] Solution developers will concentrate on the unique character and knowledge of the company, which accounts for the company's competitive advantage. The extension and tailoring of components will focus on the user interfaces and will involve both graphical and task-centered customization. In the long run, corporations will no longer need to waste resources designing their own applications. Instead, they will buy component-based enterprise application packages. These packages, however, will not be the complex, confusing packages available in the current market. Instead, the framework of these packages will be based on distributed object architectures, allowing for individual components to be mixed and matched regardless of the individual software vendor. The disclosed system is such a framework. But rather than an ancillary function of merging different systems, the disclosed framework represents the core of the business to which the other components are attached. Only with a granular data structure and the necessary exercise engines can the component approach be implemented in a flexible fashion. The disclosed system is specifically tailored to the forecast, sales, contracting, supply chain and settlement process that are at the foundation of any business.
[0038] SAP and other enterprise resource planning (ERP) vendors are aggressively implanting their software based on case studies into business (not computer science) curriculums at both the graduate and undergraduate levels. This will result in business graduates who can build information systems from frameworks. The programmer as “translator” between the business and the digital domain will fade into history. However, the true benefits of component assembly will not be realized without the disclosed structured products approach providing the framework to which the components may be attached.
SUMMARY OF THE INVENTION
[0039] In one aspect, the disclosed system serves as a development language for business users. CommerceNet is working on a Common Business Language (CBL) to blend e-commerce components into their evolving eCo System architecture. Other high level tools, such as VisualAge for Java, serve as component assemblers that suppress the details and complexity of the underlying technologies and systems. Basic, Pascal and similar high-level languages were created to hide the complexity of machine code. The novelty in the structured products system is that the language of the business user is used to create the business functions. The disclosed system lies between the abstract level of CommerceNet and higher-level languages. This business user accessibility allows for the creation of truly agile business solutions.
[0040] The basis of the disclosed system is the process of disassembling a service into its individual atomic Rights. These Rights are then defined and assembled within the system to create mass customized services. At the most basic level, the Rights specify a unique collection of parameters. Thus, the user is not tied to any database type structure and the Rights are amorphous.
[0041] An additional feature of the disclosed invention is the exposure of the Right parameters to the business user. The parameters are accessible and, therefore, allow Rights to be configured as a typical business user builds them into services.
[0042] Another novel feature of the disclosed system allows for the Rights to be associated into complex structures, such that they depend upon other Rights or services. This allows for both Rights and services to be inter-related. This results in one Right or service having the ability to affect others, depending upon the actual utilization of the Right or service adopted by the customer.
[0043] Furthermore, each Right can be associated with other objects or parameter groups, including: scheduling priority, pricing, marginal cost, and actual cost. These additional structures enable the seller to configure management systems for the services he provides.
[0044] Another novel feature of the disclosed system is that the pricing object associated with a Right is modeled as an option. Option pricing format allows a base charge for actually having the Right/Service and an incremental charge for the utilization of the Right/Service.
[0045] Another novel feature is the system's capacity to manage products in the service industry. The use of the term Service to represent an assembly of Rights was intentionally used to accent the applicability of the system to all industries, including; those that sell tangibles and intangibles.
[0046] Additionally, the disclosed system allows for the entire scheduling system to be changed by simply modifying the scheduling priorities of each Right. This can be done without writing any additional code, a revolutionary feature of this system. During Right definition and service creation each Right is assigned a scheduling value. After a Right has been utilized in a given circumstance (exercised), a scheduling value is automatically read from each Right. For the Rights exercised, scheduling values are subsequently summed to determine the scheduling priority of the individual service. The scheduling of the actual services is achieved by sorting the totaled scheduling priorities. Thus, scheduling is simply a number map schema of all of the scheduling priorities and their summation under different conditions.
[0047] Other aspects and advantages of the present invention will become apparent from the following detailed description taken in conjunction with the accompanying drawings illustrating by way of example the principles of the present invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0048] FIG. 1 is a flow diagram that shows the basic elements of a Right.
[0049] FIG. 2 is a flow diagram that shows a more advanced version of the Right definition process.
[0050] FIG. 3 is a flow diagram that shows a Right with Objects (Parameter Groups) attached to individual parameters.
[0051] FIG. 4 is a flow diagram that shows a Right with an Object or Parameter group attached directly to the Right.
[0052] FIG. 5 is a flow diagram that shows the detailed view of the pricing object.
[0053] FIG. 6 is a flow diagram that shows the most elemental method of Right assembly yielding a complex Business function.
[0054] FIG. 7 is a flow diagram that depicts the elements of a fully featured Right assembly system.
[0055] FIG. 8 depicts the role of input parameter mapping for the population of the Rights defined in a service template.
[0056] FIG. 9 shows a generic business process and the engines, which support the process.
[0057] FIG. 10 is a flow diagram that shows some of the business functions supported by the structured products core.
[0058] FIG. 11 shows the structured products core supporting multiple business areas and functions.
[0059] FIG. 12 is a flow diagram that shows the concept of a service within the framework of the Rights, Right hierarchy, input mapping and the Rights operation/Exercise engines
[0060] FIG. 13 is a graph that presents one concept of the “Cube”, which is an analysis tool for the visualization of the multi-dimensional data.
DETAILED DESCRIPTION OF THE INVENTION
[0061] FIG. 1 is a flow diagram showing the basic elements of a Right. A Right represents an elemental function defined by the business. The Right has sufficient granularity to preclude the summation of business detail. Maintaining the Rights at this level of granularity allows for the Rights to form the basis of every system within the enterprise. If data were not stored at the finest granularity required by any system within the enterprise, business details would be lost during the processing. The loss of data would prevent the system from being able to “see” every aspect of the business. The only alternative to maintaining the data at the finest level of granularity would be to store the data in redundant databases in which, each is specialized for its specific business process. This approach would defeat the benefit of using the Rights based processing as the basis for the enterprise system.
[0062] There are many different types of Rights, including: scheduling, pricing, transportation, transformation and storage. Each of these Rights represents an elemental business function. As shown in FIG. 1 , a Right is composed of parameters and an element of code. Multiple parameters may be attached to each Right. Each parameter defines a certain aspect of the Right. For example, a Transportation Right, which deals with the shipping of a product, will need parameters defining: the item(s) being transported, the quantity transported, the location and destination of the item(s), the mode of transportation, and the transportation route. A Transformation Right can be used as another example. A Transformation Right, which defines the conversion of starting material(s) into product(s), will require parameters detailing the raw and finished products, conversion rates, and conversion efficiencies. The parameters defining a Right are comprised of name value pairs: the parameter name (what is being tracked) coupled with the associated value.
[0063] Code elements define the way in which a Right is processed by the system. In particular, the code element covers unique processing requirements of the specific type of Right. For example, certain aspects related to the processing of a transportation Right will obviously differ from a transformation Right. The processing is independent of any particular value input for the name value pair. The code should use these name value pairs in a fashion similar to variable declarations where the code processes regardless of the actual values.
[0064] Code elements are created in many ways. The simplest is to directly hard code the functioning of the Right. This approach benefits from simplicity and rapid processing speeds. However, hard code is inflexible and requires an experienced software engineer to develop. Typically, the software engineer does not have the necessary business domain knowledge and, thus, requires the translation of business knowledge by a domain expert. An alternative is to “code” the business logic using a natural language system, which allows the business user to input domain knowledge in the language of the business user. This generally results in slower processing speeds since the system is now responsible for the translation. The actual approach will depend on the system requirements and will probably be a synthesis of both approaches.
[0065] FIG. 2 shows a more advanced version of the Right definition process. The main difference between FIGS. 1 and 2 is the incorporation of a configurable logic engine. The configurable logic engine is able to enhance the basic functioning of the Right defined in the hard-coded code block. The logic engine pulls the values from the name value parameter pairs. The logic engine is then configured to perform a variety of processing functions, including basic mathematical calculations: addition, subtraction, multiplication and division. The system can also handle more advanced calculations: summations, minimum/maximum selection and averaging. Simple logical expressions are also included as basic processing functions. The logical expressions include Boolean queries and if—then selections. The logic engine can also process looping functions, which allows for the expression of iterative processes. Finally, the logic engine may allow for the creation and definition of input and output variables. This effect would be similar to the creation of parameters in an as-needed fashion. The combination of some of these capabilities in a logic engine will enhance the definition and ability to configure the Rights, without the need to hard-code Right behavior.
[0066] FIG. 3 shows—a Right with Objects (Parameter Groups) attached to individual parameters. In the system, Objects and Parameter Groups are used interchangeably. Parameter Groups are logical groupings of parameters where the parameters are organized by their specific function. Objects, while similar to Parameter Groups, also include an element of behavior to encompass the operations or functions that can be accomplished by the parameters. Objects and Parameter Groups are used to provide packaged functionality to the generic Rights. The concepts of Tiering, Recurrence and Pricing are examples of parameter groups that can be attached to individual parameters.
[0067] FIG. 4 shows a Right with an Object or Parameter group attached directly to the Right. In FIG. 4 , the additional functionality provided by the object is tied to the Right in its entirety instead of only being attached to a single Right Parameter as in FIG. 3 . The Object/Parameter group may include one or more parameters that link the functioning of the Object back to the Right parameter(s). Linking the Object to a single Parameter would have a similar effect to attaching the Object or Parameter group to the Right Parameter as in FIG. 3 . The types of Objects and Parameter groups that may be attached to the Right are again the same as in FIG. 3 (tiering, recurrence, pricing).
[0068] FIG. 5 is a detailed view of the pricing object. The pricing object has both demand and commodity components. This structure facilitates option-based pricing. In the event that either the demand or commodity is not priced, the parameters can be zeroed or the corresponding component eliminated. Five structures representing different pricing methods are shown feeding into both components. The simplest method is straight-fixed cost where an absolute value is assigned to the Demand and/or Commodity component. A slightly more complex version is a fixed-cost per unit. This pricing method requires both the cost per unit (fixed cost component) and a Parameter specifying the unit and quantity. This scheme demonstrates the benefits of providing access to the configurable logic engine within the pricing component. These benefits are even more apparent as the complexity of the pricing structures increases. Although a logic engine is not depicted in FIG. 5 , the inventors fully anticipate the implementation of this feature. The floating-pricing method allows for pricing relative to a moving index, examples include: spot prices set by exchanges, such as the Chicago Mercantile Exchange. This pricing method requires input of the floating index and potentially an offset from the index (fixed price). A fourth pricing alternative is based on swaps. With swap-pricing one element of value is exchanged for another element of value. The value can be defined by any of the preceding pricing methods; thus, swap pricing must encompass the other pricing methodologies. The use of swap pricing allows the seller and/or buyer to couple a financial instrument to the good being sold. For example, transportation prices could be based upon the difference between two liquid markets. The last pricing method shown is limits. Limits are intended to place caps, both floor and ceiling limits,) either in terms of total dollar figure or cost per unit on the value of an exchange.
[0069] In addition to the Demand and Commodity component, a group of parameters similar to these elements are attached directly to the Right. This Parameter group allows for the combination of Demand and Commodity limits. It can also be used to price additional elements of a Right. For example, in the gas transport industry the basic transportation Right is charged a Demand, a Commodity and a fuel usage fee. The currency used to pay the fuel fee is not necessarily a dollar denominated figure. As in options trading, payment is frequently made in-kind, (i.e. the payment is made in the commodity traded). FIG. 5 is intended to show generic pricing structures and not limit alternative pricing strategies.
[0070] FIG. 6 shows the most elemental method of Right assembly yielding a complex Business function. The situation pictured by FIG. 6 assumes independent action by the Rights. Many Business functions are supported by this simple approach. The incorporation of the logic engine with the Rights ( FIG. 2 ) maintains a high-level of flexibility.
[0071] FIG. 7 depicts the elements of a fully featured Right assembly system. A hierarchy structure and access to a logic processing component enables full flexibility. The hierarchy component is similar to the tier structures within a Right. The main difference is the level of action required (entire Rights vs. Right parameters). The logic processing between Rights can potentially be maintained by the same logic engine, which creates dynamic logical processing within individual Rights. Just as with the Right hierarchy, the primary difference between the logic processing for Rights vs. Parameters is the level of action required.
[0072] FIG. 8 depicts the role of input parameter mapping for the population of the Rights, which are defined in a service template. The magnitude of the work involved in: identifying each Right, defining the logic, establishing the hierarchy and populating all the parameters each time a complex business function (service) is initiated, leads to the creation of service templates to minimize the workload associated with the creation of any recurring or frequent business function. FIG. 8 shows the process of developing these service templates. This process, “templating”, is applicable to all services defined by the process depicted in FIG. 7 . The “templating” process requires the author of each template to identify the necessary input parameters. These input parameters are the values that the template user(s) will be required to supply in order to create an instance of the desired business function. The input parameters feed into the Input Parameter Mapping module, which coordinates the population of all Right parameters included in the particular service template. There are several levels of mapping. The foundation level directly maps an input parameter to a Right parameter. The next level takes an input parameter and maps it to the Right parameter using a formulaic expression. The formulaic expression can use the input or Right parameters to create a single Right parameter. The most complex mapping scheme allows the dynamic creation of input parameters. These input parameters are created as the instance of the service is generated from the template. These potential input parameters may or may not be present for any one instance created by the template. A simple example of this situation is the creation of tiers. During instantiation of a Service, one to many tiers may be defined in which, each tier maintains a subset of parameters. These parameters also require mapping. If the number of tiers is dynamically set at the time of instantiating an instance of the template, the mapping function necessitates the creation of additional input parameters for each new tier. This creates the cyclical process of FIG. 8 where additional input parameters are created and passed back into the input parameter mapping module.
[0073] FIG. 9 shows a generic business process and the engines, which support the process. The generic business process follows the sequence of requesting a transaction, physical exercise of the transaction and financial settlement for receipt of the transaction. This scenario assumes the existence of an instantiated Service agreement. The transaction request is first processed by a validation engine, which determines whether the transaction requester has the Rights in a service to fulfill the requested transaction. The validation engine accesses the database of Rights available to the requester and the previous Rights exercised by the requester. Upon the successful validation of a transaction request, the business process moves to the physical exercise of the transaction. A scheduling engine and operational engine support this process. The scheduling engine queues the validated transaction request instead of other pending requests. The operational engine exercises and updates the Rights required by the transaction request. Upon completion of the physical exercise, the business process moves to financial settlement. Financial settlement includes the creation of an “Invoice”, where the user is charged for the Rights purchased and exercised. The potential exists for Rights to be created that are only exercised upon a settlement procedure. A credit limit trigger is an example of a Right, which is exercised only during settlement. A credit limit results in Rights being recalled or the request for an additional credit deposit. A reporting engine supports the business process. The reporting engine provides the means for internal or external business groups to access the granular Rights data. The view of the Rights is defined by the requirements of the user. The summation is determined by the assembly structure, contained within the Rights and services.
[0074] FIG. 10 shows some of the business functions supported by the structured products core arranged over the corresponding Rights-based process, which manage the functions. The Rights-based process includes: the Right definition, the Right assembly, the Right operation, and finally the Right analysis. This combination depicts a Right's life cycle. Each stage in the life cycle supports the corresponding business functions. The listed business functions are not intended to be comprehensive merely provide examples of possible business functions.
[0075] FIG. 11 is a pictorial view of the structured-products core, which supports multiple business areas and functions. The actual implementation of the business areas will ideally be accomplished with a component-based architecture. Preferably, the components will be selected from those already commercially available. Alternatively, custom-made components will be created to provide tailored user-functions. In either case, the structured products system, with its granular data storage, the Rights assembly process and various exercise engines, facilitates the implementation of component-based enterprise systems.
[0076] FIG. 12 shows the concept of a service within the framework of Rights, the Rights hierarchy, input mapping, and the Rights operation/Exercise engines. In the context of the Structured Products System, a service and a business process are used interchangeably. In FIG. 12 , the junctions between Right/Service and input parameter/service are many-to-one relationships, (i.e. many Rights or input parameters have one service). The details of the other relationships can be found in the description of the other Figures.
[0077] FIG. 13 presents the concept of the “Cube”, which is an analysis tool for the visualization of the multi-dimensional data. The cube allows for the user to view three-dimensions of the possible n-dimensions defined by the particular industry. The multi-dimensions arise from different methods of summing the fundamental data sets. While the cube is one method for the expression of data, it holds the possibility of maintaining all system data. Therefore, it may be used as the basis for the entire on-line analytical processing (OLAP).
[0000] Operation of Invention
[0078] The basis of the Rights Based System (RBS) is the process of decomposing services into core constituent Rights. These core constituent Rights are then recombined through the flexible Rights Based System such that any service can be managed. This general system overview is intended to show how the envisioned Rights Based System could operate. In this example there are nine primary elements, which cover the life cycle of the Right from Right definition through Right analysis as shown in FIG. 10 .
[0079] Service Decomposition
[0080] The first and critical aspect of the structured products based management process is to break the business processes into their core components. The accurate and complete definition of the core components is essential for the subsequent reassembly process to work properly and to be sufficiently flexible to accommodate variations within business processes. Many of these basic Rights are actually applicable across industries. Examples of Rights and their functional description are given in Table 1.
TABLE 1 Right Functional Description Travel Path (Defined & Specifies the route that a product can Undefined) take. Segmentation of Path Allows the use of different elements (Rights) of the service in multiple transactions rather than linking all Rights to a single transaction. Secondary Market Can the initial purchaser resell the service? Defines how these transactions can be structured and any limitations. Secondary Market Recall Can the service being sold be recalled by the seller? Revenue/Volume Commitments The purchaser guarantees to use a (Price) certain amount of a service determined either with a volume or revenue. Notification Period Defines the time periods that the customer can schedule the delivery of a product or service. Defines the sellers guaranteed lag time between a request by a customer and the subsequent fulfillment of that request. Volume The quantity allowed under the terms of the transactions. Scheduling Priority This Right defines the priority for delivery of the service relative to the requests of other potential customers. Scheduling priority can also be implemented as a parameter on a specific Right. Contract Extension Can the term of the contract be extended and what are the implications to underlying Rights. Contract Termination This covers the implications of premature contract termination. Banking Facilitates the storage of a commodity. Overall Rate Ceiling/Floor Maximum and minimum pricing. (Price)
[0081] It is evident that with a set of fundamental Rights it is possible to address a variety of cross industry processes. While it is possible to address many processes with the already described set of Rights the inventors fully anticipate the need to create additional Rights that serve functions unique to an industry. Once created these become part of the tools available for subsequent system upgrades ad base functionality on new system installations.
[0082] Right Properties
[0083] At a fundamental level the Rights are composed of two elements: parameters and an optional code block ( FIG. 1 ). The parameters are further composed of a name value pair. The parameter maintains information on a certain aspect of the Right. Table 2 covers example parameters. The code block is specific for how the Right is processed within the system. Optionally the entire processing of the Right can be managed through the various exercise engines, which are discussed later.
TABLE 2 Parameter Name Parameter Description Right Type This information is utilized by the Rights Exercise Configurator & Schedule engines and determines the code that should act on the Right. Right Status Status covers the state of the Right in terms of active, inactive, exercised, scheduled etc. Right Contract Term This defines the Right start date, end date, creation date, and other overall contract term specifics. Commodity Specifies what (in a physical sense) the Right is covering. Exercise Periodicity This determines how often the Right can be exercised. (Second, Minute, Hourly, Daily, Weekly, Monthly, Yearly, Term . . . ). Alternatively this parameter may be part of the recurrence object. Volume The volume that can be utilized at each exercise. Also, there is a volume associated with the term of the option. Time Between Exercises The time that is required before the customer can exercise this Right again. Right Term The term of this Right. It should be noted that this is different from the term of the contract. The term of the option can be considered daily for hourly business. Minimum/Maximum commitment Specifies whether a Right must be exercised to a minimum or maximum condition. It covers an obligation of a customer. Premium The premium is a two-part figure. The first part is associated with the exercisable volume, and the second part is associated with the term volume for the Right. (Can be part of the pricing object) Exercise Cost Exercise cost is also a two-part figure. The first part is associated with the exercised volume and the second part is associated with the overall term exercised volume. . (Can be part of the pricing object) Overall Cost Defines the parameters based around an overall cost number for the non-exercise or exercise of this Right. (Can be part of the pricing object) Number of Exercises Allowed This determines how many times during the day there can be an exercise of this Right. Guaranteed or Not This is a special characteristic that we include to help in scheduling and forecasting. The issue is, does the customer have firm Rights or not. Must Exercise This characteristic requires that the Right must be exercised. This is used in special cases, when one Right exercise triggers a must exercise Right.
[0084] The parameter values such as commodity of interest will tend to be highly industry specific. However, the fundamental processing of the parameters will transfer across industries. For example in the chemical processing industries the transformation Right may take unsaturated fats as input and produce saturated fats as an output. The from and to parameters would be unsaturated fats and saturated fats respectively. In the gas industry the transformation Right may take Liquefied Natural Gas (LNG) and convert this to pipeline grade gas. The from and to parameters now being LNG and pipeline gas. While the values of the parameters may be changing the processing remains the same. In a general sense product A goes to B (B=f(A)). Once processing for rate, time interval, multiple products or multiple starting materials is implemented, the actual transformation handled is mainly a matter of specifying the variables.
[0085] System flexibility is provided by the parameters and the potential to dynamically redefine and enhance parameter operation utilizing the configurable logic engine ( FIG. 2 ). At a basic level the logic engine allows a parameter to be expressed as a function of another parameter(s). In a more complex application the logic engine serves as a source for additional parameters, which the system maintains and are available for subsequent processing. This flexibility allows customization of the fundamental Rights to address additional processes not initially envisioned.
[0086] While the Rights can be constructed with an extensive parameter list the grouping of parameters and associated functions into logical subunits allows for simplified configuration. FIGS. 2, 3 and 5 show examples of Pricing, Recurrence and tiering structure objects/parameter groups.
[0087] The tiering object allows a single Right to have multiple values for a single or group of parameters that are dependent upon the condition or value of a parent parameter. Accounting for minutes on a typical cellular phone plan can be expressed in a tiered structure. For example a plan may allow 100 on peak and 500 off peak minutes. Minutes used in excess of the allowed minutes results in an incremental charge. There are several accounting rules that apply to the minutes. Off and on peak are accumulated at specified times during the day. After all off peak minutes have been used additional off peak minutes are accounted for as on peak. After all on peak minutes have been used additional on peak minutes are accounted for as charged minutes. To express the business logic in the preceding example requires separate tiers for the on peak, off peak and charged minutes. The applicable tier is based on the time at which the minutes are used. Thus the time window at which the call is placed is the parent. In addition several logical rules must be applied to redirect the system to the correct tier on the occasion that the airtime in a tier exceeds the specified level of minutes. Traversal of the tiered constructs requires the tier to maintain both its structural relationships and the logic rules dictating the type of call being placed.
[0088] The concept of time is also maintained by the parameters. In the Rights Based System time is a relative concept. There is no set definition of time, nor is there any time periods which the process is built around. Everything is defined in terms of start time and end time. By defining time boundaries, industries that need second by second tracking can be accommodated along with industries that simply need hourly or daily tracking. Additionally, a combination of time granularities can be achieved within the same process. The recurrence/profile object or parameter group serves to neatly package more advanced timing concepts but still adheres to the original timing principle where no fixed clock cycle is set.
[0089] Recurrence covers the details of complex timing sequences. To deal with business processes that involve multiple transactions occurring over extended periods certain Rights are replicated over variable time durations at uniquely defined intervals. Recurrence is designed to easily express the periodicity of the fundamental Rights using a uniform process and set of parameters. The defined recurrence then facilitates the expansion of the Right with a recurrence pattern to multiple expressions of the Right each with the desired time parameters sufficiently detailed. The basic parameters in recurrence are the start time and end time. This start time and end time is further defined by a recurrence pattern. For example the Right to attend a college course associated with a scheduling application may have a recurrence object. The particular course may have a start time and end time of 10 and 11 respectively. The recurrence pattern may be M, W, and F and apply for the duration of the semester. The recurrent object and attendance Right thus express the student's Right to attend class.
[0090] The pricing object is the most complex object ( FIG. 5 ). The pricing object allows a value to be associated with the individual Rights. The value of the pricing object is structured as a financial option with separate demand and commodity attributes. This approach increases system flexibility by separately accounting or charging for the demand—the ability to exercise a Right versus commodity—exercise of that Right. The distinction between demand and commodity can be illustrated with the example of a home purchase. During a typical home purchase the buyer provides earnest money with an offer to the seller. Once the seller accepts the offer the earnest money guarantees the buyer the Right to purchase the house (demand). The commodity is the subsequent payment for the house upon closing. Any Right defined in the system can potentially be priced. Maintaining pricing as an object increases system flexibility because the price object may potentially be attached anywhere in a Right including the parameters, parameters within tiers and directly at the Right level. Pricing at each level is potentially required. A simple case is commodity usage charged different rates. A hypothetical utility may charge $0.10/kWatt for 0 to 400 kWatt per day usage, $0.09/kWatt for >400 to 2000 kWatt per day usage, and $0.08/kWatt for >2000 kWatt per day usage. This scenario could be expressed in the Rights based system as a rate Right that has three tiers each with a separate commodity charge. An infinite number of pricing scenarios can be described but the fundamental point is that by structuring pricing as an option allows the flexibility to capture most pricing structures especially when combined with the minimum, maximum, knockout and swap parameters.
[0091] Additionally the pricing object allows for costing in terms of non-financial costs. The external interaction of companies is typically financial in nature but internal functions are often resource constrained vs. financially controlled. Tracking the non-financial costs is essential for any supply chain management function. It is also applicable to operations optimization. The options based pricing in conjunction with pricing based on resource utilization allows a company to fully address marginal costs, marginal revenues and decision making based on incremental modification versus management by the aggregate. Management in aggregate allows companies to maximize revenue but is does not allow for maximization of profit. Maximizing profit requires the separation of demand and commodity costs in addition the incremental impact of exercising a particular Right must also be calculated. Only then can a business be managed for maximal return.
[0092] Services:
[0093] Once the fundamental Rights of a business or business process have been defined, these Rights can be reassembled into services. Services are the unique combination of Rights that represent a product offering by a company. In one regard services are merely a placeholder for an aggregation of Rights. However, services are potentially more than a product offering. The Rights can be assembled to create other business functions. For example supply chain management can be expressed in a Rights based system. The performance of a particular supply chain function such as delivery of good G from location A to location B may require X, Y, and Z resources which when requested are expressed as Rights X, Y, and Z used to accomplish the movement of G.
[0094] Each time a product is sold, it could be assembled starting from the individual Rights. It is more expedient to preassemble these Rights into services. Unlike Rights which may be applicable across industries, services will be unique to an industry. FIGS. 6 and 7 show how Rights can be assembled to create the complex business functions. Obviously FIG. 6 represents the simplest method for Right assembly. In this situation the Rights are fully independent. The simple e-commerce transactions that involve a selection, payment, delivery and termination can be managed with these types of Rights based services. The more complex services or eCommerce transactions requiring multiple events with interlaced dependencies require the more complex modeling structures that can be created using the process of FIG. 7 . FIG. 7 shows services (complex business functions) that are an organized assembly of Rights. The service maintains a hierarchy of Rights and logic functions to assist in the transversal of the Right hierarchy.
[0095] Once the service has been assembled it is immediately obvious that instantiation of an instance of a service will require the population of a significant number of Right parameters. In order to minimize the input required by the user especially for services that are frequently used the concept of a service template was conceived. Creation of a service template requires the identification of the “input” parameters. The input parameters are the essential parameters that define a service. These inputs are subsequently mapped to all the parameters of all the Rights on the service. The mapping function can use constants, simple math and logic functions to convert these inputs into populated Rights. The end result is the service template. Now the user can simply select a template, provide the input parameters and the result is a populated service. Within the concept of the service template is the utility to have optional Rights. Optional Rights are expressed as part of the mapping process and increase the flexibility of the templates. For example: If a service was generated whose only difference from an existing service was the existence or lack of a specific Right, this scenario could be managed with a single template and an optional Right.
[0096] Structured Products Usage
[0097] Contracting
[0098] Use of the structured products starts with the concept of contracting. In the structured products world contracting entails not just the contractual relationship between a buyer and seller of a good. Contracting also covers the complex relationship involved in service industries where the product supplied has a complex lifecycle or the fulfillment of a contract takes multiple actions by both the seller and purchaser. Additionally the contracts may cover internal company processes. Prime examples are supply chain and manufacturing production management.
[0099] Creation of a contract can take the form of instantiating a service template by supplying the input parameters, populating all the parameters under a service or assembling the Rights independently and then populating the parameters. Each contracting process requires an increasing level of knowledge about the business and Rights based operation.
[0100] During contracting the recurrence object may have been invoked on one or more Rights. Once the recurrence parameters are fully populated the Rights can be expanded according to the timing sequence defined in the recurrence. For example in an injection molding shop a contract was created for the production of 100 k injection molded pieces per day over the course of 6 months. The shop works Monday to Friday from 8 to 5. The Right for creation of the 100 k pieces per day would be duplicated to every weekday for the duration of the 6 month contract. For contracting we capture all the Right information within the recurrence, and it is not necessary to do the expansion for the expression of the contract. However, this level of granularity is required for utilization of the Rights. While not absolutely necessary we can keep the contract at the most granular level required by the business thus minimizing some of the system processing requirements.
[0101] After the contract has been fully expressed it is then possible to perform business using the contract. The contract and its Rights define what the customer can do or request and the required response of the company. Obviously the business being performed is completely dependent upon the industry; however, the basic Rights and the assembly process should traverse the industries. It is anticipated that several generic Right operation engines will be required. The first engine is a validation engine. Obviously when a request is received by the system, the request must be confirmed against available Rights to ensure that the request is valid. The incoming request is broken down into the same granularity that the contracted Rights are stored at. The request is then stored to the database with a status parameter indicating where the request is in the overall business process.
[0102] Upon validation of the Right the request will be passed to a scheduling engine. The scheduling engine prioritizes the incoming requests and creates a que for subsequent action. The prioritization algorithm can take many different forms. The primary factor is what variable(s) determine priority. Obviously the service provider will want to prioritize for maximal return while the purchaser will have certain prioritization benefits due to the type of service purchased. This engine potentially requires the storage and processing of a significant number of business rules. One alternative to a strictly business rules approach is to assign a priority to each contracted Right. To prioritize a request a summation of the priorities of the Rights to be exercised is executed. This sum determines the priority for action. The obvious benefit is the simplicity of action versus traversing actual business rules. In addition it is easier to change the priority of a Right (simply a Right parameter) as opposed to recoding fixed business rules.
[0103] Once the requests have been queued according to Right priority the service provider can optimize their operations to handle the requests. Since each request is a compilation of the atomistic operations, as expressed in the Rights, the service provider is able to truly see the impact for each operation. This level of detail allows for a more complete systems operation. Realistically, the quantity of data generated will exceed an operator's ability to efficiently process all of it. This necessitates a method to provide data summation or a method to automate the optimization process.
[0104] After the requests have been appropriately scheduled, the actions specified by the Rights are allowed to proceed. It should be noted that the Rights Based System would not necessarily carry out the activities. In most cases the actions will entail some physical process, which the system will only monitor. Once the actions have been completed the results of the actions are passed back into the RBS where they go to the settlement engine.
[0105] The settlement engine determines the final charge monetary or other for the actions. The engine will have to perform the following tasks. First the demand charge is calculated. The demand charge can actually be calculated at the time of contracting but the calculation is none he less processed by the settlement engine. Once actions are completed the system imports the results of the actions. The actions must first be associated to a particular contract. In most industries the allocation of an action to a contract is strait forward. However, some industries operate with shared capital resources and commodity products. Here the allocation can be more complex and the business rules must be coded into the settlement engine. Once the actions are assigned to a contract the commodity charges can be calculated. The pricing object allows for a very complex pricing scheme. While for basic cases only a demand and commodity charge is calculated, the more sophisticated pricing will require checking for minimums, maximums and inter Right dependencies. Additionally settlement will have to manage any unique pricing event such as penalties or overruns for non-compliance with contracted terms. Ideally the structured products system would prevent the customer from exercising Rights which they do not have. In reality many industries do not have the ability to fully control their operations, and they are forced to respond to customer actions after the fact. The result is that there is the potential requirement for some manual adjustment of the settlement process.
[0106] Portfolio Analysis
[0107] Portfolio analysis is one of the strengths of the Rights Based System. Since all the data is maintained at an atomistic level, the status of the entire business can be viewed according to the needs of the individual user. The “cube” as shown in FIG. 13 is one means for visualizing the data source. The actual database can store the results in n-dimensions but we can only visualize any three dimensions simultaneously, thus the cube. Table 3 provides an indication of possible dimensions for the cube.
TABLE 3 Dimensions Description Asset These are the major physical resources owned by the company. They may or may not be totally independent. State Forecast, Requested, Scheduled, Confirmed and any other state a Right may be assigned as it goes through the business work flow. Scenario Forecast scenarios will be the primary use of this dimension. It allows a look at the business assuming different input conditions. Segment Subset of the Asset dimension. Segments are dependent upon the adjacent segments. Contract(s) The individual business agreements made between the service provider and the customer. Deal The RBS term for umbrella contracts which combine multiple contracts. Time Time includes the present time providing a business “snap shot”, past performance and future forecasts. Right Any of the Rights from table 1 Parameter This could include any of the specific Right parameters such as Right type, volume, rate, tier and quantity.
[0108] Once plotted the cube allows dynamic resizing of the X, Y, and Z axis scales such that the resolution of the data can be adjusted to the required granularity. For dimensions that are continuous such as electricity transported, it is a simple process to take a derivative of one dimension with respect to time or other parameter. This allows the system operators to identify swing events and transients which are the critical variables to manage in many industries. It also allows for forecasts based on business momentum. The portfolio analysis provided by the structured products system is far more flexible than what can be achieved with presently available online analytical processing tools (OLAP). The reason is that today's OLAP tools are placed on top of presently existing systems and are designed to integrate many different data sources and allow for their combined analysis. The Rights Based System starts with the database defined at an atomistic level of granularity. The primary business functions are managed through this database. Each stage of the business is represented as a status in the original database or a separate database still maintaining the low level granularity. The benefit for analysis is that all the data is readily available. The integration achieved by an OLAP often requires summation processes that obscure essential business details. | The field of invention is in Information Technology based management systems for the natural gas, data communications, electricity, medical, government supply chain and vehicle markets. The disclosed system manages core commercial activities and business for companies in these industries. These systems are specifically designed to not only handle complex transactions but to also allow the same system to be used across all core business functions, including: marketing, sales, contracting, production, delivery, business optimization and financial settlement. | 68,537 |
TECHNICAL FIELD
[0001] This invention relates to microturbines engines and more particularly to a system for generating hot water in a boiler and for selectively boosting the temperature of the medium for heat exchange relation by utilizing the turbine exhaust.
BACKGROUND OF THE INVENTION
[0002] As one skilled in this art appreciates the microturbine has in the last few years become extremely useful for generating electricity. Typically, the microturbine comprises a compressor, combustor, turbine and a recuperator which serves to pre-heat the compressor discharge air prior to being injected into the combustor. The work produced by the turbine serves to rotate the armature of the electrical generator and an invertor converts the electrical current and controls its frequency. Details of the microturbine can be obtained by referring to co-pending patent application Ser. No. 09/934,640 filed on Aug. 22, 2001 by William R. Ryan entitled RECUPERATOR FOR USE WITH TURBINE/TURBO-ALTERNATOR, published and U.S. Pat. No. 6,314,717 granted to Teets et al on Nov. 13, 2001 entitled ELECTRICITY GENERATING SYSTEM HAVING AN ANNULAR COMBUSTOR both of which are commonly assigned to the assignee of this patent application, and both being incorporated by reference herein. Also, for more details of this invention reference should also be made to the microturbines manufactured by the assignee, Elliott Energy Systems, Inc., of Stuart, Fla. and, particularly of the types exemplified by Model Number TA-80.
[0003] In certain residential or commercial applications the microturbine can also be utilized for powering a boiler for obtaining hot water or powering a chiller that can be used in a refrigeration absorption system. A simple system for obtaining these objectives is illustrated in FIG. 1 where a boiler is connected to the discharge of the recuperator. The temperature of the engine working medium discharging from the recuperator is typically over 500 degrees Fahrenheit and obviously, this temperature can be utilized wherever heat is needed, given that the heat can be transported efficiently and economically. The simple boiler application will be described hereinbelow in connection with the details of this invention.
[0004] This invention contemplates that the microturbine system includes a microturbine engine, a recuperator, an electrical generator and a boiler as described in the immediate above paragraph. This invention augments the above-described simple microturbine/boiler system by incorporating a second boiler. The second boiler can be utilized for the purpose of obtaining hot water at a higher temperature that is available in the single boiler system or obtaining steam. In this system the second boiler is optionally preset so that both of the boilers are in continuously or alternatively is turned-off one of the boilers is rendered inoperative, i.e. all of the turbine exhaust flows into the recuperator and then to the first boiler and by-passes the second boiler. This invention also contemplates utilizing the water for cooling purposes of some of the systems components prior to the water flowing to the boiler.
[0005] Another aspect of this invention is the use of the by-pass system to boost the temperature of the waste heat when used as a heat transport medium so as to assure that the delta temperature between this medium and the water is sufficient whereby efficient heat transfer will be effectuated. As one skilled in this technology appreciates, as the efficiency of the microturbine engine increases, the temperature of the exhaust being emitted from the turbine of the microturbine engine becomes reduced. Hence, given the need for a particular delta temperature in the indirect heat exchange relationship occurs, and the temperature of the engine working medium waste is not sufficient in the boiler, the amount of engine working medium waste can be throttled to provide the necessary delta to achieve efficient heat transfer.
[0006] This invention should not be confused with the microturbine bypass system described and claimed in U.S. patent application contemporaneously filed by Gregory Brian Dettmer entitled MICROTURBINE DIRECT FIRED ABSORPTION CHILLER, and assigned to a common assignee. This system utilizes the recuperator exhaust heat to power a direct fired absorption chiller which would otherwise be unacceptable without the provisions of the Dettmer invention. In the Dettmer patent application, supra, the system includes a by-pass system for the recuperator, and is uniquely designed to provide a predetermined constant temperature for the direct fired absorption chiller. As mentioned above this by-pass system allows the use of a microturbine which was heretofore not practical since the available temperature for powering the chiller fluctuated.
[0007] In the present invention, the purpose of the by-pass system for the recuperator is to flow the turbine exhaust into a heat exchanger or boiler and to divert the turbine exhaust when the heat exchanger is not in operation or is not required. To this end the turbine exhaust is directed directly into the recuperator rather than being directed into the heat exchanger. Obviously, when the temperatures of the working fluids that are in indirect heat exchange relation with each other are at or near parity, the ability to transfer heat is difficult and at best, inefficient. This system serves to increase the output temperature of the recuperator by utilizing the high temperature exhaust from the turbine. That is to say, that the higher temperature turbine exhaust fluid is utilized to boost the usable output temperature. Consequently, the available temperature of the fluid discharging from the recuperator is efficiently increased by virtue of this invention so that useable temperature required for heat transfer is attained.
SUMMARY OF THE INVENTION
[0008] An object of this invention is to provide for a microturbine engine that utilizes a recuperator and is designed to generate electricity and run a water boiler to include in the system a second boiler that serves to either obtain hot water that may be hotter than the water in the first boiler and/or steam.
[0009] A feature of this invention is to mechanically adjust the flow of turbine exhaust into the second boiler by-passing that amount of flow entering the recuperator or alternatively, by-pass the second boiler so that all of the turbine exhaust flow enters the recuperator.
[0010] A still further feature of this invention is to provide a control system that throttles the turbine exhaust to maintain the desired temperature in the first and second boiler.
[0011] A still further feature of this invention is to provide a system having at least one boiler that utilizes the water from the water source to cool certain components of the microturbine system before entering the boiler for generating hot water.
[0012] A still further feature of this invention is to provide for a microturbine as described a by-pass system that boost the temperature of the recuperator/boiler so as to efficiently transfer heat when the temperature of the heat exchange transport fluid is at or close to parity of the other fluid that is in heat exchange relationship.
[0013] The foregoing and other features of the present invention will become more apparent from the following description and accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] [0014]FIG. 1 is a schematic illustrating the details of a microturbine system utilized for generating electricity and modified to power a boiler for generating hot water;
[0015] [0015]FIG. 2 is a schematic illustrating the microturbine system depicted in FIG. 1 and including a second boiler and by-pass system made in accordance with this invention;
[0016] [0016]FIG. 3 is a schematic illustration of the system depicted in FIG. 2 modified to provide a controller to maintain the desired heat transfer to both boilers and to assure that sufficient delta heat is maintained between the fluids in heat exchange relation; and
[0017] [0017]FIG. 4 is a schematic illustration of another embodiment of this invention where the second boiler is mounted in tandem with the first boiler.
DETAILED DESCRIPTION OF THE INVENTION
[0018] While this invention pertains to a microturbine system powering an electrical generator it is to be understood that the microturbine can be utilized for other types of systems and hence, is not limited to an electrical generating system. The microturbine engine has become popular in the last several years and essentially is a jet engine that includes a turbine, compressor, combustor and recuperator. The microturbine is a miniaturized gas turbine engine that in recent years have been almost totally utilized for powering electrical generators. In certain configurations, the turbine and compressor are attached back-to-back on one end of a shaft that is common to the shaft connecting the armature of the electrical generator. Fuel and relatively hot pressurized air discharging from the compressor and pre-heated by the recuperator are fed to an annular combustor where they are combined and combusted to further heat and accelerate the engine's working medium for powering the turbine. The engine working medium is adiabatically expanded in the turbine for extracting energy which, in turn, is utilized for rotating the compressor and armature. The working medium after leaving the turbine is directed to the recuperator where it is placed in indirect heat exchange with the compressor discharge air prior to being admitted into the combustor. The turbine exhaust is ultimately discharged from the recuperator. As mentioned above further details of the microturbine reference should can be had by referring to co-pending patent application Ser. No. 09/934,640 filed on Aug. 22, 2001 by William R. Ryan, supra and U.S. Pat. No. 6,314,717 and the microturbines manufactured by the assignee, Elliott Energy Systems, Inc., of Stuart, Fla. and, particularly of the types exemplified by Model Number TA-80.
[0019] Referring now to the FIG. 1, which is a microturbine system designed to generate electricity to which is added a boiler for generating hot water. The microturbine engine is generally illustrated by reference numeral 10 and includes a compressor 12 for compressing the air admitted therein which is preheated by being placed in indirect heat exchange with the turbine discharged gases in the reucperator 14 . The preheated compressor discharge air is combined with a fuel, which could either be a liquid or a gas, in the combustor 16 where it forms a gaseous engine working medium for powering the turbine 18 . The turbine 18 drives the compressor 12 and the turbine exhaust gases are routed to the recuperator 14 where it is placed in indirect heat exchange which serves to preheat the compressor discharge air. The power generated by the microturbine 10 serves to power the alternator 20 which through an inverter and associated electronic circuitry 22 produces the desired electrical output. This system just described is an illustration on how the microturbine/electrical generating system can simply be modified to take advantage of the energy of the high temperature turbine exhaust and obtain hot water by routing the exhaust through heat exchanger or boiler 24 which is indirect heat exchange with the water circuit 26 .
[0020] According to this invention and as shown in FIG. 2, another boiler 28 is added to the microturbine system in order to obtain either water at a hotter temperature than is available at the boiler 24 or steam. For this modified system by-pass valve 30 is connected between the boiler 28 discharge and the discharge end of the turbine 18 (the same reference numerals are used to identify the same or similar elements depicted in all of the Figs.) so that opening valve 30 will dump turbine exhaust gases directly in the heat exchanger or boiler 28 . Hence, the waste heat from the turbine can be utilized directly in the heat exchanger 32 or directed into the recuperator 14 or a portion of the water heat from the turbine can be directed in the recuperator 14 while the remaining portion can be directed to boiler 28 . By-pass valve 30 may be either operated manually by adjusting handle 32 or automatically (see FIG. 3) by including a suitable temperature sensor 34 , a comparator or controller 36 , which could be digital or analog, and an actuator 38 . All of these elements are commercially available and a description thereof, for the sake of convenience and simplicity, is not included herein. Suffice it to say that the temperature sensor 34 measures the temperature of the waste heat and relays a signal to the controller 36 . The controller that has been set to a particular temperature schedule, measures the difference between the actual temperature measured by the temperature sensor 34 and a desired temperature. This output of the comparative signal is then relayed to actuator 38 that adjusts the by-pass valve to proportion the flow of waste heat to assure the proper temperature of the waste heat in the heat exchanger and hence maintain a difference in heat between the waste heat and the medium being heated so as to assure that the heat transfer efficiency is satisfactory.
[0021] In this system, the microturbine not only powers the alternator for generating electricity, it is also functions to provide heat and cooling to the system components as is needed and as is compatible with the efficiency of the system. As disclosed herein, the fluid flow circuitry for both hot waste exhaust and water will be described immediately hereinbelow, it being understood that the water can be obtained from the public available water system or from storage containers or it may be from a process where water is cycled continuously. The water circuit flows from the inlet 40 , through line 42 and is divided by the divider valve 44 to flow in heat exchanges 46 and 48 for cooling the alternator and inverter 20 and electronic components 22 , respectively, and then flows through line 50 and combines with the divided flow in line 52 and directed into boiler 24 .The water in boiler 24 is in indirect heat exchange with the hot waste heat discharging from recuperator 14 An outlet valve 56 serves to tap hot water from boiler 24 as desired and the size of outlet valve is selected so that continuous water flow via line 58 is directed to the boiler 28 . Hot water or steam is tapped from boiler 28 vial line 60 . It is apparent from the foregoing that the water circuit not only cools the electrical and electronic equipment, but also allows tapping hot water from boiler 24 and hotter water or steam from boiler 28 .
[0022] The heat is delivered to the boiler 24 via lines 62 , 64 and 66 . The temperature of the waste heat in line 66 is predicated on the output of the recuperator 14 . Obviously, the main purpose of recuperator 14 is to pre-heat the compressor discharge air and the remaining energy in the waste heat fluid serves to power the boiler 24 and hence, the temperature of the water in the boiler 24 is determined by the outlet temperature of the recuperator 14 and the flow of the waste heat is continuous, and hence, since the residence time of the waste heat fluid in boiler 24 is limited and the amount of heat at the discharge end of the recuperator is limited, the boiler 24 is incapable of reaching temperature sufficient to obtain steam.
[0023] The inclusion of the boiler 28 in accordance with this invention, augments the system by generating water that can be hotter than the water in boiler 24 or can be steam. The by-pass system serves to control the heat transfer in boiler 28 . For example, valve 30 can be fully opened and permit all of the turbine exhaust fluid to enter the boiler 28 . Since the residence time of the water remaining in the boiler 28 is determined by tapping the water in line 60 , the temperature of this water can easily reach the boiling temperature of 212° F. and become saturated to produce steam.
[0024] It is apparent from the foregoing description that the water medium is in indirect heat exchange with the turbine discharge air as it flows through the recuperator 14 , the boilers 24 and 28 and since the by-pass valve can control the amount of heat transported to either or both boilers, the system can be designed to assure that the use of this energy is done efficiently. Hence, where the temperature difference between the medium being heated (water) and the waste heat is close to each other, the by-pass valve is utilized to assure that the delta temperature is sufficient to obtain effective heat transfer by boosting the boiler's working medium by adding turbine exhaust directly to the boiler 28 .
[0025] [0025]FIG. 4 exemplifies another embodiment of this invention where the boilers are mounted in tandem or “piggy back” to lower the cost of the system and make it more efficient. In this embodiment, the function of boilers 24 and 28 are combined in the tandem boiler 70 . Both systems, i.e. the system depicted in FIG. 3 and the system depicted in FIG. 4 are identical to each other. The only difference is that the boiler 70 contains two water coils that are in indirect heat exchange with the turbine discharge air and the turbine discharge air after being spent in the recuperator 14 . For the sake of simplicity and convenience details of the description of this system is omitted and the description of FIG. 3 is incorporated herein by reference.
[0026] What has been shown by this invention is a system for obtaining higher temperature water and/or steam by adding a second boiler and a by-pass valve for regulating the turbine waste heat that is in heat exchange relation with the water in the additional boiler. The system is designed to assure good heat transfer notwithstanding the fact that the efficiency of the microturbine engine is increasing. Hence, the turbine exhaust is utilized to the boost of the output temperature of the working fluid in the boiler to assure that the temperature difference between it and the water will provide efficient heat transfer.
[0027] Although this invention has been shown and described with respect to detailed embodiments thereof, it will be appreciated and understood by those skilled in the art that various changes in form and detail thereof may be made without departing from the spirit and scope of the claimed invention. | The microturbine engine that is typically utilized to power an electrical generating system and/or boiler, chiller and the like includes a second boiler and a by-pass system for providing heated water at two different levels or where one of the boilers provides steam. The turbine exhaust is utilized as the heat transport medium and is directly connected to one of the boilers while the other is connected to the recuperator. The system can optionally provide cooling to the electrical and electronic components of the system by providing a water circuit for leading water into the electric and electronic components prior to feeding the boilers. The system is designed to assure that the delta heat difference between the medium being heated and the waste heat of the turbine is sufficient so that the heat exchange will be done efficiently. | 19,065 |
[0001] This invention has already been filed as a provisional patent, application No. 61/258,071 which was filed on Nov. 4, 2009.
BACKGROUND OF THE INVENTION
[0002] Currently, attaching night vision goggles or similar devices to a military helmet is a common process in the military. As technology has advanced, it has become necessary to attach sophisticated electronic devices to military helmets. Those electronic devices, in addition to performing normal functions, require multi-conductor electrical interfaces with both power and high bandwidth signals to be connected from the electronic devices, through the front or side walls of the helmet to the rear of the helmet, and through the rear wall to additional electronics or a battery power source. This has to be achieved without either exposing the interconnections to external damage under the rim of the helmet or by adding or enlarging additional holes or in some other way degrading the ballistic protection properties of the helmet.
[0003] Thus, what is needed is a helmet bracket system for attaching electronic head-mounted quick disconnect devices to military combat helmets without passing cables carrying high bandwidth electrical signals underneath the rim of a helmet or affecting the ballistic integrity of the helmet.
BRIEF DESCRIPTION OF THE DRAWINGS
[0004] FIG. 1 shows an isometric view of a helmet bracket system and a helmet in accordance with an embodiment of the present invention;
[0005] FIG. 2 shows a view of a head cable assembly routed under a helmet and connected to a docking station in accordance with an embodiment of the present invention;
[0006] FIG. 3 shows a view of a head cable assembly passing through a modified fastener located on the front of a helmet in accordance with an embodiment of the present invention;
[0007] FIG. 4 shows an isometric view of a portion of a docking station and its sealed electrical contacts in accordance with an embodiment of the present invention;
[0008] FIG. 5 shows an isometric view of a break-away unit assembled to an electro/mechanical interface shoe in accordance with an embodiment of the present invention;
[0009] FIG. 6 shows a view of a shoe port on the bottom of a break-away unit in accordance with an embodiment of the present invention;
[0010] FIG. 7 shows an isometric view of an electro/mechanical interface shoe and its electrical contacts in accordance with an embodiment of the present invention;
[0011] FIG. 8 shows a view of a break-away unit including a housing in which a tilt switch sensor resides in accordance with an embodiment of the present invention;
[0012] FIG. 9 shows a view of a break-away unit in a deployed position with a tilt switch sensor and an actuator in accordance with an embodiment of the present invention; and
[0013] FIG. 10 shows a view of a break-away unit in the a stowed position in accordance to an embodiment of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0014] The following detailed description is of the best currently contemplated modes of carrying out exemplary embodiments of the invention. The description is not to be taken in a limiting sense, but is made merely for the purpose of illustrating the general principles of the invention, since the scope of the invention is best defined by the appended claims.
[0015] Broadly, an embodiment of the present invention generally relates to a helmet bracket system for attaching electronic head-mounted, quick disconnect devices to military combat helmets without passing cables underneath the rim of the helmet or affecting ballistic integrity of the helmet.
[0016] The helmet bracket system may comprise modified fasteners, a round-to-flat-to-round cable harness, a docking station, a break-away arm, a tilt switch, a shoe switch, and a shoe capable of connecting electrically via contact pads.
[0017] The helmet bracket system may be an articulated mechanical device attached by integrated fasteners to the helmet. The helmet bracket system may be attached and detached from the helmet by means of an integrated electro-mechanical plug and socket that provides mechanical strength for mounting the helmet bracket system as well as providing the necessary electrical pathways. A similar arrangement may be used at other attachment sites in the front, rear, or sides of the helmet. The helmet bracket system may also include sensors and switches that are combined into electrical pathways to allow the status of the helmet bracket system, such as docking connection status and position, to be sent to an attached electrical device, thus allowing power to be saved by powering down the electrical device upon receiving signals indicating that the electrical device is in a stowed position.
[0018] The electrical pathways between the helmet bracket system and the attached electrical device may comprise spring-loaded pins having integrated sealing such that they are seated when a mechanical connection is made between the helmet bracket system and the attached electrical device. The electrical pathways may be sealed to protect against the environment, thus enabling it to survive submersion to a water depth of at least 30 meters seawater pressure.
[0019] The helmet bracket system may allow an electrical device to be attached and secured to a helmet via the helmet bracket system. Once the electrical device is attached to the helmet, the helmet bracket system may allow the electrical device to be stowed or deployed and may further allow the position of the electrical device to be sent to the connected electrical device. Further, the helmet bracket system may also allow for the electrical device to be broken away from the helmet if the electrical device is subjected to ay external forces.
[0020] Existing holes manufactured into ballistic combat helmets may be used to transfer highly flexible conductors through the center of a high-grade fastener, thus avoiding the need to create a separate wiring harness path around the rim of the helmet that exposes the conductors to physical damage or the need to drill new holes on the helmets that might affect the structural integrity of the helmet.
[0021] Power and communications signals carried by the conductors may be passed along to the electrical device that is docked with the helmet bracket system. Signals provided by a tilt switch and a shoe disconnect switch may interface with the docked electrical device to relay information about the helmet bracket system.
[0022] FIG. 1 presents an overall view of a helmet bracket system for attaching an electronic device to a helmet 100 , featuring the helmet 100 , a head cable 103 , a docking station 105 , a break-away unit 108 , and an electro/mechanical interface shoe 113 . The head cable 103 may carry electrical power and data signals to be passed from the front 100 D of the helmet 100 to the rear 100 A of the helmet 100 without passing the head cable 103 over the top 100 B of the helmet or under the rim 100 C of the helmet 100 . As shown in FIG. 2 , the head cable 103 may enter the rear 100 A of the helmet 100 by passing through a modified M6 fastener 102 , which may be used to secure the helmet's chin strap. The head cable 103 may then proceed to pass along the underside 100 E of the helmet 100 where it may transition from a round cable 103 A to a flat cable 1038 for ease of routing, and then may return to the form of a round cable 103 C, where it may exit the helmet through another modified fastener 104 . The modified fasteners 104 and 102 may mate with the helmet 100 through existing bolt holes (not shown). After exiting the helmet 100 through modified fastener 104 , the head cable 103 D may be routed into the docking station 105 , where the electrical power and signals may be passed through an electrical breakaway mechanism (shown in more detail in FIG. 4 ). FIG. 3 shows an enlarged detail view of the modified fastening hardware 104 , located on the front 100 D of helmet 100 , and the head cable sections 103 C and 103 D transitioning through it.
[0023] The electrical breakaway mechanism, which may be part of the helmet docking station 105 , is elaborated upon in FIG. 4 . The electrical breakaway mechanism may include sealed spring-loaded electrical contacts 106 and an additional overall contact seal 107 that may surround the cluster of contacts 106 . These spring-loaded contacts 106 may mate with the sealed conductive pads 109 incorporated into the break-away unit 108 depicted in FIG. 5 . By passing the signal along with electrical cable 110 , the electrical power and signals may be relayed from the sealed conductive pads 109 to the shoe port 111 . The shoe port 111 is shown in FIG. 6 where the break-away unit 108 has been re-oriented to view the bottom of the shoe port 111 . This view allows for the sealed electrical contacts 112 contained within the shoe port 111 to be revealed.
[0024] Mating with the shoe port 111 may be the electro/mechanical interface shoe 113 shown in FIG. 7 . This shoe 113 may contain several sealed spring-loaded contacts 114 , which may allow power and data signals to be passed from the break-away unit 108 to the shoe port 111 and through the shoe 113 into an external device. A cable 115 may allow for electrical connectivity to an undefined external device.
[0025] When a release button is depressed, the shoe 113 may be disengaged from the break-away unit 108 , and a separate signal may be provided to indicate that the shoe 113 is no longer secured to the break-away unit 108 .
[0026] FIG. 8 depicts a view of the break-away unit 108 oriented as to show tilt switch sensor housing 116 . The tilt switch sensor 117 may provide a signal indicating whether the break-away unit is in its stowed or deployed position. FIG. 9 shows the break-away unit 108 rotated again. The tilt switch sensor 117 may be located such that it interfaces with tilt switch actuator 118 . The orientation of the tilt switch actuator 118 in reference to the tilt switch sensor 117 may be dependant on whether the break-away unit 108 is in its stowed or deployed position. FIG. 9 depicts the break-away unit 108 in its deployed position. FIG. 10 shows the break-away unit 108 in its stowed position.
[0027] The helmet bracket system may allow for a cable carrying power and communication signals to pass through modified existing fasteners on the back of a helmet, pass along the interior surface of the helmet changing from a round cable wire harness to a flat cable wire harness during this phase, change back to a round wire harness, and pass through modified existing fasteners on the front of the helmet to a docking station, pass through the break-away arm, and exit the helmet bracket system by means of an electrical connection on the helmet bracket shoe. Because the helmet bracket system may use existing bolt hole patterns on the helmet without changing the structural integrity of the helmet shell, the system may obviate the need to route electrical connections from being routed under the rims of helmets.
[0028] Further, existing fastening hardware used to secure the helmet webbing, chin-straps, and currently-deployed helmet bracketry may be modified to allow electrical routing. The fastening hardware may be modified by adding a concentric port along the functional axis of the thread, thus allowing electrical connections to pass through the port without affecting the functional integrity of the fastening hardware.
[0029] The helmet bracket system may include a break-away arm that may be movable between a stowed and deployed position. A tilt-switch mechanism on the break-away arm may provide a signal indicating whether the break-away arm is in the stowed or deployed position. The helmet bracket system may further incorporate a mechanism for electrical disconnect during mechanical breakaway of the break-away arm from its docking station. Electrical connections between the break-away arm and its docking station may be achieved by sealed spring-loaded contact pins and contact pads.
[0030] When a release button is depressed to disengage the shoe from the breakaway arm, a separate signal may be provided to indicate that the shoe is no longer secured to the breakaway arm. Power and communication signals may also be passed through the shoe via sealed contact pads and spring-loaded contact pins.
[0031] The wire harness carrying the head cable 103 may be a round-to-flat-to-round wire harness that follows the curvature of the helmet in order to increase the comfort of a user. In alternative embodiments, the wire harness carrying the head cable 103 may be a round wire harness.
[0032] The helmet bracket system may be operated using only one hand, although two hands may be used if deemed necessary by the user.
[0033] While the helmet bracket system may be used during military combat, it may also be used during search and rescue operations, recreational sports, emergency services, maintenance/repair activities, or any other suitable activity.
[0034] The helmet bracket system may be made and assembled by using machining, injection molding, printed circuit board (PCB) fabrication, or any other suitable methods.
[0000] It should be understood, of course, that the foregoing relates to exemplary embodiments of the invention and that modifications may be made without departing from the spirit and scope of the invention as set forth in the following claims. | The helmet bracket system is an electro-mechanical device for mounting digital head-mounted systems. The Helmet bracket system is lightweight, supports one-handed adjustment, has a breakaway base, and is mechanically low profile. The device also supports the transfer of high bandwidth digital data. | 14,120 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] The Application is related to application Ser. No. ______ Attorney Docket No. 133632 (07783-0213), filed contemporaneously with the Application on Dec. 22, 2004 entitled “A METHOD FOR FABRICATING REINFORCED COMPOSITE MATERIALS” assigned to the assignee of the present invention and which is incorporated herein by reference in its entirety, and to Application No. ______ Attorney Docket No. 161341 (07783-0215), filed contemporaneously with the Application on Dec. 22, 2004 entitled “A REINFORCED MATRIX COMPOSITE CONTAINMENT DUCT” assigned to the assignee of the present invention and which is incorporated herein by reference in its entirety.
FIELD OF THE INVENTION
[0002] This invention relates to an apparatus for making composite materials. In particular, the present invention involves apparatus for making reinforced matrix composite materials.
BACKGROUND OF THE INVENTION
[0003] Aircraft engine design continually requires components of aircraft engines to have lighter weight materials to increase the aircraft's fuel efficiency and thrust capabilities. In the past, aircraft components have been made with steel. However, steel is relatively heavy and has been replaced with lighter weight high strength materials, such as aluminum or titanium. A further development in producing lightweight parts has resulted in the advent of non-metallic materials, such as composites comprising graphite fibers embedded within a polyimide resin. Composite materials are materials that include embedded fibers inside of a matrix material. The fibers provide reinforcement for the matrix material. The fiber structure prior to being embedded in the matrix is generally referred to as a preform. Graphite fibers embedded within a polyimide resin have drawbacks, including difficulty molding the material into parts, high porosity, microcracking, delamination, and expensive equipment and processes.
[0004] A composite fan duct for use in a gas turbine engine is required to have high strength flanges and composite material that is substantially devoid of wrinkles and waves.
[0005] Graphite epoxy composite fan ducts have been manufactured using a cross-over tool, disclosed in U.S. Pat. No. 5,145,621 to Pratt (the '621 Patent), which is herein incorporated by reference in its entirety. In the '621 Patent woven graphite fiber preform is mounted on a large spool to form the graphite epoxy composite fan duct. The fibers are situated to provide a flange at either end of the spool. The shape of the spool substantially defines the final shape of the finished composite. The cross-over tool pulls the fibers of the graphite on a spool to provide tension. The tool pulls the fiber through the use of a complex spider tool that encircles the flange portion of the fibers and provides pressure when in combination with three independent vacuum envelopes. The drawbacks of the cross-over tool and method disclosed in the '621 Patent includes a complicated process, and an expensive tool that is difficult to use.
[0006] Graphite epoxy composite fan cases have also been manufactured using a mold system utilizing a elastomeric material to assist in providing a force on plies of reinforcing material during manufacture, disclosed in U.S. Pat. No. 5,597,435 to Desautels et al. (the '435 Patent), which is herein incorporated by reference in its entirety. To produce a composite matrix, uncured fiber-reinforced prepreg-type plies (i.e., plies) are mounted onto a mold. Prepreg plies are plies that are impregnated with uncured matrix material before being mounted on the mold. A forcing member and restraining member are placed onto the plies to hold the plies in place. The forcing member is placed between the restraining member and the plies on the mold. The mold, plies, restraining member and forcing member are placed into a furnace and heated. As the assembly is heated, the forcing member uniformly expands and a uniform pressure is applied to the plies. The result is that the plies are compacted as the temperature is raised. The '435 Patent process has the drawback that it only debulks the material and does not pull taut the fabric to provide fiber orientation that provides the finished composite with high strength and uniformity.
[0007] Current methods for impregnating matrix material into reinforcing fiber preforms involves placing a matrix material film layer or layers on or within layers of the reinforcing fiber preforms to cover all or the majority of the preform. The entire preform is coated so that during a heated resin infusion phase, the matrix material melts and flows through the thickness of the preform to impregnate it. The impregnation is done using single layer or multiple layers of resin film. The resin film is applied onto the entire surface of the reinforcing fiber preform. Alternatively, the matrix material may be interleaved between layers of the preform to cover all the layers of reinforcing fiber preform. Full coverage of the resin layers on the preform entrap air, volatile material from the matrix material or other gases that may form voids (i.e. void space), which can form undesirable porosity in the body of the cured part. The porosity is particularly undesirable in more complex parts at or near part features. Features include portions of composite material that extend from planar sections of the part. Examples of features include stiffener sections or inserts in gas turbine engine parts. Porosity resulting from void space in the cured reinforced matrix composite may reduce the parts' mechanical properties and may create unacceptable surface features such as pitting. The complete coverage of the reinforcing fiber preform has the additional drawback that the method is difficult to practice and requires a significant amount of time to apply, because the resin must be applied over the entire surface area of the preform.
[0008] The present invention solves the problems of the prior art by providing a method and tool that forms the fiber reinforced matrix composite without the disadvantages of the prior art.
SUMMARY OF THE INVENTION
[0009] The present invention is a mold tool for forming a reinforced matrix composite part for a gas turbine engine, comprising a body. The body comprises a first end, a second end and a body surface capable of receiving a first portion of a composite preform. A first endplate is releasably secured to the first end of the body and has a substantially planar surface disposed perpendicularly to the body surface. A second endplate is attached to the second end of the body and has a substantially planar surface perpendicular to the body surface. A first set of plates is attached to a first surface of the first endplate. The first set of plates comprises at least one first plate disposed adjacent to the body surface. A second set of plates is attached to a first surface of the second endplate. The second set of plates comprises at least one second plate adjacent to the body surface. The first plate and second plate are releasably secured and comprise a substantially planar first plate surface and a substantially planar second plate surface. The first plate and first endplate have a geometry that includes a first cavity bounded by the first plate and first endplate. The second plate and second endplate have a geometry that includes a second cavity bounded by the first plate and first endplate. The first and second cavities have a volume sufficient to receive a second portion of a composite preform. The second cavity is fluidly connected to the first cavity. The first cavity is in fluid communication with a vacuum source.
[0010] The method and tool of the present invention forms a lightweight reinforced matrix composite material suitable for use as composite containment ducts, such as fan casings, wherein the composite materials have high strength and uniformity.
[0011] The method of the present invention is particularly suitable for fabrication of turbine airfoil components for gas turbine engines. In particular, the method of the present invention is suitable for the fabrication of composite containment ducts, such as fan casings. An advantage of the present invention is that the present invention allows the fabrication of composite containment ducts capable of containing fan blades that break loose from the gas turbine engine during operation.
[0012] The method and tool of the present invention is particularly suitable for fabrication of large composite parts, including cylindrical parts having a diameter of greater than about 5 feet, including parts having a diameter of about 10 feet. An advantage of the present invention is that the tool and method are capable of fabricating large parts, such as large composite fan casings, while maintaining the containment properties, the lighter weight, the high strength and the substantial uniformity throughout the part.
[0013] The method and tool of the present invention provides a method for manufacturing fiber reinforced matrix composites having the shape of the finished product, requiring little or no trimming prior to installation. An advantage of the present invention is that the tool and method produce parts that require little or no additional steps prior to installation and use. The reduction or elimination of addition steps decrease cost and time for fabrication.
[0014] The method and tool of the present invention provides a method for manufacturing fiber reinforced matrix composites that has a high uniformity of composition and less defects, such as porosity and wrinkling. Uniform composition and less defects allows for less scrapped and/or repaired parts. Less scrapped and/or repaired parts allows for fabrication of composite parts, including large composite parts, with less cost.
[0015] The method and tool of the present invention provides a method for manufacturing fiber reinforced matrix composites using simple, inexpensive equipment. Additionally, part removal from the tool requires little or no additional disassembly of the tool. An advantage of the present invention is that the equipment and labor costs required to fabricate fiber reinforced composite containment ducts are decreased because the equipment is less expensive and does not require extensive assembly or disassembly during fabrication of the part.
[0016] The method and tool of the present invention provides a method for manufacturing fiber reinforced matrix composites wherein the process only requires a single vacuum envelope. An advantage of the present invention is that the tool and method is that a single vacuum envelope can provide the necessary containment and forces required to fabricate fiber reinforced composite containment ducts without the use of multiple vacuum envelopes. The use of the single envelope provides a more substantially uniform application of vacuum and requires less assembly and disassembly than multiple envelopes.
[0017] Other features and advantages of the present invention will be apparent from the following more detailed description of the preferred embodiment, taken in conjunction with the accompanying drawings which illustrate, by way of example, the principles of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] FIG. 1 is a perspective view of a tool according to the present invention.
[0019] FIG. 2 is a side view of a tool according to the present invention
[0020] FIGS. 3 and 4 are cross sectional views alternate embodiments of a first portion of a tool according to the present invention.
[0021] FIG. 5 is a cross sectional view of a second portion of a tool according to the present invention.
[0022] FIGS. 6 to 9 illustrate stages of the composite forming method using a tool according to the present invention.
[0023] FIG. 10 is a schematic view of a matrix material distribution system according to the present invention.
[0024] FIG. 11 is a perspective view of a composite containment duct according to the present invention
DETAILED DESCRIPTION OF THE INVENTION
[0025] FIG. 1 shows a composite duct-forming tool 100 according to the present invention. The tool 100 includes a substantially cylindrical body 105 . A first endplate 101 and a second endplate 103 are positioned adjacent to the opposed planar ends of the body 105 . The body 105 and first and second endplates 101 and 103 are fabricated from a material having a greater thermal coefficient of expansion than the workpiece held by the tool 100 . Material for the body 105 and first and second endplates 101 and 103 include, but are not limited to, metals or alloys. Suitable materials for the body 105 include aluminum and steel. The first endplate 101 is fastened to the body 105 with stress relief fasteners 111 . The second endplate 103 adjacent to the body 105 is attached to the body 105 . The body 105 has a substantially cylindrical geometry. The substantially cylindrical body 105 preferably tapers from a smaller diameter adjacent to the first endplate 101 to a larger diameter at the second endplate 103 . Although FIG. 1 illustrates a cylindrical body 105 , the body is not limited to a cylindrical shape. Alternate geometry for the body include, but are not limited to, rectangular, oval, and triangular geometries. In an alternate embodiment, the body 105 has substantially cylindrical geometry with a smaller diameter at the midpoint between the first and second endplates 101 and 103 and a larger diameter at each of the ends of the body 105 . The body 105 may be fabricated in multiple detachable pieces to facilitate removal of finished reinforced matrix composite parts.
[0026] FIG. 1 shows a first set of flange shoes 119 positioned adjacent to the first endplate 101 circumferentially around the body 105 on the surface of the first endplate 101 nearest to the second endplate 103 . A second set of flange shoes 107 are positioned adjacent to the second endplate 103 circumferentially around the body 105 on the surface of the second endplate 103 nearest to the first endplate 101 . The flange shoes 107 of each of the first and second set of flange shoes 119 and 121 contact each other at a flange shoe junction 108 . Flange shoes 107 are plates fabricated from a material having a greater thermal coefficient of expansion than the workpiece held by the tool. Material for the flange shoes 107 include, but are not limited to, metals or alloys. Suitable materials for the flange shoes 107 include aluminum and steel. The flange shoes 107 are fastened to the first and second endplates 101 and 103 by stress relief fasteners 111 . In addition to fastening the first and second endplates 101 and 103 , the stress relief fasteners 111 also fasten the first endplate 101 to the body 105 . As shown in FIG. 1 , the stress relief fasteners 111 fastening the flange shoes 107 extend through the first and second endplates 101 and 103 and through the flange shoes 107 . The stress relief fasteners 111 fastening the first endplate 101 to the body 105 extend through the first endplate 101 and into the body 105 . The stress relief fasteners 111 , according to the present invention, are any fasteners capable of positioning the first endplate 101 and the flange shoes 107 of the first and second flange shoe sets 119 and 121 during the loading of the workpiece, but yield to pressure due to thermal expansion or other forces. Stress relief comes when the fasteners holding the flange shoes 107 yield under appropriate radial stress and the fasteners holding the end flange plate yields to relieve the axial stress. Suitable materials for stress relief fasteners 111 include, but are not limited to, nylon. One or more reservoirs 109 are located on the surface of the first endplate 101 . The reservoirs 109 fluidly communicate with a vacuum source via vacuum lines 115 . The reservoirs 109 are shown as separate components, but they may be manufactured integral to the first endplate 101 .
[0027] FIG. 2 illustrates one embodiment of the tool 100 oriented with the first and second endplates 101 and 103 oriented horizontally on the drawing. The orientation shown in FIG. 2 illustrates the embodiment of the invention wherein the tool 100 is loaded into an autoclave with the first endplate 101 oriented substantially horizontally above the second endplate 103 and with the center axis of the body 105 being oriented substantially in the vertical direction. Although this embodiment refers to an autoclave, any chamber having the ability to heat and provide pressure to the tool is suitable for use with the present invention. FIG. 2 shows the flange shoes 107 arranged circumferentially around the body 105 . A first set of flange shoes 119 are fastened to the first endplate 101 on the surface nearest to the second endplate 103 . A second set of flange shoes 121 are fastened to the second endplate 103 on the surface nearest to the first endplate 101 .
[0028] A channel 201 is machined in flange shoe junction 108 between individual flange shoes 107 along the surface adjacent to the second endplate 103 to form a fluid connection from the inner surface 205 adjacent to the body 105 to the outer periphery of the flange shoe junctions 108 . At the outer periphery of the flange shoe junction 108 , a siphon tube 113 is attached and placed in fluid connection with the channel 201 adjacent to the second endplate 103 . The siphon tube 113 is in fluid connection with a reservoir 109 adjacent to the first endplate 101 . Each reservoir 109 is a hollow chamber that is capable of containing matrix material under vacuum. Each reservoir 109 is in fluid connection with a cavity 203 defined by the flange shoes 107 , the lower surface of the first endplate 101 and the inner surface 205 of body 105 . The cavity 203 is of sufficient volume to permit insertion of a portion of a workpiece (shown as fiber fabric 301 in FIGS. 3-5 ). The workpiece is preferably a portion of a reinforcing fiber fabric. The reservoirs 109 are also in fluid connection with a vacuum source 117 through vacuum lines 115 . The vacuum source 117 provides vacuum to the reservoirs 109 to draw vacuum on the material in reservoirs 109 .
[0029] FIG. 3 shows a cross sectional view representing view 3 - 3 in FIG. 2 . The cross section shown in FIG. 3 provides an enlarged view of a portion of the first endplate 101 wherein the first endplate 101 oriented vertically in the drawing. The first endplate 101 and body 105 are loaded with a fiber fabric preform 301 . The fiber fabric preform 301 includes a flange portion 305 that extends from the body 105 along the first endplate 101 . Flange shoes 107 are fastened to the first endplate 101 with a stress relief fastener 111 . Likewise, the first endplate 101 is fastened to the body 105 with a stress relief fastener 111 .
[0030] FIG. 3 shows the fiber fabric preform 301 positioned along the body 105 and angled at an angle of about 900 to form a flange shape in the cavity 203 defined by the flange shoes 107 , the first endplate 101 and the inner surface 205 of the body 105 . Cavity 203 defined by flange shoes 107 , first endplate 101 and body 105 is in fluid communication with the reservoirs 109 through a matrix material distribution channel 303 . The reservoirs 109 are in fluid communication with at least one vacuum line 115 and at least one siphon tube 113 .
[0031] FIG. 4 shows a cross sectional view representing view 3 - 3 in FIG. 2 . The sectional view shows a portion of the composite duct-forming tool 100 having the same arrangement of body 105 , flange shoes 107 , fiber fabric preform 301 , and first endplate 101 as FIG. 3 . However, the embodiment illustrated in FIG. 4 has the siphon tube 113 inserted into a siphon tube recess 401 in the flange shoes 107 . The siphon tube 113 is in fluid communication with a matrix material distribution channel 403 . The matrix material distribution channel 403 extends from the siphon tube 113 to the cavity 203 defined by the flange shoes 107 , the first endplate 101 and the inner surface 205 of the body 105 . Cavity 203 defined by flange shoes 107 , first endplate 101 and inner surface 205 of body 105 is in fluid communication with reservoirs 109 through reservoir channel 405 . The reservoirs 109 are in fluid communication with a vacuum source 117 via vacuum line 115 .
[0032] FIG. 5 shows a cross sectional view representing view 5 - 5 in FIG. 2 . The cross section shown in FIG. 5 provides an enlarged view of a portion of the second endplate 103 oriented vertically in the drawing, loaded with a workpiece of fiber fabric preform 301 . FIG. 5 also shows flange shoes 107 fastened to the second endplate 103 with a stress relief fastener 111 . The second endplate 103 is fastened to the body 105 by a second endplate fastener 505 . The second endplate fastener 505 is a fastener that does not yield under pressure, like the stress relief fastener 111 . The second endplate fastener 505 may be any fastener that does not yield under the stresses generated by the tool 100 . In an alternate embodiment, the second endplate 103 and the body 105 may be permanently attached or a machined single piece. In this embodiment, the second endplate 103 is integral to the body 105 and may be machined or cast as a single piece having the body 105 extend from the second endplate 103 . Alternatively, the body 105 and the second endplate 103 may be welded together.
[0033] The embodiment illustrated in FIG. 5 has the siphon tube 113 inserted into a siphon tube recess 501 in flange shoes 107 . The siphon tube 113 is in fluid communication with a matrix material discharge channel 503 . The matrix material distribution channel 503 extends from the siphon tube to cavity 203 defined by flange shoes 107 , second endplate 103 and inner surface 205 of body 105 .
[0034] FIGS. 6-9 illustrate the composite duct-forming tool 100 according to the present invention loaded with the workpiece 301 and matrix material 601 to be formed into a composite. FIGS. 6-9 illustrate various stages in the matrix material infiltration and curing process. FIG. 6 illustrates the tool 100 before loading into the autoclave (not shown). FIG. 7 and 8 illustrate the tool 100 during heating. FIG. 9 illustrates the tool 100 under autoclave pressure. FIGS. 6-9 show a cross section taken radially from the center axis of the cylinder portion of the body 105 of the tool 100 shown in FIGS. 1 and 2 . FIGS. 6-9 illustrate the tool 100 having a body 105 , a first endplate 101 , a second endplate 103 , and flange shoes 107 , arranged as shown in FIGS. 1 and 2 . For illustration purposes, FIGS. 6-9 do not show the stress relief fasteners 111 and 505 , the siphon tubes 113 , the reservoirs 109 , the vacuum lines 115 , the matrix material discharge channels 503 or the matrix material distribution and vacuum channels 303 , 403 and 405 . It is noted that each of the above element are present in the tool 100 loaded into the autoclave, as well as a vacuum membrane or bag 605 surrounding the tool 100 .
[0035] FIG. 6 shows the tool 100 before loading into the autoclave. The tool 100 is first loaded with a fiber fabric preform 301 . On the fiber fabric preform 301 , a layer of matrix material 601 is coated on the surface. The matrix material 601 is preferably bulk resin weighed out into discrete portions. Bulk resin is uncured resin that has not been processed into a final form (e.g., sheets or plies) and is capable of being separated into discrete portions. At room temperature, the bulk resin is preferably a pliable solid. The bulk resin is separated into substantially rectangular portions, which are placed on the surface of the fiber fabric preform 301 . It is noted that any shape portion that provides resin to the surface of the fiber fabric preform 301 is suitable for use with the invention. After placing the portions onto the surface of the fiber fabric preform 301 , the rectangular portions are conformed to the surface shape. The rectangular portions are preferably pliable at room temperature. The rectangular sections of bulk resin may optionally be pre-heated to increase the pliability of the resin to assist in conforming the rectangular portions to the surface shape. A suitable resin may include, but is not limited to, epoxy or polyamide resin. The matrix material 601 is coated onto the surface of the fiber fabric preform 301 so that a greater amount of matrix material 601 (i.e., a greater amount of matrix material per unit of surface area) is coated onto the center 607 of the fiber fabric preform 301 (i.e., the midpoint between the first and second endplates 101 and 103 ) and a lesser amount (i.e., a lesser amount of matrix material per unit of surface area) is coated on the edges 609 of the fiber fabric preform 301 (i.e., the area adjacent the first and second endplates 101 and 103 ). Although this embodiment refers to bulk resin, any matrix material capable of forming a reinforced matrix composite may be used with the present invention.
[0036] After the tool 100 is loaded with the matrix material 601 , an elastomer caul 603 is placed onto the matrix material 601 coated fiber fabric preform 301 . The caul 603 is formed from a material that is a barrier to the passage of matrix material 601 . Suitable material for the caul 603 , includes, but is not limited to, silicone. Any material which will not bond with the matrix material and which can withstand the heat and pressure and is flexible may be used as the material for the caul 603 . The caul 603 is positioned so that the matrix material 601 may only travel along the fiber fabric preform 301 , into the area adjacent to the first and second endplates 101 and 103 where the matrix material 601 may enter the matrix material discharge channels 503 or the matrix material distribution and vacuum channels 303 , 403 and 405 , the siphon tubes 113 or the reservoirs 109 , as illustrated in FIGS. 1-5 . Once the tool 100 is loaded, the loaded tool 100 is placed inside a vacuum bag 605 . Tool 100 of the present invention provides a method for manufacturing fiber reinforced matrix composites wherein the process only requires a single vacuum bag 605 .
[0037] FIG. 7 illustrates the tool 100 and the movement of matrix material 601 when exposed to heat, during heating and holdings steps of a curing cycle. The matrix material 601 upon heating becomes liquid or fluid and begins to infiltrate the fiber fabric preform 301 to create a partially impregnated fiber fabric preform 701 . As the matrix material 601 becomes liquid or fluid, the material flows from the center 607 of the fiber fabric preform 301 (i.e., the midpoint between the first and second endplates 101 and 103 ) in the direction of arrows 703 . As the matrix material 601 , now a liquid resin, moves from the center 607 of the fiber fabric preform 301 to the outer edges 609 , air, volatile gases devolve from the matrix material 601 , and other materials, such as impurities or gases trapped in the fiber fabric preform 301 , that potentially could cause void space are pushed by the flow of bulk matrix material 601 toward the outer edges 609 of the fabric adjacent to the first and second endplates 101 and 103 . Excess matrix material 601 , air, volatile gases from the bulk matrix material 601 and other materials that potentially could cause void space flow into the siphon tube 113 and are drawn into either the reservoirs 109 or into cavity 203 defined by flange shoes 107 , second endplate 101 and inner surface 205 of the body 105 through the matrix material distribution channel 403 , as illustrated in FIGS. 1-5 .
[0038] FIG. 8 illustrates the tool 100 and partially impregnated fiber fabric preform 701 when exposed to heat, during the heat up and hold steps of the curing cycle. The first endplate 101 , second endplate 103 , the body 105 , and the flange shoes 107 are fabricated from a material that has a greater thermal coefficient of expansion than the partially impregnated fiber fabric preform 701 . As a result, during heat-up, as shown in FIG. 8 , each of the first endplate 101 , second endplate 103 , the body 105 , and the flange shoes 107 expand in all directions as shown by arrows 801 . The partially impregnated fiber fabric preform 701 expands very little in comparison to the body 105 . The difference in the amount of thermal expansion of the tool 100 against the partially impregnated fiber fabric preform 701 results in a tensional force shown by arrows 803 that acts to pull the partially impregnated fiber fabric preform 701 taut. Fiber fabric preforms 701 that are pulled taut before matrix material curing provide uniform materials with high strength substantially free of waves and wrinkles.
[0039] FIG. 9 illustrates the tool 100 when exposed to pressure, during the heat up and hold steps of the curing cycle. Flange shoes 107 are fabricated with a large surface area 903 in the plane parallel to the first and second endplates 101 and 103 . As the pressure in the autoclave is increased during the curing cycle, the force of the pressure of the autoclave atmosphere shown by arrows 901 on the vacuum bag 605 and flange shoes 107 surface is multiplied by the surface area 903 of flange shoes 107 . Flange shoes 107 surface is greater in surface area 903 than the fiber fabric preform 701 forming the flange-like shape so as to add substantial position holding force from autoclave pressure. The pressure holds the fiber fabric preform 701 in place while the body 105 expands and pulls the fiber fabric preform 301 taut.
[0040] FIG. 10 illustrates a matrix material distribution system 1000 according to the present invention for fabricating a fiber-reinforced matrix composite (not shown). A fiber fabric preform 1005 is loaded with matrix material 1001 , wherein a greater amount of matrix material 1001 is positioned in the center 1019 of the fiber fabric preform 1005 than at the edges 1021 .
[0041] In order to form the fiber reinforced matrix composite (not shown) according to the present invention, the fiber fabric preform 1005 coated with the matrix material 1001 is mounted vertically and the system 1000 is exposed to vacuum through vacuum line 1007 and sufficient heat to make the matrix material 1001 viscous. The movement of the matrix material 1001 within the fiber fabric preform 1005 is illustrated as arrows 1015 and 1016 in FIG. 10 . Initially, the viscous matrix material 1001 travels in two directions shown by arrows 1015 and 1016 . A larger portion of the matrix material 1001 (shown as arrow 1015 ) travels in the direction of gravity (arrow 1009 ) and a smaller portion (shown as arrow 1016 ) is drawn in a direction toward the vacuum line 1007 . The vacuum line 1007 is fluidly connected to vacuum source 1023 .
[0042] The matrix material 1001 traveling in the direction of gravity (shown by arrow 1009 ) gathers in a collection well 1011 . The collection well 1011 fluidly communicates with a distribution well 1013 through a siphon tube 1003 . The distribution well 1013 is a chamber adjacent to the vacuum line 1007 and the upper edge of the fiber fabric preform 1005 . Matrix material 1001 is drawn from the collection well 1011 to the distribution well 1013 by suction from the vacuum line 1007 , as shown by arrows 1017 . The system is self-regulating and continues until the matrix material 1001 throughout the fiber fabric preform 1005 material is substantially uniformly distributed throughout the fiber fabric preform 1005 . The system is self-regulating in that siphon tube 1003 continues to draw matrix material 1001 from the collection well 1011 to the distribution well 1013 as long as the pressure differential across the matrix material 1001 impregnated fiber fabric preform 1005 is greater than the pressure differential across the siphon tube 1003 . Once the pressure across the siphon tube 1003 is equal to the pressure across the impregnated fiber fabric preform 1005 , the matrix material 1001 is no longer drawn from the collection well 1011 to the distribution well 1013 . The resultant matrix impregnated fiber fabric preform 1005 contains substantially uniform distribution of matrix material 1001 . The impregnated fiber fabric preform 1005 is further heated to complete the curing cycle and to produce a fiber reinforced matrix composite.
[0043] FIG. 11 illustrates a composite containment duct 1100 according to the present invention. Composite containment duct 1100 is the product made by tool 100 (see FIGS. 1 - 2 ). Composite containment duct 1100 is a single piece having a duct body 1103 and integral high strength flanges 1101 . Additionally, holes 1105 are machined into the flange 1101 to allow fasteners to attach the composite containment duct 1100 to other bodies. Flanges 1101 provide a surface to which composite containment duct 1100 may be attached to another body. Another body may include a second composite containment duct 1100 . The attachment of two containment ducts has the advantage of additional length and the ability to create ducts that have converging and diverging duct areas. In this embodiment, a composite containment duct 1100 has a tapered duct body 1103 , wherein the diameter of the duct at one flange is larger than the diameter of the duct at the other flange. In some containment duct applications, a containment duct having both a converging portion and a diverging portion is desirable. To form a containment duct 1100 that converges in one portion and diverges in another portion, a tapered containment duct 1100 is attached by the flanges at the end of the containment duct having the smaller duct diameter to a second substantially identical tapered containment duct 1100 . Attachment of the flanges at the smaller duct diameter permits a duct that diverges from one end of the combined containment duct to the center and diverges from the center of the combined containment duct to a second end of the combined containment duct. The flanges may also be fastened to a portion of a gas turbine engine (not shown). In one embodiment, the flanges may be fastened to the gas turbine engine so that the fan blades (not shown) of the gas turbine engine are positioned in the interior portion 1107 of the duct body 1103 substantially along the outer periphery of the path of the fan blade tips to provide containment of the fan blades.
[0044] One embodiment of the present invention includes providing a tool 100 having a surface having the shape of the desired composite. In one embodiment of the invention, the body 105 is substantially the shape of a cylindrical containment duct. In this embodiment, the cylindrical duct preferably tapers inward toward the center axis of the body 105 . The shape of the finished reinforced matrix composite is not limited to substantially cylindrical shapes. Any shape having flanged outer edges may be fabricated by the method of the present invention. Suitable shapes, in addition to the substantially cylindrical ducts, include, but are not limited to, ducts having complex cross-sectional geometry (e.g., rectangular ducts, triangular ducts or oval ducts), flat panels, and other complex shapes having wall-structures. Additionally, wall-structures having features may be formed using the tool 100 and method of the present invention. The tool 100 of the present invention, likewise, has body 105 of substantially the same shape as the finished composite.
[0045] The tool 100 is fabricated from a material having a coefficient of thermal expansion greater than the coefficient of thermal expansion of the fiber fabric preform 301 . One criteria for selection of the tool material is the amount of tension desired in the fiber fabric preform 301 . The greater the tension desired, the greater the coefficient of thermal expansion should be for the tool material. The less tension desired, the less the coefficient of thermal expansion should be for the tool material. Preferably, the tool 100 is fabricated from a metallic material. Fibers that make up the fiber fabric preform 301 have a relatively low coefficient of thermal expansion when compared to metallic materials. Therefore, when the tool 100 is exposed to heat, the tool material expands at a rate much faster than the rate of expansion for the fiber fabric preform 301 . The tension created by the expansion of the tool 100 in relation to the expansion of the fiber fabric preform 301 acts to pull the fiber fabric preform 301 taut and substantially aligns the fibers to produce a high strength, uniform composite substantially devoid of waves and wrinkles. The greater the thermal expansion of the tool 100 in relation to the fibers, the greater the tension created. Suitable materials for fabrication of the tool 100 include, but are not limited to, aluminum and steel.
[0046] The reinforcing material for the composite matrix is preferably woven fiber fabric. The fiber fabric is a preform capable of forming a reinforced matrix composite. A variety of fibers is suitable for use in composite matrix materials. The fibers may be woven or plied upon each other to form a composite preform. In one embodiment of the invention, the fiber fabric preform 301 is a triaxial woven fabric of strand bundles. The triaxial woven fabric has one strand bundle running axially, with another stand bundle oriented at about +60° from the bundle in the axial direction and a third strand bundle oriented at −60° from the bundle in the axial direction. Suitable fibers for forming the fiber fabric preform 301 include, but are not limited to, carbon, graphite, glass and polyamide fibers. The fiber fabric preform 301 is preferably dry. By dry, it is meant that there is no matrix material impregnated into the fiber fabric prior to loading the fiber fabric preform 301 onto the tool 100 .
[0047] The matrix material 601 for use in the reinforced matrix composite of the present invention is a curable material that forms a high strength matrix composite when reinforced with reinforcing fibers. Suitable matrix materials 601 for use in the reinforced composite material of the present invention include, but are not limited to, epoxy and polyimide.
[0048] The process of the present invention includes loading the tool 100 with the material for forming the reinforced matrix composite. The tool 100 is first loaded with the material for reinforcement of the matrix in the finished composite material. The reinforcing material is preferably a fiber fabric preform 301 . The fabric of fibers is preferably a fabric having a woven structure. Preferably the woven structure has three independent bundles of fibers woven so as to have orientations of 60° angles to each other. The fibers are preferably graphite fibers. The fabric may include, but is not limited to triaxial graphite fiber. A preferred fiber fabric preform 301 includes the triaxial graphite fiber with a 24 k (i.e., 24,000 strand) bundle tow in the axial direction and two 12 k (i.e., 12,000 strand) bundles in the +600 direction from the tow in the axial direction and two 12 k bundles in the −60° direction from the tow in the axial direction.
[0049] In one embodiment of the invention, the tool 100 preferably has a preselected geometry of a spool. The spool shape includes a substantially cylindrical body 105 affixed to two endplates 101 and 103 . At least one of the two endplates 101 and 103 is fastened to the body and is detachable. In this embodiment of the present invention, the tool 100 is oriented with the endplates 101 and 103 positioned having their planar surfaces oriented vertically in order to load the tool 100 with the reinforcing fiber material. The graphite fiber fabric preform 301 is positioned around the body 105 of the spool. A flange portion 305 of the preform is positioned along the length of each of endplates 101 and 103 . The flange portion 305 of the fabric extending along the first and second endplates 101 and 103 forms a flange-like shape.
[0050] Once the fiber fabric preform 301 is loaded onto the tool, a plurality of plates (i.e., flange shoes 107 ) are arranged abutting one another along the periphery of the tool 100 along the endplates 101 and 103 . A first set of plates is adjacent to the first endplate 101 . A second set of plates is adjacent to the second endplate 103 . The plates are preferably metallic and have at least one surface having a surface area 903 greater than the surface area of the length of material extending along the length of the endplates 101 and 103 . The plates are positioned to provide support for the fabric material extending along the endplates 101 and 103 and forming the flange portion 305 and are fastened to the endplates with stress release fasteners 111 . Each stress release fastener 111 is a fastener that positions the shoe at room temperature prior to the curing cycle and releases the flange shoes 107 from the first and second endplates 101 and 103 during the heat up portion of a curing cycle. As the tool expands axially, the stress release fasteners are designed to yield rather than prevent movement of the tool. So, the fastener maintains the flange shoes 107 in position, against the flange, but yields to allow the tool to expand axially.
[0051] In one embodiment of the invention, one or more of the plates are provided with channels 201 , 303 , 403 , 405 , 503 to facilitate circulation of excess resin. The channels 201 , 303 , 403 , 405 , 503 permit passage of matrix material 601 from the area of the tool carrying the matrix coated fibers to outside the area of the tool carrying the matrix coated fibers. The channels 201 , 303 , 403 , 405 , 503 allow excess matrix material 601 to pass into or out of the area of the tool 100 holding the fiber fabric preform 301 . When the tool 100 is positioned to have the first and second endplates 101 and 103 aligned horizontally with respect to the autoclave during loading, the second endplate 103 at the bottom includes one or more openings that are fluidly communicate to the area of the tool providing the vacuum, preferably at or near the top first endplate 101 of the tool. The tool 100 includes reservoirs 109 positioned on the top of the first endplate 101 when the first and second endplates 101 and 103 are aligned horizontally. In this embodiment, the vacuum fluidly communicate with reservoirs 109 , as well as fluid communication with openings in the flange shoes 107 . The fluid communications act as a siphon allowing excess matrix material 601 that pools because of gravity to travel to the area of the tool having suction, thereby providing matrix material 601 to areas of the fiber having less matrix material 601 , including the areas at or near the first endplate 101 . The siphon tubes 113 allow a uniform distribution of the matrix material 601 across the fiber fabric preform 301 .
[0052] The tool 100 is then covered with matrix material 601 , preferably in bulk form. The matrix material 601 is loaded onto the fiber fabric preform 301 by coating matrix material 601 directly onto the surface of the fiber fabric preform 301 . The placement of the matrix material 601 onto the reinforcing fiber fabric preform 301 includes placing a preselected amount of matrix material 601 onto the surface of the fiber fabric preform 301 . The preselected amount of matrix material 601 is an amount sufficient to impregnate the preform. The matrix material 601 is stacked or laid up on the surface in discrete portions. Once the matrix material 601 is placed onto the surface of the fiber fabric preform a barrier caul 603 is placed over the matrix material 601 to hold it in place until the tool is loaded into the autoclave. During the heating phase, the stacked or laid up matrix material layers (i.e. lay up) will melt and infiltrate into the fiber fabric preform 301 . Force applied to the matrix material 601 from the autoclave pressure on the caul 603 will assist the matrix material 601 in penetrating the fiber fabric preform 301 and in spreading outward across the fiber fabric preform 301 . The molten matrix material mass forms a wavefront as it flows across the fiber fabric preform 301 that forces the gaseous pockets out of the preform before the resin begins to set up and cure. In particular, the wavefront pushes out air, volatile material from the bulk matrix material 601 , such as solvent vapor, and other gases that are capable of forming voids, such as impurity gas pockets remaining in the matrix material or in the fiber fabric preform 301 . The placement of the matrix material 601 also permits the impregnation of preforms having complex shapes. Complex shapes include preforms having more complex geometric features than a flanged cylinder. Features may be present in preforms having more than one pathway for matrix material flow prior to curing. For example, reinforced matrix composite parts may include planar wall portions having attached stiffener or insert features.
[0053] In one embodiment of the invention, the matrix material 601 is resin separated into rectangular block sections, positioned onto the surface, and conformed to the surface of the fiber fabric preform. A suitable resin may include, but is not limited to, epoxy and/or polyimide. The matrix material 601 is coated onto the surface of the fiber fabric preform 301 so that a greater amount of matrix material 601 is coated onto the center 607 of the fiber fabric preform 301 (i.e., the midpoint 607 between the first and second endplates 101 and 103 , as illustrated in FIG. 6 ) and less is coated on the edges 609 of the fiber fabric preform 301 (i.e., the area adjacent the first and second endplates 101 and 103 , as illustrated in FIG. 6 ).
[0054] 0054 Once the fiber fabric preform 301 is coated with the matrix material 601 , the matrix material coated fiber fabric preform 301 is coated with an elastomeric sheet (i.e., caul 603 ). The caul 603 acts as a barrier to isolate and control the flow of matrix material into the fiber fabric preform 301 . After the caul 603 is positioned, the caul 603 is sealed against the tool 100 to form a barrier and prevent flow of matrix through the caul 603 , but allow flow along the fiber fabric preform 301 .
[0055] 0055 Once the caul 603 has been placed around the fabric-matrix material and sealed, the tool 100 , including caul 603 and matrix material 601 coated fiber fabric preform 301 , is placed inside a vacuum envelope or bag 605 . A vacuum source 117 is connected to the vacuum bag 605 and the tool 100 to provide reduced pressure (i.e., vacuum). The vacuum source 605 preferably draws a vacuum of up to about 28 inches of mercury and more preferably up to about 30 inches of mercury. The vacuum provides a driving force for distribution of the matrix material 601 during the heat up and curing phases of the process. The vacuum is drawn on the tool 100 through the vacuum bag 605 . The loaded tool 100 is then heated. While the tool 100 is being heated, a positive pressure of gas external to the vacuum bag 605 is provided. The positive pressure is preferably provided with an inert gas, such as nitrogen. During the heating and holding cycle the positive pressure is preferably increased to pressures of up to about 200 lb/in 2 or more, and preferably up to about 220 lb/in 2 or more. When loaded into the autoclave, the tool 100 is preferably oriented with the plane of the first and second endplates 101 and 103 aligned horizontally with respect to the autoclave.
[0056] In order to form the composite, the caul-covered fiber fabric preform 301 loaded with matrix material 601 is heated. The matrix material 601 becomes viscous at higher temperatures and flows into (i.e., impregnates) the fiber fabric preform 301 . Simultaneously, the tool 100 on which the fiber fabric perform 301 is loaded expands due to thermal expansion. Since the fiber fabric preform 301 experiences little or no thermal expansion, the fiber fabric preform 301 is pulled taut, providing at least some tension and alignment of fibers in the fiber fabric preform 301 . The tool 100 and the matrix coated fiber fabric preform 301 is then heated to a temperature to permit the matrix material to fully impregnate the fiber fabric preform 301 . After the fiber fabric preform 301 is substantially impregnated, the tool 100 and fiber fabric preform 301 are heated to a curing temperature, and is held at the curing temperature until the fiber reinforced matrix composite is cured. The method includes at least the following steps: a first heating step, a first holding step, second heating step, a second holding step and a cooling step. The temperature is slowly increased to the first holding temperature. A suitable rate of temperature increase includes but is not limited to range of from about ½° F./min to about 1° F./min. The temperature and time for the first holding step is sufficient to allow the matrix material to infiltrate the reinforcing fibers. A suitable temperature for the first holding step includes, but is not limited to the range of from about 300° F. to about 325° F. Suitable temperatures for the first holding step include, but are not limited to about 310° F. The temperature and time for the second holding step is sufficient to cure the matrix material. A suitable temperature for the second holding step includes, but is not limited to the range from about 350° F. to about 375° F. Suitable temperatures for the second holding step include, but are not limited to about 360° F. Once cured, the reinforced matrix composite is slowly cooled to room temperature.
[0057] During the heating steps, the heating gases of the autoclave are distributed across the tool 100 to provide uniform heating of the matrix impregnated fiber fabric. Preferably, the body 105 is hollow and/or has an interior surface, opposite the surface on which the fiber fabric preform 301 is positioned. In this embodiment, the interior surface is exposed to the heating atmosphere to heat the fiber fabric preform 301 and matrix material 601 through the body 105 . In a preferred embodiment as shown in FIG. 1 , the tool body is hollow and substantially cylindrical in shape. The exterior (i.e., the surface on which the fiber fabric preform 301 is positioned) and the interior of the cylinder are exposed to the heating atmosphere through the vacuum bag 605 . The inlet to the hollow portion of the cylinder may include a diffuser to uniformly distribute the heating atmosphere. The heating atmosphere distributes the heat uniformly across the matrix impregnated fiber fabric 701 to uniformly cure of the reinforced composite matrix.
[0058] During the heating and vacuum cycle, the caul 605 permits the matrix material 601 to travel either in the direction toward the vacuum or in the direction of gravity. More matrix material 601 travels in the direction of gravity than in the direction of the vacuum. The openings in the flange shoes 107 permit excess matrix material to exit the portion of the tool 100 holding the fiber. When the tool 100 is positioned with the first and second endplates 101 and 103 aligned horizontally, the endplate at the bottom (i.e., second endplate 103 ) includes one or more openings 201 that are fluidly connected to the area of the tool 100 providing the vacuum at or near the reservoirs 109 . The area of the tool 100 providing the vacuum is preferably at or near the top endplate (i.e., first endplate 101 ) of the tool 100 . In one embodiment, the tool 100 includes reservoirs 109 positioned on the top of the first endplate 101 when the first and second endplates 101 and 103 are aligned horizontally. In this embodiment, the vacuum source 117 is connected to the reservoirs 109 , as well as the fluid connection to the openings in the flange shoes 107 . The fluid connections act as a siphon allowing excess matrix material that pools because of gravity to travel to the area of the tool 100 having suction and providing matrix material to the area of the fiber having less matrix material 601 .
[0059] As the tool 100 is heated, it thermally expands. The tool 100 is made of a material that expands at a rate in excess of the rate of expansion of the fiber fabric preform 301 and matrix material 601 . Therefore, as the tool 100 expands, the fiber fabric preform 301 expands at a significantly lesser rate and is pulled taut by the expanding tool 100 , creating pre-stressed fiber reinforcement. Once the matrix material 601 has been substantially distributed and cured at the larger tool surface area 903 , the tool 100 is then permitted to cool down to ambient temperatures. The tool 100 material thermally contracts with the falling temperature. However, the fiber consolidated with matrix material, which was pulled taut and cured at the size of the tool 100 surface at the higher temperature, thermally contracts at a significantly lesser rate. As the tool 100 material cools, the fiber consolidated with matrix material 601 exerts a force on at least one of the first and second endplates 101 and 103 because the surface of the cured reinforced matrix material 601 at lower temperatures is larger than the tool surface at lower temperatures. The at least one first and second endplate 101 and 103 is allowed to move and the fasteners holding the at least one of the endplates (i.e., first endplate 101 ) yield, allowing the endplate to be moved as the body of the tool 100 expands. Thus, the yielding of the fasteners 111 does not allow the flange assembly to restrain the body of the tool 100 . Once the cycle is complete and reinforced bulk matrix material 601 having the prestressed reinforcing fibers are cured and cooled, the reinforced bulk matrix material 601 is removed from the tool 100 and trimmed, if necessary. Also, if necessary due to the geometry of the finished part, the body 105 may be disassembled to facilitate removal of the cured, reinforced matrix composite part. The fasteners 111 are disposable and are not reused.
[0060] The various surfaces of the tool 100 that come in contact with the matrix material 601 may optionally be coated with a release film, such as polytetrafluoroethylene. The release does not stick to the tool components and facilitate easy removal of the finished part. For example, the body 105 , the first and second endplates 101 and 103 , the flange shoes 107 , and/or the caul 605 may be coated with polytetrafluoroethylene.
[0061] In alternate embodiment of the present invention, a pre-impregnated fiber fabric preform 301 is loaded onto the tool 100 of the present invention. Pre-impregnated fiber fabric preform 301 is fabric that is loaded with uncured matrix material 601 prior to being loaded onto the tool 100 of the present invention. Flange shoes 107 are positioned on the tool 100 and adjacent to the pre-impregnated fiber fabric preform 301 . Flange shoes 107 for use with pre-impregnated fiber fabric preform 301 additionally have rails, guides or a similar mechanism, to guide flange shoes 107 displacement when autoclave pressure is applied. As in the embodiment having the fiber fabric preform 301 that is not pre-impregnated with matrix material 601 , flange shoes 107 are greater in surface area than the fiber fabric preform 301 in the flange portion 305 to add substantial position holding force from autoclave pressure. As the tool 100 expands during cure cycle heat up, it pulls the fibers of the fiber fabric preform 301 taut over the flange shoes 107 radius. The rails, guides, or similar mechanism, are positioned to permit the flange shoes 107 to only allow force on the fabric once the tool 100 has expanded to an extent corresponding to heat sufficient to make the matrix material 601 in the pre-impregnated fiber fabric viscous. Once the matrix material 601 is viscous, the flange shoes 107 are permitted to exert force on the fiber fabric preform 301 and pull the fiber fabric taut. As in the embodiment with the dry fiber fabric, pulling the fiber fabric taut creates a pre-stressed fiber reinforced matrix composite. The tool 100 and finished product cool down and the tool 100 thermally contracts but the finished reinforced matrix composite does not contract as much. Flange shoes 107 and the first endplate 101 are fastened with stress relief fasteners 111 . Relief comes when the stress relief fasteners 111 holding the flange shoes 107 give under appropriate radial stress and the stress relief fasteners 111 holding the first endplate 101 gives to relieve the axial stress.
[0062] One embodiment of the invention includes a composite containment duct 1100 having less than or equal to 2.5% void space. The composite containment duct 1100 preferably has less than 2.0% void space and most preferably less than 1% void space.
[0063] The composite containment duct 1100 according to the present invention has improved containment properties. One embodiment of the present invention is a graphite fiber-epoxy matrix composite containment duct 1100 . The graphite-fiber epoxy matrix composite of the present invention has the properties of having high strength, including strong flanges, being lightweight and successfully passing a blade-out test. A blade-out test is a test wherein a gas turbine engine is mounted with a full set of fan blades and a containment duct around the periphery of the blade path. The fan blades are subjected to rotational speeds equivalent to the rotational speeds achieved during aircraft takeoff. One or more blades are ejected from the mounting and are allowed to impact the containment duct. A successful blade-out test holds the blade inside the containment duct. The method of the present invention is particularly suitable for fabrication of turbine airfoil components for gas turbine engines. In particular, the method of the present invention is suitable for the fabrication of containment ducts, such as fan casings, which withstand a blade-out test.
[0064] The method and tool 100 of the present invention is capable of fabricating large parts. The size of the part is slightly less than the size of the surface of the tool 100 . The tool 100 and method of the present invention are particularly suitable for fabrication of parts having large wall-structures, including cylindrical parts having a diameters of about 5 feet or greater, including cylindrical parts having a diameter of about 10 feet. In one embodiment, the tool of the present invention may create a cylindrical part having a diameter of about ten feet or greater that maintain substantially uniform matrix distribution and the low void content.
[0065] The flanges 1101 of the containment duct 1100 of the present invention have high strength. One contributing factor for high strength is the fact that the flanges 1101 are formed as an integral part of the containment duct 1100 . Additionally, the fibers within the flange 1101 are pulled taut, providing substantially alignment and increased strength. Additionally, the matrix distribution within the containment duct is substantially uniform across the duct body 1103 and across the flanges 1101 . The substantially uniform distribution within the flanges 1101 contribute the high strength of the flanges 1101 . The flanges 1101 , like the wall-portions have pre-stressed reinforcing fibers and uniform matrix distribution.
[0066] The method and tool 100 of the present invention provides composites of near-net-shape after impregnation and curing of the fiber fabric preform 301 . The tool 100 provides the fiber fabric preform 301 with the shape of the desired product, while impregnating it with matrix material 601 . Once cured, the matrix material 601 impregnated fiber fabric preform 301 is of near-net-shape, requiring little or no trimming. The method for manufacturing fiber reinforced matrix composites according to the present invention provides composite parts substantially having the shape of the finished product, requiring little or no trimming prior to installation.
[0067] Removal of the finished part from the tool 100 of the present invention is relatively simple and inexpensive. In addition to the optional release film, the first endplate 101 detaches from the body allowing removal of the part from the body 105 . The tool 100 does not require disassembly beyond the components of the tool 100 that detach during the curing cycle. Therefore, the removal of the finished part requires very little labor and is inexpensive.
[0068] While the invention has been described with reference to a preferred embodiment, it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted for elements thereof without departing from the scope of the invention. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the invention without departing from the essential scope thereof. Therefore, it is intended that the invention not be limited to the particular embodiment disclosed as the best mode contemplated for carrying out this invention, but that the invention will include all embodiments falling within the scope of the appended claims. | A mold tool for forming a reinforced matrix composite part for a gas turbine engine, comprising a body. The body comprises a body surface capable of receiving a first portion of a composite preform. A first endplate and second endplate are attached to the body and include a substantially planar surface disposed perpendicular to the body surface. A first and second set of plates are attached to the first and second endplate adjacent to the body surface and have a geometries that includes a first and second cavity bounded by the first and second plate and first and second endplate. The first and second cavities have a volume sufficient to receive a second portion of a composite preform. The second cavity is in fluid communication with the first cavity, which is in fluid communication with a vacuum source. | 63,618 |
BACKGROUND OF THE INVENTION
1. FIELD OF THE INVENTION
This invention relates to the field of orthopedic surgery, and more particularly, to devices used to assist in the repair of pronounced bunion deformities, commonly known as hallux valgus.
Hallux valgus has been described as a "static subluxation of the first metatarsophalangeal joint with lateral deviation of the great toe and medial deviation of the first metatarsal." This condition is occasionally accompanied by rotational pronation of the great toe in severe cases.
One of the common causes of hallux valgus is prolonged deformation of the foot brought about by wearing shoes which do not fit properly. In such cases, the great toe is forced into an abnormal orientation for a long period of time, which eventually stretches out the joint capsule, promoting abnormal migration of the muscles. Due to the prevalence of narrow high-heel shoes, women tend to acquire bunions much more commonly than do men. Other factors which may contribute to the condition of hallux valgus include rounded unstable metatarsophalangeal joint surfaces and oblique joint surfaces located at the proximal first metatarsal joint. Once the muscles have migrated laterally outside of the joint line, the hallux valgus deformity reinforces itself and tends to become even more pronounced.
The severity of hallux valgus deformities is usually quantified by taking measurements from x-ray pictures of the foot. One common measurement is the intermetatarsal (IM) angle, which is measured between the line of the first and second metatarsal shafts. The IM angle, in the normal foot, is roughly 6-9 degrees. The second common measurement is the hallux valgus (HV) angle, which is measured between the line of the first metatarsal shaft and the proximal phalanx. The HV angle usually measures about 9-10 degrees. A typical patient having the hallux valgus deformity would have an IM angle of 15°, and an HV angle of 30° (any HV angle greater than 12° would be uniformly regarded as abnormal).
2. DESCRIPTION OF THE RELATED ART
Many procedures exist to correct the hallux valgus deformity. Review of the literature and surgical experience indicate that a five-degree correction of the IM angle and a maximum of ten-degree correction of the HV angle is reproducibly possible using distal osteotomy procedures, of which the most commonly used are the Mitchell, and more recently, the distal Chevron osteotomy. These procedures are most applicable for mild cases of hallux valgus; for more severe cases, the Roger Mann proximal osteotomy of the metatarsal shaft, or the technique patented by Clarke (U.S. Pat. No. 5,529,075), are required. The choice of repair from among the prior art procedures is to some degree guided by the preoperative IM and HV angles. That is, for preoperative angles of 15° or less, and HV angles of 30° or less, a distal Chevron osteotomy is sufficient.
The difficulties involved with hallux valgus repair procedures are many. The main problem which the osteotomy guides of the present invention address is the inability of surgeons to adequately reproduce their osteotomy cuts, case-to-case, and even within the same case. A common occurrence is that the first of the osteotomy cuts in a V-shaped osteotomy, such as the Chevron, is located at a certain pitch and angle with relation to the first metatarsal, and the corresponding second cut (done free-hand) is then very difficult to accomplish at the exact pitch and angle desired by the surgeon for the required correction. Once the bone cuts have been made in this case, the osteotomy, when impacted back on itself, does not precisely fit. The resulting instability makes the bunionectomy site less suitable for weightbearing and increases the chances of nonunion and nonhealing despite internal fixation. Even the act of fixation is very difficult, since attempting to drive a pin or drill and screw through bone that is moving causes problems with fixation alignment, prolonging the surgical case and causing great variations in both long and short-term outcome. Osteotomy cut angles can vary by as many as 20 degrees from case-to-case and surgeon-to-surgeon.
Chevron, Youngswick, and Reverdin osteotomy procedures are all commonly used in the repair of hallux valgus deformities. The decision to use a Youngswick procedure versus a simple Chevron procedure is determined when the patient has a secondary deformity of the hallux valgus known as a hallux limitus/rigidus deformity, which is a limitation of movement at the joint. Many times this is caused by metatarsus primus elevatus, where the first metatarsal is congenitally elevated above the plane of the second metatarsal, thereby producing more pressure at the second metatarsal and a jamming effect as the hallux is prevented from dorsiflexure during the gait cycle. This produces arthritis and pain, as well as increasing the amount of bunion deformity.
The Youngswick procedure is designed to remove a bone wedge from the dorsal aspect of the osteotomy cut, thereby decompressing the joint. As the resulting capital fragment is impacted back on the shaft, it will be plantar flexed from 3 to 5 mm downward, reducing the amount of elevatus plantar flexing so that a normal weight-bearing parabola and increased joint motion are provided. This decompression helps prevent arthritis and is in addition to the secondary plane correction provided by the simple Chevron osteotomy.
The Reverdin procedure improves stability via an L-shaped "stage-one" cut, which provides an almost horizontal plantar shelf produced by the osteotomy, and decreased movement during fixation. The stage-one cut also allows lateral transposition to correct for the intermetatarsal angle in a forefoot bunionectomy. The osteotomy can also be plantar flexed, leaving a small gap between the plantar shelf and the base of the bone, providing correction in up to three planes.
The Reverdin procedure is used in severe bi- and tri-plane deformities of the metatarsal where there is a large hallux abductovalgus angle or hallux abductus angle within the toe caused by a deviated joint at the head of the first metatarsal, also known as the proximal articular set angle. When this angle deviates beyond a range of 0 to 8 degrees (i.e., the normal range), a very high hallux abductus angle results, and must be corrected by removing a pie-shaped wedge from the metatarsal (i.e., the "stage two" cut) to realign the joint in a rectus position that is perpendicular to the long axis of the metatarsal.
The Chevron procedure can also be effected as a two-stage process which allows correction of the proximal articular set and HV angles, as well as adjusting the amount of plantar flexion and transposition. Stage one of the revised Chevron procedure is accomplished in the same manner as is the basic Chevron osteotomy. Stage two of the revised procedure adds removal of a pie-shaped bone wedge from each of the dorsal and plantar Chevron cuts, giving increased mobility in the correction-fixation process, as well as increased stability over the Reverdin osteotomy procedure.
Conducting any of the above-mentioned procedures currently involves the free-hand cutting of bone by the surgeon. Considering the size of the bones involved, and the use of extremely sharp cutting instruments by surgeons with gloved hands, it is easily seen that such cutting procedures are prone to alignment errors and require great care to conduct properly. The present invention is directed toward overcoming this problem. It is desirable to have a device for correcting the hallux valgus deformity which involves a minimal amount of free-hand effort by the surgeon. This reduces the time requited for surgery and also the possibility of error. It is also desirable that any device used to assist in the conduct of such osteotomy procedure be compact, inexpensive to manufacture, user-friendly, and rugged.
SUMMARY OF THE INVENTION
In accord with one aspect of the present invention, an apparatus for assisting in the conduct of a Chevron osteotomy procedure is presented. The Chevron guide body serves to facilitate the angular cuts required for Chevron osteotomies especially in the repair of the hallux valgus deformity. The Chevron osteotomy guide body consists of two saw slots intersecting at an apex, which is coincident with a bone pin hole through which Kirschner wire can be inserted to firmly affix the guide to the bone. The Chevron guide body also provides at least one other bone pin hole to precisely locate the cuts on the bone surface.
Other features of the apparatus include a visualizer element, which allows the surgeon to gauge the amount of correction to be expected from a particular saw cut. The visualizer element is formed so as to fit snugly within the saw slots of the guide body and is used prior to making the actual cut in the bone.
In another aspect of the present invention, an apparatus for assisting in the conduct of the Youngswick osteotomy procedure is presented. In this embodiment of the present invention, the Youngswick guide body comprises the same quantity and arrangement of individual elements as does the Chevron guide body. However, the Youngswick guide body further comprises a third saw slot which runs parallel to the first saw slot and intersects the second saw slot. The parallel distance between the first and third saw slots is variable, to accommodate varied widths of bone wafers which may be extracted from the osteotomy after excision via the third saw slot. The distance is selected according to the surgeon's preference for the amount correction desired. The above-mentioned visualizer element is also accommodated by the Youngswick guide body and can be used to indicate the amount of correction to be effected by the Youngswick osteotomy procedure before actual cuts in the bone are made.
In another aspect of the present invention, an apparatus for assisting in the conduct of the Reverdin osteotomy procedure is presented. The Reverdin stage one guide body also consists of an intersecting pair of saw slots. However, the angle of intersection is quite different from that of the Chevron and Youngswick guide bodies. In addition, none of the bone pin holes are normally located at the apex of the saw slot intersection. In the case of the Reverdin stage one guide body, the bone pin holes are preferably located along a line which is perpendicular to the first saw slot and within the arcuate area swept out by both saw slots. The visualizer element is also accommodated by the saw slots of the Reverdin guide for use by the surgeon in visualizing the amount of correction to be effected by Stage one of the Reverdin procedure.
In another aspect of the present invention, a supplementary apparatus to assist in the conduct of the Reverdin osteotomy procedure is presented. A Reverdin stage one body, comprising a pair of saw slots which intersects so as to form a continuous single slot, can be used in the second stage of the Reverdin osteotomy procedure to extract a pie-shaped wedge of bone for correction of severe hallux valgus deformities. The Reverdin stage two body is designed to accommodate the same bone pin hole locations as used by the Reverdin stage one guide body. In use, the Reverdin guide body is fixed in place with two or more Kirschner wires and the Stage one osteotomy is made. After the first osteotomy is complete, the Reverdin stage one guide body is removed and the Reverdin stage two body is put into place, to effect a second osteotomy and complete Stage two of the Reverdin procedure. As is the case with all of the osteotomy apparatus described, the visualizer element can also be accommodated by the saw slots in the Reverdin stage two body.
Another aspect of the present invention provides two different guide bodies for effecting a two stage (revised) Chevron osteotomy procedure. The Chevron stage one guide body is similar to the previously described basic Chevron guide body, but has an elongated central component to which is added an additional bone pin hole. While stage one of the revised Chevron procedure is carried out as per the basic Chevron procedure, an additional Kirschner wire is inserted into the third bone pin hole and is left in place after the Chevron stage one guide body and first Kirschner wire are removed. The Chevron stage two guide body is also similar in appearance to the basic Chevron guide, but instead of vertical saw slots (parallel to the center lines of the bone pin holes), the Chevron stage two guide has saw slots which are angled away from the center lines of the bone pin holes. In addition, the bone pine holes of the Chevron stage two guide are located so as to coincide with the second and third bone pin holes of the Chevron stage one guide, so that the Chevron stage two guide can be placed over the second and third Kirschner wires left in place after stage one of the revised Chevron procedure has been accomplished. It should be apparent to those skilled in the art that the adjustment process involved in stages one and two of the revised Chevron procedure is analogous to that involved in stages one and two of the Reverdin procedure.
Other features of the apparatus include the ability to use the visualizer element as a preventative measure; the visualizer can be placed within the saw slot of the Reverdin stage two body during Stage two of the Reverdin procedure to prevent incursion of the saw into the medial shelf created during the Stage one Reverdin osteotomy procedure.
BRIEF DESCRIPTION OF THE DRAWINGS
FIGS. 1A and 1B are top and side views, respectively, of the (Chevron) osteotomy guide of the present invention.
FIGS. 2A and 2B are top and side views, respectively, of an alternative embodiment of the osteotomy guide of the present invention.
FIGS. 2C and 2D are top and side views, respectively, of an alternative embodiment of the osteotomy guide of the present invention.
FIGS. 3A and 3B are side and front views, respectively, of the visualizer element for the osteotomy guide of the present invention.
FIGS. 4A and 4B are bottom and side views, respectively, of an alternative embodiment of the osteotomy guide of the present invention.
FIGS. 5A and 5B are bottom and side views, respectively, of an alternative embodiment of the osteotomy guide of the present invention.
FIGS. 5C and 5D are bottom and side views, respectively, of an alternative embodiment of the osteotomy guide of the present invention.
FIG. 6 is a dorsal view of the bones of an abnormal right forefoot with the intermetatarsal and hallux valgus angles indicated.
FIGS. 7A and 7B are dorsal and medial views, respectively, of the forefoot after the medial eminence of the first metatarsal shaft has been excised, and the first K-wire inserted.
FIG. 8A is a medial view of the first metatarsal shaft with the osteotomy guide of the present invention applied over the first K-wire.
FIG. 8B is a top view of the osteotomy guide of the present invention pinned in place on the first metatarsal shaft.
FIG. 9A is a medial view of the first metatarsal shaft after the osteotomy has been completed and the K-wires have been removed.
FIG. 9B is a dorsal view of the first metatarsal osteotomy after manipulation to effect corrective alignment.
FIGS. 10A and 10B are dorsal and medial views, respectively, of the first metatarsal shaft after the correctly aligned capital fragment has been fixed in place.
FIGS. 11A and 11B are dorsal and medial views, respectively, of the correctly aligned first metatarsal shaft after insertion of a fixating screw.
FIG. 12A is a dorsal view of the first metatarsal shaft indicating the portion of the medial shelf (created by the osteotomy) which is to be excised.
FIG. 12B is a dorsal view of the completed corrective repair of the first metatarsal shaft.
FIG. 13 is a perspective view of the first metatarsal shaft with an alternative embodiment of the osteotomy (Youngswick) guide of the present invention applied over the first K-wire.
FIG. 14 is a perspective view of the first metatarsal shaft with an alternative embodiment of the osteotomy (Reverdin-Stage one) guide of the present invention applied over the first K-wire.
FIG. 15 is a perspective view of the first metatarsal shaft with an alternative embodiment of the osteotomy (Reverdin-Stage one) guide of the present invention applied over the first K-wire.
FIG. 16 is a medial view of the visualizer element of the present invention as applied to the Chevron osteotomy guide body.
FIGS. 17A-17C are top views of the (Chevron stages one and two) osteotomy guides of the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
FIG. 1 illustrates one embodiment of the osteotomy guide of the present invention. In this particular instance, the embodiment is useful for making Chevron osteotomies. The Chevron guide body 10 is preferably fabricated from stainless steel, but can be made from any other material which is relatively hard, impervious to damage by accidental contact with an osteotomy saw blade, non-corrosive, and biocompatible. First saw slot 20 and second saw slot 30 converge at apex 40, which is also coincident with first bone pin hole 50. First saw slot 20 and second saw slot 30 sweep out an osteotomy angle 90 of about 180° or less. More preferably, the swept out angle 90 should be from about 40° to about 60° for execution of a Chevron osteotomy, and most preferably, the osteotomy angle 90 should be approximately 55°. Second bone pin hole 60 should be located somewhere within the planar arcuate area 70 swept out by the intersection of first saw slot 20 and second saw slot 30. Most preferably, second bone pin hole 60 is located along bisecting line 45, an imaginary line that bisects the planar arcuate area 70 described previously. While there may be a multiplicity of bone pin holes, exemplified by first bone pin hole 50 and second bone pin hole 60, the invention requires at least two such holes to properly affix Chevron guide body 10 to the osteotomy site. Other bone pin holes, through which Kirschner wires (i.e., K-wires) may be inserted, will normally be located within and perpendicular to, planar arcuate area 70.
FIG. 1B illustrates a side view of the Chevron guide body 10. Here it can be seen that first bone pin hole 50 is located slightly behind apex 40 such that the circumference of first bone pin hole 50 is coincident with apex 40. Additionally, it should be noted that first saw slot 20 and second saw slot 30 are cut vertically through Chevron guide body 10. That is, a saw blade entering directly through first saw slot 20 will never intersect with a similar saw blade entering second saw slot 30. In the case of a mild hallux valgus condition, such parallel, non-converging saw blade entry is all that is necessary for producing a corrective Chevron osteotomy.
FIGS. 2A and 2B illustrate top and side views of an alternative embodiment of the osteotomy guide of the present invention, respectively. In FIG. 2A, a guide which is useful for effecting a Youngswick osteotomy is illustrated. Youngswick guide body 75 also contains first saw slot 20 and second saw slot 30, which intersect at apex 40. First bone pin hole 50 is also coincident with apex 40, as described previously in the case of Chevron guide body 10. The location of second bone pin hole 60 is determined as described previously, and normally resides within and perpendicular to the planar arcuate area 70 formed by the intersection of first saw slot 20 and second saw slot 30. Again, osteotomy angle 90 can be set to any angle of 180° or less, but is more preferably fixed at from about 40° to about 60°, and is most preferably fixed at approximately 55°. In this embodiment of the invention, Youngswick guide body 75 further comprises third saw slot 80, which originates at some point along second saw slot 30 and continues on for some distance in parallel with first saw slot 20. FIG. 2C illustrates another embodiment of the osteotomy guide (i.e., Youngswick guide body 75); it can be seen in this illustration that Youngswick distance 95, which is the parallel distance between first saw slot 20 and third saw slot 80, can be varied to accommodate the need for greater or lesser adjustment in the Youngswick osteotomy procedure. FIGS. 2B and 2D illustrate side views of the Youngswick guide body 75 embodiments of the present invention, respectively.
In FIGS. 3A and 3B, visualizer 100, which is an optional element of the osteotomy guide of the present invention, can be seen. Visualizer 100 further comprises key 110 and indicator arm 120. Key 110 is preferably fashioned so as to fit snugly within first saw slot 20 or second saw slot 30 of Chevron guide body 10, and alternatively, within first saw slot 20, second saw slot 30, or third saw slot 80 of Youngswick guide body 75. In use, visualizer 100 is positioned so that key 110 is fitted into one of the aforementioned saw slots (20, 30, or 80) and indicator arm 120 extends outwardly away from apex 40 along the axis of the selected saw slot. Indicator arm 120 extends beyond the end of the selected guide body (10 or 75) for some distance, and is used to create a visual reference for the surgeon so that the extent of the osteotomy correction can be seen before any bone cuts are made. Indicator arm 120 is formed so that it prevents visualizer 100 from slipping completely through the saw slot into which it is placed. The bottom of visualizer 100, key 110, rests against the patient's bone structure and serves as an additional obstacle to migration of visualizer 100 through the selected saw slot.
Turning now to FIGS. 4A and 4B, the bottom and side views, respectively, of an alternative embodiment of the osteotomy guide of the present invention can be seen. This particular embodiment facilitates the Reverdin osteotomy procedure. Reverdin stage one guide body 140 is also characterized by the intersection of first saw slot 20 and second saw slot 30 at apex 40, as are the Chevron guide body 10 and Youngswick guide body 75. Similarly, first bone pin hole 50 and second bone pin hole 60 are required to properly fix the Reverdin guide body in place during use. However, due to the nature of the procedure, bone pin holes 50 and 60 are now located along a perpendicular line 150 which originates at some point along first saw slot 20 and penetrates into the planar arcuate area 70 swept out by first saw slot 20 and second saw slot 30. While not absolutely necessary for the use of the invention, it is preferred that first bone pin hole 50 and second bone pin hole 60 are both located along perpendicular line 150. However, it is possible to effectively construct the Reverdin stage one guide body 140 so that bone pin holes 50 and 60 are not located along perpendicular line 150, but are somewhere else within the planar arcuate area 70. While osteotomy angle 90 may again be 180° or less, it is preferred that osteotomy angle 90 measures from about 95° to about 115°, and it is most preferred that osteotomy angle 90 is fixed at approximately 105°.
FIGS. 4A and 4B illustrate an embodiment of the osteotomy guide which is used during the first stage of the Reverdin surgical osteotomy procedure. The osteotomy guide embodiment used in the second stage of the Reverdin procedure is illustrated in FIGS. 5A and 5B, which show bottom and side views of Reverdin stage two body 170, respectively. In this case, osteotomy angle 90 is equal to 180° and, therefore, first saw slot 20 and second saw slot 30 form a continuous single saw slot opening. There is no bone pin hole located at apex 40, but as is the case with Reverdin stage one guide body 140, first bone pin hole 50 and second bone pin hole 60 are located within the 180° planar arcuate area 70 swept out by the intersection of first saw slot 20 and second saw slot 30. Perpendicular line 150 extends into and is coplanar with the arcuate area 70, originating at some point along first saw slot 20 or second saw slot 30, depending on whether the Reverdin stage two body 170 is to be used on the left or right foot, respectively. Of course, it is also possible to locate perpendicular line 150 at the apex of first and second saw slots 20 and 30. As is more clearly apparent in FIG. 5B, first and second saw slots 20 and 30 are cut at an angle, Reverdin angle 180, into Reverdin stage two body 170. This is in contrast to the other illustrated embodiments, in which first saw slot 20, second saw slot 30, and third saw slot 80 are all vertical, running in a direction parallel to first center line 55 of first bone pin hole 50 and the second center line 65 of the second bone pin hole 60 and perpendicular to arcuate area 70.
Reverdin stage two body 170 is formed so that it may be used on the same patient (during Stage two of the Reverdin procedure), directly after Reverdin stage one guide body 140 (used during Stage one of the Reverdin procedure), if the surgeon so desires. A pair of bone pin holes, first bone pin hole 50 and second bone pin hole 60 are located on Reverdin stage two body 170 so that they coincide directly (i.e. are coincident) with the first and second center lines 55 and 65 of a selected pair of bone pin holes, first bone pin hole 50 and second bone pin hole 60 of Reverdin stage one guide body 140. In use, Reverdin stage two body 170 can be placed directly over the same K-wires used to fix the Reverdin stage one guide body 140 in place. When overlaid in this manner, the exit path 73 of the Reverdin stage two body 170 is located so as to parallel the location of the entry path 72 of the Reverdin stage one guide body 140. However, the exit path 73 is offset by some distance (preferably about 2-5 mm, depending on the amount of correction needed) from the entry path 72. As will be demonstrated subsequently, Reverdin stage two body 170 is used to effect the second stage of the Reverdin osteotomy procedure, which removes a pie-shaped wedge from the metatarsal using artifacts left behind by the surgeon after use of the Reverdin stage one guide body 140. FIGS. 5C and 5D illustrate an alternative embodiment of Reverdin stage two body 170 in which Reverdin angle 180 has been increased to accommodate greater corrections in the hallux valgus condition, as desired by the physician. All other elements of this particular embodiment are identical to that illustrated in FIGS. 5A and 5B.
FIG. 6 illustrates a dorsal view of the bones of an abnormal foot 200 afflicted by the hallux valgus condition. IM angle 210 and HV angle 220 are indicated. That is, it can be clearly seen that the IM angle 210 is the angle swept out by the first metatarsal 230 and second metatarsal 240. The HV angle is described by the intersection of the median axis of the first metatarsal, as it intersects with the median axis of the first phalangeal bone 250.
In accordance with the practice of the instant invention as used in a Chevron osteotomy procedure, the medial eminence 260 of the first metatarsal 230 is exposed and excised along eminence resection line 270. Exposure of the medial eminence 260 is effected by performing a soft tissue release through a medial incision or dorsal medial incision at the first metatarsal, per the surgeon's preference. This is followed by a capsulotomy of the tibial side of the metatarsophalangeal joint. The medial eminence 260 of the first metatarsal 230 head is then deeply exposed and excised.
Turning now to FIGS. 7A and 7B, it can be seen that flat surface 290 is created by excising the medial eminence 260. Flat surface 290 is located along the medial aspect of the distal first metatarsal 230 bone. Once medial eminence 260 has been excised, the surgeon places a 0.045 dia. first K-wire 280 into the first metatarsal at some location on the flat surface 290 where it is desired to locate the apex of the intended Chevron osteotomy. Other sizes of K-wire may also be used, per the surgeon's preference.
Turning now to FIG. 8A, placement of the Chevron guide body 10 can be seen. First bone pin hole 50 is penetrated by first K-wire 280 and Chevron guide body 10 is located so as to directly contact flat surface 290. The exact location of first saw slot 20 and second saw slot 30 can then be visualized, and once the surgeon locates the future cuts precisely, second K-wire 300 is inserted into first metatarsal 230 through second bone pin hole 60 to firmly fix Chevron guide body 10 in place against flat surface 290. If further stability of the Chevron guide body 10 is desired, a mosquito hemostat may be attached to first K-wire 280 and/or second K-wire 300 to firmly fix Chevron guide body 10 against flat surface 290 (not shown). FIG. 8B depicts Chevron guide body fixed in place by first K-wire 280 and second K-wire 300.
A sagittal saw, or equivalent, is placed within first saw slot 20 and second saw slot 30 to cut down and through first and second slots 20 and 30 into first metatarsal 230 to form the Chevron osteotomy. First and second saw slots 20 and 30 are most preferably 0.5 mm wide, so as to accommodate a 0.5 mm sagittal saw blade. The osteotomy is most effectively performed by cutting along the entire distance of first and second saw slots 20 and 30, until the first K-wire 280, located at apex 40 is encountered.
Turning now to FIG. 9A, the first metatarsal 230 is depicted after the osteotomy is complete and Chevron guide body 10 has been removed. First and second K-wires 280 and 300 have also been removed to form first K-wire hole 330 and second K-wire hole 340, respectively. First saw cut 310 and second saw cut 320, created by insertion of a sagittal saw into first saw slot 20 and second saw slot 30, respectively, are also shown.
Once the osteotomy is complete, the surgeon utilizes manual pressure on capital fragment 350 for lateral transposition toward the second metatarsal 240 to a point of correction deemed appropriate by the surgeon. At this time, capital fragment 350 is impacted upon the first metatarsal 230 shaft.
A temporary fixating K-wire 370 is inserted into capital fragment 350 and first metatarsal 230 so as to solidly fixate the osteotomy in place. Fixating K-wire 370 is inserted from a dorsal distal position to a plantar proximal position in preparation for screw fixation. FIG. 10B clearly illustrates the fixating K-wire 370 in place, as the capital fragment 350 has been properly located along the surface of medial shelf 360.
Turning now to FIG. 11A, the placement of a 2.0 mm or 2.7 mm screw, preferably, is shown. Fixating screw 390 is used to effect permanent fixation of the osteotomy so that temporary fixating K-wire 370 can be removed. Insertion of fixating screw 390 is effected using standard surgical techniques. FIG. 11A illustrates the relative locations of fixating K-wire 370 and fixating screw 390. FIG. 11B illustrates a lateral view of first metatarsal 230 after permanent fixation by fixating screw 390 and removal of fixating K-wire 370.
Turning now to FIG. 12A, the shelf resection line 380 can be clearly seen. The medial shelf 360 of bone created by transposition of the capital fragment 350 is now cut away along shelf resection line 380, preferably utilizing a sagittal saw, creating a smooth surface along the proximal side of the first metatarsal 230. FIG. 12B illustrates a dorsal view of the foot 200 after the Chevron osteotomy procedure has been completed. It can be easily seen that the IM angle has now been normalized and the HV angle is drastically reduced.
FIG. 13 illustrates use of the Youngswick guide body 75 when the surgeon has decided that a Youngswick osteotomy is the most appropriate corrective procedure. As in the Chevron osteotomy procedure, the Youngswick guide body 75 is secured to first metatarsal 230 by the use of first and second K-wires 280 and 290 inserted into first and second bone pin holes 50 and 60. However, an additional cut into the bone of first metatarsal 230 is made via third saw slot 80. This has the effect of creating a Chevron osteotomy with an additional wafer of bone to be excised. Bone wafer 400 is created by the intersection of first saw slot 20 and third saw slot 80 with second saw slot 30. Once the Youngswick guide body 75 is removed and the osteotomy is complete, the capital fragment 350 created by the osteotomy is then impacted upon the first metatarsal 230 to provide a transposed relocation of the capital fragment 350, and additionally, a lowered location of the capital fragment 350 in relation to the first metatarsal 230. The choice of guides to use is made by the surgeon preoperatively based on x-rays as previously mentioned. However, it is often not until the wound is opened and the joint can be directly visualized (since the cartilage orientation cannot be adequately viewed on an x-ray) that the proper procedure will be known. The Chevron guide and Youngswick guide systems are designed to be used concurrently, so that if a surgeon has committed a Chevron cut, but later determines that more joint motion is needed, he can position a Youngswick guide of varying correctability over the same K-wires used to fix the Chevron guide in place, and perform a second osteotomy cut to reduce the hallux limitus/rigidus component.
FIGS. 14 and 15 illustrate the use and placement of the Reverdin stage one guide body 140 and Reverdin stage one body 170, respectively. In FIG. 14, it can be seen that placement of the Reverdin stage one guide body 140 on the first metatarsal 230 after resection of the medial eminence 260 is quite similar to placement of the Chevron guide body 10 and Youngswick guide body 75. As mentioned previously, the Reverdin procedure is chosen by the surgeon when tri-plane correction is needed. As is the case with the Chevron guide body 10 and the Youngswick guide body 75, once Reverdin stage one guide body 140 is fixed in place using first and second K-wires 280 and 300 inserted into first and second bone pin holes 50 and 60, the osteotomy can be easily effected by the surgeon by inserting a sagittal or oscillating saw, or equivalent, into the first and second saw slots 20 and 30. Use of mosquito hemostats to secure the Reverdin stage one guide body 140 against the flat surface 290 is optional.
Because the requirements of the Reverdin procedure are somewhat different than those of the Chevron and Youngswick procedures, use of the Reverdin stage two body 170 may be optionally indicated as determined by the surgeon. FIG. 15 illustrates placement of the Reverdin stage two body 170 against flat surface 290 after the Reverdin stage one guide body 140 has been removed and the first osteotomy has been completed. As can be clearly seen in FIG. 15, Reverdin stage two body 170 is designed so as to fit directly over first and second K-wires 280 left in place after removal of the Reverdin stage one guide body 140. Reverdin angle 180 employed by Reverdin stage two body 170 is selected so as to provide, preferably, a base width of two, three, or four millimeters of bone to removed along the length of first saw cut 310. Bone wafer 400 in this case is no longer rectangular in shape (as for the Youngswick procedure), but is pie-shaped. This is caused by the angular cut effected by use of the Reverdin stage two body 170. In the case of the Youngswick guide body 75, first saw slot 20 and third saw slot 80 are parallel, so the bone wafer 400 removed will have parallel sides. Since the entry path 72 of the first saw slot 20 of Reverdin stage one guide body 140 and the exit path 73 of the saw slots in the Reverdin stage two body 170 are non-parallel, and offset, the bone wafer 400 subsequently removed will have non-parallel sides. The shape of the wafer removed is dictated by the requirements of the Reverdin osteotomy procedure and the amount of correction necessary.
FIG. 16 illustrates use of visualizer 100 with the Chevron guide body 10. Visualizer 100 can be inserted into any of the saw slots (20, 30, or 80) of the osteotomy guides of the present invention. Visualizer 100 is intended to temporarily reside in any one of the selected saw slots so that the surgeon can determine the amount of correction which will occur when a particular cut is made. That is, visualizer 100 extends along the line of the cut and for some distance beyond the guide body, making it easy for the surgeon to visualize the amount of correction which will occur. Specifically, visualizer 100 can be used with either the Chevron guide body 10, Youngswick guide body 75, Reverdin stage one guide body 140, or the Reverdin stage two body 170. By way of experimentation, it has been determined that visualizer 100 is also useful during the second stage of the Reverdin osteotomy procedure as a preventative measure. During the second stage of the process, in which the bone wafer 400 is excised using the Reverdin stage two body 170, key 110 of visualizer 100 can be inserted into the end of second saw slot 30 of Reverdin stage two body 170 to prevent incursion into the plantar shelf created by the first stage osteotomy previously effected (by use of the Reverdin stage one guide body 140).
As mentioned previously, the Chevron osteotomy procedure can be performed in two stages to give increased corrective ability, as well as stability. The Chevron stage 1 guide body 410 (shown in FIG. 17A) is very similar to the Chevron guide body 10 illustrated in FIG. 1. First saw slot 20 and second saw slot 30 converge at apex 40, which is also coincident with the first bone pin hole 50. The osteotomy angle 90 swept out by the first and second saw slots 20 and 30 will be about 180° or less. More preferably, the swept out angle 90 should be from about 40° to about 60° for execution of a Chevron osteotomy, and most preferably, the osteotomy angle 90 should be approximately 55°. Second bone pin hole 60 should be located somewhere within the planar arcuate area 70 swept out by the intersection of first saw slot 20 and second saw slot 30. Most preferably, second bone pin hole 60 is located along bisecting line 45, an imaginary line that bisects the planar arcuate area 70 described previously. In the Chevron stage 1 guide body 410, there is also a third bone pin hole 415 located along the bisecting line 45. Other bone pin holes, through which additional Kirschner wires (i.e., K-wires) may be inserted, are located within planar arcuate area 70.
In use, the Chevron stage 1 guide body 415 is applied in the same way as shown for the Chevron guide body 10 in FIGS. 8A and 8B. However, in the case of the two-stage Chevron procedure, a third K-wire is inserted through third bone pin hole 415 before the Chevron stage one guide body 415 and the first K-wire 280 are removed from the site of the osteotomy (after the first Chevron cut is made). This pair of bone pin holes, first and second bone pin holes 430 and 440 of the Chevron stage two guide body 420 (shown in FIGS. 17B and 17C), are designed to coincide (i.e. be coincident) with the second and third bone pin holes 60 and 415 of the Chevron stage one guide, so that they can then placed over the K-wires originally inserted through the second and third bone pin holes 60 and 415 of the Chevron stage one guide body 410, respectively.
FIG. 17B illustrates a top view of the Chevron stage two guide body 420. While a pair of saw slots, first saw slot 20 and a second saw slot 30, converge at an apex 40, it can be seen that the apex 40 is not coincident with the first bone pin hole 430 of the Chevron stage two guide body 420. Furthermore, the first and second exit paths 450 and 460 of the first and second saw slots 20 and 30, respectively, are not located directly underneath the entry points of the saw slots 20 and 30, but exit at an angle which converges above the Chevron stage two guide body 420, and diverges below the body 420. That is, a long saw blade inserted into first saw slot 20 will intersect with a similar saw blade inserted into second saw slot 30. The pair of saw slots, first saw slot 20 and second saw slot 30, are not parallel to the pair of bone pin holes, first bone pin hole 430 and second bone pin hole 440 of the Chevron stage two guide body 420.
FIG. 17C depicts a top view of the Chevron stage two guide body 420 superimposed on a phantom view of the Chevron stage one guide body 410. Here it can be clearly seen that a saw blade entering the first saw slot 20 of the Chevron stage two guide body will exit at an angle back toward the dorsal Chevron stage one osteotomy cut. Similarly, a saw blade entering the second saw slot 30 of the Chevron stage two guide body will exit at an angle back toward the plantar Chevron stage one osteotomy cut. The angle of the first and second exit paths 450 and 460 can be varied to suit the preference of the surgeon and the amount of correction necessary, and will result in various sizes of pie-shaped bone wedges being removed from the dorsal and plantar Chevron cuts.
While the instant invention has been described as used in the repair of a hallux valgus deformity, it should be apparent to those skilled in the art that the invention can also be applied to the repair of many other bone structures, including those of the hands, arms and legs. The guide bodies illustrated herein make it possible for the surgeon to effect various corrective procedures in a minimal amount of time and therefore, at a reduced cost to the patient. In addition, while the use of mosquito hemostats as fixation devices has been specifically described, other devices, such as clamps, adhesives, or other known means of preventing the migration of the guide body along the K-wire shaft can be used. The various osteotomy guides described herein can be used at various angles and various positions as they are mounted to the bones of the foot, as well as to other areas of the body where they can be applied. They can also be employed in various sizes, i.e. various slot lengths and outside diameter variations to be used for both smaller and larger bones in the human body. Also, various angles can be produced within any range from 0 to 180 degrees maintaining the same basic structural configuration. Slot widths will vary depending on the size of the guide and the type of saw and saw blade used for the corresponding procedures.
The preferred embodiment of the present invention is now fully described. The above description, however, is only illustrative of the invention and is not intended to limit the invention in spirit or scope. Only the following claims and their equivalents limit the scope of the invention. | An osteotomy guide apparatus for assisting in the conduct of Chevron, Youngswick, and Reverdin osteotomy procedures. The osteotomy guide comprises a first and second saw slot converging at an apex. The apparatus further comprises a multiplicity of bone pin holes to firmly fix the osteotomy guide in place and optionally, a visualizer element to indicate to the surgeon the amount of correction which may be expected from the procedure before actual bone cuts are made. The guide may also comprise a first and second stage body which operate in a cooperative fashion to increase the amount of correction and stability provided by any given procedure. | 43,073 |
BACKGROUND OF THE INVENTION
[0001] The present invention relates to non-volatile memory devices and methods for operating them. More particularly it relates to a NAND-type flash memory device capable of shortening a copy-back program time by changing an operation of a page buffer, and a method for operating the page buffer.
[0002] Recently, there has been increasing demand for semiconductor memory devices which do not require periodic refresh operations and are electrically programmable and erasable. A program operation writes data to the memory cells.
[0003] To achieve high integration of semiconductor memory devices, NAND-type flash memory devices have a plurality of memory cells that share a common connection. In other words, neighboring cells share a drain and source with each other. Unlike NOR-type flash memory cells, NAND-type flash memory cells are capable of reading out information sequentially.
[0004] NAND-type flash memory devices employ a page buffer in order to store large quantities of information or read out stored data within a short time. The page buffer receives a large amount of data from I/O (Input/Output) PAD to provide the data to a memory cell or store the data in the memory cell to output it. In general, page buffers are comprised of a single register so as to temporarily store data. Recently, NAND-type flash memory devices with a dual register have been introduced for the purpose of improving programming speed when programming a large amount of data.
[0005] Copy-back program operation refers to transmiting data stored in a defective cell to a normal cell utilizing page buffers.
[0006] FIG. 1 is a block diagram illustrating a copy-back program operation of a conventional NAND-type flash memory device.
[0007] With reference to FIG. 1 , a conventional copy-back program operation is carried out as follows. Data stored in a defective cell is read out to a first latch unit 24 of a page buffer 20 . The data read out from the first latch unit 24 is transmitted to a second latch unit 25 . The transmitted data in the second latch unit 25 is programmed to another memory cell that presumably functions properly (or “normal cell”).
[0008] FIG. 2 is a block diagram illustrating program, read, and verification operations of a conventional NAND-type flash memory device.
[0009] With reference to FIG. 2 , if the first latch unit 24 is selected from the first and second latch units 24 and 25 , the second latch unit 25 is inactivated, and program operation 51 and read and verification operation 52 are carried out in the first latch unit 24 . In contrast, if the second latch unit 25 is selected, the first latch unit 24 is inactivated, and program operation 61 and read, and verification operation 62 are carried out in the second latch unit 25 .
[0010] In the above-mentioned copy-back program operation, there is a high probability that errors occur in transmitting data between the first latch unit 24 and the second latch unit 25 . Accordingly, a timing margin may not be sufficiently secured during a copy-back program operation.
BRIEF SUMMARY OF THE INVENTION
[0011] According to embodiments of the present invention, there is provided a non-volatile memory device capable of eliminating errors and reducing copy-back program operation time by changing operations of latch units at page buffers in transmitting data between latch units during a copy-back program operation and a method for operating the page buffers thereof.
[0012] In further embodiments of the present invention, a non-volatile memory device comprises an array including memory cells disposed at intersections of word lines and bit lines and a plurality of page buffers connected to the array by a sensing line. Each of the page buffers comprises a first latch unit and a second latch unit. The first latch unit becomes activated during a copy-back program operation and reads data programmed to a defective memory cell to store the data in a normal cell. The second latch unit is inactivated during the copy-back operation and activated during program, read, and verification operations. In addition, the second latch unit is configured to receive data to be programmed in the memory cells and store the data during the program operation. Furthermore, the second latch unit is configured to read the data programmed in the memory cells and store the read out data during the read and verification operations.
[0013] In another embodiment of the present invention, a method for operating a page buffer of a non-volatile memory device comprises an array including memory cells disposed at intersections of word lines and bit lines and a plurality of page buffers connected to the array by a sensing line and having first and second latch units. The method according to the present invention comprises activating the first latch unit of the page buffer and inactivating the second latch unit of the page buffer during a copy-back program operation and activating the second latch unit and inactivating the first latch unit during program, read, and verification operations.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] The accompanying drawings are included to provide a further understanding of the invention, and are incorporated in and constitute a part of this specification. The drawings illustrate example embodiments of the present invention and, together with the description, serve to explain principles of the present invention. In the drawings:
[0015] FIG. 1 is a block diagram illustrating a copy-back program operation of a conventional NAND-type flash memory device;
[0016] FIG. 2 is a block diagram illustrating program, read, and verification operations of a conventional NAND-type flash memory device;
[0017] FIG. 3 is a block diagram illustrating a copy-back program operation of a NAND-type flash memory device according to one embodiment of the present invention;
[0018] FIG. 4 is a block diagram illustrating program, read, and verification operations of a NAND-type flash memory device according to one embodiment of the present invention;
[0019] FIG. 5 is a circuit diagram the NAND-type flash memory device shown in FIGS. 3 and 4 ;
[0020] FIG. 6 is a circuit diagram illustrating the copy-back program operation of the NAND-type flash memory device shown in FIG. 5 ; and
[0021] FIG. 7 is a circuit diagram illustrating program, read, and verification operations of the NAND-type flash memory device shown in FIG. 5 .
DETAILED DESCRIPTION OF THE INVENTION
[0022] The present invention will be described below in more detail using specific embodiments and the accompanying drawings. The present invention may, however, be embodied in different forms and should not be construed as being limited to the embodiments set forth herein. Rather, these embodiments are provided for illustrative purposes to those skilled in the art. Like numerals refer to like elements.
[0023] Hereinafter, the invention will be described with reference to an exemplary embodiment of the present invention in conjunction with the accompanying drawings.
[0024] FIG. 3 is a block diagram illustrating a copy-back program operation of a NAND-type flash memory device according to a preferred embodiment of the present invention.
[0025] With reference to FIG. 3 , a copy-back program operation is performed as follows. Data is read out from a defective cell by charging a sensing line S 0 utilizing a precharging unit 220 to store the read out data in a first latch unit 230 (step S 401 ). Then, the read out data stored in the first latch unit 230 is reprogrammed to a normal cell (step S 402 ).
[0026] As stated above, the NAND-type flash memory device performs a copy-back program operation utilizing the first latch 230 and not the second latch 240 .
[0027] FIG. 4 is a block diagram illustrating program, read, and verification operations of a NAND-type flash memory device according to a preferred embodiment of the present invention.
[0028] With reference to FIG. 4 , program 410 , read 420 , and verification 430 operations are performed by the second latch unit 240 . The first latch unit 230 is in an inactivated state during the program, read, and verification operations.
[0029] FIG. 5 is a detailed circuit diagram showing the NAND-type flash memory device of FIGS. 3 and 4 .
[0030] With reference to FIG. 5 , the NAND-type flash memory device includes a memory cell array 100 , a page buffer 200 , and a column selection unit 300 .
[0031] In the memory cell array 100 , BLe indicates even numbered bit lines, and BLo indicates odd numbered bit lines. A multiplicity of memory cells MC 1 through MCn are connected to the bit line BLe, and the remainder of memory cells are connected to the bit line BLo. The memory cells connected to one word line (e.g., WL 1 ) forms one page.
[0032] The page buffer 200 is connected between the memory cell array 100 and the column selection unit 300 . Although only one page buffer is shown in FIG. 5 , a plurality of page buffers 200 may be present in the flash memory device. The page buffer 200 is connected through the sensing line S 0 to the bit lines BLe and BLo and includes a bit line selection unit 210 , the precharging unit 220 , the first latch unit 230 , and the second latch unit 240 .
[0033] The bit line selection unit 210 includes transistors N 11 through N 14 . One end of the transistor N 11 is connected to the bit line BLe, and the other end of that is connected to a line providing a power supply signal VIRPWR. The transistor N 11 is turned on/off by applying a gate control signal DISCHe to a gate. This transistor N 11 is turned on by the gate control signal DISCHe so as to apply a power voltage VCC as the power supply signal VIPWR to the bit line BLe and program the corresponding memory cells. One end of the transistor N 12 is connected to the bit line BLo, and the other end of is connected to a line providing a power supply signal VIRPWR. The transistor N 12 is turned on/off by applying the gate control signal DISCHo to a gate. This transistor N 12 is turned on by the gate control signal DISCHo so as to apply the power voltage VCC as the power supply signal VIRPWR to the bit line and program the corresponding memory cells. The NMOS transistor N 13 connects the bit line BLe to the sensing line S 0 in response to a bit line selection signal BSLe. The NMOS transistor N 14 connects the bit line BLo to the sensing line S 0 in response to a bit line selection signal BLe.
[0034] The precharging unit 220 is connected between the power voltage VCC and the sensing line S 0 and includes a PMOS transistor P 11 turned on/off by receiving a precharge signal PRECHb. The PMOS transistor P 11 precharges the sensing line S 0 to the power voltage VCC in reading out data stored in the memory cell.
[0035] The first latch unit 230 is activated only during copy-back program operation and includes NMOS transistors N 21 through N 24 , a first latch circuit LT 1 , and an inverter IV 3 . The first latch circuit LT 1 comprises inverters IV 1 and IV 2 and stores data read from the memory cells. The NMOS transistor N 23 is connected between a node QA of the first latch circuit LT 1 and a ground voltage VSS. In addition, the NMOS transistor N 23 initializes the node QA to “0” and the node QAb to “1” when a reset signal MRST is applied to its gate. The NMOS transistor N 21 is turned on/off in response to a signal of the sensing line S 0 , and the NMOS transistor N 22 is turned on/off in response to a latch signal MLCH. Turning on the NMOS transistor N 21 and the NMOS transistor N 22 at the same time, changes the node QAb to “0” and the node QA to “1”. The inverter IV 3 inverts data of the node QA and then outputs the data. The NMOS transistor N 24 is turned on by a copy-back signal CPBK during a copy-back program operation to transmit data outputted by the inverter IV 3 to a selected bit line (e.g., BLe) through the sensing line S 0 .
[0036] The second latch unit 240 is activated during program, read, and verification operations. The second latch unit 240 includes NMOS transistors N 31 through N 37 , a second latch circuit LT 2 , and an inverter IV 6 . The second latch circuit LT 2 includes inverters IV 3 and IV 4 and stores data that is read out from the memory cells. The NMOS transistor N 33 is provided between a node QA of the second latch circuit LT 2 and a ground voltage VSS. In addition, the NMOS transistor N 33 initializes the node QB to “0” and the node QBb to “1” when a reset signal CRST is applied to its gate. The NMOS transistor N 31 is turned on/off in response to a signal of the sensing line S 0 , and the NMOS transistor N 32 is turned on/off in response to a latch signal CLCH. Turning both NMOS transistor N 31 and NMOS transistor N 32 on at the same time changes the node QBb to “0” and the node QB to “1”. The inverter IV 6 inverts data of the node QBb and then outputs the data. The NMOS transistor N 34 transfers the data that is received from a data line DL to the second latch circuit LT 2 in response to a data input signal DL. The NMOS transistor N 35 transfers the data that received from the data line DL to the second latch circuit LT 2 in response to a data input signal nDI. The NMOS transistor N 36 is turned on by a program signal PGM during a program operation, thereby transferring data outputted from the inverter IV 6 to the sensing line S 0 in order to program the data to the memory cells, i.e., the memory cells that that are associated with the selected bit line BLe or BLo. The NMOS transistor N 37 is turned on by a read-out signal PBD 0 during a read operation, thereby transferring data outputted to the selected bit line BLe or BLo, that is, data outputted from the inverter IV 6 to the data line DL by the column selection unit 300 . A PMOS transistor P 13 is connected between the power voltage VCC and a node nWD 0 and is turned on/off by applying data of the node QB of the second latch circuit LT 2 to the gate. The PMOS transistor P 13 verifies pass/fail of a program according to whether the node nWD 0 is in a floating state or logically high.
[0037] The NMOS transistor N 38 is turned on by a signal CELLIV during a test operation and employed to measure voltage and current of the page buffer.
[0038] The column selection unit 300 connected between the page buffer 200 and the data line DL includes two NMOS transistors N 41 and N 42 , which are controlled by column selection signals YA and YB. The column signal YA and YB are generated by a column addressing unit (not shown).
[0039] FIG. 6 is a circuit diagram illustrating a copy-back program operation of the NAND-type flash memory device according to a preferred embodiment of the present invention.
[0040] A copy-back program operation proceeds in accordance with the following steps. A word line WL 1 is enabled, and stored data in the memory cell MC 1 is read out by selecting the bit line BLe in order to reprogram the stored data to the memory cell MC 2 .
[0041] Nodes QA and QAb of the first latch circuit LT 1 are initialized to “0” and “1”, respectively. Then, the PMOS transistor P 11 is turned on, thereby precharging the sensing line S 0 to a level of the power voltage VCC. Since the memory cell MC 1 is a programmed cell, the sensing line S 0 is maintained in a precharged state.
[0042] The NMOS transistors N 21 and N 22 are turned on so that the nodes QA and QAb of the first latch circuit LT 1 are inverted to “1” and “0”, respectively (Read operation 401 ). Data “1” of the node QA of the first latch circuit LT 1 is inverted to “0” by the inverter IV 3 to be outputted. In this case, the NMOS transistor N 24 is turned on by the copy-back signal CBPK, so that data “0” outputted from the inverter IV 3 is transmitted to the selected bit line BLe by the sensing line S 0 . As a result, the memory cell MC 2 is reprogrammed (Program operation 402 ).
[0043] As mentioned above, the copy-back program operations 401 and 402 are carried out by the first latch unit 230 .
[0044] FIG. 7 is a circuit diagram illustrating program, read, and verification operations of the NAND-type flash memory device according of one embodiment of the present invention.
[0045] For example, a method for programming data in a memory cell selected by the word line WL 1 and the bit line BLo (Program operation 410 ) will be explained herein.
[0046] During a program operation, if data “0” transmitted from the data line DL is inputted to the NMOS transistor N 35 by the column selection unit 300 , the NMOS transistor N 35 is turned on by the data input signal nDI, thereby storing the data “0” in the second latch circuit LT 2 . As a result, the nodes QB and QBb of the second latch circuit LT 2 become “0” and “1”, respectively. At this time, the inverter IV 6 inverts data “1” of the node QBb of the second latch node LT 2 to “0”. The NMOS transistor N 38 is turned on by the program signal PGM to program data in the memory cell by applying the data “0” to the selected bit line (e.g., BLo) by the sensing line S 0 .
[0047] Next, a method for reading data stored in a memory cell selected by the word line WL 1 and the bit line BLo (Read operation 420 ) will be explained.
[0048] During a read operation, the PMOS transistor P 11 is turned on to precharge the sensing line S 0 to power voltage VCC. In this case, if the sensing line S 0 is maintained in a precharged state, the NMOS transistors N 31 and N 32 are turned on. As a result, the nodes QBb and QB of the second latch circuit LT 2 become “0” and “1”. At this time, the inverter IV 6 inverts data “0” of the node QBb of the second latch circuit LT 2 to output data “1”. Contemporaneously, the NMOS transistor N 37 is turned on by the read out signal PBD 0 , thereby transmitting the data “1” to the data line DL through the column selection unit 300 .
[0049] Next, a method for verifying whether data is normally programmed in a memory cell selected by the word line WL 1 and the bit line BLo (Verification operation 430 ) will be explained.
[0050] The PMOS transistor P 11 is turned on to precharge the sensing line S 0 to power voltage VCC. In this case, if the sensing line S 0 is maintained in a precharged state, the NMOS transistors N 31 an N 32 are turned on, so that the nodes QBb and QB of the first latch circuit LT 2 become “0” and “1”, respectively. If so, the PMOS transistor P 13 is turned off by data “1” of the node QB of the second latch circuit LT 2 . Consequently the node nWD 0 is placed in a floating state and the program result is evaluated as “pass”. By contrast, if the sensing line S 0 is discharged, the NMOS transistors N 31 and N 32 become turned off, so that the nodes QBb and QB of the second latch circuit LT 2 are initially maintained to “1” and “0”. Thus, the PMOS transistor P 13 is turned on by data “0” of the node QB of the second latch circuit LT 2 . Consequently the node nWD 0 is raised to the power voltage VCC, and the program result is evaluated as “fail”.
[0051] As previously mentioned, data is read out from a defective memory cell to be stored in a first latch unit. Then, the stored data of the first latch unit is not transmitted to a second latch unit but directly transmitted to a selected bit line. The transmitted data can then be reprogrammed in a memory cell. Therefore, the copy-back program operation speed is advantageously improved over a convention method where the second latch unit is used to reprogram the data.
[0052] The present invention has been described in connection with the specific embodiments of the present invention and the accompanying drawings. It will be apparent to those skilled in the art that various substitution, modifications and changes may be made thereto without departing from the scope and spirit of the invention. | A non-volatile memory device includes a memory cell array including memory cells, each memory cell being defined at an intersection of a word line and a bit line. A page buffer is coupled to the memory cell array via a sensing line. The page buffer comprises a first latch unit including a first latch circuit and coupled to the sensing line, the first latch unit being configured to be activated during a copy-back program operation to read data stored in a first memory cell and reprogram the data to a second memory cell that is different from the first memory cell. The page buffer also includes a second latch unit including a second latch circuit and coupled to the sensing line, the second latch unit being configured not to be activated during the copy-back operation and be activated during program, read, and verification operations, the second latch unit configured to receive data to be programmed in the memory cells and store the data during the program operation, the second latch unit configured to read the data programmed in the memory cells and store the read data during the read and verification operations. | 20,843 |
FIELD OF THE INVENTION
An improved process and apparatus for the production of polyester or other polycondesation polymers is disclosed. In particular, polymerization is conducted in a reaction vessel equipped with a specially designed agitator that exposes the polymer melt within the reaction vessel to inert gas flowing through the vessel. The agitator comprises a plurality of elements that lift a portion of the polymer melt in the reaction vessel and generate films of the polymer melt which films extend in planes that are substantially parallel to central axis of the agitator and the flow of gas through the reaction vessel.
TECHNICAL BACKGROUND
Polyester production from terephthalic acid (TPA) or its esters, such as dimethyl terephthalate (DMT), and glycols is known. This has been accomplished by stage-wise melt polymerization of the dihydroxy ester of the bifunctional carboxylic acid, or low molecular weight oligomers thereof, under successively higher vacuum conditions. In order for the polymerization to continue to the degree needed for most commercial applications, the condensation by-products, especially ethylene glycol, must be removed from the reaction system at vacuums as high as 1-3 mm Hg. Such processes require costly high vacuum equipment, multistage steam jets to create the vacuum, and N 2 purged seals and flanges to minimize leakage of air into the system. Condensate from the steam jets and organic by-products from the system end up as a waste water stream that requires treatment and contributes to volatile organic emissions to the air. The present invention relates to a less costly polymerization process that can be carried out at atmospheric pressure.
Atmospheric pressure processes employing an inert gas have have been disclosed in the prior art, but these suffer from one or more drawbacks such as (1) the quantity of inert gas used is too large to be economical; (2) the reactor size might not be feasible for commercial-scale operation; (3) inert-gas velocities may be too high to be feasible for commercial-scale production, or (4) contact between the inert gas and the polymer melt in the reactor be inadequate or non-uniform. Because of such drawbacks, the processes and apparatus presently employed for commercial production of polyester continue to be conducted under high vacuum. One object of the present invention is to provide further improvement in a process, at about atmospheric pressure, for continuous or batchwise production of polyesters, particularly polyethylene terephthalate, of high molecular weight. In another aspect of the present invention, an improved apparatus that may be employed in a reaction process involving mass transfer of a volatile by-product into an inert gas, is disclosed.
SUMMARY OF THE INVENTION
The present invention is directed to a process for conducting condensation polymerization in a molten state in which an inert gas is employed to assist in removing a volatile condensation by-product. The process further comprises employing a substantially horizontally disposed cylindrical reactor vessel partly filled with a polymerization reaction mass in the form of a melt, which reactor vessel is equipped with the following:
a) a reactor inlet for introducing a polymerizable feed into the reactor vessel;
b) a gas inlet for introducing an inert gas at or near one end of the reactor vessel and a gas outlet for removing the inert gas at or near an opposite end of the reactor vessel, thereby resulting in gas flow past the reaction mass in the reactor vessel;
c) means for maintaining the reaction mass in the molten state; and
d) an agitator that substantially spans the length of the vessel and that rotates on its axis during operation, said agitator comprising a plurality of elements that are longitudinally disposed to convey a portion of the melt as said elements move through the reaction mass and shed the melt as said elements move out of the melt, the elements being positioned such that said elements generate films, the planes of the films being substantially parallel to the central axis of the agitator and the flow of inert gas which is predominantly in the axial direction; and
e) a reactor outlet for removing product polymer from the reactor vessel.
The agitator according to the present invention is different from agitators used in conventional vacuum processes, which agitators consist essentially of rotating disks or screens. Such prior art agitators generate films that are perpendicular to the axis of the reaction vessel.
In a preferred embodiment of the present process, polymerization is conducted at atmospheric pressure. A dihydroxy ester of a bifunctional carboxylic acid, or of a low molecular weight polymerizable oligomer thereof, is polymerized to a product with a high degree of polymerization (DP), preferably in the presence of a polyester polymerization catalyst, wherein by-products of the polymerization are removed from the system by means of an inert gas. This higher degree of polymerization is useful in fibers and films. This process provides an improved method for producing linear aromatic polyesters, especially polyethylene terephthalate (PET), also referred to as polyethylene glycol terephthalate. The bifunctional acid in the production of PET is terephthalic acid (TPA). The process involves the production of polyethylene terephthalate from terephthalic acid and ethylene glycol (EG) by esterification, or from dimethyl terephthalate (DMT) and ethylene glycol by a transesterification stage, followed by polycondensation. The process is conducted at atmospheric pressure or above, thereby avoiding high vacuum equipment and eliminating possible air contamination that causes product decomposition and gel formation. The process comprises esterifying terephthalic acid or transesterifying dimethyl terephthalate with ethylene glycol to produce dihydroxy ethyl terephthalate or its low molecular oligomers, and intimately contacting the dihydroxy ethyl terephthalate or its low molecular weight oligomers in melt form with an inert gas. The volatile reaction by-products are removed with the inert gas, so that the polymerization is complete in less than about 5 hours, preferably less than 3 hours, of contact time while the reactants are kept at a suitable temperature to maintain them in the melt form so as to produce polyethylene terephthalate.
The above processes are preferably conducted in the presence of a polyester polymerization catalyst. However, a catalyst is not needed for the esterification step if the starting material is terephthalic acid. In a preferred embodiment of the invention, a single stream of inert gas is recycled through a polymer finishing stage, a polycondensation stage and a stage wherein ethylene glycol is recovered for reuse in the process.
The invention is also directed to a novel apparatus for carrying out polycondensation or other reaction in which a volatile by-product is removed by mass transfer from a melt to an inert-gas stream.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 represents a schematic drawing of one embodiment of an apparatus that is suitable for carrying out the polymerization of the invention, wherein material having a lower degree of polymerization is converted to material having a high degree of polymerization.
FIG. 2 represents a schematic drawing of one embodiment of a rotatable agitator frame.
FIG. 3 illustrates a rotatable agitator frame comprising an additional inner concentric "cage" formed by another set of agitator elements.
FIGS 4a, b, c, and d illustrate in isometric and cross-sectional views of an agitator employing rectangular screens as agitator elements for the generation of film surface.
FIGS. 5a, b, and c illustrate side and cross-sectional views of an agitator assembly consisting of concentric cylindrical wire cages.
FIG. 6 illustrates concentric octagonal wire cages that can be employed in an agitator assembly.
These figures are for the purpose of schematic illustration and are not drawn to scale.
DETAILED DESCRIPTION OF THE INVENTION
Polymerization according to the present process can be carried out in one vessel or more than one physically distinct vessel in series, wherein the reaction mass is polycondensed to some degree of polymerization in one vessel and then transferred to another vessel for further polymerization. The number of vessels may depend on mechanical considerations related to handling of the polymeric melt as its viscosity increases with the degree of polymerization, heat input requirements to volatilize the by-products of the reaction, and cost. Preferably, a single vessel may be employed to covert a prepolymer to a final product having the desired degree of polymerization (DP).
The process of the present invention may be carried out batchwise or continuously. Batchwise production may be preferred for preparing specialty polymers when the production required is not very large and strict quality control is required particularly with respect to additives. For large scale production for commodity applications, such as staple and yarn, it is more cost effective to carry out the above steps continuously wherein the reactants are fed substantially continuously into the processing vessels and the products are removed substantially continuously. The rates of feed and product removal are coordinated to maintain a substantially steady quantity of the reactants in the reaction vessels while the inert gas flows countercurrently to the flow of the melt.
If two or more vessels are employed in series for conducting the polycondensation, it is preferred that a single stream of inert gas is employed that flows countercurrently to the flow of the melt in the process, i.e., the inert gas leaving a final stage of polymerization is led through the preceeding stage and finally through a stage wherein the ethylene glycol is recovered for reuse and the inert gas is recycled back to the final stage of polymerization.
Polyethylene terephthalate (PET) is manufactured in this process by first reacting terephthalic acid (TPA) or dimethyl terephthalate (DMT) with ethylene glycol (EG). If DMT is the starting material, a suitable transesterification catalyst such as zinc or manganese acetate is used for the reaction. In a preferred process, esterified DMT/TPA is polymerized as a melt at atmospheric pressure or above by intimately contacting the melt with a stream of inert gas (for example, but not limited to, N 2 or CO 2 ) to remove the condensation by-products, mainly, ethylene glycol. Preferably, the inert gas is preheated to about polymerization temperature or above, prior to its introduction into the polymerization equipment. It is preferred that the inert gas velocity through the polymerization equipment be in the range of 0.2 to 3 ft/sec, most preferably 0.3 to 1.5 ft/sec. The vapor leaving the polymerization (containing the ethylene glycol removed) is treated to recover the ethylene glycol for recycle to the esterification stage or for other uses. The inert gas stream is then cleaned up and recycled. Thus, the overall process operates as a closed loop system which avoids environmental pollution and integrates ethylene glycol purification and its recycle into the process.
The quantity of inert gas flow should be sufficient to carry the ethylene glycol to be removed at a partial pressure of ethylene glycol below the equilibrium partial pressure of ethylene glycol with the reaction mass at the operating temperature. The operating temperature during polycondensation is maintained sufficiently high so as to keep the reaction mass in a molten state. Preferably the temperature range is about 270° C. to 300° C. The polymerization equipment is designed so that the interfacial area between the melt and the inert gas is at least 20 square feet, preferably at least about 30 square feet, per cubic foot of the melt and that this surface area is renewed frequently. Under these process conditions, the high degree of polymerization useful for fibers and films can be achieved in less than 5 hours of residence time, and preferably in less than 3 hours of residence time.
To produce good quality product of the desired high degree of polymerization, the polymerization should be completed in a reasonably short period such as less than 5 hours, preferably less than about 3 hours. The polymerization is considered completed when the degree of polymerization (DP) desired for a particular application is achieved. For most common applications, such as fibers, the DP should be at least 50, preferebly at least 60, and most preferably at least 70. By "degree of polymerization" is meant the number average degree of polymerization. Exposure of the polymeric melt to high operating temperatures for prolonged period causes chain cleavage and decomposition reactions with the result that the product is discolored and a high degree of polymerization is not achieved. If the inert gas velocities are too low, polymerization takes longer. If the velocity is too high it can lead to entrainment of the reaction mass in the gas. In a continuous mode of operating, high inert gas velocities in a countercurrent direction can also hinder the flow of the melt through the equipment. Also, higher velocities may require larger quantities of gas flow without substantially increasing the effectiveness of polymerization.
The quantity of inert gas flow employed to remove the ethylene glycol that evolves is sufficiently high so that the partial pressure of ethylene glycol in the gas, at any point in the process, is well below the equilibrium partial pressure of ethylene glycol with the melt at this point. Larger quantities of gas flow generally increase the rate of polymerization but the increase is not proportionately greater. Therefore, very large mounts of gas are not usually necessary or desirable as large quantities increase the size of recycling equipment and the cost. Very large quantities may also require larger size polymerization equipment in order to keep the gas velocity in the desired range.
In the continuous embodiment of this invention, wherein the inert gas flows countercurrently to the flow of the molten reaction mass, effective polymerization rates can be achieved with about 0.3-0.7 pounds of N 2 per pound of the melt (equivalent to about 2 to 5 moles of inert gas per mole of the polymer repeat unit) as long as the inert gas velocity is at least about 0.2 ft/sec, preferably at least about 0.3 ft/sec. The N 2 flow, however, should be at least 0.2 lbs/lb of polymer (equivalent to 1.5 moles of inert gas per mole of polymer repeat unit). Larger quantities of gas flow may however be needed to obtain the preferred gas velocities.
In the process of this invention, the reactant is kept in a molten state, i.e., above its melting point which is about 260°-265° C. At temperatures much above 300° C., decomposition reactions cause product discoloration which interferes with the quality of the product. The reaction mass should preferably be maintained at about 270° C. to about 300° C.
For the polycondensation to continue, ethylene glycol generated must be removed from the reaction mass by the inert gas. This removal is facilitated if there is a high interfacial area between the melt and the gas phase. To complete the polymerization in a reasonably short period, the surface area should be at least about 20 ft 2 /ft 3 of the melt, preferably at least about 30 ft 2 /ft 3 of the melt. A higher surface area is preferred to increase the rate of polymerization. The reaction equipment for contacting the melt and the inert gas should also be designed to frequently renew the interfacial area and mix the polymer melt. This is particularly important as the degree of polymerization increases and the melt becomes very viscous.
The rate of polymerization can be increased by using a suitable polymerization catalyst, particularly where a high interfacial area is provided for inert gas--melt contact. The increase in the overall rate, however, is not proportional to the concentration of catalyst as the removal of ethylene glycol starts to limit the overall polymerization.
The catalyst also increases the rates of decomposition reactions. An effective concentration of catalyst for a set of reaction conditions, such as temperature, gas flow, velocity and surface area, is such that it gives the most enhancement in the rate of polymerization without substantial decomposition. The optimum concentration of catalysts of various species can be determined by experimentation. It would generally be in the range of a few parts per million parts of the polymer, such as about 5-300 parts per million.
Catalysts for facilitating the polymerization are any one or more polyester polymerization catalysts known in the prior art to catalyze such polymerization processes, such as, but not limited to, compounds of antimony, germanium and titanium. Antimony trioxide (Sb 2 O 3 ) is an especially effective catalyst which may be introduced, for convenience, as a glycolate solution in ethylene glycol. Examples of such catalysts are found in U.S. Pat. No. 2,578,660, U.S. Pat. No. 2,647,885 and U.S. Pat. No. 2,789,772, which are incorporated herein by reference.
Dihydroxy esters of various bifunctional carboxylic acids may also be used in the processes described herein. These are monomeric compounds that can polymerize to a polymer. Examples of such compounds are bis(2-hydroxyethyl) terephthalate, bis(3-hydroxypropyl)terephthalate, bis(4-hydroxybutyl) terephthalate, bis(2-hydroxyethyl) naphthalenedioate, bis(2-hydroxyethyl) isophthalate, bis 2-(2-hydroxyethoxy)ethyl!terephthalate, bis 2-(2-hydroxyethoxy)ethyl!isophthalate, bis (4-hydroxymethylcyclohexyl)methyl!terephthalate, bis (4-hydroxymethylcyclohexyl)methyl!isophthalate, and a combination of bis(4-hydroxybutyl) terephthalate and their oligomers. Mixtures of these monomers and oligomers may also be used to produce copolymers.
By a "polymerizable oligomer" is meant any oligomeric material which can polymerize to a polyester. This oligomer may contain low molecular weight polyester, and varying amounts of monomer. For example, the reaction of dimethyl terephthalate or terephthalic acid with ethylene glycol, when carried out to remove methyl ester or carboxylic groups usually yields a mixture of bis(2-hydroxyethyl) terephthalate, low molecular weight polymers (oligomers) of bis(2-hydroxyethyl) terephthalate and oligomers of mono(2-hydroxyethyl) terephthalate (which contains carbonyl groups). This type of material is referred to herein as "polymerizable oligomer".
The process may also be used to produce various polyesters such as poly(ethylene terephthalate), poly(propylene terephthalate), poly(1,4-butylene terephthalate), poly(ethylene naphthalenedioate), poly(ethylene isophthalate), poly(3-oxa-1,5-pentadiyl terephthalate), poly(3-oxa-1,5-pentadiyl isophthalate), poly 1,4-bis(oxymethyl)cyclohexyl terephthalate! and poly 1,4-bis(oxymethyl)cyclohexyl isophthalate!. Poly(ethylene terephthalate) is an especially important commercial product.
The process avoids high vacuum polymerization processes characteristic of the conventional art. Advantages of the process are a simpler flow pattern, lower operating costs and the avoidance of steam jets, hot wells and atmosphere emissions. The process also has environmental advantages due to the elimination of volatile organic emissions and waste water discharge. Furthermore, polymerization is conducted in an inert environment. Therefore, there is less decomposition and gel formation which results in better product quality. Ethylene glycol and inert gas (e.g., N 2 or CO 2 ) are recycled continuously.
In a preferred embodiment of the process, an oligomer exiting the esterifier is prepolymerized to a degree of polymerization (DP) of about 15-30 and this prepolymer is fed to a finisher in order to polymerize it further to a higher DP of between about 50 and 150, preferably about 60 to about 120 and more preferably about 70 to about 90. The finisher is maintained at a temperature greater than about 260° C. but not too high to cause polymer decomposition. A temperature range of about 270° C. to 300° C. is preferred. The polymerization product is continuously removed from the finisher. An inert gas, preferably nitrogen, is heated in a heater to a temperature of from about 280° C. to 320° C. and is introduced into the finisher to flow countercurrent to the direction of polymer flow in order to remove volatile reaction by-products, primarily ethylene glycol. Preferably, the nitrogen is employed in a closed loop and all processing equipment for cleaning and recycling the nitrogen is operated at atmospheric pressure (or above, as is necessary to ensure the flow of nitrogen through the equipment in the loop). The quantity of inert gas introduced into the system is sufficient so that the partial pressure of the by-products is maintained below the equilibrium pressure of the by-products with the melt in order to provide for the continuous polymerization. The quantity of inert gas may be as small as about 0.3-0.7 pounds for each pound of polyethylene terephalate produced.
FIG. 1 illustrates one embodiment of a reactor or finisher that is suitable for carrying out the polymerization of the invention, especially for producing high viscosity polymers having a degree of polymerization encountered in a finisher. The reactor comprises a horizontal, agitated cylindrical reaction vessel 1. The reactor housing 2 is conveniently constructed with a cylindrical body (shell) and end plates 4 and 6 that close off the ends of the cylindrical body. A reactor jacket 8 through which a heat transfer material is passed surrounds the cylindrical body. An exemplary heat-transfer material is Dowtherm® vapor, commercially available from Dow Chemical (Michigan). A reactor inlet 14 for introducing a prepolymer feed into the reactor is shown at one end of the reactor, a reactor outlet 16 for discharging product from the reactor vessel is shown at the opposite end of the reactor.
The esterified DMT or TPA, or low molecular weight oligomers or prepolymers thereof, is continuously introduced as stream 3 at one end of the reaction vessel. A preheated inert gas, such as nitrogen, is continuously introduced as stream 7 at the other end, so as to provide flow countercurrent to the polymer flow. The nitrogen stream 9 carrying reaction by-product vapors, mostly ethylene glycol, leaves the reaction vessel as stream 11. The reaction mass flows as the polymer melt stream 5. The polymerized product, polyethylene terephthalate, is removed as stream 15. The flow rates of streams 3 and 15 are coordinated to be equivalent to each other and controlled so as to provide the desired hold up of the melt in the finisher, usually about 1 to 3 hours, which is equivalent to a melt level at about 1/4 to 1/3 of the diameter of the vessel. The quantity of nitrogen introduced into the system is sufficient so that the partial pressure of the evolving reaction by-products is maintained at less than the equilibrium pressure of the by-products in the, for example, poly(ethylene) terephthalate (PET) melt, so as to provide adequate driving force to remove ethylene glycol from the melt into the gas stream. The diameter of the vessel is designed so that the superficial velocity of the inert gas stream is in the desired range.
In one embodiment of the process, use of Dowtherm® heat transfer fluid or other heating means is eliminated by employing the preheated nitrogen stream itself for heating. In this embodiment the nitrogen stream is first led through the heating jacket 8 in FIG. 1 to maintain the reactor wall above the melting point of the reaction mass, and is then fed as stream 7 to the reaction vessel.
The reaction vessel in FIG. 1 is equipped with an agitator 20 attached via drive shaft 18 to a drive 22 so that the agitator can be rotated at a controlled speed. The mechanical design of the agitator is such that
(a) the walls of the vessel are wiped;
(b) a large interfacial area of at least 20 ft 2 /ft 3 of the melt preferably greater then 30 ft 2 /ft 3 of the melt is created;
(c) the surface area is renewed frequently; and
(d) good mixing is provided.
Although shown horizontally disposed, it is possible for the reactor vessel to be positioned at a grade to facilitate the flow of reaction melt.
The agitator can have various designs, so long as they provide the desired surface area that is substantially parallel to the flow of inert gas during use, which is predominantly axial along the longitudinal central axis of the reaction vessel. In one embodiment, shown in FIG. 2, the agitator 20 comprises paddles 21 attached to rotatable ends 23 and 24 that rotate during use, to form a rotatable frame.
A central axle attached to the agitator in the reactor vessel may extend outside the housing of the reactor vessel where it is attached to a motor or drive for providing rotation of the agitator at a suitable rate.
The frame may comprise at least two sets of a pluraltity of arms that radially extent from the longitudinal axis of the reaction vessel. Each pair of arms can support a wiper, which is suitable as an elongated paddle. The edge of the paddle may be beveled to better wipe the internal surface of the reaction vessel. The wipers, or wiper blades, may be set at a suitable angle to move a suitable amount of melt as they move through the melt pool, so shedding of the melt for generating films can last through most of the rotation outside the pool. If the angle is such that the space between the wiper and the cylindrical wall is too narrow, the wipers will carry only a small amount of melt which may become quickly depleted by running through the clearance between the wipers and the cylindrical wall, and not enough left to generate films or be wiped on the inside cylindrical wall. If the angle is to large, on the other hand, more melt unnecessarily will be carried around.
The number of wiper blades and the number of arms attached to them at a point along the length of the reaction vessel may vary. Large diameter vessels would generally have more wipers. Also, there may be more wipers near the feed end, where the melt is less viscous, and less near the product end where the melt is very viscous. The wipers may, for example, be 2 to 32 in number, preferably 4 to 12 in number.
The wiper-frame assembly is of mechanically strong construction to withstand the torque required to move through the viscous polymer melt and carry it. In one embodiment, cross rods are attached between the wiper blades for mechanical reinforcement.
As the wipers or paddles move out of the pool of reaction mass, they shed the polymer melt as films that last for a short distance as the surface tension starts to gradually pull the melt film together into thicker streams that have much less surface area. It has been observed that the films last for about 1/2 inch when the DP is about 30-40, about 1 inch at about 50 DP and about 2 inch at 60-80 DP. Therefore, to maximize the surface area, additional longitudinal elements are placed under the wipers, at suitable distances, over which the melt can fall and continue to shed as films. It is advantageous to maintain the spacing between the elements narrow near the feed end where the melt is quite fluid and easily spreads into thin films, and to increase the spacing towards the product end where the melt is very viscous and flows as thick films. If the spacing is too narrow, the viscous melt would stagnate between the elements and not generate the desired surface area. Thus, the spacing may be as small as 1/2 inch near the feed end and 2-4 inch near the product end. Spacing can be optimized for a given diameter reaction vessel and speed of rotation. The longitudinal elements may be rectangular bars, rods, wires, meshed screen or sheets of metal punched out or cut to form grids of desired spacing. These may be arranged to form a "cage" or a plurality of concentric "cages" as shown in FIG. 3.
Alternatively, as shown in FIG. 4, the elements may be arranged in a rectangular geometry, these rectangles being substantially parallel to each other and extending longitudinally, again keeping the spacing larger at the viscous end and smaller at the less viscous end. The agitator may be thus built in sections that appear like a "stack" or a "sandwhich" of rectangular assemblies. These sections may be installed in the agitator frame staggered, e.g., the plane of one section may be perpendicular to those of the next section to as to keep the inert gas well distributed and to minimize by-passing (running through) of the melt by making the path more tortuous.
In FIG. 4, the elements are meshed screens, but these could be of other configurations such as rods or punched sheets of metal. In this type of agitator, the melt picked up by the wipers during their travel through the pool at the bottom, and thereafter shed by the wipers, flows along the rectangular elements to generate surface area.
The agitator is rotated at a rate (rpm) that maximizes the generation of surface area and provides frequent surface renewal. Faster surface renewal is advantageous for increasing the coefficient of transfer of volatile products from the reaction melt to inert gas but rotation that is too fast can result in the viscous polymer melt being held as "globs" between the elements and, in fact, decrease the surface renewal rate. For attaining a reasonably good transfer coefficient it is preferred that the surface be renewed at least once per minute. The agitator speed is also important to surface area generation. If the rotation is too slow, sufficient melt is not lifted from the pool, or is shed too early, and all the elements do not generate films. If the rotation is too fast the melt may be caught up as "globs" and does not flow effectively to generate surface area. The rate of transfer of the volatile by-products, and hence the rate at which the polymer DP increases is proportional to both the transfer coefficient (k) and the surface area (a). The rate of rotation, or revolutions per minute (rpm) for a given agitator geometry and vessel diameter may be optimized to maximize the product k×a. Preferably, the agitator is rotated at about 1 to 60 rpm, more preferably at about 1-30 rpm and most preferably at about 2-18 rpm.
To illustrate a "cage" type construction in detail, one embodiment of an agitator is shown in FIG. 5 in which the elements are wires, the circumferential spacing of which varies along the length of the reactor vessel. The spacing is narrower at the feed end and wider at the discharge end. The agitator is divided into sections, and a plurality of concentric "cages" can exist in each section, the number of which may vary from section to section.
Surface area in this type of configuration is generated in two ways, first by filming of the melt circumferentially over the "cage" and, second, by drainage of the melt from the elements of one "cage" down to a smaller diameter "cage" below. The spacing and rpm are optimized so as to obtain good circumferential coverage and drainage at all points along the length of the agitator. The carrying of melt "globs" is minimized as discussed earlier. At the preferred 2-12 rpm, the spacing near the feed end may be as narrow as 1/2 inch and, near the product end, it may be 2-3 inches. Thus, it is preferable to have more concentric "cages" near the feed end and less at the discharge end. The surface area generated per unit length is, therefore, greater near the feed end and decreases along the length towards the product end as the number of "cages" decreases. To compensate for this, sections of larger spacing can be made proportionately longer. In this manner, the surface generated at each spacing, and hence the increase in DP at each spacing, is about the same.
The surface area created in the reactor equals the sum of (A) the wiped surface on the inside wall of the reactor, (B) the surface area of the melt pool, (C) the surface area of the agitator elements and those of the melt films generated as the agitator rotates. The area of the film is to be multiplied by 2 to account for the surface area available for mass transfer from both the sides of the films.
As the reactor size increases, contributions to the surface area from (A) and (B) decreases in relation to that from (C). Thus, for large, commercial scale finishers, most of the surface area is from the films generated by the agitator elements and the area due to (A) and (B) may be neglected for design purposes. For example, a 7 ft. diameter×29 ft. long reactor, designed to generate 15,000 square ft. of surface area, the contribution from (A) and (B) is less than 4%.
In calculating the surface area, that could be generated with an agitator assembly being considered, it is first assumed that an optimum combination of agitator RPM and element spacing is selected to maximize films generation, e.g., in the screens and wire "cage" type agitators, the screens and circumferential area of the "cages" are completely covered with melt. The film surface area is twice the covered area to account for the two sides of the films. Preferably, the reactor is designed for a higher area to compensate for less than complete coverage during operation under sub-optimal conditions.
The overall agitator for the reactor is conveniently built in sections or "spool pieces" that may be fastened together by suitable means. Fabricating the agitator in spool pieces offers the flexibility of providing different spacings or other variations depending on the particular application or conditions of use.
Such sectionalized fabrication of the agitator also allows the insertion of baffles, for example discs and donuts which contribute to the distribution of inert gas and improves contact between inert gas and the reaction mass. This also compartmentalizes the reactor longitudinally so that when it is operated continuously it acts like a number of reactors in series and the performance approaches that of a plug flow or a batch reactor.
The length and spacing of each Section can be conveniently determined by the following equations in which L is the total length of the agitator, N is the number of sections desired. The length of the first section (at the feed end) is given by the following equation: ##EQU1##
where X=number of folds increase in the DP which is equal to DP of product/DP of the feed.
For subsequent sections, the nth section length is preferably defined as follows: ##EQU2##
wherein p n is the pitch or spacing of the wires in the nth section and p 1 is the spacing in the first section. The parameter P n is related to p 1 by the following equation. ##EQU3##
For concentric "cages" in a given section, the spacing between the consecutive cages equals the pitch.
The length of each section as calculated above may be rounded to a convenient figure for fabrication, such that:
L.sub.1 +L.sub.2 +L.sub.3 . . . L.sub.N =L
The wires selected for this construction are of suitable gauge and have adequate mechanical strength to withstand the shear stresses of the viscous polymer melt. The wires may be 1/16" diameter near the feed end and of thicker gauge, for example, 3/16" diameter, near the viscous product end. Cross wires may be welded circumferentially at suitable distances, e.g., 3 to 5 times the pitch or wire spacing, for mechanical strength.
For ease of fabrication, a long rectangular wire mat of desired pitch and cross-wires distance may be first constructed and then rolled into a "spiral", instead of constructing individual "cages," while keeping the separation between consecutive winding of the spiral about the same as the distance between consecutive concentric "cages," i.e., about equal to the wire spacing.
The "cages" need not be necessarily cylindrical. For ease of fabrication, these may be of geometries such as hexagonal, octagonal, etc. FIG. 6 shows an octagonal assembly of wire cages as viewed from the end of the agitator. Rectangular sections of wire mats 30 are attached to the radial arms 33 of a rotatable end. Such geometries allow the wire mats to be cut or made in rectangular sections that can be welded to the radial arms.
The reaction vessel and the agitator is constructed from a suitable material of construction having the adequate mechanical strength at the operating temperature and which material, in order to produce a quality product, is not easily corroded or reactive with the reaction mass so as to contaminate the product. Stainless steel is one suitable material having the requisite properties.
The surface area needed to achieve a given degree of polymerization (DP) can be estimated, as a first approximation, by using the following simple equation which has been found to hold when polymerization is conducted under batch or plug flow conditions and a large quantity of inert gas is employed:
DP-DP°=kat
In this equation:
DP=the desired product DP
DP°=DP of the feed prepolymer or oligomer
a=surface area in square feet
t=residence time or hold up time in hours
k=overall transfer coefficient for transfer of the volatile condensation by-products, mostly ethylene glycol, from the melt to the insert gas. The units are ft/hr.
The transfer coefficient, k, depends upon several factors, such as temperature, surface renewal rate, catalyst concentration and inert gas velocity. Under the conditions of Example 1, its value was found to be about 0.79 ft/hr.
Thus, for polymerizing a prepolymer of 20 DP to a product of 80 DP in 2 hours of residence time, the surface area required, using this value for k, can be calculated as: ##EQU4##
For continuous polymerization, the reactor is preferably designed to provide a larger surface area, such as 50-75 ft 2 /ft 3 of melt for the above example, to compensate for using less inert gas flow, e.g., 0.3-0.7 lbs N 2 /lb of melt, and for deviations of the melt flow from the ideal plug flow. The higher than calculated surface area also permits operating flexibility. If the reactor has less area, the hold up time would need to be proportionately longer than 2 hours. The agitator configurations described herein can provide the required high surface areas.
For running the polymerization reaction continuously, it is desirable that the residence time distribution of the melt flow be narrow, i.e., it is closer to plug flow, and by-passing is prevented. By-passing can potentially occur around the straight paddles and agitator elements, particularly when the melt is not highly viscous.
The reactor may also be divided longitudinally into a number of compartments by introducing baffles such that melt flows from one compartment to the next and the reactor thus performs like several smaller reactors in series. One convenient way to achieve this is to insert along the length of the agitator rings or donuts with an outside diameter equal to that of the agitator. The inside diameter of the donuts is such that the reactor operates at the desired level. The inside diameter may be about 0.7 times the outside diameter. Disks may also be inserted in between the donuts to form a donut-disk-donut pattern, to keep the inert gas flow well distributed and improve contact with melt by forcing it to go through the donut and then around the disk, and so on. The baffles are sized such that the velocity of gas through, around or between them is not too high to cause entrainment or push melt in the direction of the inert gas flow.
Similarly, another embodiment of the agitator comprises partial disks or partial rings installed such that the inside edges are staggered at 180°, i.e., alternate baffles face in opposite directions, so that inert gas will zigzag as well as swirl, creating greater turbulence and more effective contact with the melt, as these are rotated.
The process of this invention may also be carried out for batchwise preparation of polyester wherein a batch of low molecular weight oligomer is charged to the polymerization equipment and contacted with the inert gas as described until the desired high degree of polymerization is achieved. The oligomer is prepared by esterification as described except that it may also be prepared batchwise either in a separate vessel or in the polymerization vessel itself. The gas and melt contacting equipment may be similar to that described for the continuous embodiment of this invention except that it is not necessary to vary the spacing between the agitator elements along the length of the vessel. Also, compartmentalization to approach plug flow is not required. The spacing of agitator elements should be chosen to accommodate the viscosity and flow characteristics of the final high molecular weight product. For batchwise preparation it is advantageous to adjust the speed of the agitator as the viscosity of the melt increases. Initially, when the viscosity is low, the agitator may operate at as high as 100 rpm but toward the completion of polymerization a low speed of about 1 to 20 rpm, preferably about 2-12 rpm is desirable. Batchwise production is suitable for economic reasons when relatively small quantities of polyester are to be prepared or when a strict control of additives concentrations is required for product quality considerations. When the quantities to be prepared are very small, it may be more economical to not provide equipment for recycling the inert gas, or the ethylene glycol, and discharge it to the atmosphere after rendering it harmless to the environment by known methods such as scrubbing it thoroughly with water and disposing off the water in an environmentally safe manner.
The invention can also be conducted in a semi-batch fashion wherein the polymerization equipment is fed intermittently, reaction mass is polymerized to a higher degree, and the product is discharged intermittently.
EXAMPLE 1
This examples illustrates polymerization on a pilot scale in a polymerization reactor according to the present invention. The reactor consisted of a nominal 6 inch diameter glass tube of 2 feet length. It was held inside an 8 inch diameter glass tube of similar length with the help of end plates so as to form an even annular space around the reactor and served as the heating jacket. The heating medium was air heated to 295°-300° C. which was introduced into the annular space at one end and flowed out from the other end.
The agitator consisted of two end pieces each with four arms in the shape of a cross. Each pair of arms held an approximately 20" long, 1" wide paddle or a wiper. Two rings were mounted inside this frame, each a few inches inside from the ends to hold four more such blades, such that the 8 blades formed a "cage" of slightly smaller diameter than the 6" diameter of the reactor so it could be freely rotated inside the reactor. Shafts were attached to the two cross end pieces which could be rotated inside bearings provided in the center of each end plate of the reactor. The agitator was rotated by use of a motor having a variable speed gear reducer attached to the shaft on one end of the reactor. The temperature of the polymer melt and the inert gas was monitored by placing thermocouples inserted into the reactor from each of its two ends.
The reactor was charged with 9 pounds of a prepolymer of about 20 DP obtained from a commercial plant where it was made by esterifying TPA with ethylene glycol and prepolymerizing it to a DP of about 20. It contained about 200 ppm antimony as catalyst. The charging was done by feeding the solid prepolymer through a melt extruder which melted the prepolymer and heated it to about 280°-295° C. The agitator was rotated at 12 rpm, and N 2 preheated to about 295° C. was flowed through the reactor at a velocity of 0.57 ft/sec based on an empty cross-section of the reactor. Since the reactor was about 30% filled with melt the contact velocity was about 0.82 ft/sec. The N 2 was introduced at one end and was discharged to the atmosphere from the other end. Thus, the reactor was essentially at atmospheric pressure. The temperature of the reaction mass was maintained at about 280° C. by controlling the temperature of the hot air in the annulus. Polymerization was continued under these conditions for two hours. Samples of the polymer were taken every half hour and analyzed for DP by gel permeation chromatography (GPC). The number average DP was found to be approximately 36, 52, 68, and 80, after 1/2, 1, 11/2 and 2 hours of polymerization, respectively. These DP values when plotted against time fit a straight line:
DP-DP°=(ka)t
with a slope=ka of 30 hr.sup.-1.
The reactor was estimated to provide on the average 4.58 ft 2 of film area which for 9 lbs. of the melt translates to a value of "a" equal to 38 ft 2 /ft 3 of melt. The value of k was thus 30/38=0.79 ft/hr.
Initially, when the melt was at 20 DP, it was shed from the agitator blades as streamlets but after a few minutes it started becoming viscous and falling as films that extended about 1/4-1/2" from the edges of the blades. As the polymerization proceeded to higher DP's the filming became more pronounced. The melt extended as films 3/4-1" from the blades and towards the end the shed films extended 1-11/2". Thus, larger surface area could have been generated if additional elements had been placed in the agitator, under the blades, over which the melt could fall and drop further as films. Also, instead of using hot air in the annular heating jacket, preheated N 2 could have been first passed through the annulus and then fed to the reactor.
EXAMPLE 2
This example illustrates a design of a prototype finisher according to the present invention to be operated continuously at a rate of 100 to 150 lbs/hr. It will be continuously fed with a prepolymer of 20 DP prepared in an upstream esterifier and a prepolymerizer. The reactor is designed to produce product PET of about 80 DP useful for spinning into fibers or producing flakes. The reactor is 9 ft long and has a diameter of 18 inches. It has a heating jacket heated with Dowtherm® vapor. It is fired with a 7.5 ft long agitator to leave about 9 inches of space on each end for feed and discharge nozzles. The agitator has end pieces or plates that each extend to 8 arms which are attached to the shafts for rotation. To each pair of arms is attached a 11/2" wide wiper blade positioned at a 45° angle to the inside wall of the reactor. Held inside this eight wiper frame are spools of concentric "cages" of varying pithces fabricated from stainless steel wires such that, starting from the feed end, there is a 9 inch long section of 1/2" pitch (and spacing between the consecutive concentric "cages"), then 18" length of "cages" of 1" pitch, followed by 27" length "cages" that are at 11/2" pitch and finally 36" length concentric cages of 2" pitch where the concentric "cages" are 2" apart. Donuts and disks are inserted alternatively between the spool pieces so the reactor is compartmentalized to act as 4 reactors in series. The agitator can be rotated at 3-12 rpm. Spools of each of the 1/2", 1", 11/2" and 2" pitches can provide about 57 ft 2 of surface area for a total of 228 ft 2 of surface area. The reactor is operated with about 300 lbs or 4 ft 3 of melt hold up. This translates to an average surface area of 57 ft 2 /ft 3 of the melt which is about 50% more than what would be required if it performed as an ideal plug flow reactor. N 2 is flowed countercurrently to the flow of the melt at 90 to 120 lbs/hr. The superficial gas velocity under the operating condition of about 1 atmosphere pressure and 285° C., based on an empty cross-section, is 0.36 to 0.48 ft/sec. | An improved process and apparatus for the production of polyester or other polycondesation polymers is disclosed. In particular, polymerization is conducted in a reaction vessel equipped with a specially designed agitator that exposes the polymer melt partially filling the reaction vessel to inert gas flowing through the vessel. The agitator comprises a plurality of elements that lift a portion of a polymer melt in the reaction vessel and generate films of the polymer melt which films extends in planes that are substantially parallel to the axis of the agitator and the flow of gas through the reaction vessel. In a preferred process, a melt of dihydroxy ethyl terephthalate, or its low molecular oligomers, obtained by esterifying terephthalic acid or transesterifying dimethyl terephthalate with ethylene glycol, is intimately contacted with an inert gas at about atmospheric pressure in order to remove the reaction by-products and facilitate polymerization. | 48,895 |
FIELD OF THE INVENTION
This invention relates generally to sub-miniature switches and is more particularly concerned with momentary and alternate action toggle switches of relatively narrow configuration. The principles of the invention may also be applied to pushbutton and slide switches.
DISCUSSION OF THE PRIOR ART
Many types of prior art sub-miniature switches of the alternate action or momentary type are available. The degree of miniaturization of such switches is limited, however, because most of them require separate operating members to perform the functions of making contact, providing a bias to the actuating means, and acting as a detent for the actuating means. Normally, in a toggle switch, and in a pushbutton switch, an internal coil spring is required to bias the switch actuator, such as the toggle or the pushbutton. Furthermore, such switches are subject to periodic failure because of the large number of parts involved. In addition, tolerances become a significant factor in the fabrication of the switches, and may very well prevent the use of standard fabrication techniques, thereby increasing the manufacturing costs of such devices. The large number of parts also contributes to relatively high manufacturing cost.
Several examples of these prior art toggle switches are shown in U.S. Pat. Nos. 3,989,915; 3,935,411; and 3,852,557. Each of the above-referenced toggle switches employs a coiled spring within the toggle lever to provide the necessary biasing pressure, and each employs a non-flexible, conductive blade pivotally mounted within the switch body. Examples of prior art switches using leaf springs are shown in U.S. Pat. Nos. 3,742,171 and 3,670,121, wherein a rocker actuating member mounted onto the housing by laterally disposed pins pivots a leaf spring into a desired operative position by means of an intermediate actuating member. The switches shown therein are of a single throw configuration. A general example of a prior art pushbutton switch is shown in U.S. Pat. No. 4,095,070, assigned to the assignee of the present invention.
SUMMARY OF THE INVENTION
This invention relates to sub-miniature switches which may be actuated either by toggle means, pushbutton means or sliding means, and which may be constructed for use either in an alternate action or a momentary mode. In each instance, a pre-formed wire contact performs the operations of biasing the actuating means, creating an electrical connection between two terminals and acting as a detent to retain the actuating means in the desired operating position.
In the preferred embodiment, the pre-formed wire contact has a generally U-shaped configuration with a lower arm and an upper arm. The lower arm is pivotally disposed on a raised central terminal located between two other electrical terminals. The contact is adapted to be pivoted about the central terminal in response to the action of a switch actuator on the upper arm and to selectively engage the other two terminals. Preferably, the switch actuator is a toggle mechanism having an actuator tip formed of a dielectric material, which rides along the upper arm, an external lever and an enlarged portion captured within the switch by peripheral shoulders formed on the switch housing. The actuator tip is biased away from the terminals and the enlarged portion is biased against the shoulders by the spring action of the contact and, therefore, any additional internal biasing spring of the type found in most prior art toggle switches is not required. Furthermore, by appropriately shaping the contact for the desired switch functions, the contact also satisfies the need for a detent for the actuator tip so that the switch has one or more stable operative positions.
Because of the narrow configuration of the contacts in this switch, a two-pole switch may be constructed merely by placing the wire contacts and the corresponding sets of terminals immediately adjacent one another, and all wire contacts may be operated simultaneously by the same actuator. The size of the switch thus need not be increased to provide a double-pole operation.
In both the slide and pushbutton configurations of this invention, the pre-formed wire contact again serves the three functions of biasing, acting as a detent and providing electrical contact. A pushbutton has a plunger configuration provided with a finger above one of the outer terminals for urging the contact into connection with the terminal and for pivoting the contact about the central terminal. In the slide configuration, the actuator is provided with an actuator tip that rides along the upper arm of the contact to pivot the contact about the central terminal into the desired operative position.
BRIEF DESCRIPTION OF THE DRAWINGS
The objects, advantages and features of this invention will be more clearly appreciated from the following detailed description taken in conjunction with the accompanying drawing in which:
FIG. 1 is a cut-away perspective view of one embodiment of the switch of this invention;
FIG. 2 is an exploded perspective view of the switch of FIG. 1;
FIG. 3 is a cross-sectional side view of the switch of FIG. 1 configured for ON-ON action;
FIG. 4 is a cross-sectional side view of the switch of FIG. 1 configured for a momentary action;
FIG. 5 is a cross-sectional side view of the switch of FIG. 1 configured for ON-OFF-ON action;
FIG. 6 is a cross-sectional front view of the switch of FIG. 1;
FIG. 7 is a cut-away perspective view of the switch of FIG. 1 showing the modifications necessary for use of the switch as a double-pole device;
FIG. 8 is a cut-away perspective view of the switch of FIG. 1 showing a pushbutton actuator;
FIG. 9 is a cross-sectional side view of the switch of FIG. 8; and
FIG. 10 is a cut-away perspective view of the switch of FIG. 1 showing a slide actuator.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
With reference now to the drawing and more particularly to FIGS. 1 and 2 thereof, there is shown a switch 10 comprising an insulative case 12, and insulative base 16 and a normally metal bushing 11. These three elements together comprise the overall static envelope or housing for the switch 10. Extending through bushing 11 is a bore 30, the central portion of which is narrowed to form an annular shoulder 22. Within case 12 is formed a cavity 13 for receiving the operative portions of the switch to be later described.
Extending outwardly from the base 16 of the housing are center electrical terminal 17 and end electrical terminals 18 and 19 preferably spaced symmetrically on either side thereof. Terminals 17, 18 and 19 also project through base 16 into cavity 13 and terminate therein. Center terminal 17 preferably projects a greater distance into cavity 13 than do terminals 18 and 19. The end of terminal 17 within cavity 13 preferably has a raised central portion toward terminals 18 and 19. The ends of terminals 18 and 19 within cavity 13 generally have a flat configuration.
Contact 40 is pivotally disposed on the central portion of raised terminal 17 within cavity 13. Contact 40 is a wire spring which may be pre-shaped into any one of a number of desired configurations and which may be formed of any suitable material having a substantial spring function and long life. Contact 40, as shown, has a substantially U-shaped configuration and includes an upper arm 46, a lower arm 48, a curved resilient bight 50 and a substantially open end 52. Lower arm 48 rests on terminal 17 which serves as a fulcrum for contact 40 to pivot thereabout. Bight 50 of contact 40 is tensioned during shaping and bending so that a bias is imparted to the contact, causing it to have a tendency to pivot upper arm 46 and lower arm 48 away from one another about bight 50 and to thereby enlarge open end 52. Shoulders 69 and 71 formed on side walls of the interior of cavity 13 define grooves 42 and 43 respectively therebetween, as shown in FIGS. 1 and 3. Open end 52 of the contact is laterally confined within groove 43, while bight 50 is laterally confined within groove 42, so that contact 40 is retained in the desired upright position within cavity 13. Grooves 43 and 42 permit end 52 and bight 50 to ride up and down therein as contact 40 pivots about terminal 17.
The actuator assembly 20 extends downwardly through bore 30 and into cavity 13. The actuator 20 includes a toggle lever 28, an enlarged portion 24 and actuator tip 31. Actuator tip 31 includes laterally spaced legs 33 and 34 having a downwardly open channel 32 formed therebetween. Wedge 80, having a downwardly facing apex, is disposed between legs 33 and 34 at the upper termination of channel 32. Legs 33 and 34 are adapted to closely straddle upper arm 46, and the bias applied to contact 40 drives upper arm 46 against the apex of wedge 80 to provide continual tensioned contact therebetween. An upward bias is thereby applied to enlarged portion 24, as shown in FIG. 1, urging portion 24 against shoulder 22 to capture portion 24 within bore 30 and to retain actuator assembly 20 in the desired upright position. This upward bias applied to enlarged portion 24 assists in sealing the switch at bore 30 and in maintaining actuator assembly 20 in a positive condition so that it moves smartly from one operative position to another and stays firmly in a desired operative position. Enlarged portion 24 also is the point about which actuator assembly 20 rotates when lateral force is applied to toggle lever 28. An O-ring seal may be affixed around enlarged portion 24 to provide an oscillatory seal between the enlarged portion 24 and shoulders 22. The combination of the upward bias applied to portion 24 and the presence of O-ring seals 26 would provide an environmentally tight seal between portion 24 and shoulders 22. If desired, the switch may be assembled without an O-ring and its operation is not affected.
Associated with legs 33 and 34 are arcuate ramps 21 and 23, respectively. Ramps 21 and 23 are disposed on base 16 within cavity 13 in confronting relationship with the distal ends of legs 33 and 34, respectively. Ramps 21 and 23 serve as stops so that excessive longitudinal force applied to toggle lever 28 will not urge actuator tip 31 into cavity 13 past a predetermined point. When such longitudinal forces are applied to toggle lever 28, the distal ends of legs 33 and 34 are driven against ramps 21 and 23 when the predetermined point has been reached. This predetermined point depends upon the length of legs 33 and 34 and the displacement of the top of ramps 21 and 23 above the surface of base 16. In this manner, contact 40 is protected from damage or deformation by such forces. Legs 33 and 34 are preferably of sufficient width to provide the strength necessary to withstand any anticipated longitudinal forces.
Lower arm 48 of the contact is pre-shaped to selectively provide an electrical connection between terminal 17 and either terminal 18 or terminal 19, depending on the position of actuator tip 31. Arm 48 is urged into firm electrical connection with the desired terminals by the bias built into contact 40. Upper arm 46 is shaped to serve as a detent for actuator tip 31. The combination of the upper arm 46 configuration and the bias applied to contact 40 maintains actuator tip 31 in a desired operative position. In FIG. 3, for example, a slight upward curve 45 is provided on the left portion of the upper arm 46 to assist in retaining actuator tip 31 in the operative position indicated. The position of actuator tip 31 may be altered by the application of external force to toggle lever 28 which overcomes the detenting effect of arm 46 and the bias applied to contact 40, and which causes actuator 20 to pivot about enlarged portion 24. Actuator tip 31 then rides along arm 46 in continual contact therewith to a new desired operative position. Contact 40 is positioned and shaped so that as actuator tip 31 passes over terminal 17, the distal ends 138 and 139 of arms 46 and 48 are urged tightly together at open end 52. Consequently, upper arm 46 becomes slightly bowed in its center because of the downward force of actuator tip 31 applied at that point. This bowed effect increases the upward bias applied to actuator tip 31 and thus to enlarged portion 24, and it causes actuator tip 31 to snap into the desired operative position from the over-center position. This feature increases the speed of the switching action from one operative position to another and it sharpens the change in operative positions.
The shape of upper arm 46, lower arm 48 and bight 50 also determines the type and number of permitted operative positions. In FIG. 3, for example, the contact 40 is pre-shaped to permit the operative positions of electrical connection between terminals 17 and 18, an ON operative position, and electrical connection between terminals 19 and 17, also an ON operative position. No operative position of OFF is permitted in the configuration of FIG. 3. In FIG. 5, upper arm 46 has been shaped to permit an OFF operative position in which terminal 17 is in electrical connection with no other terminal. Also, terminal 17 has a flattened configuration similar to that of terminals 18 and 19 within cavity 13. Thus, the switch of FIG. 5 is provided with ON (terminals 17 and 18); OFF; and ON (terminals 17 and 19) functions. In FIG. 4, upper arm 46 has been shaped to provide for a momentary function of ON. Thus, when actuator tip 31 is moved to the right along upper arm 46, causing lower arm 48 to create an electrical connection between terminals 17 and 19, tip 31 can only be maintained in that position by the continued application of external pressure to toggle lever 28. Upon the release of external pressure to toggle lever 28, actuator tip 31 will return of its own accord along upper arm 46 to a position to the left end thereof in FIG. 4 and into an ON operative position for connection between terminals 17 and 18.
Operation of the present toggle switch will be understood by reference to FIG. 1 and to FIGS. 3-5 which show various examples of permitted operating modes. In FIG. 3, an electrical connection is made between the central terminal 17 and terminal 18 by means of lower arm 48. It will be noted that the lower arm is in firm contact with terminals 17 and 18 because of the previously described bias imparted to contact 40. In FIG. 3, when external force is applied laterally to the left to toggle lever 28, actuator tip 31 is moved to the right as actuator 20 pivots about its enlarged portion 24 within bore 30. As actuator tip 31 moves to the right in FIG. 3, wedge 80 slides along upper arm 46 which is captured between legs 33 and 34. At the same time, the distal ends 138 and 139 of arms 46 and 48 are urged toward one another at open end 52 until they eventually touch. As actuator tip 31 approaches a position over terminal 17, in its movement to the right, arm 46 becomes progressively more bowed, as actuator tip 31 pushes downwardly on the arm. The combination of curve 45 and this bowing effect cause contact 40 to continue to interconnect terminals 17 and 18 until actuator tip 31 reaches a position to the right of terminal 17 in FIG. 3. Once such a position has been reached, contact 40 pivots rapidly about terminal 17, snapping out of connection with terminal 18 and into connection with terminal 19. Once a connection has been effected between terminals 17 and 19, upper arm 46 snaps back into an unbowed configuration as the distal ends of arms 46 and 48 move apart. When actuator tip 31 reaches the right-hand portion of the cavity 13, upper arm 46 exerts an upward force upon the apex of wedge 80, tending to urge actuator tip 31 further to the right and because of the tilt of assembly 20, actuator tip 31 is retained in that position.
In FIG. 5, a notch 62 is provided in the upper arm 46 of the contact 40, so that as external force is applied to the left to toggle lever 28, and actuator tip 31 is urged to the right in FIG. 5, the apex of wedge 80 settles into notch 62 until further external force is applied to toggle lever 28. When the apex of wedge 80 is settled into notch 62, lower arm 48 is disengaged from terminal 18 and is not yet in connection with terminal 19, thus placing contact 40 in an OFF operative position. Also, the distal ends of arms 46 and 48 are again urged together, thus causing upper arm 46 to be slightly bowed. When additional lateral force is again applied to the left to toggle lever 28, actuator tip 31 moves to the right, pivoting contact 40 into a position in which lower arm 48 is in an ON operative position in which terminal 17 is electrically connected to terminal 19. Actuator tip 31 is biased in that position and is retained there as previously described until lateral force to the right is applied to toggle lever 28. In FIG. 4, upper arm 46 in the vicinity of bight 50 is at a greater distance from lower arm 48 than is upper arm 46 in the vicinity of open end 52. When actuator tip 31 is moved to the right along upper arm 46 under a leftward force applied to toggle lever 28, actuator tip 31 is urged leftwardly again into its original position by the upward slope of upper arm 46, and unless continued external force is applied to the left to toggle lever 28, actuator tip 31 will indeed return of its own accord to the position shown in FIG. 4. Thus, the positioning of actuator tip 31 in the extreme right position of FIG. 4 creates only a momentary ON operative position in which terminal 17 is connected to terminal 19.
The switch of this invention can be easily modified to be a slide-operated switch as shown in FIG. 10. Like numbers for like parts are used wherever possible. A slide actuator 100 is secured to the top of the case 12 for slidable relation therewith by tongue 112 on actuator 100 and grooves 110 formed in case 12 in a manner known in the art. The slide actuator 100 has an upper lever portion 101 and a lower actuator tip 102 composed of a dielectric material. Actuator tip 102 includes substantially parallel legs 107 and 108 extending downwardly from lever portion 101 through slot 103 and into cavity 13. A channel 104 containing wedge 106 is formed between legs 107 and 108. An apex of wedge 106 rides along the upper arm 46 of contact 40 as slide actuator 100 is moved from one operative position to another. Slide actuator 100 is slidable from left to right and right to left in FIG. 10 along grooves 110 which are engaged by tongue 112 of slide actuator 100. Flexible seal 114, sandwiched between surface 115 of slide actuator 100 and the underside of the case 12 within cavity 13, seals cavity 13 from the external environment. Cutouts 119 on either side of slide actuator 100 accommodate seal 114. Cutouts 121, two of which are provided on each longitudinal end of slide actuator 100, allow actuator 100 to be laterally flexible so that tongue 112 may be snapped into grooves 110 and so that the spring bias provided by cutouts 121 retains tongue 112 securely within groove 110. Contact 40 is provided with a bias as described for the embodiment of FIG. 1 which urges slide actuator 100 in a direction away from terminals 17, 18 and 19, such that tongue 112 remains in sliding engagement with grooves 110. As in the embodiment of FIG. 1, the upper arm 46 of contact 40 serves as a detent and the combination of the bias applied to upper arm 46, the location and the shape of wedge 106 and the shape of upper arm 46 will act to retain actuator 100 in a desired operative position. Also, the shape of contact 40 determines which operative positions are available. The switch shown in FIG. 10 is provided with an ON (terminals 17 and 18)-ON (terminals 17 and 19) function. The provision of a notch in upper arm 46 would permit an ON-OFF-ON function.
When it is desired to change the operative position of the switch from the ON operative position shown in FIG. 10, lateral external pressure is applied to lever portion 101 urging it to the right. In response thereto, actuator tip 102 similarly slides to the right, and wedge 106 rides along upper arm 46 of contact 40. As actuator tip 102 moves to the right, contact 40 pivots about terminals 17, thereby disconnecting lower arm 48 from terminal 18 and connecting lower arm 48 with terminal 19 as actuator tip 102 moves to a position to the right of terminal 17 in FIG. 10. Lower arm 48 now is in electrical contact with terminals 17 and 19. When it is desired to return the switch to the original operative mode, shown in FIG. 10, lateral leftward external pressure is again applied to lever 101, urging actuator tip 102 to the left. As actuator 100 moves to the left, actuator tip 102 again rides along upper arm 46, thereby causing contact 40 to pivot about terminal 17 and causing lower arm 48 to disconnect from terminal 19 and connect with terminal 18.
The switch shown in FIG. 1 can also be easily modified to be a momentary action pushbutton switch, as shown in FIGS. 8 and 9. Like numerals are used for like parts wherever possible. Plunger 120 extends through bore 132 in bushing 11 and into cavity 13. The lower portion of plunger 120 includes a dielectric actuator tip 136 which has legs 126 and 128 extending downwardly into cavity 13 and a groove 130 formed therebetween. Upper arm 46 of the contact is disposed within groove 130, straddled by legs 126 and 128. Within groove 130 is actuator finger 124 disposed generally above terminal 19. O-ring seals 122 may be used to slidingly seal plunger 120 with the inner surface of bore 132 to environmentally seal chamber 13, but seal 122 is not essential to the functioning of the switch. Lower arm 48 is pre-formed so that it assumes a slightly bowed configuration symmetrically disposed about terminal 17 whereby open end 52 and bight 50 of lower arm 48 dip toward terminals 18 and 19, respectively. Upper arm 46 of contact 40 is directed at an angle away from lower arm 48 such that the distal end 138 of upper arm 46 is in constant contact with a portion 123 of actuator tip 136 within groove 130. The bias applied to contact 40 serves to urge plunger 120 in an upward direction and to provide the necessary spring action thereto. In addition, the bias also insures that lower arm 48 makes firm electrical contact with terminals 17 and 18 or 19.
Plunger 120 is restricted in its upward movement by upper surface 141 of actuator tip 136 which extends beyond the edges of bore 132 within cavity 13. Thus, as pressure is removed from plunger 120, surface 141 is driven against upper surfaces of cavity 13 by contact 40 which prevents further upward movement. Contact 40 is protected from damage or deformation from excessive downward longitudinal forces by legs 126 and 128 which limit the permissible downward incursion of plunger 120 into cavity 13 to a predetermined distance.
The operative position shown in FIGS. 8 and 9 is that of an ON position in which terminals 17 and 18 are interconnected. If the operative position is desired to be changed, downwardly directed external pressure is applied to plunger 120, and thus to actuator tip 136, which drives finger 124 into engagement with upper arm 46 in close proximity to bight 50. Contact 40 is thereby pivoted about terminal 17 such that lower arm 48 moves into connection with terminal 19 adjacent bight 50 and disconnects from terminal 18 near open end 52. When external pressure is released from plunger 120, the spring bias imparted to contact 40 causes upper arm 46 to move away from lower arm 48 and return plunger 120 to its original position, as shown in FIG. 9. Thus, finger 124 no longer exerts a downward pressure on arm 46 near bight 50. Contact 40 then pivots of its own accord about terminal 17 toward the left under the influence of the previously described bias, causing lower arm 48 to disconnect from terminal 19 and to connect with terminal 18.
As seen in FIG. 7, the concept of this invention can easily be extended to a multiple-pole switch. A double-pole configuration does not require that the switching case or housing be wider than that found in the single-pole switch of FIG. 1. A double-pole switch 200 has two sets of terminals 161-163 and 185-187, and their associated pre-shaped wire contacts, 150 and 152, respectively. Contacts 150 and 152 can be formed in any of the shapes shown for contacts 40 in FIGS. 1 through 5. Contacts 150 and 152 are disposed adjacent the walls of case 12 and are laterally restrained and retained in an upright position by respective grooves 166 and 167 disposed adjacent their bights 50 and open ends 52. Actuator tip 180 has a wedge 175 and a single leg 170 extending therefrom. Leg 170 serves to maintain a separation between contacts 150 and 151 and to retain these contacts in their desired positions. Leg 170 has a width similar to that shown in FIG. 1. Leg 170 has an associated arcuate ramp 201 similar to ramps 21, 23 of FIG. 1. Portions of an apex of wedge 175 ride along upper arms 189 and 191, thereby causing contacts 150 and 152 to pivot about central terminals 162 and 186, respectively, on lower arms 193 and 195, as previously described for the embodiment of FIG. 1. In all other respects, this configuration is identical to and operates in substantially the same manner as that previously described for the single-pole, double-throw switch shown in FIG. 1.
Some of the components of this switch may be formed in several different configurations for specialized purposes, but their shape, in general, forms no part of this invention. Furthermore, the switch itself may be mounted in a panel by known means and it is not necessary that these means be discussed in detail herein. The case 12 is typically composed of a non-conductive material such as thermoplastic or thermoset plastic material. The bushing 11 may be formed of a metallic material such as plated brass which is insert-molded or otherwise attached to case 12. Bushing 11 may also be plastic and form an integral part of the molded case 12. The actuator tip 31 is composed of a dielectric material, preferably a heat-resistant plastic, while the lever 28 may be metallic or the lever 28 and actuator tip 31 may be a single piece of plastic molding. The contact 40 may be formed from any conductive resilient material, such as plated beryllium copper.
For reference purposes, examples of the dimensions of a single-pole switch of this invention are set forth. It is to be understood that by providing such examples, the scope of the invention is in no way limited. The casing and housing form a combination typically of 0.30 inch (7.62 mm) high 0.30 inch (7.62 mm) wide, and 0.20 inch (5.08 mm) thick. The terminals typically project 0.25 inch (6.35 mm) outwardly from the case and the bushing and toggle lever extend 0.567 inch (14.4 mm) above the housing.
In view of the above description, it is likely that modifications and improvements will occur to those skilled in the art which are within the scope of this invention. | A sub-miniature switch having a pre-shaped wire spring contact movable to one of a plurality of operating positions. The pre-shaped wire spring contact performs the biasing and the detenting functions in addition to the contact function in the switch. Either a toggle, pushbutton or slide may be used for the actuating means of the switch. The wire contact may be pre-formed to provide whichever operating positions are desired. A multiple-pole switch may be constructed using the principles of this invention having a size substantially the same as a similar purpose single-pole switch. | 27,247 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is the National Stage of International Application No. PCT/EP2015/001634, filed on 7 Aug. 2015, which claims priority to and all advantages of German Patent Application No. 10 2014 013 356.7, filed on 8 Sep. 2014, the content of which is hereby incorporated by reference.
FIELD OF THE INVENTION
[0002] The invention generally relates to a support and, more specifically, to a support for a sensor element, an assembly including the same, and to a rotational speed sensor.
BACKGROUND OF THE INVENTION
[0003] Active rotational-speed sensors for motor vehicles or other applications may exhibit a Hall sensor by way of sensor element. Such a Hall sensor is also designated as a Hall IC and interacts with a pulse wheel. Depending on the type of construction, the pulse wheel is a magnetic multipole wheel or a toothed wheel that is not magnetized. In the latter case, a permanent magnet is assigned to the Hall sensor. An active wheel-speed sensor with Hall sensor element with permanent magnet and punched ring by way of pulse transmitter is disclosed in WO 2011/012399 A1.
[0004] The operation of the sensor element can easily be impaired by dust, dirt and moisture. The sensor element may therefore have been completely encapsulated by an injection-molding compound, see DE 10 2009 008 457 A1.
[0005] In the course of encapsulation a defined position of the sensor element and, where appropriate, of the permanent magnet has to be guaranteed. For this purpose it is known to hold the sensor element or the permanent magnet in a support, see KR 20110057455 (A).
[0006] The sensor element exhibits electrical contacts which in the region of the support have to be connected to contact wires of electrical leads. A connecting region of electrical contacts and contact wires has to be accessible for the connection of the same. The support exhibits apertures or recesses for this purpose.
[0007] A relatively large amount of injection-molding compound has to be supplied through the apertures and recesses in the course of encapsulating the support and the sensor element. Associated with this are a high influx of thermal energy and also the risk of impairments of the components that are present in the course of encapsulation and/or in the course of the subsequent cooling of the injection-molding compound.
SUMMARY OF THE INVENTION
[0008] The present invention provides a support that is particularly well suited for encapsulation with an injection-molding compound.
[0009] The support according to the invention comprises an at least partially hollow body for receiving electric contacts and a potting compound. The support further comprises a cover for covering and filling out a recess defined by the body. The existing recess of the body is at least partially filled out by the cover. By virtue of this measure, the injection-molding compound to be injected into the support altogether and the resulting thermal loading can be distinctly reduced. The cover may also have been adapted to the external shape of the support, so that the external surface of the support becomes more uniform by virtue of the cover than without the cover. Greatly differing cross sections and thicknesses of the injection-molding compound are avoided by virtue of the cover.
[0010] In certain embodiments, the body exhibits a substantially cylindrical basic shape. At the same time, the cover can be inserted into the recess along a part of a radially exterior side. In this way, the cover complements the cylindrical basic shape and contributes to filling it out.
[0011] In these or other embodiments, the body is of elongated design, and that the recess is located along a part of a longitudinal side. In particular, the cover and the recess each exhibit a length that corresponds to approximately one half of the length of the body. In this way, the recess has been dimensioned sufficiently to enable access to the electrical contacts during production. The cover fills out the contour of the recess—also in the direction toward the contacts—as far as possible.
[0012] The depth of the recess typically corresponds to approximately one half of the thickness of the body. The same typically applies to the cover, though the latter may also exhibit a somewhat smaller depth.
[0013] In certain embodiments, the cover exhibits an external surface, and that the body defines an outlet aperture for the potting compound, the outlet aperture of the body and the external surface of the cover being designed and arranged relative to one another in such a way that the potting compound emerging from the outlet aperture presses against the external surface of the cover. In the course of the supply of the injection-molding compound into the support, some of it emerges from the outlet aperture, presses against the external surface, and in this way holds the cover securely in its closed position. As a result, it is guaranteed that the cover will not be lifted by the flowing injection-molding compound.
[0014] In various embodiments, the external surface extends, at least partially, obliquely with respect to a longitudinal extent of the body or of the cover. Opposite the external surface the cover may exhibit a detent element which holds the cover securely. The detent element then acts at one end of the cover, and the injection-molding compound applied to the external surface acts at the other end.
[0015] In certain embodiments, the body is of elongated design and in the region of a front side exhibits an inlet aperture for the potting compound. The inlet aperture is typically connected to the aforementioned outlet aperture or is arranged adjacent thereto. The outlet aperture has then also been provided close to the front side.
[0016] In various embodiments, the cover and/or the body exhibit(s) surfaces with elevations directed radially outward. In this case it is typically a question of burls, spigots or lugs for centering in a mold in the course of potting. At the same time, the elevations have the effect of spacers from insides of the mold. As a result, after the potting all the external surfaces of the body and the cover have been covered with the potting compound, where appropriate apart from front faces or external surfaces of the elevations.
[0017] In certain embodiments, the body exhibits at least one aperture for access to the electrical contacts, in particular to the contacts to be connected to one another. The aperture is typically an aperture situated opposite the recess of the body. Without a cover, the contacts are accessible from two sides, namely through the aperture, on the one side, and through the recess, on the other side.
[0018] In various embodiments, the body is of elongated design. At the same time, a receptacle for a sensor element has been provided in the region of a front side. Moreover, a partition may have been provided between the receptacle and the body, in particular with a passage for the potting compound. By virtue of the partition, the thermal loading of the sensor element in the course of potting is reduced.
[0019] The invention also provides an assembly, in particular for producing a rotational-speed sensor, with at least one sensor element and with a support according to the invention. The support and the sensor element have typically already been potted together.
[0020] Finally, the invention also provides a rotational-speed sensor, with a support according to the invention and with a sensor element, the support and the sensor element having been potted together. A rotational-speed sensor designed in such a manner can be produced inexpensively and is reliable in application.
BRIEF DESCRIPTION OF THE DRAWINGS
[0021] Further features of the invention will become apparent from the description in other respects, and from the claims. Advantageous exemplary embodiments of the invention will be elucidated in more detail in the following on the basis of drawings, in which:
[0022] FIG. 1 shows a representation of various stages in the production of a rotational-speed sensor,
[0023] FIG. 2 shows a support with raised cover in a side view;
[0024] FIG. 3 shows the support with cover according to FIG. 2 in a front view,
[0025] FIG. 4 shows the support with cover according to FIG. 2 in perspective representation,
[0026] FIG. 5 shows the support with cover according to FIG. 2 in a radial top view,
[0027] FIG. 6 shows the support with attached cover in a side view,
[0028] FIG. 7 shows the support with attached cover according to FIG. 6 in a radial top view,
[0029] FIG. 8 shows the support with cover according to FIG. 6 in perspective representation,
[0030] FIG. 9 shows a support with raised cover in side view, similar to FIG. 2 but with differently configured cover,
[0031] FIG. 10 shows the finished rotational-speed sensor in a representation analogous to FIG. 9 , namely with cover sketched radially outside and with representation of the direction of flow of the material in the course of hypothetical potting of the support without cover, and
[0032] FIG. 11 shows a representation corresponding to FIG. 10 , but with inserted cover, with representation of the direction of flow of the material in the course of potting of the support.
DETAILED DESCRIPTION
[0033] In FIG. 1 , various components and manufacturing stages of a complete rotational-speed sensor can be discerned. Inside the rotational-speed sensor, a support 10 with sensor element 11 and connecting lead 12 has been provided. An external casing of the rotational-speed sensor is formed by a metal cylinder 13 which is open on one side.
[0034] Above the stated parts 10 , 11 a further cylindrical part 14 is visible. It is a question of the support 10 at a certain stage of manufacture, namely surrounded by the potting compound and after removal from an injection mold. The metal cylinder 13 is pushed over part 14 , so that a circumferential collar 15 of the metal cylinder 13 extends over a circumferential shoulder 16 of part 14 . For the purpose of sealing, an O-ring (not shown) has been provided under the collar 15 .
[0035] The connecting lead 12 consists here of at least three different portions, namely a cable 17 , two conductors 18 and two conductor contacts 19 . Part 16 exhibits at one end an elbow 20 , into which the connecting lead 12 has been potted. Part 14 , however, has been drawn in FIG. 1 without the connecting lead 12 . In fact, only the cable 17 protrudes upward out of the elbow 20 .
[0036] The sensor element 11 has been provided with sensor contacts 21 which have been electrically connected in the support 10 to the conductor contacts 19 .
[0037] The support 10 comprises a partially hollow body and exhibits an elongated, cylindrical basic shape, with a front region 22 for receiving the sensor element 11 , with an opposing front region 23 for entry of the connecting lead 12 , with a central region 24 of reduced thickness, and with a cover 25 abutting the central region 24 . The cover compensates for the smaller thickness of the central region 24 and is situated, just like the central region 24 , between the two front regions 22 , 23 . The combination of cover 25 and central region 24 exhibits a somewhat smaller cross section or outer perimeter than the two front regions 22 , 23 .
[0038] FIG. 3 shows the front view of front region 22 for receiving the sensor element 11 .
[0039] The central region 24 is shown in greater detail in FIG. 4 . Discernible are a partly solid region 26 , adjacent to front region 23 and with two parallel channels extending in the longitudinal direction, the apertures 27 of which are visible in FIG. 4 . The conductors 18 are guided in the channels.
[0040] Between region 26 and front region 22 the central region 24 exhibits, in addition, a window region 28 , with two windows 29 extending parallel to one another. The stated channels with the apertures 27 lead laterally into the windows 29 . The windows 29 are permeable at right angles to the longitudinal direction or, to be more exact, in the radial direction of the support 24 . In the region of the windows 29 , contacts 19 are connected to contacts 21 in overlapping manner. By virtue of the arrangement of the windows 29 , it is possible to machine the contacts 19 , 21 inserted into the support 24 for the purpose of connecting the contacts, for example to solder them together, in the view of FIG. 2 from above and from below.
[0041] The central section 24 exhibits in a longitudinally-directed plane a circumferential frame 30 on which the cover 25 comes to be situated in a closed position. For this purpose the cover 25 may exhibit on its underside a circumferential shoulder 31 —see, in particular, FIG. 2 . The shoulder 31 is bounded inwardly by a projection 32 which can be inserted into the frame 30 in fitting manner. As a result, the cover 25 has been positioned unambiguously on the support 24 .
[0042] On its front sides 33 , 34 the cover 25 may exhibit detent elements which interact with detent elements, not shown, of the front regions 22 , 23 of the support 24 .
[0043] Channels, not shown, for the transmission of the potting compound may have been provided in the cover 25 . Discernible in FIG. 4 are a cover-side outlet aperture 35 in front region 23 and an outlet aperture 36 on front side 33 . Outlet apertures directed toward the support 24 may also have been provided on the cover 25 , in particular so as to correspond to the windows 29 .
[0044] On its front regions 22 , 23 the support 10 exhibits elevations directed radially outward, namely burls 37 , 38 . In the present exemplary embodiment, each front region 22 , 23 exhibits circumferentially four burls 37 and 38 , respectively. Analogously thereto, the cover 25 has been provided on its upper side with burls 39 which follow one another in the longitudinal direction of the support 10 .
[0045] The burls 37 , 38 , 39 bring about a centering of the support 10 in the course of the potting in the mold which is not shown. At the same time, it is ensured by the burls 39 that the cover 25 does not lift off in the course of potting.
[0046] Front region 23 for the connecting lead 12 is bipartite. A frontal end 40 exhibits a somewhat larger diameter than a portion 41 directed toward the central region 24 ; see, in particular, FIGS. 6 and 7 . The end 40 exhibits on its front side 42 at the edge a depression 43 for entry of the connecting lead 12 . In addition, apertures, not shown, may have been provided for the entry of the potting compound, in particular so as to correspond to the outlet aperture 35 .
[0047] Front region 22 is substantially of pot-like design with a thick circumferential wall 44 , with a circumferential front face 45 of the wall 44 , and with a partition 46 with respect to the central region 24 ; see FIG. 3 . The partition 46 may have been provided with an aperture 47 for the 2 5 passage of the potting compound, and with channel apertures 48 for the passage of contacts 21 .
[0048] The circumferential wall 44 is interrupted by a resilient detent element 49 —see, in particular, FIG. 7 —with which the sensor element 11 inserted into front region 22 is held there.
[0049] Elevations 50 may have been provided on the circumferential front face 45 . The elevations act, like the burls 37 , 38 , 39 , in centering manner and/or for the purpose of guiding the potting compound in the course of potting.
[0050] FIGS. 9 to 11 show a modified embodiment of the support 10 and the cover 25 . The cover 25 here has been provided with an oblique external surface 51 which is subjected to incident flow of the potting material in the course of potting (in the injection-molding process); see, in particular, FIG. 11 . With respect to a longitudinal axis of the support 10 the oblique external surface 51 exhibits an angle of approximately 30 degrees and faces toward the outlet aperture 35 . The potted support 10 in the metal cylinder 13 is shown in FIG. 11 . A thick arrow 52 points in the longitudinal direction toward front side 42 and indicates from which direction and at which point the potting compound was injected into the mold, which is not represented in any detail. The many small black arrows 53 illustrate the path of the potting compound through front region 23 . A long, narrow arrow 54 points from the oblique external surface 51 to the central region 24 and illustrates the location and direction of the force acting on the cover 25 by virtue of the flowing potting compound.
[0051] FIG. 10 shows, purely hypothetically for the purpose of clarification on the basis of arrows 53 , the flow of the potting compound if no cover were attached. In this case, the potting compound would arrive directly through the windows 29 at a connecting region 55 of the contacts 19 , 21 and would subject the contacts to a relatively high pressure from above, with higher pressure than from below. The connection can be impaired thereby. In the connecting region 55 a low pressure and a low rate of flow are striven for. This too is obtained by virtue of the cover 25 and the configuration thereof described with reference to the figures. | Disclosed is a support ( 10 ) for a sensor element ( 11 ). The support ( 10 ) is for potting and manufacturing a rotational speed sensor. The support ( 10 ) comprises an at least partially hollow body for accommodating electric contacts and a potting compound. According to the invention, a cover ( 25 ) is provided for covering and filling a recess defined by the at least partially hollow body. | 18,280 |
BACKGROUND OF THE INVENTION
This invention relates to an improved temperature regulating device or thermostat and in particular it relates to a miniature electric thermostat used to regulate or control the temperature of a clothes iron or similar heater systems.
Current practice in thermostats of this type is to compose the thermostat of a sandwich of ceramic insulators, metal switch elements and a metal bracket.
Ceramics are required for the stability of high temperatures, especially for non-periodic excursions of high temperature sometimes occuring during initial calibration. The construction necessitates many separate pieces and an assembly technique that is difficult to automate.
Current practice also is to build into clothes irons or other similar appliances, a separate over-temperature "one shot" type switch to limit the maximum temperature of the appliance. This is a safety feature, and in current practice the temperature control thermostat and over-temperature are two separate controls mounted at different places in the appliance.
BRIEF SUMMARY OF THE INVENTION
The object of the present invention is to provide an improved assembly which will be more readily manufactured and applied to a clothes iron or the like and will act both to control the temperature of the sole plate of the iron as well as safeguarding against any over heating which is not controlled by the thermostat.
The invention comprises an assembly which integrates the temperature control thermostat and the over-temperature switch and is fabricated with an easy-to-assemble "bracket" of organic or plastic material in place of a sandwich, or stack of ceramic insulators, the proposed combination using high temperature plastic for the bracket, but has the advantage that an integral over-temperature switch limits the maximum temperature that the plastic of the bracket would be exposed to, assuring additional stability.
The thermostat itself may be a creep or snap type, and the over-temperature switch is preferably a bimetal type, or a "change-of-phase type" such as an eutectic device, or other one shot device.
In some applications a manually resettable over-temperature device could be used.
DESCRIPTION OF THE DRAWINGS
To enable the invention to be fully understood an embodiment thereof will now be described with reference to the accompanying drawings in which;
FIG. 1 in side elevation a thermostatic switch according to the invention,
FIG. 2 a transverse section to show the general arrangement of the components,
FIG. 3 is a plan, and
FIG. 4 an elevation showing the switch from the side opposite to that shown in FIG. 1.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
According to a preferred embodiment as shown in the drawings, the temperature regulating device of the invention comprises a bracket 1 formed of a desired, low-cost, temperature-resisting organic or plastic material. The bracket is mounted by means of a rivet 1a or other conventional means (shown in broken lines in FIG. 2) on a clothes iron 23 having a sole plate 24 (shown in broken lines in FIG. 1). The sole plate is adapted to be heated in conventional manner by a heating element (shown diagrammatically at 25 in FIG. 3) energized from a power source (shown diagrammatically by the line terminal 26 in FIG. 3). The bracket carries a thermally-responsive bimetallic strip 2 so that when the bracket is mounted on the iron, the bimetallic strip directly contacts the sole plate 24 and is adapted to flex in response to change in sole plate temperature. A conventional switch blade 3 is fixed at one end 4 to the bracket 1 and has a central tongue part 3.1. A pin 22 is secured to the bimetallic strip and is adapted to transfer a force representative of the sole plate temperature to the tongue 3.1 as the bimetallic strip flexes. The opposite free end of the switch blade 3 is also in engagement with a temperature adjusting means 5. The temperature adjusting means comprises a shaft 6 which is rotatable in the bracket 1 and which has a cam 7 associated with a cam surface 8 on the bracket so that rotation of the shaft adjusts application of a force to the free end of the switch blade by the screw 14. The shaft 6 is hollow and the screw 14 is rotatably adjustable therein independent of rotation of the shaft 6. A conventional snap action blade 12 which is adapted to be overbalanced by its loading blade 13 in conventional manner is secured at one end to the free end of the switch blade 3 and has its loading blade secured to the tongue 3.1 of the switch blade in conventional manner. A contact 9 is carried on the snap action blade 12 to be engaged and disengaged with a contact 20 carried on another switch blade 21 which is also mounted on the bracket 1. A contact 16 is supported insulatedly on the bracket 1 and a terminal 18 is connected to the contact 16. A terminal 19 is also provided on the switch blade 3.
The temperature regulating device of the invention also includes an additional thermally responsive means for protecting the clothes iron or other appliance against occurrence of an over-temperature condition. In the preferred embodiment shown in the drawings, a tail portion 15 on the switch blade 21 is normally biased to move away from the contact 16 but is urged into a closed circuit position engaging the contact 16 by action of a fusible link pin 17 as indicated by the broken line 15a in FIG. 4. The fusible link pin is slidable in the bracket 1 and is adapted to engage the sole plate of the clothes iron when the bracket 1 is mounted on the iron thereby to press the fusible link pin end 17.1 flush with the bottom of the bracket as indicated by the dotted line 17a in FIG. 4, whereby the tail portion 15 of the blade 21 is engaged with the contact 16. The end 17.1 of the fusible link pin engages the sole plate 24 in closely spaced relation to the bimetallic strip 21. The end portion 17.1 of the pin is formed of a metal material or the like having a melting point selected to melt when a predetermined over-temperature condition occurs in the sole plate, that over-temperature level being selected to prevent damage to the organic bracket material when that over-temperature condition occurs.
In that arrangement, the contacts 9 and 20 are normally engaged in a closed circuit position as shown in FIG. 2 for energizing the heater element 25 from the power source 26. Rotation of shaft 6 selects the temperature adjusting force applied to switch blade 3 and selects the operating temperature of the iron so that flexing of the bimetallic strip 2 in response to occurrence of the selected operating temperature in the sole plate causes snap-acting movement of the blade 12 to separate contact 9 from contact 20 to deenergize the heater. When the sole plate then cools, bimetallic strip movement reengages the contacts to reenergize the heater. Adjustment of the screw 14 permits calibration of those temperature regulating means. However, when a predetermined over-temperature condition occurs in the sole plate due to a fault condition or the like, the end 17.1 of the fusible link pin melts in prompt response to the over-temperature condition to permit the tail portion 15 of the blade 21 to move away from contact 16 in response to its normal bias to interrupt the heater energy circuit, thereby to protect the organic material of the mounting bracket from damage due to the over-temperature condition.
The advantages of this construction are:
(1) The clothes iron assembler would only mount, connect and calibrate a single control thermostat bracket over-temperature switch unit; thus eliminating assembly, mounting and connecting a separate over-temperature switch.
(2) The thermostat/over-temperature unit would inherently allow the temperature control thermostat and the over-temperature switch to sense the appliance temperature at nearly the same location. This would offer better overall control and simpler calibration of the over-temperature device (current practice is to mount the over-temperature switch in a location remote from the control thermostat).
(3) The overall cost would be less for the appliance manufacturer.
(4) The plastic bracket on the temperature control thermostat could allow the use of a low cost cam type means for achieving temperature adjustment.
Present designs using metal brackets use expensive screw mechanisms for achieving temperature adjustment. The present assembly therefore further reduces the cost.
It should be understood that although particular embodiments have been described by way of illustrating the invention, this invention includes all modifications and equivalents of the disclosed embodiments falling within the scope of the appended claims. | A thermally responsive control especially for a clothes iron combines an adjustable, temperature-regulating thermostat and an over-temperature control for limiting maximum temperature levels on a plastic mounting bracket where the over-temperature control also protects the mounting bracket against damage from overheating. | 8,917 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is based upon and claims the benefit of priority from the prior Japanese Patent Application No. 2001-272072, filed Sep. 7, 2001, the entire contents of which are incorporated herein by reference.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates to an electrically erasable and programmable nonvolatile semiconductor memory device (EEPROM), particularly relates to, in the semiconductor memory device having a plurality of banks in which memory elements of a MOS type of transistor structure are formed with the memory elements arranged in a matrix form, the semiconductor memory device having an arrangement in which a certain bank can be read while erase or write is being performed in another bank, and it is utilized for a flash erasable semiconductor memory device (flash memory).
[0004] 1. Description of the Related Art
[0005] A NMOS transistor having double layer stacked gate structure on a double well formed on a semiconductor substrate is known as a memory cell of the EEPROM.
[0006] [0006]FIG. 4 is a cross-sectional view showing an example of a cell including the NMOS transistor having the double layer stacked gate structure.
[0007] In FIG. 4, reference numeral 30 is a P type substrate (Psub), 31 is an N type well (Nwell) and 32 is a P type well (Pwell) formed in the N type well. In the N type well 31 , a well leading electrode is formed of an N+type diffusion layer 33 . In the P type well 32 , a source S and a drain D of the NMOS transistor are formed by an N+type diffusion layer 34 and the well leading electrode of the well is formed by a P+type diffusion layer 35 .
[0008] A floating gate FG made of a poly-crystalline silicon layer of a first layer is formed on a gate insulation film 36 , a control gate CG made of the poly-crystalline silicon layer of a second layer is formed with the control gate CG separated by a insulation film 37 .
[0009] In the actual semiconductor memory device, a plurality of cells are arranged in a matrix form on one well, any one of cells is selected by a plurality of row lines WL connected to the control gate CG of the cell of each row and a plurality of column lines BL connected to the drain D of the cell of each row. The source S, the N type well 31 and the P type well 32 of all cells are commonly connected with a source line SL.
[0010] Operation of the cell will be briefly described as an example of an NOR type memory cell which applies high voltage to the channel to erase.
[0011] In-case of erasing data, for example, by applying 10V to the source line SL, the voltage of 10V is applied to the source S, the N type well 31 and the P type well 32 of the cell. By applying, for example, −7V to all row lines WL, the voltage of −7V is applied to all control gates CG. The drain D is made to be a floating state. At this point, electrons in the floating gate FG are emitted into a channel by Fowler-Nordheim (FN) tunneling. A threshold of the cell becomes lower at this state, and data of this erase state is normally referred to as “1”.
[0012] In case of writing data, for example, any one of a plurality of row lines WL is set to 9V, for example, any one of a plurality of column lines BL is set to 5V, for example, and the source line SL is set to 0V in order to select the cell to be written. At this point, in the selected cell, electrons are injected into the floating gate FG by hot electron injection. The threshold of the cell becomes higher at this state, and data of this write state is normally referred to as “0”.
[0013] In case of reading data, for example, any one of a plurality of row lines WL is set to, for example, 5V, any one of a plurality of column lines BL is set lower voltage (for example, 0.7V) and the source line SL is set to 0V in order to select the cell to be read. At this point, in case that the selected cell is in the write state (data are “0”), current does not flow because the cell is not turned on. On the other hand, in case that data of the selected cell is in the erase state (data are “1”), cell current of about 40 μA flows because the cell is turned on. The amplitude of the current is sensed and amplified by a sense amplifier circuit (not shown) or the like to read data.
[0014] Though the NOR type memory cell which applies high voltage to the channel to erase is taken as the example in the above description of the operation, the same operation is also performed in a memory cell which applies high voltage to the source to erase.
[0015] Recently, the semiconductor memory device is used, for example, as a component of a portable device and utilized for storing various programs and personal data, there are strong demands storing programs or data in one semiconductor memory device in order to reduce the number of required memory chips in a system.
[0016] However, required time for re-writing data becomes relatively longer in case that the cell shown in FIG. 4 is used. Normally it takes about 10 μsec to write data and it takes about several hundreds of msec to as much as several sec for a block to erase data, it is impossible to read data during re-writing the data.
[0017] A memory system known as a RWW (Read While Write) type, which is able to read data in a certain memory area while data are written or erased in another memory area, has been proposed.
[0018] The present applicant has proposed Japanese Patent Application No. 2000-127106 of “semiconductor device” which can concretely realize a flash memory capable of writing or erasing data and reading data simultaneously by using the NMOS transistor of the double layer stacked gate structure shown in FIG. 4 as the cell.
[0019] [0019]FIG. 5 shows an example of concrete arrangement of a part of a flash memory, which is proposed at the moment, capable of writing or erasing data and reading out data simultaneously.
[0020] As shown in FIG. 5, in a plurality of banks BNK 0 to BNKk, one or a plurality of block circuit groups (in the example, BA 0 to BAi) are arranged in a first direction, the plurality of banks BNK 0 to BNKk are arranged in a second direction perpendicular to the first direction.
[0021] In each of the block circuit groups BA 0 to BAi, electrically rewritable memory cells having the MOS structure are arranged in a matrix form respectively, a cell array MA 0 divided by an erase unit, a sub row selection decoder RS 0 , the row line WL, the column line BL, a column selection gate CG 0 and a block decoder BD 0 are provided.
[0022] In the banks BNK 0 to BNKk, main row selection decoders RM 0 to RMk, j data line switching circuits DLSW 0 to DLSWk and power supply decoders VD 0 to VDk are provided correspondent to each bank.
[0023] In each of the banks BNK 0 to BNKk, main row selection line Mi connected commonly to the block circuit groups BA 0 to BAi in the same bank and j sub data lines SDLj (for example, eight lines or sixteen lines) are also formed.
[0024] The sub data lines SDLj on the block circuit groups BA 0 to BAi in the same bank are formed by a first wiring layer in the first direction, connected to j column selection gates CG 0 in each of block circuit groups BA 0 to BAi and connected correspondent to the j data line switching circuits DLSW 0 to DLSWk every bank BNK 0 to BNKk.
[0025] The power supply decoders VD 0 to VDk are circuit groups performing power supply control in case of write or erase by a bank unit and decode control for selecting the memory cell.
[0026] Out of the bank areas, j main data lines MDL_Rj for read, in which data of the memory cell in a bank selected by read operation (a first operation mode) are read through the j sub data lines and the j data line switching circuits DLSW 0 to DLSWk, are formed by a second wiring layer in the second direction. The j main data lines MDL_Rj for read are connected to j amplifier circuits SA_Rj for read.
[0027] Out of the bank areas, j main data lines MDL_Aj for auto, in which data of the memory cell in a bank selected by write or erase operation (a second operation mode) are read through the j sub data lines and the j data line switching circuits DLSWi, are formed by the second wiring layer in the second direction. The j main data lines MDL_Aj for auto are connected to j amplifier circuits SA_Aj for auto. Here, “auto” is used to mean verifying cell data automatically in the memory system.
[0028] In the above-described arrangement, selection of the cell is performed as follows.
[0029] One row line WL is selected by the main row selection decoder RM 0 and the sub row line selection decoder RS 0 according to an address signal. And block selection and column selection are performed by the block decoder BD 0 according to the address signal, and the column line BL is connected to the sub data line SDLj.
[0030] In case of reading data, by switching control of the data line switching circuits DLSW 0 to DLSWk, the sub data lines SDLj are connected to the amplifier circuits SA_Rj for read through the main data lines MDL_Rj for read. The read of the cell data by the amplifier circuits SA_Rj for read is performed simultaneously correspondent to the number of output circuits (not shown), for example, byte data of eight lines or word data of sixteen lines.
[0031] In case of writing or erasing data, by switching control of the data line switching circuits DLSW 0 to DLSWk, the sub data lines SDLj are connected to the amplifier circuits SA_Aj for auto through the main data lines MDL_Aj for auto. A check of a write or erase level of the cell is automatically performed by a control circuit (not shown). In this case, the erase of data is performed by a block circuit unit, the block decoder BDi controls such as electric potential control of the source line in case of erasing data.
[0032] According to the above-described arrangement, in case that a block in a bank (for example the bank BNK 0 ) is being erased, the sub data lines SDLj in the bank BNK 0 are connected to the main data lines MDL_Aj for auto by the data line switching circuit DLSW 0 of the bank BNK 0 . In case that data of other bank (for example the bank BNKk) are wanted to read at the same time, it is possible to read the data of the bank BNKk in a manner that the sub data lines SDLj in the bank BNKk are connected to the main data lines MDL_Rj for read by the data line switching circuit DLSWk of the bank BNKk.
[0033] Recently, by demands for high speed of effective read cycle of the flash memory, high performance is required for a device operating in page mode and a device operating in burst mode. These devices have specifications that, for example, data are read together by eight words as one page and outputted serially by a word unit, so that many data lines (SDLj, MDL_Rj and MDL_Aj) are required.
[0034] [0034]FIG. 6 shows a pattern layout of a wiring layer in case that the flash memory shown in FIG. 5 is realized by using double layer metal wiring.
[0035] In the figure, row lines WLi which are output of sub row selection decoder RSi are made of poly crystalline silicon layer PoSi, column lines BLi are made of a metal M 1 of a first layer. Main row selection lines Mi which are output of main row selection decoders RMi are made of a metal M 2 of a second layer on cell arrays MAi. Sub data lines SDLj are made of the metal M 2 of the second layer on column selection gates CGi or on a side of the column selection gates CGi. Main data lines MDL_Rj for read and main data lines MDL_Aj for auto are made of the metal M 2 of the second layer on a power supply decoder VDDi or on a side of the power supply decoder VDDi.
[0036] However, in this layout of the wiring layer, as increasing each data line (SDLj, MDL_Rj and MDL_Aj) in the above-described device correspondent to dual work, a chip area of the semiconductor memory device is increases by the increased area for the device correspondent to dual work.
[0037] When the device operating in dual work is realized by using the double layer metal wiring, assuming that a pitch of the metal M 2 of the second layer, for example, is 1 μm, the chip area of the device will be discussed in case that two shield lines (CND electric potential) are added to a side of the data lines. That each cell array MAi includes a cell of 512K bits, each bank BNKi includes eight block circuit groups (a cell of 4M bits) and there are eight banks BNKi (a cell of 32M bits) in the device chip will be considered as an example.
[0038] In this case, each of data lines (SDLj, MDL_Rj and MDL_Aj) has (8+2) lines in a device reading by a byte unit, so that the occupied area of the data line DLA becomes about 10 μm, though a ratio of the occupied area of the data line DLA to the chip area is small. In a device reading by a word unit, each of data lines (SDLj, MDL_Rj and MDL_Aj) has (16+2) lines, so that the occupied area of the data line DLA becomes about 18 μm, though the ratio of the occupied area of the data line DLA to the chip area is also small.
[0039] However, for example, in the device operating in page mode of eight word which one word is one page (eight page device), since each of data lines (SDLj, MDL_Rj and MDL_Aj) has (128+2) lines, the occupied area of the data line DLA becomes about as much as 128 μm, which causes the ratio of the occupied area of the data line DLA to the chip area not to be neglected. This results in an increase of the chip area and a rising cost of production.
[0040] As described above, there is a problem that the data lines remarkably increases and the chip area also increases by the increase of the data line area, in case that the device operating in page mode correspondent to dual work is realized to the conventional semiconductor memory device by using the double layer metal wiring.
BRIEF SUMMARY OF THE INVENTION
[0041] According to an aspect of the present invention, there is provided a semiconductor memory circuit comprising a plurality of memory cell blocks arranged in a first direction, each of the memory cell blocks including a plurality of memory cells arranged in a matrix form, the plurality of memory cells being of MOS structure and being electrically data rewritable; a plurality of bit lines formed of a plurality of first wiring layers, a plurality of sub data lines formed of a plurality of second wiring layers, the plurality of sub data lines extending in the first direction on the plurality of memory cell blocks and being connected to the plurality of memory cell blocks; a first bank region including at least the plurality of memory cell blocks and the plurality of sub data lines; at least one of second bank region arranged in a second direction perpendicular to the first direction, the second bank region having the same structure as the first bank region; a plurality of data read lines formed of third wiring layers and arranged on the first and second bank regions, the plurality of data read lines configured so that data are read by way of the plurality of data lines from the plurality of memory cells of a bank region of the first and second bank regions selected in a first operation mode; a plurality of first amplifier circuits connected to the plurality of data read lines; a plurality of auto data lines extending in the second direction on a region out of the plurality of memory cell blocks of the first and second bank regions, the plurality of auto data lines configured so that data are read in a second operation mode by way of the plurality of sub data lines from the plurality of memory cells; a plurality of second amplifier circuits connected to the plurality of auto data read lines; a plurality of switch circuits provided in correspondence to the plurality of memory cell blocks of the first and second bank regions, the plurality of switch circuits configured to switch the plurality of sub data lines of the first and second bank regions and the plurality of data read lines between a connection state and a non-connection state in correspondence to the first and second operation modes, wherein data in the plurality of memory cells of the second bank region are readable from the plurality of first amplifier circuits, even when data in the plurality of memory cells of the first bank region is being read from the plurality of second amplifier circuits.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING
[0042] [0042]FIG. 1 is a block diagram showing an example of a chip configuration of a simultaneously executable flash memory to which a semiconductor memory device of the invention is applicable.
[0043] [0043]FIG. 2 is a circuit diagram showing a part of a flash memory according to a first embodiment of a semiconductor memory device of the invention.
[0044] [0044]FIG. 3 shows an example of a pattern layout when the flash memory shown in FIG. 2 is realized by a wiring layer structure in which three metal layers are superposed.
[0045] [0045]FIG. 4 is a cross-sectional view showing an example of a cell including a NMOS transistor of double layer stacked gate structure.
[0046] [0046]FIG. 5 shows an example of a configuration extracted from a part of simultaneously executable flash memory which is presently proposed.
[0047] [0047]FIG. 6 shows an example of a pattern layout of a wiring layer when the flash memory shown in FIG. 5 is realized by double layer metal wiring.
DETAILED DESCRIPTION OF THE INVENTION
[0048] Preferred embodiments of the invention will be described in more detail below referring to the accompanying drawings.
[0049] [0049]FIG. 1 shows an example of a chip configuration of a simultaneously executable flash memory as a semiconductor memory device to which the present invention is applicable.
[0050] In FIG. 1, a memory cell array 1 includes m cores 0 to m- 1 in which n blocks B 0 to Bn- 1 are arrayed respectively. Each of blocks B 0 to Bn- 1 is a minimum unit, a plurality of memory cells are arrayed in each of blocks B 0 to Bn- 1 . The memory cell is a kind of nonvolatile memory cell having stacked gate structure. The core is defined as a set of one or a plurality of blocks, each bank is formed by n blocks B 0 to Bn- 1 in an example of FIG. 1.
[0051] A row/column decoder 2 containing a row decoder and a column decoder for selecting the memory cell, a switching circuit (address line SW) 3 for switching address lines or power supply lines, a local data line 4 and a data line switching circuit 16 are provided in each core.
[0052] A first address bus line (address bus line for read) 6 a for selecting the memory cell in case of read operation of data and a second address bus line (address bus line for write/erase) 6 b necessary to auto operation in case of writing or erasing data are provided commonly to all cores in the memory cell array 1 .
[0053] A first data bus line (data bus line for read) 7 a utilized to the read operation of data and a second data bus line (data bus line for write/erase) 7 b utilized to the write or erase operation of data are provided commonly to all cores.
[0054] A sense amplifier circuit (sense amplifier line for read) 11 a for read operation of data and a second amplifier circuit (sense amplifier line for verify) 11 b for write or erase operation of data are provided correspondent to the data bus lines 7 a and 7 b respectively.
[0055] A first power supply line (power supply line for read) 8 a to which a potential of power supply for read is supplied from a power supply 12 a for read and a second power supply line (power supply line for write/erase) 8 b to which a potential of power supply for write or erase is supplied from a power supply 12 b for write or erase are provided commonly to all cores. Booster voltage is given to the first power supply line 8 a from a power source VCC in case of reading data and supplied to the gate of the memory cell, which enables to read.
[0056] An address buffer circuit 10 for supplying an address signal to the address bus line 6 a for read and the address bus line 6 b for write/erase and an interface circuit 14 for interfacing an external unit are provided.
[0057] That is to say, the flash memory includes a electrically rewritable non-volatile memory cell, the memory cell array in which a plurality of cores are arrayed, wherein one core is a set of one or a plurality of blocks and one block is a range of the memory cell to be a unit of data erase, core selection means for selecting a predetermined number of cores in the plurality of cores in order to write or erase data, data write means for writing data in the selected memory cell in the core which is selected by the core selection means, data erase means for erasing data of the selected block in the core which is selected by the core selection means, and data read means for reading data of the memory cell in the core which is not selected by the core selection means.
[0058] Operation of the flash memory will be simply described below.
[0059] The address signal inputted from the outside is supplied to the address buffer circuit 10 through an address input circuit in the interface circuit 14 . An address for read and an address for write or erase are supplied from the address buffer circuit 10 to the address bus lines 6 a and 6 b according to an operation mode respectively. The addresses supplied to each of address bus lines 6 a and 6 b are selectively transferred to the row/column decoder 2 in each core by the switching circuit (address line SW) 3 , which is provided in each core, for switching the address line and the power supply line. The power supply lines 8 a and 8 b are also supplied to the row/column decoder 2 in each core with the power supply lines 8 a and 8 b selectively switched by the switching circuit 3 .
[0060] In each core, the local data line 4 is connected to the data bus line 7 a for read by a data line switching circuit 16 in case of reading data and connected to the data bus line 7 b for write/erase by a data line switching circuit 16 in case of writing or erasing data.
[0061] That is to say, data in the selected memory cell of each core are read to the local data line 4 , transferred to the data bus line 7 a or 7 b by the data line switching circuit 16 according to the operation mode and detected by the sense amplifier circuit 11 a for read or the sense amplifier circuit 11 b for verify to amplify respectively.
[0062] The result of the read by the sense amplifier circuit 11 b for verify is sent to a write/erase control circuit 15 . In the write/erase control circuit 15 , it is decided whether write or erase is successful or not, control of re-write or re-erase is performed in case that it is unsuccessful.
[0063] As described above, even though the read operation of data and the write or erase operation of data are performed simultaneously, each operation can be controlled by the independent address bus line, data bus line, sense amplifier circuit and power supply circuit.
[0064] As an example in case that the write operation of data and the read operation of data are performed simultaneously, the operation that the write of the data is performed to the core 0 and the cell data in other cores are read will be described concretely.
[0065] When the selection address signal of the core 0 portion is inputted and a write command is inputted from the outside of the chip, the write command is decided by the interface circuit 14 , which causes a write flag to be on. When the flag is on, by the switching circuit 3 in the core 0 portion, the address signal of the address bus line 6 b for write/erase is inputted to the row/column decoder 2 and power of the power supply 12 b for write and erase is supplied. By the data line switching circuit 16 , the data line 4 in the core 0 portion is connected to the data bus line 7 b for write/erase connected to the sense amplifier circuit 11 b for verify.
[0066] By setting the address bus line, data bus line and the power supply line in such a way, boosted write voltage is applied to a selected row line and high voltage or low voltage is applied from the write control circuit 15 to a column line correspondent to the write data in the core 0 . This causes hot electrons to be injected to the floating gate in the selected memory cell to write data in case that the memory cell is the floating gate type of MOS transistor structure. When the write of the data of one time is finished, the data are read to be detected by the sense amplifier circuit 11 b for verify. Then verify of the data is decided by the write/erase control circuit 15 , the operation is finished in case that the write of the data is successful, or additional re-write of the data is performed in case that the write of the data is unsuccessful.
[0067] It is possible to read data in any other core, for example in the core 1 during writing data to the core 0 . That is to say, the address signal of the address bus line 6 a for read and the power supply output of the power supply 12 a for read are supplied to the row/column decoder 2 of the core 1 including the memory cell to be wanted to read by the inputted address from the outside. The data line 4 is connected to the data bus line 7 a for read through the switching circuit 16 . The address signal is not inputted to the row/column decoders 2 of the cores except the cores 0 and 1 , namely the cores not to be written and read, and the data bus line is not connected to them, either.
[0068] The data read from the selected memory cell in the core 1 are detected by the sense amplifier circuit 11 a through the data bus line 7 a for read to be amplified. The data are outputted to the outside of the chip through the interface circuit 14 .
[0069] Any core, namely any one of the core 1 , the core 2 , the core 3 and the core m- 1 , except the core 0 in which the write of the data is being performed can be read optionally. It is prohibited that the address of the core 0 in which the write of the data is being performed is inputted to perform the read of the data. In case that the read of the data is required to the core in which the write of the data is being performed, a busy signal showing that the selected core is in operation of writing the data is outputted to inform to the outside.
[0070] The operation that the erase operation of data and the read operation of data are performed simultaneously is also basically the same as the operation that the write operation of data and the read operation of data are performed simultaneously.
[0071] The operation when the erase of the data is performed to, for example, the selected block of the core 0 and the cell data in other cores are read will be described.
[0072] When the selected address signal of the block in the core 0 and an erase command are inputted from the outside of the chip, the erase command is decided by the interface circuit 14 to raise an erase flag. When the erase flag is on, by the switching circuit 3 of the core 0 , the address signal of the address bus line 6 b for write/erase is inputted to the row/column decoder 2 of the core 0 and electric potential of the power supply for erase of the power supply 12 b for write/erase is supplied. The data line 4 of the core 0 is connected to the data bus line 7 b for write/erase connected to the sense amplifier circuit 11 b for verify by the data line switching circuit 16 .
[0073] By setting the address bus line, the data bus line and the power supply line, negative voltage is applied to all row lines of the selected block of the core 0 and positive high voltage for erase is applied to open and source lines of the column line, which causes the data of the block in the core 0 to be erased.
[0074] When the erase of the data of one time is finished, the data are read to be detected by the sense amplifier circuit 11 b for verify. Then verify of the data is decided by the write/erase control circuit 15 , the operation is finished in case that the erase of the data is successful, or the additional erase of the data is performed in case that the erase of the data is unsuccessful.
[0075] In case that the read of the data is required to any other core except the core 0 during erasing the data to the core 0 , the read of the data in the core is performed.
[0076] [0076]FIG. 2 is a circuit diagram showing a part of a flash memory according to an embodiment of the invention.
[0077] In the flash memory shown in FIG. 2, though a basic circuit configuration is the same as that of the flash memory shown in FIG. 1, the flash memory shown in FIG. 2 is characterized in that the device operating in page mode correspondent to dual work is realized by forming the main data line MDL_R 1 for read on the memory cell array, forming the main data line MDL_Aj for auto in an area separated from the memory cell array and using a wiring layer in which three metal layers are superposed.
[0078] The flash memory in FIG. 2 is different from following points compared with the flash memory described referring to FIG. 5. Since other parts of the flash memory in FIG. 2 are the same as that of the flash memory described referring to FIG. 5, the same numerals and signs are used.
[0079] (1) In each of the block circuit groups BA 0 to BAi, a sub data line switching circuit SDLSW for switching connection/disconnection between the sub data line SDLj and the main data line MDL_R 1 for read is added.
[0080] (2) In the outside of the memory cell array, the main data line MDL_R 1 for read is connected selectively to the read data line RDL 1 by a read data line switching circuit RDLSW, the read data line RDL 1 is connected to the amplifier circuit SA_R 1 for read.
[0081] In FIG. 2, one to a plurality of block circuit groups (BA 0 to BAi in the example) are arranged in a first direction to constitute the plurality of banks BNK 0 to BNKk, the plurality of banks BNK 0 are arranged in a second direction perpendicular to the first direction.
[0082] Each of the block circuit groups BA 0 to BA 1 is constituted with the electrically writable MOS structure memory cell arranged in a matrix form, the cell array MA 0 divided by an erase unit, the sub line selection decoder RS 0 , the row line WL, the column line BL, the column selection gate CG 0 , the block decoder BD 0 and the sub data line switching circuit SDLSW are provided in each of the block circuit groups BA 0 to BA 1 .
[0083] In each of the banks BNK 0 to BNKk, the main row selection decoders RM 0 to RMk, the j data line switching circuits DLSW 0 to DLSWk, the power supply decoders VD 0 to VDk are provided correspondent to each of the banks BNK 0 to BNKk.
[0084] The main row selection line Mi and the j sub data lines SDLj (for example eight lines or sixteen lines), which are connected commonly to the block circuit groups BA 0 to BAi in the same bank, are formed in each bank BNK 0 to BNKk.
[0085] The sub data line SDLj is formed on the block circuit groups BA 0 to BAi in the same bank by a first wiring layer in the first direction, and connected to the j column selection gates CG 0 of each of the block circuit groups BA 0 to BAi through the sub data line switching circuit SDLSW. The sub data line SDLj is also connected correspondent to the j data line switching circuits DLSW 0 to DLSWk every bank BNK 0 to BNKk.
[0086] The power supply decoders VD 0 to VDk are a circuit group performing power supply control in case of write/erase by a bank unit and decode control for memory cell selection.
[0087] On each of the banks BNK 0 to BNKk, the j main data lines MDL_R 1 for read, in which the memory cell data in the selected bank in the read operation (the first operation mode) are read through the sub data line switching circuit SDLSW, are formed by a second wiring layer in the second direction.
[0088] Out of the bank areas, the read data line switching circuit SDLSW connected to the read data line RDL 1 and the read data line RDL 1 are provided, the read data line RDL 1 is connected to the amplifier circuit SA_R 1 for read.
[0089] Furthermore, out of the bank areas (or on an area eliminating the block circuit groups BA 0 to BAi), the j main data lines MDL_Aj for auto, in which the memory cell data are read through the j sub data lines the j data line switching circuits DLSW 0 to DLSWk in the write/erase operation (the second operation mode), and the j amplifier circuits SA_Aj for auto connected to the main data line MDL_Aj for auto are provided.
[0090] The sub data line switching circuits SDLSW in each of the block circuit groups BA 0 to BAi have a function switching connected state/disconnected state between the sub data line SDLj and the main data line MDL_R 1 for read correspondent to the read operation (the first operation mode) and the write/erase operation (the second operation mode).
[0091] On the other hand, the data line switching circuits DLSW 0 to DLSWk in each of the banks BNK 0 to BNKk are used for switching connected state/disconnected state only between the sub data line SDLj and the main data line MDL_Aj for auto, the data line switching circuits DLSW 0 to DLSWk have a function reducing parasitic capacity of the main data line MDL_Aj for auto by making the disconnected state in case of unnecessity of connection. It is also possible that the data line switching circuits DLSW 0 to DLSWk are omitted and the sub data line SDLj is connected directly to the main data line MDL_Aj for auto.
[0092] [0092]FIG. 3 shows an example of a pattern layout in case that the flash memory shown in FIG. 2 is realized by a wiring layer in which three metal layers are superposed.
[0093] The row line WL of the memory cell which is output of the sub line selection decoder RS 0 is made of a poly-crystalline silicon layer PoSi, the column line BL is made a metal M 1 of a first layer (hereinafter referred to as “M 1 layer”).
[0094] The main row selection line Mi which is output of the main row selection decoder RM 0 is made of a metal M 2 of a second layer (hereinafter referred to as “M 2 layer”) on the cell array MA 0 of each block circuit group BA 0 to BAi in a first direction.
[0095] The sub data line SDLj is made of the M 2 layer on the sub data line switching circuit SDLSW or along a side of the sub data line switching circuit SDLSW in the first direction.
[0096] The main data line MDL_R 1 for read is made of a metal M 3 of a third layer (hereinafter referred to as “M 3 layer”) on the block circuit groups BA 0 to BAi of each of the banks BNK 0 to BNKk in a second direction.
[0097] The main data line MDL_Aj for auto is made of the M 3 layer or the M 2 layer on the power supply decoders VD 0 to VDk of each of the banks BNK 0 to BNKk and the data line switching circuits DLSW 0 to DLSWk or along a side of them in the second direction.
[0098] The read data line RDL 1 is made of the M 3 layer or the M 2 layer in the first direction.
[0099] For obtaining an effect of electrical shield between the main data line MDL_R 1 for read and the main data line MDL_Aj for auto, one or a plurality of shield lines SLD may be provided between them, for example, on the bank area.
[0100] The wiring layer of the main row selection line Mi of output in the main row selection decoder RM 0 the wiring layer of the main data line MDL_R 1 for read may be reversal.
[0101] According to the flash memory described above, the device operating in page mode correspondent to dual work can be realized by using a wiring layer made of superposed three metal layers in a manner that the main data line MDL_R 1 for read is formed on the memory cell array and the main data line MDL_Aj for auto is formed in an area separated from the memory cell array.
[0102] An example of a modification of the pattern layout will be described hereinafter.
[0103] In the embodiment of the flash memory, however it is necessary that the main data line MDL_R 1 for read has the number of lines (128 lines for 8 words a page) correspondent to a specification to be read simultaneously, it is not always necessary that the number of the main data lines MDL_Aj for auto is the same number of the main data lines MDL_R 1 for read, for example an arrangement of about sixteen main data line MDL_Aj for auto is not a problem.
[0104] By modifying the number of the main data lines MDL_Aj for auto so as to reduce the number of the main data lines MDL_Aj for auto than that of the main data lines MDL_Rj for read, the increase of the chip area of the memory can be restrained to the minimum.
[0105] As described above, according to the semiconductor memory device according to the embodiment of the invention, when the device operating in page mode correspondent to dual work is realized, even though the memory cell to be read is increased, the increase of an occupied area of the read data line is restrained, which enables the increase of the chip area and the rising cost of the production to be restrained.
[0106] Additional advantages and modifications will readily occur to those skilled in the art. Therefore, the invention in its broader aspects is not limited to the specific details and representative embodiments shown and described herein. Accordingly, various modifications may be made without departing from the spirit or scope of the general inventive concept as defined by the appended claims and their equivalents. | A semiconductor memory circuit is disclosed, which comprises a plurality of memory cell blocks, a plurality of sub data lines, a first bank region including the plurality of memory cell blocks and the plurality of sub data lines, at least one of second bank region arranged, a plurality of data read lines, a plurality of first amplifier circuits connected to the plurality of data read lines, a plurality of auto data lines, a plurality of second amplifier circuits connected to the plurality of auto data read lines, a plurality of switch circuits provided in correspondence to the plurality of memory cell blocks, wherein data in the plurality of memory cells of the second bank region are readable from the plurality of first amplifier circuits, even when data in the plurality of memory cells of the first bank region is being read from the plurality of second amplifier circuits. | 39,300 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to a touch panel input device for vibrating a movable plate which is pressed, or a support substrate for supporting the movable plate, and generating an input operation feeling for an operator when the operator presses the movable plate. More specifically, the present invention relates to a touch panel input device for using a piezoelectric substrate to vibrate the movable plate or the support substrate.
[0003] 2. Description of the Related Art
[0004] A touch panel input device includes a movable plate and a support substrate which are laminated with a slight gap between them to separate conductor layers on the opposing surfaces of the movable plate and the support substrate. The input device electrically detects a contact between the conductor layers at a pressed position when the movable plate is pressed, and provides information to a processing device such as a personal computer about the pressed position.
[0005] When the movable plate, the support substrate, the conductor layers, and the like are formed of a transparent material, and the touch panel input device is overlaid on a display screen such as a liquid crystal panel or a CRT, a user can press an input operation surface of the touch panel input device while seeing the display through the touch panel input device. The touch panel input device detects the pressed position and provides a processing device such as a personal computer with data on the location of the pressed part corresponding to the display.
[0006] Because the movable plate and the support substrate are laminated with a very small insulation gap between them in this type of a touch panel input device as described above, the stroke for pressing the movable plate is 0.1 to 0.5 mm, which is extremely small. An operator who presses the movable plate has difficulty knowing whether or not an input operation is completed.
[0007] A force feedback type touch panel is known to solve this problem. Such a force feedback type touch panel vibrates the movable plate or the support substrate to generate a tactile feedback to the finger of the operator when the input operation on the touch panel input device is successful.
[0008] Referring to FIG. 8, a conventional touch panel input device 100 includes a movable plate 101 and a support substrate 103 . The movable plate 101 is a flexible transparent plastic sheet. The support substrate 103 is made of glass, with a transparent plastic sheet 102 attached on a surface opposing to the movable plate 101 . A large number of insulating protrusions 104 hold the movable plate 101 separated from the plastic sheet 102 . Together, these elements constitute the touch panel 100 A.
[0009] Conductor layers (not shown), made of a uniform resistive coating, cover opposing surfaces of the movable plate 101 and the plastic sheet 102 . The conductor layers come in contact with each other, and conduct at a pressed position when a conductive sheet on the movable plate 101 is pressed into contact with the conductive sheet on the support substrate 103 . The contact is position is detected based on voltages between leader electrodes (not shown) electrically connected to peripheral edges of the conductor layers. The voltages provide information about the x and y position of the position that is pressed.
[0010] The support substrate 103 is supported on a plurality of cylindrical cushion pillars 106 affixed to a bottom surface of a housing 105 . The cushion pillars 106 are a rubber material on which the entire touch panel 100 A is supported. A rubber with a hardness of 50 to 60 is used because the use of a rubber material that is too soft would absorb the pressure on the movable plate 103 .
[0011] A display panel 107 is placed in a space formed by the cushion pillars 106 between the support substrate 103 and the housing 105 . Parts formed on the support substrate 103 are made of a transparent material to permit display of the display panel 107 seen from above the movable plate 101 .
[0012] A piezoelectric actuator 108 , formed by laminating multiple piezoelectric substrates made of piezoelectric ceramic or the like, is disposed at one end of the rear side of the support substrate 103 . The piezoelectric actuator 108 uses an electrostriction effect to vibrate itself. The piezoelectric actuator 108 serves as a vibration generating source when a drive voltage is applied thereto.
[0013] The piezoelectric actuator 108 has its base end fixed on a support stand 109 and its center rotatably supported by a support shaft 110 . A contactor 111 is fixed to the outer end of the piezoelectric actuator 108 in contact with a rear surface of the support substrate 103 .
[0014] When a position on the movable plate 101 is pressed for an input operation, the conductor layers come into contact with each other at the pressed position. A pressure detecting means (not shown) detects the pressure and the pressed position, and provides a processing device such as a personal computer with pressed position data.
[0015] When a pressure is detected, a drive voltage is impressed on drive electrodes of the piezoelectric actuator 108 . This causes the piezoelectric actuator 108 to vibrate. The vibration is transmitted to the support substrate 103 through the contactor 111 at the end of the piezoelectric actuator 108 . A fingertip pressing the movable plate 101 feels the vibration.
[0016] Thus, when an operator who presses the touch panel input device presses the movable plate 101 , the operator feels the vibration at the fingertip to confirm that the input operation is conducted.
[0017] While the conventional touch panel input device uses a vibrator such as a piezoelectric actuator or a vibrating motor as a source for generating vibration to vibrate the movable plate 101 and/or the support substrate 103 , because the vibration generating source is provided in a space independent to the movable plate 101 or the support substrate 103 constituting the touch panel, the thickness and the size of the housing 105 and thus the size of the entire input device increases. The design of the exterior of the device is also restricted.
[0018] Because the piezoelectric actuator 108 as the vibration generating source has to transmit sensitive vibrations to the touch panel 100 A in contact with the piezoelectric actuator 108 , the piezoelectric actuator 108 must generate a displacement with a certain amplitude, and is constituted while laminating multiple piezoelectric substrates. As a result, the thickness of the piezoelectric actuator 108 is increased. Because the manufacturing process for laminating multiple piezoelectric substrates comprises multiple processes including attaching a pair of drive electrodes to the individual layers, and then laminating the piezoelectric substrates to which the drive electrodes are attached in the thickness direction for integration, the cost of the part is relatively high.
[0019] When a vibrating motor is used as the vibration generating source, the size of the vibrating motor itself is large, and the parts cost is high.
[0020] Because the vibration of the touch panel 100 A is an indirect vibration transmitted from the vibration generating source, it is difficult to transmit a delicate feeling of the vibration from the vibration generating source to the touch panel 100 A. For example, if the frequency of the vibration is changed to transmit different information to an operator, because the touch panel 100 A does not precisely move accordingly, it is impossible for the operator to discern the different information.
[0021] Because a delay exists between the generation of the vibration of the vibration generating source and the vibration of the touch panel 100 A, it is difficult to directly transmit a slight change of the vibration.
[0022] Because it is necessary to vibrate the vibration generating source such as the piezoelectric actuator 108 and a vibrating motor continuously for a certain time period, a drive circuit for driving the vibration generating source is a complicated circuit which uses an oscillation circuit. That is, because the vibration source such as a vibrating motor does not respond to a drive voltage in a momentary pulse waveform, the drive circuit must operate for a certain time period including a start operation control. When a drive voltage in the form of a momentary pulse waveform is applied to the piezoelectric actuator 108 , although the piezoelectric actuator 108 momentarily contracts and expands accordingly, because of damping of the expansion and contraction (a vibration) transmitted to the touch panel 100 A, as described before, an operator cannot sense the momentary vibration. There is also a problem of generating an input operation feeling as well.
[0023] In addition, a complicated structure such as the support stand 109 and the support shaft 110 for rotatably supporting the center of the vibration generating source 108 as described above is necessary to secure the vibration generating source 108 in the housing 105 . The vibration generating source 108 merely vibrates to generate noise which is not transmitted to the touch panel 100 A unless the vibration generating source 108 is secured in a mounting.
[0024] Manufacturing precision is required for the vibration generating source 108 , and the vibration transmission mechanism of the touch panel 100 A such as the support substrate 104 . If a gap is present between the contactor 111 and the support substrate 104 , for example, noise is generated during vibrating, but the vibration is attenuated during transmission.
OBJECTS AND SUMMARY OF THE INVENTION
[0025] In view of these conventional problems, it is an object of the present invention to provide a touch panel input device in which the size of the entire device is not increased and the exterior design is not restricted while a structure of vibrating a movable plate or a support substrate is adopted.
[0026] Another object of the present invention is to provide a touch panel input device for freely and finely controlling the vibration of the movable plate or the support substrate.
[0027] Still, another object of the present invention is to provide a touch panel input device using a simple drive circuit to generate a vibration sensitive to an operator on the movable plate or the support substrate.
[0028] A touch panel input device according to a first aspect of the present invention comprises a movable plate including an input operation surface on its surface, a support substrate placed with a slight insulating gap to the movable plate for supporting a back surface of the movable plate, pressure detecting means for detecting a pressure and a pressed position on the input operation surface based on a contact between conductor layers formed respectively on opposing surfaces of the movable plate and the support substrate, and providing pressed position data, and a piezoelectric substrate including a pair of drive electrodes fixed on both opposing surfaces, and fixed directly or through the drive electrode to the movable plate or the support substrate, wherein a drive voltage is impressed on the pair of drive electrodes, and the contracting and expanding piezoelectric substrate vibrates the movable plate or the support substrate to generate an input operation feeling when a pressure is detected on the input operation surface.
[0029] When a drive voltage is impressed between the pair of drive electrodes, the piezoelectric substrate contracts and expands because of electrostriction effect. Because the piezoelectric substrate is directly fixed to the movable plate or the support substrate thorough one of the drive electrodes, the contraction and expansion of the piezoelectric substrate generates a stress which vibrates with a large amplitude on the movable plate or the support substrate itself to which the piezoelectric substrate is fixed.
[0030] Because the movable plate or the support substrate itself vibrates, changing the waveform of the drive voltage which drives the piezoelectric substrate provides the movable plate or the support substrate with a delicate vibration action.
[0031] A touch panel input device according to a second aspect of the invention is the touch panel input device according to the first aspect, further comprising a spacer member placed at peripheral frames between inner surfaces of the movable plate and the support substrate for laminating and placing the movable plate and the support substrate with a slight gap to each other, and is characterized in that the piezoelectric substrate is fixed directly or through the drive electrode on either one of the inner surfaces of the movable plate and the support substrate facing each other at the frames, and is installed in a space where the spacer is placed.
[0032] Because a single layer substrate made of a piezoelectric material can constitute the piezoelectric substrate, the thickness of the piezoelectric substrate can be made thin, and can be interposed in a slight gap between the movable plate and the support substrate.
[0033] Because a space for placing the spacer member which laminates and places the movable plate and the support substrate slightly separated to each other is used to place the piezoelectric substrate and the pair of drive electrodes on both sides thereof, it is not necessary to provide an independent space for storing the structure which generates the vibration.
[0034] A touch panel input device according to a third aspect of the invention is the touch panel input device according to the second aspect, characterized in that the pressure detecting means impresses a detecting voltage on, or detects a voltage of any leader electrode electrically connected with a peripheral edge of the individual conductor layer of the movable plate or the support substrate to detect the pressure and the pressed position on the input operation surface, the leader electrode fixed on the inner surface of the frame of the movable plate or the support substrate serves as one of the drive electrodes of the piezoelectric substrate, and the piezoelectric substrate is fixed through the leader electrode.
[0035] Because the leader electrode electrically connected with the peripheral edge of the conductor layer is shared by one of the drive electrodes for the piezoelectric substrate, it is not necessary to form one drive electrode independently.
[0036] Because the leader electrode is an electrode for electrically connecting the conductor layer with the outside, it is possible to use the leader electrode and wiring connected with the outside for impressing the drive voltage on the one of the drive electrodes.
[0037] A touch panel input device according to a fourth aspect of the invention is the touch panel input device according to the first aspect, characterized in that the piezoelectric substrate is fixed directly or through the drive electrode on a rear surface of the support substrate.
[0038] Because the piezoelectric substrate is simply fixed through the one of the drive electrodes on the rear side of the support substrate of the touch panel input device, the vibration feature is added without changing the conventional structure.
[0039] A touch panel input device according to a fifth aspect of the invention is the touch panel input device according to the fourth aspect, characterized in that the movable plate and the support substrate are made of a transparent material for transmitting emitted light from a light-emitting element for illumination provided on a rear side of the support substrate, and the piezoelectric substrate is fixed directly or through the drive electrode to a part of a rear surface of the support substrate where the leader electrodes electrically connected with the peripheral edge of the conductor layer are formed.
[0040] Because the piezoelectric substrate is fixed on the rear side of the support substrate between wiring for the light-emitting element and the leader electrodes, the leader electrodes are shielded by the drive electrodes fixed on both surfaces of the piezoelectric substrate opposing to each other, and a high frequency noise generated on the wiring for the light-emitting element is prevented from transmission to the leader electrodes as a result of static capacitive coupling.
[0041] A touch panel input device according to a sixth aspect of the invention is the touch panel input device according to any one of the first to fifth aspects, characterized in that an output voltage present on both ends of a coil when a low voltage trigger pulse is supplied is impressed as a drive voltage on the pair of drive electrodes of the piezoelectric substrate when a pressure is detected on the input operation surface.
[0042] Because the movable plate or the support substrate itself vibrates with a large amplitude, simply impressing the drive voltage in a momentary pulse waveform present on both ends of the coil when a trigger pulse is entered on the piezoelectric substrate generates a vibration sensitive to an operator on the movable plate or the support substrate.
[0043] A touch panel input device according to a seventh aspect of the invention is the touch panel input device according to any one of the first to fifth aspects, characterized in that, when a pressure is detected on the input operation surface, a drive voltage with an audio band frequency is impressed on the pair of drive electrodes to contract and expand the piezoelectric substrate for vibrating the movable plate or the support substrate at the audio band frequency, and a sound representing an input operation is generated.
[0044] Because the movable plate or the support substrate vibrates at the audio band frequency, and generates an operation sound for representing a pressure detection, it is possible to use the operation sound to generate an input operation feeling without providing an independent speaker.
[0045] The above, and other objects, features and advantages of the present invention will become apparent from the following description read in conjunction with the accompanying drawings, in which like reference numerals designate the same elements.
BRIEF DESCRIPTION OF THE DRAWINGS
[0046] [0046]FIG. 1 is an exploded perspective view of a touch panel input device according to an embodiment of the present invention.
[0047] [0047]FIG. 2 is a longitudinal sectional view of a principal part of the touch panel input device of FIG. 1.
[0048] [0048]FIG. 3( a ) is a descriptive drawing showing an installation of a piezoelectric substrate.
[0049] [0049]FIG. 3( b ) is a perspective view of a principal part showing a connection between a pair of drive electrodes and leads.
[0050] [0050]FIG. 4 is a block diagram of a first drive circuit for driving the piezoelectric substrate of FIG. 1.
[0051] [0051]FIG. 5( a ) shows a drive voltage waveform for generating a click feeling in the embodiment of FIG. 1.
[0052] [0052]FIG. 5( b ) shows a drive voltage waveform for generating moderate vibration feeling in the embodiment of FIG. 1.
[0053] [0053]FIG. 5( c ) shows a drive voltage waveform for generating an audible sound in the embodiment of FIG. 1.
[0054] [0054]FIG. 5( d ) shows a drive voltage waveform for generating an audible sound after a click feeling in the embodiment of FIG. 1.
[0055] [0055]FIG. 6 is a block diagram of a second drive circuit for driving the piezoelectric substrate of FIG. 1.
[0056] [0056]FIG. 7 is a sectional view of a principal part of a touch panel input device according to a second embodiment of the present invention.
[0057] [0057]FIG. 8 is a longitudinal sectional view showing a conventional touch panel input device.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0058] Referring first to FIGS. 1 and 2, a touch panel input device 1 according to the present embodiment adopts a so-called resistance-sensitive tablet system where uniform resistor films form conductive layers on facing surfaces. Voltages generated upon touching the external surface are processed to detects a contact position (a pressed position) between the conductive layers.
[0059] A movable plate 3 is a flexible rectangular sheet of a suitable transparent plastic material such as, for example, PET (polyethylene terephthalate). Although an arbitrary material which slightly bends toward a support substrate 4 described below is used as a material for the movable plate 3 , when a transparent material is used for showing a display part (not shown) provided inside the support substrate 4 as the present embodiment, the material therefor could include a glass substrate, an acrylic board for providing a certain degree of stiffness, and a polycarbonate (PC), a polyethersulfone (PES), and a polyimide (PI) for providing flexibility.
[0060] A transparent hard coat agent (not shown) is applied on the surface of the movable plate 3 to protect its top surface which is contacted by an operator as it serves as an input operation surface 3 a.
[0061] The support substrate 4 is a transparent substrate formed as a rectangular thin plate with the same contour as that of the movable plate 3 using soda lime glass. Although the support substrate 4 is a substrate for supporting the rear side of the movable plate 3 to be pressed, and requires a certain degree of stiffness, it is not always necessary to form the support substrate 4 of a transparent material when the display part is not included inside the support substrate 4 . The support substrate 4 is not limited to a glass plate, but may be a plastic plate such as an acrylic substrate or a metal plate such as an aluminum or steel.
[0062] The movable plate 3 and the support substrate 4 are laminated with a slight gap therebetween. An adhesive layer 5 is interposed between individual frames 3 A and 4 A on peripheries of the movable plate 3 and the support substrate 4 to maintain the required gap. A movable conductor layer 6 and a fixed conductor layer 7 , which are made of a transparent conductor film, are fixed with an even film thickness facing each other on opposing surfaces of the movable plate 3 and the support substrate 4 , respectively. The movable conductor layer 6 and the fixed conductor layer 7 are formed with ITO (indium tin oxide) with even film thicknesses. As a consequence of this uniformity, the resistance per length is equal at individual positions on the conductor layers.
[0063] Dot spacers (not shown) made of insulating synthetic resin are fixed at a predetermined spacing on the fixed conductor layer 7 . These dot spacers prevent the movable conductor layer 6 and the fixed conductor layer 7 from accidentally being brought into contact with each other when the hand of an operator unintentionally touches a part of the input operation surface 3 a. The dot spacers have a height that is less than the gap between the movable conductor layer 6 and the fixed conductor layer 7 separated by the adhesive layer 5 .
[0064] An X impressing side leader electrode 8 a , and an X ground side leader electrode 8 b connected with the movable conductor layer 6 are printed in the Y direction on opposed edges of the movable conductor layer 6 on the rear surface of the movable plate 3 . The X impressing side leader electrode 8 a , and the X ground side leader electrode 8 b are transparent conductor thin plates in a stripe shape made of silver. Leads 12 a and 12 b on the rear surface of the movable plate 3 for the X impressing side leader electrode 8 a and the X ground side leader electrode 8 b are led out to an external connector 3 b of the movable plate 3 .
[0065] In the same way, a Y ground side leader electrode 9 b electrically connected with the fixed conductor layer 7 is printed on one edge of the fixed conductor layer 7 in a Y direction orthogonal to the X direction in FIG. 1 on the surface of the support substrate 4 facing the movable plate 3 . The Y ground side leader electrode 9 b is a transparent conductor thin plate in a stripe shape made of silver. The Y ground side leader electrode 9 b is led out to the external connector 3 b of the movable plate 3 by a lead 12 d on the rear surface of the movable plate 3 . The lead 12 d is electrically connected to the surface of the Y ground side leader electrode 9 b using a conductive adhesive.
[0066] A Y impressing side leader electrode 9 a electrically connected with the fixed conductor layer 7 is formed on the other edge opposite the edge of the fixed conductor layer 7 on which the Y ground side leader electrode 9 b is printed in the X direction. Because the Y impressing side leader electrode 9 a serves as one drive electrode 2 a on the piezoelectric substrate 2 , the drive electrode 2 a is fixed using conductive adhesive along the other edge of the fixed conductor layer 7 . The Y impressing side leader electrode 9 a electrically connected with the fixed conductor layer 7 is formed when the piezoelectric substrate 2 is fixed to the support substrate 4 .
[0067] Referring now also to FIG. 3, the Y impressing side leader electrode 9 a (the one drive electrode 2 a ) is bent back toward the front side on one end in the lengthwise direction of the piezoelectric substrate 2 . The Y impressing side leader electrode 9 a is electrically connected to a lead 12 c on the rear surface of the opposing movable plate 3 using conductive adhesive, and is led out to the external connector 3 b.
[0068] The other drive electrode 2 b of the piezoelectric substrate 2 is electrically connected to a lead 12 e on the rear surface of the opposing movable plate 3 using conductive adhesive. The lead 12 e is led out to the external connector 3 b in the same way as the other leads.
[0069] The individual leader electrodes 8 a , 8 b , 9 a , and 9 b , and the drive electrode 2 b which are led out to the external connector 3 b through the leads 12 a , 12 b , 12 c , 12 d , and 12 e , are electrically connected to external circuits including a pressure detecting circuit, and the drive circuits 10 and 11 described below through a conventional connector (not shown) connected to the external connector 3 b.
[0070] The wiring is simplified because simply adding the lead 12 e to the movable plate 3 allows supplying the drive voltage for driving the piezoelectric substrate 2 from the outside.
[0071] Also, because the Y impressing side leader electrode 9 a also serves as one drive electrode 2 a for the piezoelectric substrate 2 , the lead 12 c is shared for connecting to the external circuits. The Y impressing side leader electrode 9 a serves for impressing a detection voltage for detecting a pressed position, or for detecting an electric potential of the fixed conductor layer 7 . The drive electrode 2 a serves for impressing the drive voltage on the movable plate 2 when a pressure is detected as described later. Because detecting the pressed position, and impressing the drive voltage when a pressure is detected are different from each other in timing, and are not conducted simultaneously, the single electrode can be shared by both of them.
[0072] The piezoelectric substrate 2 is a single-layer substrate formed of a piezoelectric material such as piezoelectric single crystal, piezoelectric ceramic typified by PZT (lead zirconium titanate) ceramic, and polyvinylidene fluoride (PVDF), and a piezoelectric ceramic plate made of a PZT piezoelectric ceramic material which has mechanical durability, and is most widely used is used in this case. The piezoelectric substrate 2 is formed into a thin plate in a stripe shape along a side edge of the fixed conductor layer 7 . Because the piezoelectric substrate 2 is a thin plate, when it vibrates, it produces a large distortion. In addition, the piezoelectric substrate 2 operates at low voltage.
[0073] The pair of drive electrodes 2 a and 2 b which impress the drive voltage on the piezoelectric substrate 2 are attached on both the front and the rear surfaces opposing to each other of the piezoelectric substrate 2 using vapor disposition or screen printing, and then are fixed using calcination. The drive electrode 2 a which covers the rear surface of the piezoelectric substrate 2 is bent back on one end in the lengthwise direction of the piezoelectric substrate 2 , and is exposed on the front surface with a gap to the other drive electrode 2 b for avoiding contact with it.
[0074] The piezoelectric substrate 2 , with the drive electrodes 2 a and 2 b fixed on both sides, is placed between the movable plate 3 and the support substrate 4 while using a part of a space for filling the adhesive layer 5 which is filled in between opposing surfaces of the individual frames 3 A and 4 A for laminating the movable plate 3 and the support substrate 4 with a slight gap as shown in FIG. 2. While the height of the space for filling, namely the gap between the movable plate 3 and the support substrate 4 , is generally 100 μm to 1 mm, it is possible that the height of the piezoelectric substrate 2 including the drive electrodes 2 a and 2 b fixed to the both sides of the piezoelectric substrate 2 is about 200 μm because the piezoelectric substrate 2 has a single-layer thin plate structure. It is possible to find sufficient space to install the piezoelectric substrate 2 in the space for filling.
[0075] The piezoelectric substrate 2 is fixed on the surface of the support substrate 4 such that one drive electrode 2 a (the Y impressing side leader electrode 9 a ) fixed on the rear surface is placed across the other side edge of the fixed conductor layer 7 and the surface of the support substrate 4 , and is fixed to the fixed conductor layer 7 and the support substrate 4 using conductive adhesive 13 as shown in the drawing.
[0076] Because the drive electrode 2 a of the piezoelectric substrate 2 serves as the leader electrode in the present embodiment, the conductive adhesive is used to fix the piezoelectric substrate 2 to the support substrate 4 . When drive electrode 2 a is directly fixed to the support substrate 4 , the adhesive is not necessarily conductive. Therefore, different types of adhesives such as epoxy adhesive and acrylic adhesive may be applicable.
[0077] Electrostriction effect of the piezoelectric substrate 2 is used to generate a vibration on the support substrate 4 in the present invention. Because the piezoelectric substrate 2 is directly fixed to the support substrate 4 , the contraction and expansion of the piezoelectric substrate 2 generates a vibration with a large amplitude on the support substrate 4 . For example, when an electric field of 10*10 5 V/m is applied to a PZT piezoelectric material having a dielectric constant of 3400, a piezoelectric constant of 590*10 12 C/N, and an elastic compliance of 20*10 −12 m 2 /N, a distortion of 5.9*10 4 is generated. A large stress of 3*10 7 N/m is generated when this distortion is clamped.
[0078] When this electrostriction effect is used, simply impressing a drive voltage of about ±20 V between the pair of drive electrode 2 a and 2 b in a thickness direction indicated by an arrow in FIG. 3( a ) generates a vibration with an amplitude large enough for sensing with the finger even through the movable plate 3 on the support substrate 4 . Adjusting a driving voltage and/or a length of a part where the piezoelectric substrate 2 is fixed to the support substrate 4 allows adjusting the amplitude of the vibration.
[0079] Because the piezoelectric substrate 2 is fixed on the peripheral edge of the fixed conductor layer 7 , the input operation face 3 a does not become narrower. The pair of piezoelectric substrates 2 may be installed on the both peripheral edges of the fixed conductor layer 7 opposed to each other.
[0080] The piezoelectric substrate 2 is fixed on the support substrate 4 through the drive electrode 2 a . Then the adhesive layer 5 is applied between the opposing surfaces of the individual frames 3 A and 4 A to adhere the movable plate 3 and the support substrate 4 to each other as shown in FIG. 2. When the individual frames 3 A and 4 A of the movable plate 3 and the support substrate 4 are pressed with the adhesive layer 5 are placed between them, the opposing surfaces of the frames 3 A and 4 A come into close contact with each other through the adhesive layer 5 . The movable conductor layer 6 and the fixed conductor layer 7 are positioned in parallel with each other with a slight gap between them. Because the adhesive layer 5 covers the other drive electrode 2 b of the piezoelectric substrate 2 , the piezoelectric substrate 2 contracts and expands without constraint.
[0081] A pressure detecting circuit (not shown) detects a pressure and a pressed position on the input operation surface 3 a of the movable plate 3 thorough the connector connected with the external connector 3 b , and provides pressed position data on them. The following section describes this action.
[0082] A predetermined voltage for detecting pressure is applied to the X impressing side leader electrode 8 a or the X ground side leader electrode 8 b . This maintains the movable conductor layer 6 at this electric potential. The fixed conductor layer 7 is grounded through a resistor to monitor the electric potential in a wait state in the absence of pressure detection. The electric potential of the fixed conductor layer 7 is at ground electric potential when the movable plate 3 is not pressed. When the conductor layers 6 and 7 come in contact with each other as a result of pressing, the movable conductor layer 6 supplies the resistor with a current and the electric potential of the fixed conductor layer 7 increases to a certain potential level. Thus, pressing the movable plate 3 can be detected when a predetermined voltage threshold is set, and the electric potential of the fixed conductor layer 7 exceeds the predetermined threshold.
[0083] When a pressure is detected, the pressure detecting circuit operates to detect the pressed position. When the pressure is detected, the first drive circuit 10 , which impresses the drive voltage on the piezoelectric substrate 2 also starts. This operation is described later.
[0084] The pressed position is detected in the X direction and in the Y direction respectively. When the pressed position in the X direction is detected, a voltage for detecting a coordinate is impressed on the X impressing side leader electrode 8 a . Simultaneously, the X ground side leader electrode 8 b is grounded to form a constant electric potential gradient across the movable conductor layer 6 . The electric potential at the pressed position is read out as the electric potential of the fixed conductor layer 7 when the fixed conductor layer 7 , which comes in contact with the movable conductor layer 6 , is set as a high impedance. A voltage detection circuit such as an A/D converter connected with either one of the Y impressing side leader electrode 9 a and the Y ground side leader electrode 9 b reads the electric potential at the contact position. Because the constant electric potential gradient is formed across the movable conductor layer 6 , the electric potential at the contact position is a value proportional to a distance in the X direction from the X ground side leader electrode 8 b to the X impressing side leader electrode 8 a , and is used for detecting the X coordinate of the pressed position.
[0085] When the pressed position in the Y direction is detected, a constant electric potential gradient in the Y direction is formed across the fixed conductor layer 7 . A voltage detection circuit connected to the X impressing side leader electrode 8 a or the X ground side leader electrode 8 b reads the electric potential at the contact position in the same way as described above. The electric potential at the contact position is a value proportional to a distance in the Y direction from the Y ground side leader electrode 9 b to the Y impressing side leader electrode 9 a . This electric potential is used for detecting the Y coordinate of the pressed position.
[0086] These X and Y coordinate detecting modes are repeated, and the pressed position as a result of pressing the input operation surface 3 a is detected in the X and Y directions. The pressed position data, comprising the X coordinate and the Y coordinate, are provided to a processing device such as a personal computer (not shown in the drawings).
[0087] As long as the touch panel input device 1 detects pressure on the movable plate 3 , the pressure detecting circuit repeats the detection of the pressure and the pressed position. When pressure is first detected after a period of time when pressure is not present, the first drive circuit 10 starts to impress the drive voltage on the piezoelectric substrate 2 to vibrate the support substrate 4 .
[0088] The first drive circuit 10 is a simple circuit as shown in FIG. 4. The pair of drive electrodes 2 a and 2 b of the piezoelectric substrate 2 are connected with the output of the transformer circuit 14 . When a pressure is detected, a vibration trigger signal with a period of 5 to 10 msec is provided for the transformer circuit 14 , a DC low voltage power supply momentarily impresses a few volts on the transformer circuit 14 . Thus, an induction voltage from the coils is generated in the transformer circuit 14 . A drive voltage of about ±40 V is impressed on the piezoelectric substrate 2 .
[0089] When the drive voltage is impressed on the piezoelectric substrate 2 , the piezoelectric substrate 2 cyclically contracts and expands to vibrate the support substrate 4 to which the piezoelectric substrate 2 is fixed. The waveform of the drive voltage for driving the piezoelectric substrate 2 is a pulse waveform generated momentarily. The support substrate 4 vibrates while the drive voltage is impressed. Because a vibration with a large amplitude is generated, even in a momentary period, an operator feels the vibration transmitted to the fingertip through the movable plate 3 which is in contact with the support substrate 4 , with sufficient strength to recognize that the pressing operation is detected.
[0090] Thus, the first drive circuit 10 for generating the vibration can be an extremely simple circuit without requiring an oscillation circuit, or an oscillation circuit for amplification, for maintaining the vibration for a certain period.
[0091] Because the vibration of the support substrate 4 is directly associated with the contraction and the expansion of the piezoelectric substrate 2 , the drive voltage waveform for driving the piezoelectric substrate 2 can be changed as shown in individual drawings in FIGS. 5 ( a )- 5 ( d ) to provide a slight vibration change for an operator.
[0092] [0092]FIG. 5( a ) shows a drive voltage waveform for providing a click feeling similar to one generated for an operator when the operator presses a push button supported by a disc spring. A pulse with a period of 5 to 10 msec is generated twice after a pressure is detected. As a result, the support substrate 4 momentarily vibrates twice.
[0093] [0093]FIG. 5( b ) shows a drive voltage waveform of sinusoidal AC with a frequency of 20 to 30 Hz. This impresses a sinusoidal wave vibration with the same frequency on the support substrate 4 . As a result, an operator feels a vibration similar to that experienced if a vibrating motor were vibrating the support substrate 4 .
[0094] [0094]FIG. 5( c )) is a drive voltage waveform of AC with a period of several hundreds of microseconds. The support substrate 4 vibrates with the same period. Because the vibrating frequency of the support substrate 4 is several kilo hertz, although the vibration frequency is too high for an operator to detect the vibration in a finger, the vibration has the audio frequency. The vibration generates an operation sound if the support substrate 4 is a glass substrate or the like. This permits generating a sound to transmit the input operation feeling to an operator, without the necessity to provide an independent speaker for generating the operation sound.
[0095] [0095]FIG. 5( d ) shows a combination of the drive voltage waveforms from 5 ( a ) and 5 ( c ). The operator first feels a click at the fingertip, and then hears the operation sound to confirm the pressing operation.
[0096] A portable digital assistant (PDA), or a portable data terminal such as a cellular phone is provided with a display plate for showing entered characters, and the content of an incoming call in addition to a vibrating motor for notifying the incoming call, and a speaker for providing a sound for the incoming call. Since it is desirable to reduce the size and the weight of the device as much as possible, it is impossible to install an additional vibrating part such as a conventional piezoelectric actuator or a vibrating motor for vibrating the display plate. No previous product has been capable of vibrating the display plate. With the present invention, simply attaching the piezoelectric substrate 2 to the display plate, and changing the drive voltage waveform as described, above satisfies all these features.
[0097] Referring now to FIG. 6, a second drive circuit 11 is used to generate the waveforms of FIGS. 5 ( a )- 5 ( d ). An oscillation circuit for vibration 15 shown in FIG. 6 is substituted for the first drive circuit 10 , for generating the individual drive voltage waveforms shown in FIGS. 5 ( b ) to 5 ( d ) to continuously drive the piezoelectric substrate 2 for a certain period.
[0098] An oscillating circuit for step-up 16 oscillates at 20 to 30 kHz when a DC low voltage power supply of several volts is used in the second drive circuit 11 . A step-up circuit 17 connected with the oscillating circuit for step-up 16 controls switching of a current flowing through a transformer with the period determined by the oscillating circuit for step-up 16 , steps up several volts from the DC low voltage power supply to a DC voltage of several dozens of volts, and provides an amplifier circuit 18 with the voltage.
[0099] The oscillating circuit for vibration 15 generates a drive signal with a frequency for vibrating the support substrate 4 , and provides the amplifier circuit 18 with the drive signal. The amplifier circuit 18 uses the DC voltage provided from the step-up circuit 17 to amplify the drive signal, and the amplified signal to a gate circuit 19 .
[0100] A pulse width generating circuit 20 is also connected to an input of the gate circuit 19 . The pulse width generating circuit 20 generates a pulse with a width for vibrating the support substrate 4 when a pressure is detected. The pulse width generating circuit 20 receives a vibration trigger generated by the pressure detecting circuit. The gate circuit 19 impresses the drive signal from the amplifier circuit 18 as the drive voltage on the drive electrodes 2 a and 2 b of the piezoelectric substrate 2 while the gate circuit 18 receives the pulse.
[0101] The second drive circuit 11 allows freely setting the frequency of the drive signal generated from the oscillation circuit for vibration 15 , and the pulse width generated from the pulse width generating circuit 20 for generating an arbitrary drive voltage waveform such as the drive voltage waveforms exemplified in the individual drawings in FIGS. 5 ( a )- 5 ( d ).
[0102] While the piezoelectric substrate 2 is provided between the movable plate 3 and the support substrate 4 in the first embodiment, the piezoelectric substrate 2 may be fixed to any part on the movable plate 3 or to the support substrate 4 to embody the present invention.
[0103] Referring now to FIG. 7, a touch panel input device 30 according to a second embodiment of the present invention employs a piezoelectric substrate 2 fixed to the rear surface of the support substrate 4 . Because the second embodiment is the same as the first embodiment, except for the installation position of the piezoelectric substrate 2 , the same numerals are assigned to the identical parts, and detailed description is omitted.
[0104] The piezoelectric substrate 2 is fixed to a part of a rear surface of the support substrate 4 . A Y impressing side leader electrode 9 a is formed through one drive electrode 2 a using an adhesive layer 31 . Because the leads 12 c and 12 e on the rear surface of the movable plate 3 are not used for electrically connecting the pair of drive electrodes 2 a and 2 b to external circuits including the drive circuit 10 or 11 as in the first embodiment, leads provided independently (not shown) are used for electrical connection.
[0105] Because the Y impressing side leader electrode 9 a , which is electrically connected with the fixed conductor layer 7 , cannot serve as the drive electrode 2 a , the Y impressing side leader electrode 9 a is printed and formed at the position where the drive electrode 2 a is fixed in the first embodiment 1 as shown in the drawing.
[0106] The drive circuits 10 and 11 impress the drive voltage on the pair of drive electrodes 2 a and 2 b when a pressure is detected as in the first embodiment. The contraction and expansion of the piezoelectric substrate 2 vibrates the support substrate 4 . An operator feels the vibration at the fingertip through the movable plate 3 in contact with the support substrate 4 , and recognizes that a pressing operation is conducted.
[0107] The touch panel input device 30 according to the present embodiment uses a conventional touch panel input device without changing its constitution, and simply fixes a piezoelectric substrate 2 to the touch panel input device for adding a vibration feature.
[0108] The adhesive layer 5 for adhering the individual frames 3 A and 4 A of the movable plate 3 and the support substrate 4 to each other may be an adhesive layer for fixing these faces opposing to each other.
[0109] Because both the movable plate 3 and the support substrate 4 are formed with a transparent material in the present embodiment, the touch panel input device 30 is placed on a display device such as a liquid crystal panel and a CRT, an operator presses the input operation surface 3 a while seeing a displayed content, a pressed position is detected, and instruction input data corresponding to the displayed content are provided for a processing device such as a personal computer.
[0110] The display device is placed on the rear surface of the support substrate 4 . A light-emitting element for illumination such as a light-emitting diode is also placed on the rear surface of the support substrate 4 in this application form. The display device, the light-emitting element or the wiring for them may generate high frequency noise. The support substrate 4 which serves as an insulating substrate acts as dielectrics. In this case, the noise is superimposed on the leader electrode 9 a and 9 b formed on the support substrate 4 , and the superimposed noise could cause errors in detecting a pressed position.
[0111] Because the drive electrodes 2 a and 2 b adhered to the piezoelectric substrate 2 are interposed between the display device, the light-emitting element, or the wiring for them on the rear side of the support electrode 4 , and the leader electrodes 9 a and 9 b in the present embodiment, the electrodes 2 a and 2 b serve as a shield to the leader electrodes 9 a and 9 b , for cutting off high frequency noise. Thus, errors in detecting the pressed position are prevented.
[0112] While the drive voltage is impressed on the piezoelectric substrate 2 when the pressure on the movable plate 3 is detected for the first time in the first and second embodiments, the drive voltage may be impressed on the piezoelectric substrate 2 to vibrate the movable plate 3 or the support substrate 4 when the pont on the display that is pressed corresponds to the location of a specific icon displayed on the display device based on the detected pressed position data in addition to the detected pressure. The drive voltage waveform may be changed to correspond to different individual icons, so that the vibration action which an operator feels changes to indicate the type of action selected. This is useful of sighted persons, but is vital for a blind operator who can feel the type of icon contacted by the fingertip.
[0113] Though the embodiments are described with reference to resistance-sensitive tablet type analog touch panel input devices 1 and 30 , the touch panel input devices 1 and 30 may be so-called digital type touch panel input devices in which the movable conductor layer 6 and the fixed conductor layer 7 are respectively divided into a large number of parallel strips of movable contact pieces and fixed contact pieces. The strips are attached to opposing surfaces of the movable plate 3 and support substrate 4 such that they are orthogonal to each other. This forms a matrix of contact positions. The digital type touch panel input device detects a pressed position on the movable plate 3 based on a contact position of the movable contact piece and the fixed contact piece which are in contact with each other.
[0114] The piezoelectric substrate may be fixed to the front surface or the rear surface of the movable plate 3 as long as it has a certain degree of stiffness. The movable plate or the support substrate to which the piezoelectric substrate is fixed may be made of any material such as glass, plastic, or metal as long as it has sufficient stiffness to generate vibration when the piezoelectric substrate contracts and expands.
[0115] A low drive voltage can efficiently vibrate the movable plate or the support substrate when the pair of drive electrodes are affixed to the front and rear surfaces opposing to each other in the thickness direction of the piezoelectric substrate, and the piezoelectric substrate is fixed to the movable plate or the support substrate through one of the drive electrode. An electric field is present in the thickness direction of the piezoelectric substrate as shown in the embodiments. However, the method of fixing the drive electrodes is not limited to the described embodiments, and the drive electrodes may be fixed to side surfaces of the piezoelectric substrate orthogonal to the movable plate or the support substrate. The piezoelectric substrate may be directly fixed to the movable plate or to the support substrate.
[0116] When the piezoelectric substrate is attached to the movable plate 3 or the support substrate 4 as in the present invention, different types of applications are derived in addition to directly generating vibration.
[0117] For example, with the piezoelectric substrate fixed to the movable plate, a pressing operation generates a pressure from the movable plate. A voltage generated by distortion of the piezoelectric substrate bent by the pressure is detected to detect a pressure on the touch panel input device. This voltage may be used in applications for using the piezoelectric effect of the piezoelectric substrate (using a voltage signal generated from mechanical distortion). If this output voltage is integrated in an integration circuit, the force exerted on the movable plate can be determined.
[0118] When acceleration is applied on the piezoelectric substrate, the piezoelectric effect provides a voltage as well. Thus, the piezoelectric substrate can be applied to an energy saving circuit. This circuit may be the only one necessary to monitor an output from the piezoelectric substrate in a standby state. That is, the monitor is completely quiescent in the standby state, and is self-powered by the piezoelectric voltage. When an operator takes out a device bearing the touch panel input device, the circuit detects the voltage caused by an acceleration applied on the piezoelectric substrate. This voltage enables turning on the other main circuits.
[0119] If the piezoelectric substrate is exposed on the surface of the movable plate, the piezoelectric substrate may be vibrated by sound pressure from the speech of an operator. Thus, the piezoelectric substrate can be used as a simple microphone.
[0120] Further, when the piezoelectric substrates are fixed on two edges opposing to each other on the input operation surface, because bends transmitted to the individual piezoelectric substrates depend on distances from a pressed position to the fixed positions of the piezoelectric substrates when a pressure is applied, it is possible to detect the pressed position by comparing the outputs from the pair of piezoelectric substrates.
[0121] As described above, because the movable plate 3 and the support substrate 4 , which constitute the touch panel input devices 1 and 30 , vibrate by themselves according to the first aspect of the invention, it is not necessary to provide a vibration source in a space independent to these devices. Thus, the thickness and the size of the entire input devices is not increased.
[0122] Because the movable plate 3 and the support substrate 4 vibrate by themselves, it is not necessary to provide a support mechanism and a transmission mechanism for a vibration generating source. Because noise is not generated or vibration energy is not damped by transmission, a small amount of drive voltage efficiently generates vibration. Thus, simply generating momentary vibration without maintaining the vibration for a certain period makes the vibration sensitive to an operator. A simple circuit without an oscillation circuit can drive the piezoelectric substrate.
[0123] Because the movable plate 3 and the support substrate 4 vibrate simply following the contraction and expansion of the piezoelectric substrate 2 , it is possible to transmit the vibration without delay after pressure is detected, and to change the drive waveform for providing a slight change in vibration feeling for an operator.
[0124] Because the piezoelectric substrate 2 can have a single layer structure, and the thickness can be thinner, it is manufactured at a low cost. Because a low drive voltage provides a large bend, a large-amplitude vibration is efficiently generated on the movable plate 3 and on the support substrate 4 .
[0125] Because the piezoelectric substrate to which the pair of drive electrodes are fixed is installed in an installation space required for the spacer member for slightly separating the movable plate and the support substrate, additional independent space for a structure for applying the vibration action according to the second aspect of the invention is not required.
[0126] A leader electrode electrically connected to the peripheral edge of the conductor layer serves as one drive electrode of the piezoelectric substrate. It is not necessary to form that drive electrode independently according to the third aspect of the invention. Also, the lead for connecting the leader electrode with the external circuits is also shared. It is thus not necessary to provide independent wiring for supplying drive voltage to that drive electrode.
[0127] Because the piezoelectric substrate is simply fixed on the rear surface of the support substrate through a drive electrode according to the fourth aspect of the invention, a conventional touch panel input device may be modified by simply adding the vibration feature.
[0128] Because the drive electrodes shield the high frequency noise received from the rear surface of the support substrate according to the fifth aspect of the invention, errors in detecting a pressed position caused by the high frequency noise superimposed on the leader electrodes is prevented.
[0129] Because an oscillation circuit for generating a continuous vibration, and the like are not necessary according to the sixth aspect of the invention, a simple drive circuit for the piezoelectric substrate generates vibration sensitive to an operator.
[0130] Input operation feeling is provided for an operator using an operation sound without providing an independent sound source such as a speaker according to the seventh aspect of the invention.
[0131] Having described preferred embodiments of the invention with reference to the accompanying drawings, it is to be understood that the invention is not limited to those precise embodiments, and that various changes and modifications may be effected therein by one skilled in the art without departing from the scope or spirit of the invention as defined in the appended claims. | A piezoelectric substrate is fixed to the movable plate or the support substrate directly or through a drive electrode of the piezoelectric substrate. When a pressure on an input operation surface is detected, a drive voltage is impressed on the drive electrodes of the piezoelectric substrate. In response, the piezoelectric substrate vibrates the movable plate or the support substrate, thereby providing tactile feedback to an operator. Because the movable plate or the support substrate directly vibrates without an independent vibrating source, there is no energy loss or transmission delay caused by transmitting the vibration, and finely control of the contraction and expansion of the piezoelectric substrate allows fine control of the vibration. In one embodiment, the drive voltage is modulated with signals dependent on the location of the pressure. In another embodiment, the drive voltage is modulated with audio frequencies to create a speaker. | 59,374 |
This application is a continuation of U.S. patent application Ser. No. 211,126, filed Nov. 28, 1980 now abandoned.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to new and improved means for sensing temperature and, more particularly, to a temperature sensor generating a digital output by applying a thermally induced mechanical stress to a force-sensitive resonator.
2. Description of the Prior Art
Temperature is a basic physical parameter that cannot be measured directly. It can only be measured indirectly by measuring a physical change caused by a temperature change. The main methods for measuring temperature are measuring the change in density of a gas with temperature (gas thermometer), measuring the change in electrical property of an object with temperature (e.g., the platinum resistance thermometer and the thermocouple), and measuring the difference in thermal expansion coefficients of substances (e.g., the liquid thermometer and bimetallic strip thermometer). None of these previous measurement devices are inherently digital.
The only inherently digital measurements available today, as described hereinafter, all suffer from one problem or another. Commerically available digital temperature sensors utilize a quartz resonator having a temperature-induced frequency change occurring because of inherent properties of the quartz.
A number of inherently analog output thermometers may be coupled to analog-to-digital convertors in order to produce digital temperature sensors. Such devices as thermocouples with voltage-to-frequency convertors and oscillator circuits using temperature-sensitive capacitive or resistive elements can yield a digital-type output. In general, these sensors suffer from poor accuracy and stability, excessive complexity, insufficient reliability, and relatively high power consumption.
Direct digital outputs may be obtained by measuring the frequency of a quartz crystal or tuning fork whose output is a function of temperature. These units have a relatively low sensitivity to temperature and are expensive, both to fabricate and instrument.
U.S. Pat. No. 2,456,811, issued to Blackburn, discloses a temperature measuring system in which piezoelectric crystals oscillate at frequencies dependent upon temperature.
U.S. Pat. No. 2,732,748, issued to Grib, describes a temperature compensation technique for tuning forks using bimetallic elements.
U.S. Pat. No. 3,553,602, issued to Brothers et al., discloses a crystal oscillator temperature-sensing system which determines the temperature on one crystal surface with respect to a reference temperature on the other crystal surface by measuring the operating frequency of the oscillator.
U.S. Pat. No. 3,950,987, issued to Slezinger et al., discloses a piezo-optic measuring transducer in which the difference in thermal expansion of the crystals is measured by detection of the crystals' optical properties, not their resonant frequencies.
U.S. Pat. No. 4,039,969, issued to Martin, discloses a quartz thermometer using a single crystal constructed to have two separate oscillation sections. One section oscillates at a standard frequency, whereas the other section oscillates at a frequency dependent upon the temperature. The two frequencies are compared to determine the temperature.
The prior art devices as described in the above patents cannot meet the desired objectives of an inherently digital-type output, high sensitivity, excellent accuracy and stability, low power consumption, small size and weight, fast response time, high reliability, and low cost.
In an unstressed condition, under constant environmental conditions, a load-sensitive resonator has a unique resonant frequency determined by its dimensions and material composition. The resonant frequency of a flexurally vibrating resonator increases under tensile loading and decreases under compressive loading. A number of load-sensitive transducers utilizing this principle have been developed.
Force-sensitive crystals in which loads are applied to the crystals near the nodal points are described in U.S. Pat. No. 2,984,111, issued to Kritz, and U.S. Pat. No. 3,093,760, issued to Tarasevich.
U.S. Pat. No. 3,470,400, issued to Weisbord, describes a single-beam force transducer with an integral mounting system which effectively decouples the beam vibrations from the mounting points through a spring and mass arrangement.
U.S. Pat. No. 3,238,789, issued to Erdley, discloses two tines or bars vibrating 180 degrees out of phase such that the reactive forces and moments cancel.
SUMMARY OF THE INVENTION
It is an object of this invention to provide a temperature sensor with an inherently digital-type output.
It is another object of this invention to provide a temperature sensor with high sensitivity, accuracy, and stability.
It is still another object of this invention to provide a temperature sensor of small size and weight, low power consumption, and rapid response time.
It is still another object of this invention to provide a temperature sensor with high reliability and low cost.
These and other objects of the invention are accomplished through mounting arrangements and systems which apply thermally induced, mechanical stress to load-sensitive resonators. A load-sensitive resonator may be directly mounted to a base with a coefficient of thermal expansion different from that of the resonator. The relative thermal expansions and contractions between the resonator and base produce a strain and resultant stress in the resonator which changes its frequency of vibration. The term "base," as used herein, means any structure to which the resonator is secured, regardless of the material forming the structure. In another embodiment, the thermally produced strain may act through a spring or bellows to stress the resonator. In yet another embodiment, a fluid-filled bellows may use the thermally induced fluid expansions and contractions to stress a force-sensitive resonator.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an isometric view illustrating a conventional single-beam force transducer with integral mounting isolation.
FIG. 2 is a plan view illustrating a conventional closed-end tuning fork sensor.
FIG. 3 is an isometric view illustrating a temperature sensor having a force-sensitive resonator mounted on a base so that thermally induced stress is transmitted from the base directly to the resonator.
FIG. 4 is a plan view illustrating a temperature sensor having a force-sensitive resonator mounted in parallel with a bellows or spring so that thermally induced stress is transmitted from the bellows or spring directly to the resonator.
FIG. 5 is a plan view illustrating a temperature sensor having a force-sensitive resonator mounted in series with a bellows or spring so that thermally induced stress is transmitted from either the bellows or spring or a fluid in the bellows directly to the resonator.
DETAILED DESCRIPTION OF THE INVENTION
The present invention is equally applicable to load-sensitive resonators of various shapes and configurations; however, for simplicity and clarity, only the application to flexurally vibrating, force-sensitive beam and closed-end tuning fork devices will be described in detail, it being understood that the same or similar principles apply in the general case.
FIG. 1 illustrates a conventional single-beam force transducer 2 with integral mounting isolation, as disclosed in the aforementioned patent to Weisbord. The transducer 2 consists of a flexurally vibrating center beam 4, two sets of isolator masses 6, and isolator springs 8 extending from each end of the beam 4 to mounting surfaces 10. Axial forces, applied along the longitudinal axis of the transducer 2, stress the vibrating beam 4, thereby changing its resonant frequency in accordance with the magnitude of the applied loads. The isolator masses 6 and isolator springs 8 are designed to decouple the reactive forces and moments generated by the beam 4 from the mounts 10, thus reducing the energy losses. As a result, the transducer 2 has a high "Q" so that its resonant frequency is an accurate representation of the applied forces. The beam 4 may be driven at its resonant frequency using electrodes 12 and oscillator circuitry in any conventional manner, such as is described in U.S. Pat. No. 3,479,536, issued to Norris.
FIG. 2 is a plan view of a conventional closed-end tuning fork 20 as described in the aforementioned patent to Erdley. This device 20 achieves low energy loss, high "Q" operation by driving a pair of closely matched tines 22, 180 degrees out of phase, thus cancelling the reactive moments and forces which might be transmitted to a mount 24 from which the tines 22 project.
Under constant environmental conditions, the resonant frequency in Hertz, f o , of an unstressed, fixed-ended, flexurally vibrating beam of length L, thickness t, width b, modulus of elasticity E, and density d is given by the formula: ##EQU1## Although the resonant frequency is generally a non-linear function of the applied load F, the first-order load sensitivity S F may be calculated as: ##EQU2## The quantitative relationships between resonant frequency, applied load, and resonator dimensions and composition can be determined from the above formulae. In particular, thermally induced mechanical stress may be applied to load-sensitive resonators to form temperature sensors.
Equation 2 may be rewritten in terms of resonator stress σ as: ##EQU3## Within the elastic llimit, the resonator stress equals the modulus of elasticity E times the resonator strain ε, and equation 3 may be written as: ##EQU4## The resonator strain ε may be directly applied through thermal expansion/contraction means, or the resonator may be stressed through intermediate spring/bellows arrangements.
Although a number of load-sensitive resonators may be mechanically stressed through thermal means to form temperature sensors, the following discussions will illustrate the inventive devices using flexing bars resonators, such as the single-beam force transducer with integral mounting isolation and the closed-end tuning fork force sensor.
FIG. 3 illustrates a digital temperature sensor 70 consisting of a closed-end tuning fork, force-sensitive resonator with tines 72 vibrating 180 degrees out of phase, attached through mounts 74 to a base 76 having a coefficient of thermal expansion α B , different from that of the resonator α R . The length of the resonator extending between mounts 74 changes due to temperature change ΔT, causing resonator strain ε.
ε=(α.sub.B -α.sub.R)ΔT (5)
If S T is defined as the fractional resonant frequency change per unit temperature change, then from Equations 4 and 5: ##EQU5##
Equation 6 shows that, with the proper choice of resonator dimensions L and t, and coefficients of thermal expansion B and R , an extremely sensitive digital temperature sensor can be designed. Furthermore, if the resonator is fabricated from quartz crystal, then the objectives of high sensitivity, accuracy, and stability, as well as small size and weight, low power consumption, and rapid response time can be met. The resonator is connected to oscillator electronics 78 which may be integrally packaged as part of the temperature sensor 70, or the electronics may be remote from the resonator. The entire sensor 70 may be enclosed in a housing 80 such that the resonator operates in a vacuum or inert atmosphere for improved stability and accuracy.
As illustrated in FIG. 4, a load-sensitive tuning fork 60 is encapsulated by a bellows or spring 62 which is attached to tuning fork mounts 64. The bellows or spring 62 has a coefficient of thermal expansion α B which is different from the coefficient of thermal expansion R of the resonator. If the temperature is changed, the thermal mismatch causes differential thermal growth over the length l between mounts 64 which reacts against the bellows spring rate K B to load the tuning fork 60 and change its resonant frequency. The thermally induced change in load with temperature is given by: ##EQU6## Using Equation 2, the fractional change in frequency per unit temperature change S T due to the mechanical stress is thus: ##EQU7## A vacuum or inert atmosphere 66 may be contained within the bellows 62, or the entire sensor may be placed in a surrounding enclosure for improved accuracy and stability.
FIG. 5 illustrates another embodiment of a digital temperature sensor using a bellows or spring and load-sensitive resonator. An enclosure 92 surrounds a closed-end tuning fork 90 and a bellows or spring 94 which are connected in series between the end walls of the enclosure 92. In this embodiment, the bellows or spring 94 do not encapsulate the tuning fork 90 as with the embodiment of FIG. 4. Temperature sensing occurs through reactive, thermally induced mechanical stress produced by the enclosure 92 and/or bellows or spring 94. The basic difference between the embodiments of FIGS. 4 and 5 is that the bellows or spring 62 and tuning fork 60 of FIG. 4 are connected in parallel, while the bellows or spring 94 and tuning fork 90 of FIG. 5 are arranged in series.
The configuration illustrated in FIG. 5 may use thermal expansion or contraction of a fluid 98 (liquid or gas) contained within bellows 94 to stress resonator 90. The resonator 90 may operate in either a vacuum or an inert atmosphere 96 in sealed enclosure 92 such that improved resonator frequency stability is achieved. | A temperature sensor is formed by mounting a force-sensitive resonator on a resilient or non-resilient base structure, preferably in an enclosure such that thermally induced expansions or contractions of the base structure apply a stress to the resonator. The resonant frequency of the resonator is measured to provide an indication of the temperature of the base structure and resonator. | 13,862 |
This application a continuation of application Ser. No. 09/356,563, filed Jul. 19, 1999 which is a continuation of application Ser. No. 09/193,687 filed Feb. 18, 1999, now U.S. Pat. No. 6,023,907, which is a continuation of application Ser. No. 09/003,499 filed on Jan. 6, 1998, now U.S. Pat. No. 5,860,267, which is a divisional of application Ser. No. 08/436,224 filed on May 17, 1995, now U.S. Pat. No. 5,706,621 which is a 371 of PCT/SE94/00386, filed Apr. 29, 1994.
TECHNICAL FIELD
The invention generally relates to a system for providing a joint along adjacent joint edges of two building panels, especially floor panels.
More specifically, the joint is of the type where the adjacent joint edges together form a first mechanical connection locking the joint edges to each other in a first direction at right angles to the principal plane of the panels, and where a locking device forms a second mechanical connection locking the panels to each other in a second direction parallel to the principal plane and at right angles to the joint edges, the locking device comprising a locking groove which extends parallel to and spaced from the joint edge of one of the panels, and said locking groove being open at the rear side of this one panel.
The invention is especially well suited for use in joining floor panels, especially thin laminated floors. Thus, the following description of the prior art and of the objects and features of the invention will be focused on this field of use. It should however be emphasised that the invention is useful also for joining ordinary wooden floors as well as other types of building panels, such as wall panels and roof slabs.
BACKGROUND OF THE INVENTION
A joint of the aforementioned type is known e.g. from SE 450,141. The first mechanical connection is achieved by means of joint edges having tongues and grooves. The locking device for the second mechanical connection comprises two oblique locking grooves, one in the rear side of each panel, and a plurality of spaced-apart spring clips which are distributed along the joint and the legs of which are pressed into the grooves, and which are biased so as to tightly clamp the floor panels together. Such a joining technique is especially useful for joining thick floor panels to form surfaces of a considerable expanse.
Thin floor panels of a thickness of about 7-10 mm, especially laminated floors, have in a short time taken a substantial share of the market. All thin floor panels employed are laid as “floating floors” without being attached to the supporting structure. As a rule, the dimension of the floor panels is 200×1200 mm, and their long and short sides are formed with tongues and grooves. Traditionally, the floor is assembled by applying glue in the groove and forcing the floor panels together. The tongue is then glued in the groove of the other panel. As a rule, a laminated floor consists of an upper decorative wear layer of laminate having a thickness of about 1 mm, an intermediate core of particle board or other board, and a base layer to balance the construction. The core has essentially poorer properties than the laminate, e.g. in respect of hardness and water resistance, but it is nonetheless needed primarily for providing a groove and tongue for assemblage. This means that the overall thickness must be at least about 7 mm. These known laminated floors using glued tongue-and-groove joints however suffer from several inconveniences.
First, the requirement of an overall thickness of at least about 7 mm entails an undesirable restraint in connection with the laying of the floor, since it is easier to cope with low thresholds when using thin floor panels, and doors must often be adjusted in height to come clear of the floor laid. Moreover, manufacturing costs are directly linked with the consumption of material.
Second, the core must be made of moisture-absorbent material to permit using water-based glues when laying the floor. Therefore, it is not possible to make the floors thinner using so-called compact laminate, because of the absence of suitable gluing methods for such non-moisture-absorbent core materials.
Third, since the laminate layer of the laminated floors is highly wear-resistant, tool wear is a major problem when working the surface in connection with the formation of the tongue.
Fourth, the strength of the joint, based on a glued tongue-and-groove connection, is restricted by the properties of the core and of the glue as well as by the depth and height of the groove. The laying quality is entirely dependent on the gluing. In the event of poor gluing, the joint will open as a result of the tensile stresses which occur e.g. in connection with a change in air humidity.
Fifth, laying a floor with glued tongue-and-groove joints is time-consuming, in that glue must be applied to every panel on both the long and short sides thereof.
Sixth, it is not possible to disassemble a glued floor once laid, without having to break up the joints. Floor panels that have been taken up cannot therefore be used again. This is a drawback particularly in rental houses where the flat concerned must be put back into the initial state of occupancy. Nor can damaged or worn-out panels be replaced without extensive efforts, which would be particularly desirable on public premises and other areas where parts of the floor are subjected to great wear.
Seventh, known laminated floors are not suited for such use as involves a considerable risk of moisture penetrating down into the moisture-sensitive core.
Eighth, present-day hard, floating floors require, prior to laying the floor panels on hard subfloors, the laying of a separate underlay of floor board, felt, foam or the like, which is to damp impact sounds and to make the floor more pleasant to walk on. The placement of the underlay is a complicated operation, since the underlay must be placed in edge-to-edge fashion. Different under-lays affect the properties of the floor.
There is thus a strongly-felt need to overcome the above-mentioned drawbacks of the prior art. It is however not possible simply to use the known joining technique with glued tongues and grooves for very thin floors, e.g. with floor thicknesses of about 3 mm, since a joint based on a tongue-and-groove connection would not be sufficiently strong and practically impossible to produce for such thin floors. Nor are any other known joining techniques usable for such thin floors. Another reason why the making of thin floors from e.g. compact laminate involves problems is the thickness tolerances of the panels, being about 0.2-0.3 mm for a panel thickness of about 3 mm. A 3-mm compact laminate panel having such a thickness tolerance would have, if ground to uniform thickness on its rear side, an unsymmetrical design, entailing the risk of bulging. Moreover, if the panels have different thicknesses, this also means that the joint will be subjected to excessive load.
Nor is it possible to overcome the above-mentioned problems by using double-adhesive tape or the like on the undersides of the panels, since such a connection catches directly and does not allow for subsequent adjustment of the panels as is the case with ordinary gluing.
Using U-shaped clips of the type disclosed in the above-mentioned SE 450,141, or similar techniques, to overcome the drawbacks discussed above is no viable alternative either. Especially, biased clips of this type cannot be used for joining panels of such a small thickness as 3 mm. Normally, it is not possible to disassemble the floor panels without having access to their undersides. This known technology relying on clips suffers from the additional drawbacks:
Subsequent adjustment of the panels in their longitudinal direction is a complicated operation in connection with laying, since the clips urge the panels tightly against each other.
Floor laying using clips is time-consuming.
This technique is usable only in those cases where the floor panels are resting on underlying joists with the clips placed therebetween. For thin floors to be laid on a continuous, flat supporting structure, such clips cannot be used.
The floor panels can be joined together only at their long sides. No clip connection is provided on the short sides.
Technical Problems and Objects of the Invention
A main object of the invention therefore is to provide a system for joining together building panels, especially floor panels for hard, floating floors, which allows using floor panels of a smaller overall thickness than present-day floor panels.
A particular object of the invention is to provide a panel-joining system which
makes it possible in a simple, cheap and rational way to provide a joint between floor panels without requiring the use of glue, especially a joint based primarily only on mechanical connections between the panels;
can be used for joining floor panels which have a smaller thickness than present-day laminated floors and which have, because of the use of a different core material, superior properties than present-day floors even at a thickness of 3 mm;
makes it possible between thin floor panels to provide a joint that eliminates any unevennesses in the joint because of thickness tolerances of the panels;
allows joining all the edges of the panels;
reduces tool wear when manufacturing floor panels with hard surface layers;
allows repeated disassembly and reassembly of a floor previously laid, without causing damage to the panels, while ensuring high laying quality;
makes it possible to provide moisture-proof floors;
makes it possible to obviate the need of accurate, separate placement of an underlay before laying the floor panels; and
considerably cuts the time for joining the panels.
These and other objects of the invention are achieved by means of a panel-joining system having the features recited in the appended claims.
Thus, the invention provides a system for making a joint along adjacent joint edges of two building panels, especially floor panels, in which joint:
the adjacent joint edges together form a first mechanical connection locking the joint edges to each other in a first direction at right angles to the principal plane of the panels, and
a locking device arranged on the rear side of the panels forms a second mechanical connection locking the panels to each other in a second direction parallel to the principal plane and at right angles to the joint edges, said locking device comprising a locking groove which extends parallel to and spaced from the joint edge of one of said panels, termed groove panel, and which is open at the rear side of the groove panel, said system being characterised in
that the locking device further comprises a strip integrated with the other of said panels, termed strip panel, said strip extending throughout substantially the entire length of the joint edge of the strip panel and being provided with a locking element projecting from the strip, such that when the panels are joined together, the strip projects on the rear side of the groove panel with its locking element received in the locking groove of the groove panel,
that the panels, when joined together, can occupy a relative position in said second direction where a play exists between the locking groove and a locking surface on the locking element that is facing the joint edges and is operative in said second mechanical connection,
that the first and the second mechanical connection both allow mutual displacement of the panels in the direction of the joint edges, and
that the second mechanical connection is so conceived as to allow the locking element to leave the locking groove if the groove panel is turned about its joint edge angularly away from the strip.
The term “rear side” as used above should be considered to comprise any side of the panel located behind/underneath the front side of the panel. The opening plane of the locking groove of the groove panel can thus be located at a distance from the rear surface of the panel resting on the supporting structure. Moreover, the strip, which in the invention extends throughout substantially the entire length of the joint edge of the strip panel, should be considered to encompass both the case where the strip is a continuous, uninterrupted element, and the case where the “strip” consists in its longitudinal direction of several parts, together covering the main portion of the joint edge.
It should also be noted (i) that it is the first and the second mechanical connection as such that permit mutual displacement of the panels in the direction of the joint edges, and that (ii) it is the second mechanical connection as such that permits the locking element to leave the locking groove if the groove panel is turned about its joint edge angularly away from the strip. Within the scope of the invention, there may thus exist means, such as glue and mechanical devices, that can counteract or prevent such displacement and/or upward angling.
The system according to the invention makes it possible to provide concealed, precise locking of both the short and long sides of the panels in hard, thin floors. The floor panels can be quickly and conveniently dis-assembled in the reverse order of laying without any risk of damage to the panels, ensuring at the same time a high laying quality. The panels can be assembled and dis-assembled much faster than in present-day systems, and any damaged or worn-out panels can be replaced by taking up and re-laying parts of the floor.
According to an especially preferred embodiment of the invention, a system is provided which permits precise joining of thin floor panels having, for example, a thickness of the order of 3 mm and which at the same time provides a tolerance-independent smooth top face at the joint. To this end, the strip is mounted in an equalising groove which is countersunk in the rear side of the strip panel and which exhibits an exact, predetermined distance from its bottom to the front side of the strip panel. The part of the strip projecting behind the groove panel engages a corresponding equalising groove, which is countersunk in the rear side of the groove panel and which exhibits the same exact, predetermined distance from its bottom to the front side of the groove panel. The thickness of the strip then is at least so great that the rear side of the strip is flush with, and preferably projects slightly below the rear side of the panels. In this embodiment, the panels will always rest, in the Joint, with their equalising grooves on a strip. This levels out the tolerance and imparts the necessary strength to the joint. The strip transmits horizontal and upwardly-directed forces to the panels and downwardly-directed forces to the existing subfloor.
Preferably, the strip may consist of a material which is flexible, resilient and strong, and can be sawn. A preferred strip material is sheet aluminium. In an aluminium strip, sufficient strength can be achieved with a strip thickness of the order of 0.5 mm.
In order to permit taking up previously laid, joined floor panels in a simple way, a preferred embodiment of the invention is characterised in that when the groove panel is pressed against the strip panel in the second direction and is turned anglularly away from the strip, the maximum distance between the axis of rotation of the groove panel and the locking surface of the locking groove closest to the joint edges is such that the locking element can leave the locking groove without contacting the locking surface of the locking groove. Such a disassembly can be achieved even if the aforementioned play between the locking groove and the locking surface is not greater than 0.2 mm.
According to the invention, the locking surface of the locking element is able to provide a sufficient locking function even with very small heights of the locking surface. Efficient locking of 3-mm floor panels can be achieved with a locking surface that is as low as 2 mm. Even a 0.5-mm-high locking surface may provide sufficient locking. The term “locking surface” as used herein relates to the part of the locking element engaging the locking groove to form the second mechanical connection.
For optimal function of the invention, the strip and the locking element should be formed on the strip panel with high precision. Especially, the locking surface of the locking element should be located at an exact distance from the joint edge of the strip panel.
Furthermore, the extent of the engagement in the floor panels should be minimised, since it reduces the floor strength.
By known manufacturing methods, it is possible to produce a strip with a locking pin, for example by extruding aluminium or plastics into a suitable section, which is thereafter glued to the floor panel or is inserted in special grooves. These and all other traditional methods do however not ensure optimum function and an optimum level of economy. To produce the joint system according to the invention, the strip is suitably formed from sheet aluminium, and is mechanically fixed to the strip panel.
The laying of the panels can be performed by first placing the strip panel on the subfloor and then moving the groove panel with its long side up to the long side of the strip panel, at an angle between the principal plane of the groove panel and the subfloor. When the joint edges have been brought into engagement with each other to form the first mechanical connection, the groove panel is angled down so as to accommodate the locking element in the locking groove.
Laying can also be performed by first placing both the strip panel and the groove panel flat on the subfloor and then joining the panels parallel to their principal planes while bending the strip downwards until the locking element snaps up into the locking groove. This laying technique enables in particular mechanical locking of both the short and long sides of the floor panels. For example, the long sides can be joined together by using the first laying technique with downward angling of the groove panel, while the short sides are subsequently joined together by displacing the groove panel in its longitudinal direction until its short side is pressed on and locked to the short side of an adjacent panel in the same row.
In connection with their manufacture, the floor panels can be provided with an underlay of e.g. floor board, foam or felt. The underlay should preferably cover the strip such that the joint between the underlays is offset in relation to the joint between the floor panels.
The above and other features and advantages of the invention will appear from the appended claims and the following description of embodiments of the invention.
The invention will now be described in more detail hereinbelow with reference to the accompanying drawing Figures.
DESCRIPTION OF DRAWING FIGURES
FIGS. 1 a and 1 b schematically show in two stages how two floor panels of different thickness are joined together in floating fashion according to a first embodiment of the invention.
FIGS. 2 a-c show in three stages a method for mechanically joining two floor panels according to a second embodiment of the invention.
FIGS. 3 a-c show in three stages another method for mechanically joining the floor panels of FIGS. 2 a-c.
FIGS. 4 a and 4 b show a floor panel according to FIGS. 2 a-c as seen from below and from above, respectively.
FIG. 5 illustrates in perspective a method for laying and joining floor panels according to a third embodiment of the invention.
FIG. 6 shows in perspective and from below a first variant for mounting a strip on a floor panel.
FIG. 7 shows in section a second variant for mounting a strip on a floor panel.
DESCRIPTION OF PREFERRED EMBODIMENTS
FIGS. 1 a and 1 b , to which reference is now made, illustrate a first floor panel 1 , hereinafter termed strip panel, and a second floor panel 2 , hereinafter termed groove panel. The terms “strip panel” and “groove panel” are merely intended to facilitate the description of the invention, the panels 1 , 2 normally being identical in practice. The panels 1 and 2 may be made from compact laminate and may have a thickness of about 3 mm with a thickness tolerance of about ±0.2 mm. Considering this thickness tolerance, the panels 1 , 2 are illustrated with different thicknesses (FIG. 1 b ), the strip panel 1 having a maximum thickness (3.2 mm) and the groove panel 2 having a minimum thickness (2.8 mm).
To enable mechanical joining of the panels 1 , 2 at opposing joint edges, generally designated 3 and 4 , respectively, the panels are provided with grooves and strips as described in the following.
Reference is now made primarily to FIGS. 1 a and 1 b , and secondly to FIGS. 4 a and 4 b showing the basic design of the floor panels from below and from above, respectively.
From the joint edge 3 of the strip panel 1 , i.e. the one long side, projects horizontally a flat strip 6 mounted at the factory on the underside of the strip panel 1 and extending throughout the entire joint edge 3 . The strip 6 , which is made of flexible, resilient sheet aluminium, can be fixed mechanically, by means of glue or in any other suitable way. In FIGS. 1 a and 1 b , the strip 6 is glued, while in FIGS. 4 a and 4 b it is mounted by means of a mechanical connection, which will be described in more detail hereinbelow.
Other strip materials can be used, such as sheets of other metals, as well as aluminium or plastics sections. Alternatively, the strip 6 may be integrally formed with the strip panel 1 . At any rate, the strip 6 should be integrated with the strip panel 1 , i.e. it should not be mounted on the strip panel 1 in connection with laying. As a non-restrictive example, the strip 6 may have a width of about 30 mm and a thickness of about 0.5 mm.
As appears from FIGS. 4 a and 4 b , a similar, although shorter strip 6 ′ is provided also at one short side 3 ′ of the strip panel 1 . The shorter strip 6 ′ does however not extend throughout the entire short side 3 ′ but is otherwise identical with the strip 6 and, therefore, is not described in more detail here.
The edge of the strip 6 facing away from the joint edge 3 is formed with a locking element 8 extended throughout the entire strip 6 . The locking element 8 has a locking surface 10 facing the joint edge 3 and having a height of e.g. 0.5 mm. The locking element 8 is so designed that when the floor is being laid and the strip panel 2 of FIG. 1 a is pressed with its joint edge 4 against the joint edge 3 of the strip panel 1 and is angled down against the subfloor 12 according to FIG. 1 b , it enters a locking groove 14 formed in the underside 16 of the groove panel 2 and extending parallel to and spaced from the joint edge 4 . In FIG. 1 b , the locking element 8 and the locking groove 14 together form a mechanical connection locking the panels 1 , 2 to each other in the direction designated D 2 . More specifically, the locking surface 10 of the locking element 8 serves as a stop with respect to the surface of the locking groove 14 closest to the joint edge 4 .
When the panels 1 and 2 are joined together, they can however occupy such a relative position in the direction D 2 that there is a small play A between the locking surface 10 and the locking groove 14 . This mechanical connection in the direction D 2 allows mutual displacement of the panels 1 , 2 in the direction of the joint, which considerably facilitates the laying and enables joining together the short sides by snap action.
As appears from FIGS. 4 a and 4 b , each panel in the system has a strip 6 at one long side 3 and a locking groove 14 at the other long side 4 , as well as a strip 6 ′ at one short side 3 ′ and a locking groove 14 ′ at the other short side 4 ′.
Furthermore, the joint edge 3 of the strip panel 1 has in its underside 18 a recess 20 extending throughout the entire joint edge 3 and forming together with the upper face 22 of the strip 6 a laterally open recess 24 . The joint edge 4 of the groove panel 2 has in its top side 26 a corresponding recess 28 forming a locking tongue 30 to be accommodated in the recess 24 so as to form a mechanical connection locking the joint edges 3 , 4 to each other in the direction designated D 1 . This connection can be achieved with other designs of the joint edges 3 , 4 , for example by a bevel thereof such that the joint edge 4 of the groove panel 2 passes obliquely in underneath the joint edge 3 of the strip panel 1 to be locked between that edge and the strip 6 .
The panels 1 , 2 can be taken up in the reverse order of laying without causing any damage to the joint, and be laid again.
The strip 6 is mounted in a tolerance-equalising 10 groove 40 in the underside 18 of the strip panel 1 adjacent the joint edge 3 . In this embodiment, the width of the equalising groove 40 is approximately equal to half the width of the strip 6 , i.e. about 15 mm. By means of the equalising groove 40 , it is ensured that there will always exist between the top side 21 of the panel 1 and the bottom of the groove 40 an exact, predetermined distance E which is slightly smaller than the minimum thickness (2.8 mm) of the floor panels 1 , 2 . The groove panel 2 has a corresponding tolerance-equalising surface or groove 42 in the underside 16 of the joint edge 4 . The distance between the equalising surface 42 and the top side 26 of the groove panel 2 is equal to the aforementioned exact distance E. Further, the thickness of the strip 6 is so chosen that the underside 44 of the strip is situated slightly below the undersides 18 and 16 of the floor panels 1 and 2 , respectively. In this manner, the entire joint will rest on the strip 6 , and all vertical downwardly-directed forces will be efficiently transmitted to the subfloor 12 without any stresses being exerted on the joint edges 3 , 4 . Thanks to the provision of the equalising grooves 40 , 42 , an entirely even joint will be achieved on the top side, despite the thickness tolerances of the panels 1 , 2 , without having to perform any grinding or the like across the whole panels. Especially, this obviates the risk of damage to the bottom layer of the compact laminate, which might give rise to bulging of the panels.
Reference is now made to the embodiment of FIGS. 2 a-c showing in a succession substantially the same laying method as in FIGS. 1 a and 1 b . The embodiment of FIGS. 2 a-c primarily differs from the embodiment of FIGS. 1 a and 1 b in that the strip 6 is mounted on the strip panel 1 by means of a mechanical connection instead of glue. To provide this mechanical connection, illustrated in more detail in FIG. 6, a groove 50 is provided in the underside 18 of the strip panel 1 at a distance from the recess 24 . The groove 50 may be formed either as a continuous groove extending throughout the entire length of the panel 1 , or as a number of separate grooves. The groove 50 defines, together with the recess 24 , a dovetail gripping edge 52 , the underside of which exhibits an exact equalising distance E to the top side 21 of the strip panel 1 . The aluminium strip 6 has a number of punched and bent tongues 54 , as well as one or more lips 56 which are bent round opposite sides of the gripping edge 52 in clamping engagement therewith. This connection is shown in detail from below in the perspective view of FIG. 6 .
Alternatively, a mechanical connection between the strip 6 and the strip panel 1 can be provided as illustrated in FIG. 7 showing in section a cut-away part of the strip panel 1 turned upside down. In FIG. 7, the mechanical connection comprises a dovetail recess 58 in the underside 18 of the strip panel 1 , as well as tongues/lips 60 punched and bent from the strip 6 and clamping against opposing inner sides of the recess 58 .
The embodiment of FIGS. 2 a-c is further characterised in that the locking element 8 of the strip 6 is designed as a component bent from the aluminium sheet and having an operative locking surface 10 extending at right angles up from the front side 22 of the strip 6 through a height of e.g. 0.5 mm, and a rounded guide surface 34 facilitating the insertion of the locking element 8 into the locking groove 14 when angling down the groove panel 2 towards the subfloor 12 (FIG. 2 b ), as well as a portion 36 which is inclined towards the subfloor 12 and which is not operative in the laying method illustrated in FIGS. 2 a-c.
Further, it can be seen from FIGS. 2 a-c that the joint edge 3 of the strip panel 1 has a lower bevel 70 which cooperates during laying with a corresponding upper bevel 72 of the joint edge 4 of the groove panel 2 , such that the panels 1 and 2 are forced to move vertically towards each other when their joint edges 3 , 4 are moved up to each other and the panels are pressed together horizontally.
Preferably, the locking surface 10 is so located relative to the joint edge 3 that when the groove panel 2 , starting from the joined position in FIG. 2 c , is pressed horizontally in the direction D 2 against the strip panel 1 and is turned angularly up from the strip 6 , the maximum distance between the axis of rotation A of the groove panel 2 and the locking surface 10 of the locking groove is such that the locking element 8 can leave the locking groove 14 without coming into contact with it.
FIGS. 3 a - 3 b show another joining method for mechanically joining together the floor panels of FIGS. 2 a-c . The method illustrated in FIGS. 3 a-c relies on the fact that the strip 6 is resilient and is especially useful for joining together the short sides of floor panels which have already been joined along one long side as illustrated in FIGS. 2 a-c . The method of FIGS. 3 a-c is performed by first placing the two panels 1 and 2 flat on the subfloor 12 and then moving them horizontally towards each other according to FIG. 3 b . The inclined portion 36 of the locking element 8 then serves as a guide surface which guides the joint edge 4 of the groove panel 2 up on to the upper side 22 of the strip 6 . The strip 6 will then be urged downwards while the locking element 8 is sliding on the equalising surface 42 . When the joint edges 3 , 4 have been brought into complete engagement with each other horizontally, the locking element 8 will snap into the locking groove 14 (FIG. 3 c ), thereby providing the same locking as in FIG. 2 c . The same locking method can also be used by placing, in the initial position, the joint edge 4 of the groove panel with the equalising groove 42 on the locking element 10 (FIG. 3 a ). The inclined portion 36 of the locking element 10 then is not operative. This technique thus makes it possible to lock the floor panels mechanically in all directions, and by repeating the laying operations the whole floor can be laid without using any glue.
The invention is not restricted to the preferred embodiments described above and illustrated in the drawings, but several variants and modifications thereof are conceivable within the scope of the appended claims. The strip 6 can be divided into small sections covering the major part of the joint length. Further, the thickness of the strip 6 may vary throughout its width. All strips, locking grooves, locking elements and recesses are so dimensioned as to enable laying the floor panels with flat top sides in a manner to rest on the strip 6 in the joint. If the floor panels consist of compact laminate and if silicone or any other sealing compound, a rubber strip or any other sealing device is applied prior to laying between the flat projecting part of the strip 6 and the groove panel 2 and/or in the recess 26 , a moisture-proof floor is obtained.
As appears from FIG. 6, an underlay 46 , e.g. of floor board, foam or felt, can be mounted on the underside of the panels during the manufacture thereof. In one embodiment, the underlay 46 covers the strip 6 up to the locking element 8 , such that the joint between the underlays 46 becomes offset in relation to the joint between the joint edges 3 and 4 .
In the embodiment of FIG. 5, the strip 6 and its locking element 8 are integrally formed with the strip panel 1 , the projecting part of the strip 6 thus forming an extension of the lower part of the joint edge 3 . The locking function is the same as in the embodiments described above. On the underside 18 of the strip panel 1 , there is provided a separate strip, band or the like 74 extending throughout the entire length of the joint and having, in this embodiment, a width covering approximately the same surface as the separate strip 6 of the previous embodiments. The strip 74 can be provided directly on the rear side 18 or in a recess formed therein (not shown), so that the distance from the front side 21 , 26 of the floor to the rear side 76 , including the thickness of the strip 74 , always is at least equal to the corresponding distance in the panel having the greatest thickness tolerance. The panels 1 , 2 will then rest, in the joint, on the strip 74 or only on the undersides 18 , 16 of the panels, if these sides are made plane.
When using a material which does not permit downward bending of the strip 6 or the locking element 8 , laying can be performed in the way shown in FIG. 5. A floor panel 2 a is moved angled upwardly with its long side 4 a into engagement with the long side 3 of a previously laid floor panel 1 while at the same time a third floor panel 2 b is moved with its short side 4 b ′ into engagement with the short side 3 a ′ of the upwardly-angled floor panel 2 a and is fastened by angling the panel 2 b downwards. The panel 2 b is then pushed along the short side 3 a ′ of the upwardly-angled floor panel 2 a until its long side 4 b encounters the long side 3 of the initially-laid panel 1 . The two upwardly-angled panels 2 a and 2 b are therefore angled down on to the subfloor 12 so as to bring about locking.
By a reverse procedure the panels can be taken up in the reverse order of laying without causing any damage to the joint, and be laid again.
Several variants of preferred laying methods are conceivable. For example, the strip panel can be inserted under the groove panel, thus enabling the laying of panels in all four directions with respect to the initial position. | The invention relates to a system for laying and mechanically joining building panels, especially thin, hard, floating floors. Adjacent joint edges ( 3, 4 ) of two panels ( 1, 2 ) engage each other to provide a first mechanical connection locking the joint edges ( 3,4 ) in a first direction (D1) perpendicular to the principal plane of the panels. In each joint, there is further provided a strip ( 6 ) which is integrated with one joint edge ( 3 ) and which projects behind the other joint edge ( 4 ). The strip ( 6 ) has an upwardly protruding locking element ( 8 ) engaging in a locking groove ( 14 ) in the rear side ( 16 ) of the other joint edge ( 4 ) to form a second mechanical connection locking the panels ( 1, 2 ) in a second direction (D2) parallel to the principal plane of the panels and at right angles to the joint. Both the first and the second mechanical connection allow mutual displacement of joined panels ( 1, 2 ) in the direction of the joint. | 35,419 |
BACKGROUND OF THE INVENTION
This invention relates to the field of devices to aid handicapped persons and others who have difficulty in bending over in putting on as well as taking off of socks and other articles of clothing.
Prior art devices of this kind include such things as a sock expanding frame and control bar with a spreading device to spread the sock apart as shown in U.S. Pat. No. 4,284,216; a U-shaped form at the end of a pair of handle bars to also spread the sock apart and hold it open while being drawn on to one's foot as disclosed in U.S. Pat. No. 3,853,252; another U-shaped device in the form of a clamp to hold the sock opening apart and gripped while being drawn on to the foot as disclosed in U.S. Pat. No. 3,604,604, a frame for expanding the opening of socks or stockings with garter snaps to hold them as they are pulled on as shown in U.S. Pat. No. 3,231,160; a closed hoop or ring with fasteners to hold the sock opening apart for pulling on to the foot, with handles connected to the hoop as shown in U.S. Pat. No. 3,070,271; a spring biased clamping device having spaced apart clamps to grip the sock opening and hold it spread apart for insertion of one's foot, a link member holding the clamp members apart, and chains to pull the clamps open against the bias of the spring to release the sock as shown in U.S. Pat. No. 2,919,840; another U-shaped clamp disclosed in U.S. Pat. No. 2,903,170 is very similar to the one in U.S. Pat. No. 3,604,604 and by the same inventor; and another hoop or ring type of sock puller having a pair of opposed clamps to grip opposite sides of a sock and hold them apart, the clamps manipulated between open and closed positions by a pair of levers as shown in U.S. Pat. No. 1,315,096.
All of these prior art devices include means to spread the opening of the socks and stockings apart, most having clamps or other fastening devices associated with the U-shaped frames or hoops used to spread the sock openings apart, and a few relying on the frictional force of the spread apart frame to hold the sock as it is pulled on. Connecting the clamps and fastening devices of such prior art devices to opposite sides of a sock or stocking opening can be a time consuming and awkward task, particularly for the infirm. The same is true for those prior art devices which require spreading the sock apart under enough tension that the sock will stay on the frame while being pulled on. It requires some force to spread a frame member apart sufficiently to stretch the sock or stocking to the point it will not pull away from the the frame as the sock or stocking is pulled on the user's foot. It also requires some dexterity to manipulate the complicated assembly of levers and spreading devices shown on the prior art devices, a level of dexterity that the infirm and handicapped persons may not have.
The tool in accordance with the present invention overcomes such problems, and provides a more natural mechanical extension of one's hands to grip and pull on, not only socks but other items of clothing as well, and not only to pull them on but to take them off as well. One of the tools in accordance with the present invention can be held in each hand, and readily moved apart as well as together throughout the entire range of the user's own arms to whatever distance necessary for gripping a sock in one instance, farther apart to grip the opposite sides of a pair of shorts in another instance, or trousers, and the like. The invention in this case does not require a limiting spacer device, or spreader device, which all of the prior art attempts to deal with this problem require. Thus, the prior art devices can only be used for the particular item of clothing they are designed for, specifically socks or stockings. There is no way the prior art defices could be used to pull on other items of clothing such as shorts and trousers. Neither can they be used to help in removing the socks or stockings, since it would be more hindrance than help to try to reposition the hoops, U-frames, and spread-apart type frames around a person's leg, then try to refasten the snaps or clamps to the edges of the stocking, and then push the stocking off.
By discovering that the tools do not have to be mechanically held or linked together in order to perform the function of helping handicapped persons who cannot bend over pull on their socks or also be used to help pull on other clothing as well, and in addition to provide real help in removing not only socks and stockings but other clothing as well.
The tool in accordance with the present invention comprises a tong-like member having a pair of elongated arms of spring steel, or other similar material, integrally joined in a U-bend at the handle end and terminating in free ends at the gripping end, with broad surface protective pads on such free ends, the arms being in close side-by-side relationship, the free ends being normally spaced apart slightly, just enough to receive the edge of a sock or other item of clothing between the pads. The length of the arms of the tool is sufficient for the gripping end to reach the end of the user's toes when the handle end is held in the user's hand and the user is not bent over. The slightly spead apart gripping end of one tool is slipped over one edge of the sock opening, and an elongated tubular slide member through which the tool arms extend is moved down toward the gripping end forcing the pads together gripping the sock edge between. The same is done with the tool held in the other hand of the user to grip the opposite edge of the sock opening. The sock at the gripping end of the elongated tool can then be positioned in front of the toes of the user without having to bend, whereupon it can be drawn on to the foot of the user. To remove the sock, the protective gripping pads can easily be slipped over the edges of the sock opening and downward thereof, with the pads on the inside of the sock being able to slide between the user's leg and the inside of the sock to a more convenient location for pushing the sock off, then clamping the pads of each tool together and then pushing the sock off.
SUMMARY OF THE INVENTION
It is an object of the invention to provide a tool to pull on and remove socks and other articles of clothing without the user having to bend over.
It is an object of the invention to provide a tool to pull on and remove socks and other articles of clothing, comprising a pair of elongated arms joined at the handle end and having jaw members at the gripping end to grip the edge of an article of clothing, and an operating member to move said jaw members into gripping position, said operating member movable between a jaw gripping position and a jaw released position.
It is an object of the invention to provide a tool to pull on socks without the user having to bend over which can also be used to pull on trousers and other articles of clothing, and which can also be used to remove socks, trousers and other articles of clothing without the user having to bend over.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is an elevation view of a tool in accordance with this invention for pulling on and removing articles of clothing showing the jaw members in the normally slightly spread apart position, and the operating member shown in the jaw released position.
FIG. 2 is an elevation view of the tool shown in FIG. 1, with the operating member shown moved to the jaw gripping position, and the jaw members in the closed gripping position.
FIG. 3 is a section view taken on line 3--3 of FIG. 1.
FIG. 4 is a section view taken on line 4--4 of FIG. 2.
FIG. 5 is a perspective view of a pair of tools in accordance with this invention shown in position to grip opposite side edges of the opening of a sock.
DESCRIPTION OF PREFERRED EMBODIMENT
A tool for helping to pull on and remove socks or other articles of clothing in accordance with this invention includes a pair of elongated arms 2 and 4, of spring steel or other similar material which is relatively rigid but which can be flexed from an original position and when released will return to such original position.
The elongated arms 2 and 4 are integrally joined in a U-bend 6, at the handle end 8. A hand grasp 10 of a resilient material is fitted over and around the arms 2 and 4 adjacent the handle end 8 for the user to conveniently grasp the tool in his hand. The elongated arms 2 and 4 extend in side-by-side relation from the handle end 8 to the gripping end 12 of the tool.
The gripping end 12 includes a pair of jaw members 14 and 16, comprising resilient pads 18 of rubber, or soft resilient plastic material, fabric or the like which provides a cushioned protective surface to bear against articles of clothing gripped between the jaw members 14 and 16 and which increases the frictional gripping force of the jaw members 14 and 16 on the articles of clothing held therebetween. The resilient pads 18 are preferably tapered at their tip end 20 to facilitate slipping the jaw members 14 and 16 past the edge of an article of clothing to position them for gripping the article of clothing therebetween. The resilient pads 18 include a cylindrical cavity 22 to receive the free end portions 24 of the elongated arms 2 and 4 therein in a tight frictional fit.
The resilient pads 18 include relatively broad surface side walls 26 to provide increased gripping surface area when the side walls 26 of the pads 18 of jaw members 14 and 16 are brought together in gripping relationship.
The jaw members 14 and 16 are in a normally slightly open position, the elongated arms 2 and 4 being bowed outwardly from each other to a slight degree as they extend from the handle end 8 toward the gripping end 12, when the operating member 28 is in its jaw released position adjacent the hand grasp 10 at the handle end 8 of the tool. The jaw members 14 and 16 are moved to the closed or gripping position by sliding the operating member 28 toward the gripping end 12 of the tool. The operating member 28 comprises an elongated tubular length 30 of rigid metal or plastic material, having an elongated cylindrical peripheral wall 32 surrounding an elongated cylindrical bore 34.
The elongated arms 2 and 4 of the tool are received through the cylindrical bore 34 of operating member 28. The cylindrical bore 34 is large enough to enable the operating member 28 to slide along the elongated arms 2 and 4 from the handle end 8 toward the gripping end 12, drawing the outwardly bowed arms 2 and 4 together as the operating member 28 moves toward the gripping end, until the side walls 26 of the pads 18 of jaw members 14 and 16 begin to come together. The operating member can then be moved farther in the direction toward the gripping end 12 to compress the side walls 26 of pads 18 of jaw members 14 and 16 against each other for tighter gripping engagement of an article of clothing therebetween. Thus, the cross-sectional dimension of the cylindrical bore 34 of the operating member 28 in relation to that of the elongated arms 2 and 4 and of the side walls 26 of pads 18 may be stated as follows. The diameter of the cylindrical bore 34 is equal to the diameter of elongated arm 2 of cylindrical cross-section, plus the diameter of elongated arm 4 of cylindrical cross-section, plus an additional distance defined as any distance between (1) zero and (2) that distance which is equal to the thickness of two side walls 26 of resilient pads 18. If the diameter of the cylindrical bore 34 of operating member 28 were any larger than the diameters of arms 2 and 4 plus the thickness of two side walls 26 of pads 18, the operating member 28 could not draw the pads 18 of jaw members 14 and 16 together into gripping relationship.
The elongated arms 2 and 4 are long enough for the gripping end 12 to reach the end of the user's toes when the handle end 8 is held in his hand with arm extended but without the user being bent over. A convenient length for use by adults of average height is approximately twenty inches from the handle end 8 to the gripping end 12.
The length of the elongated tubular operating member 28 may vary, but it should be long enough to provide good contact surface area of its inner cylindrical wall with the arms 2 and 4 over a sufficient length to hold the jaw members 14 and 16 and their pads 18 together securely when in the gripping position. Also, it is desirable for the user to be able to easily reach the upper end 36 of operating member 28 which is nearest the handle end 8 of the tool when the operating member 28 is in its jaw closed position with its lower end 40 approaching the jaw member 14 and 16. Thus, a preferred length of the elongated operating member 28 in relation to the length of the arms 2 and 4 may be defined as between one-fourth and one-third of the length of arms 2 and 4. By way of example, for a tool in which arms 2 and 4 are twenty inches long, the operating member 28 should preferably be between five and six inches in length.
To use the tool in accordance with this invention, the user takes one tool in his right hand with the operating member 28 in the jaw released position whereby the jaw members 14 and 16 are slightly spread apart to receive the edge of a sock 42 for example on the right hand side the sock opening. The operating member 28 is then pushed downwardly toward the gripping end 12 until the pads 18 of jaw members 14 and 16 securely grip the edge of the sock on the right side. A second tool is applied to the left hand side of the sock opening in the same manner as shown in FIG. 5, and its operating member 28 pushed downwardly toward the gripping end 12 until the pads 18 of its jaw members 14 and 16 securely grip the edge of the sock on the left side.
The tool secured to the right hand side of the sock opening is taken in the right hand of the user, the tool secured to the left hand side of the sock opening is taken in the left hand of the user, he extends his arms without bending over and positions the sock opening in front of the toes of one of his feet and then pulls the sock on to his foot. If necessary, such as in the case of long stockings which pull up as far as the knee or the thigh wherein pulling on the upper edge of the stocking alone may result in tearing because of the additional force needed as more of the stocking is pulled over the foot and the leg, the jaw members 14 and 16 of each tool may be released and moved downwardly farther into the stocking for a new grip.
When the tool is used to remove socks or other articles of clothing, the tapered pads 18 of jaw members 14 and 16 of one arm 2 or 4 are readily inserted between the users leg or other body portion and the article of clothing, while the other pad 18 of the other jaw member goes on the outside of the article of clothing. The jaw members 14 and 16 are then closed by moving the operating member 28 to the jaw closed position, whereupon the user can then push the article of clothing downwardly until it clears the end of his foot or feet. Again, it is possible to push the gripping end 12 of the tool in accordance with this invention down into the sock or other item of clothing far beyond its opening, in order to start the process of removing the article of clothing from the user's body. In the case of socks and stockings for example, it is often necessary to apply pressure to a portion thereof midway between its opening end and its toe end, or nearer its toe end, in order to remove the sock or stocking without damage. The tool in accordance with this invention is able to accomplish that without requiring the user to have to bend over, by virtue of its unique construction.
While two tools as described and shown herein may be conveniently used to help in putting on and taking off of articles of clothing, one in each hand of the user, only one of such tools may be used to also accomplish the result. A single tool may be alternately applied to opposite sides of the sock opening, or opening of other articles of clothing, to move the clothing item partially on or off on one side, then doing the same on the other side, and continuing until the clothing items is completely on or completely off. | A combination tool to pull up socks, shorts and trousers for those who have difficulty in bending over, comprising a tong-like member having a pair of elongated arms extending from a handle end to a gripping end. The arms are integrally joined at the handle end in a U-bend, are of spring steel or other material which is relatively rigid but which can be flexed and will spring back to an original position when released, the arms extend parallel in close side-by-side relationship to the gripping end, and resilient protective pads are provided at the gripping end of each arm to hold a sock or other item of clothing between the protective pads. | 16,473 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to heated air data sensors and in particular to sensors which use PTC resistance material for such heaters.
2. Prior Art
In the prior art the use of positive temperature coefficient resistance material for heating various devices has been disclosed. British Patent Specification No. 1,371,709 shows a pressure head for air data sensors having a heater element or elements made of a PTC resistance material. As disclosed the material has a low level electrical resistance until it reaches a given temperature called the anomaly (or Curie) temperature and then the resistance rises substantially when that temperature is reached. The pressure head is de-iced with toroidal or tubular ring type heaters mounted inside the pressure head with the outer peripheral surfaces of the heaters against the inside wall of the body of the pressure head. Difficulties are encountered in this type of device from the manufacturing of the heater elements in the proper shape and the close tolerance required, and also there are problems of installation which limit the effectiveness of the thermal conduction between the heater and the wall of the probe.
Other applications of such PTC resistor heaters include the use in a windshield wiper blade, shown in U.S. Pat. No. 3,489,884, and also as a heating device for use with aerosol containers as shown in U.S. Pat. No. 3,338,476. A fully automatic coffee pot using a PTC resistor heater is shown in U.S. Pat. No. 3,375,774.
One important PTC material used at the present time is doped barium titanate, a material whose positive temperature coefficient properties have long been recognized. Any heater installation in an air data sensing vane must be in good thermal contact with the vane and at the same time electrically insulated from the vane. Various encapsulating materials have been used with PTC elements. For example, U.S. Pat. No. 3,824,328 indicates that a capsulation material can include silicone resins, polyamides and polyimides, and then external epoxy can be used for potting on the outside of the initial layer. A PTC resistor package is also shown in U.S. Pat. No. 3,835,434. Bonding of heating elements to a structure is illustrated in U.S. Pat. No. 3,898,422.
PTC materials have been used in other applications, such as motor starting apparatus, degaussing systems for color television tubes, and also in various current limiting applications.
SUMMARY OF THE INVENTION
The present invention relates to the use of a positive temperature coefficient resistor material as a de-icing heater assembly of an air data sensor. The heater assembly is embedded in the sensor body. The heater assembly is made up of a plurality of individual heater resistors in the form of chips connected in parallel through flexible electrically conductive connectors permitting the individual chips to move slightly relative to each other, and which also permit encapsulating the chips in a suitable temperature conductive, electrically insulating material that is sufficiently resilient to permit the individual chips to expand and contract relative to the air data sensing device during use. There is a substantial ambient temperature range during use of air data sensors, and thus thermally induced dimensional changes are substantial. Also, different coefficients of expansion of the PTC material and the sensor material must be accommodated. Ordinary resistance wire heaters can reach an exceedingly high temperature in air data sensors when the aircraft is taxiing or is standing if the heater is large enough to supply the required amount of heat during operational conditions. The PTC resistance heaters regulate the temperature of the air data sensing device automatically, and keep the temperature at a level low enough to prevent structural degradation of the probe or air data sensing device.
The PTC resistor material used in the present device is doped barium titanate, a well known ceramic material that has displayed positive temperature coefficient properties, and is used widely in other applications.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective exploded view illustrating a typical air data sensing device, in this form of the invention a vane sensor, in a partially manufactured stage and illustrates a PTC heater assembly that will be inserted into the vane;
FIG. 2 is a sectional view longitudinally along the vane of FIG. 1 illustrating the cavity for the PTC heater with the heater installed and in place;
FIG. 3 is a plan view of the heater assembly with parts broken away;
FIG. 4 is a side view of the heater assembly of FIG. 3 with parts in section and parts broken away; and
FIG. 5 is a sectional view taken on line 5--5 in FIG. 3.
DESCRIPTION OF THE PREFERRED EMBODIMENT
In the form of the invention disclosed, the air data sensor utilized is a swept vane angle of attack sensor. A typical vane sensor is illustrated in U.S. Pat. No. 3,882,721 issued May 13, 1975. The vane illustrated in the present device is shown without any mounting details, and reference can be made to the mounting details of this patent and also for an explanation of operation. In U.S. Pat. No. 3,882,721, a wire type heater is illustrated.
Referring to FIG. 1, the air data sensing device illustrated generally at 10 as stated comprises a probe which as shown is an enlarged swept vane that is mounted for pivotal movement, which mounting device is not shown, in a conventional manner through the use of mounting disc 11 at its base end. The vane 12 is attached to the mounting disc, and as can be seen the mounting disc in turn will be mounted to the suitable mounting structure as shown in U.S. Pat. No. 3,882,721. The vane is external of the aircraft in the fluid stream and is used for sensing angle of attack of the aircraft. As such it must be deiced for operation and the heater used must dissipate sufficient power to melt ice at high airflow rates past the vane or sensor and at the same time it is desirable to limit the maximum temperature to which the sensor is subjected.
In the present device, the vane 12 as shown has a suitable slot 13 formed therein which slot opens to the trailing edge of the vane. It can be seen perhaps best in FIG. 2 that the leading edge indicated at 14 is swept rearwardly from the central mounting or pivotal axis of the disc 11, and the trailing edge of the vane is swept rearwardly as well, but at a different angle than the forward edge 14. The trailing edge is illustrated at 15.
The slot 13 in the vane is used for mouting a heater assembly illustrated at 16. In this form of the invention the heater assembly is made up of a plurality of individual positive temperature coefficient resistor material elements. The makeup of the heater assembly 16 is shown perhaps best in FIGS. 3 and 4, where individual elements indicated at 17 in the main part of the heater are formed in a standard shape, and the elements 18 and 19 out near the tapered end of the heater assembly 16 are formed in a desired shape to fill the narrowed slot portion at the outer end of the vane.
In the form shown, the heater elements such as 17, 18 and 19 are flat chip elements formed so that they are substantially uniform thickness. The elements are coated with conductive material on the flat surfaces and are electrically connected in parallel through the use of top and bottom electrical connector strips illustrated at 22 and 23, respectively. These connector strips in the form shown have a plurality of apertures 24. The strips are made of an electrically conductive, solderable material such as berylium copper.
The chip heater elements 17, 18 and 19 and the connecting strips 22 and 23 are soldered together. The apertures 24 aid in permitting solder to flow down to contact the surfaces of the elements 17, 18 and 19. In manufacture of positive temperature coefficient resistor elements, the flat surfaces are metalized with silver or the like, and the strips 22 and 23 are soldered to the silver layer. Care must be taken in the soldering operation to avoid damaging the heater elements, and it has been found that when using normal soldering techniques with suitable flux and solder composition, solder has been adequate for not only electrically bonding the strips 22 and 23 to the elements, but also physically bonding them with sufficient strength to withstand the rigors of use in an air data sensing device. Solder therefore comprises an electrically conductive bonding means between the strips and the PTC elements.
Suitable electrical leads indicated at 25 are attached to each of the strips 22 and 23, in a desired location and of a desired length. These leads are run out through an aperture in the disc 11 during assembly, and will connect to a power source and controls inside the aircraft.
After soldering it has been found desirable to place the subassembly of the heater elements 17, 18 and 19, and strips 22 and 23 in an oven to drive off any solvents that may have been absorbed by the heater element material. Subsequently, the subassembly of the strips and elements are placed into a suitable mold and supported in a desired manner and then suitable potting or encapsulating material is placed around the subassembly. This material indicated at 27 is material that is flexible enough to accommodate thermally caused dimensional change, is thermally conductive to conduct heat from the elements 17, 18 and 19 to the vane at a desired rate and the material must not contain any material that degrades the resistance element material. It has been found that a silicone rubber material has exhibited satisfactory characteristics in this regard, and as can be seen in FIGS. 4 and 5, this layer of material 27 surrounds the entire subassembly, and the potting or encapsulating material enters the cavities between the adjacent ends of the heater elements 17, 18 and 19.
The assembly 16 is molded to a size to slip into the slot 13 in the vane 12. The internal slot surfaces 13 in the vane 12 are coated with a liquid or flowable silicone rubber material, indicated by stripping 13A, (which acts as a cement or bonding agent) with a sufficient amount being used so that there is an excess. Then the assembly 16, which comprises the heater elements, connecting strips 22 and 23, and the surrounding material 27, is forced into the slot 13. The excess cement or liquid silicone rubber is forced out of the slot to remove any air pockets, and to provide a prescribed thermal transmission with the probe itself. When the liquid silicone rubber has dried, excess drips or flashing can be removed and the back opening of the slot of the vane is closed. This is normally done with a cover strip or plate, which is not shown, and epoxy can be used to hermetically seal the slot opening.
The leads 25,25 are threaded through the provided openings in disc 11 before the main portion of the heater assembly 16 is placed into the cavity 13.
The PTC heater elements themselves are selected so that they will have a high enough initial resistance to prevent excessive surge currents when the heater is first turned on, and yet will have an anomaly temperature that is below the annealing temperature of the aluminum from which the air data sensing devices are normally made. In still air, therefore, the heater assembly temperature will increase to its anomaly temperature, the resistance will rise sharply, and temperature of the vane will stablize at a desired level.
In operation, when the sensor or vane is being subjected to high airflows, and to ice, the sensor will tend to cool, causing the resistance of the PTC elements to drop, and therefore causing higher power consumption, sufficient to melt the ice that otherwise would form.
PTC resistor heaters are available in a wide range of anomaly temperatures. Thus selection of the temperature at which operation is desired can be made with ease.
The electrical insulation material 27 should have high electrical resistivity, high voltage breakdown, high thermal conductivity and flexibility so that no excessive strains on the elements or chips are caused by differences in thermal expansion between the heater assembly and the vane. The flexible strips also flex so the chips can flex slightly relative to the strips and each other, under thermally induced expansion and contraction, as well. It also should be noted that the thermal conductivity of material 27 should not be too great, or in other words the elements 17, 18 and 19 should not be in extremely close thermal conductivity with the vane material because the thermal gradient from the center of the heater elements to the outside surfaces of the elements could then be great enough to cause fracture of the PTC resistor element.
It is to be understood that the vane shown is merely an example of use and other air data sensors can use the same type of heater assembly. | A positive temperature coefficient (PTC) resistance heater assembly is used in combination with an angle of attack vane to provide automatic means for maintaining the temperature of the vane at a level which will de-ice the vane. The heater assembly is embedded in a recess in the vane and is made up of a plurality of individual PTC resistors connected electrically and mechanically in parallel by flexible electrically conductive perforated strips which permit the individual resistors to move relative to each the other under thermal stress and which also permit the encapsulation of the resistors in a suitable thermally conductive, electrically oinsulative material that is sufficiently resilient to permit the individual resistors to expand and contract relative to the vane during use. | 13,163 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of U.S. provisional application 61/792,538, which was filed on Mar. 15, 2013 and which is incorporated herein in its entirety by reference.
FIELD
[0002] The present invention relates to a method of forming a lithography feature on a substrate, by use of self-assembly of a block copolymer in a recess provided on the substrate.
BACKGROUND
[0003] In lithography for device manufacture, there is an ongoing desire to reduce the size of features in a lithographic pattern in order to increase the density of features on a given substrate area. Patterns of smaller features having critical dimensions (CD) at nano-scale allow for greater concentrations of device or circuit structures, yielding potential improvements in size reduction and manufacturing costs for electronic and other devices. In projection photolithography, the push for smaller features has resulted in the development of technologies such as immersion lithography and extreme ultraviolet (EUV) lithography.
[0004] As an alternative, so-called imprint lithography generally involves the use of a “stamp” (often referred to as an imprint template) to transfer a pattern onto a substrate. An advantage of imprint lithography is that the resolution of the features is not limited by, for example, the emission wavelength of a radiation source or the numerical aperture of a projection system. Instead, the resolution is mainly limited to the pattern density on the imprint template.
[0005] For both projection photolithography and for imprint lithography, it is desirable to provide high resolution patterning of surfaces, for example of an imprint template or of other substrates. The use of self-assembly of a block copolymers (BCP) has been considered as a potential method for increasing the feature resolution to a smaller dimension than that obtainable by prior lithography methods or as an alternative to electron beam lithography for preparation of imprint templates.
[0006] A self-assemblable BCP is a compound useful in nanofabrication because it may undergo an order-disorder transition on cooling below a certain temperature (order-disorder transition temperature To/d) resulting in phase separation of copolymer blocks of different chemical nature to form ordered, chemically distinct domains with dimensions of tens of nanometres or even less than 10 nm. The size and shape of the domains may be controlled by manipulating the molecular weight and composition of the different block types of the copolymer. The interfaces between the domains may have a line width roughness of the order of about 1-5 nm and may be manipulated by modification of the chemical compositions of the blocks of the copolymer.
[0007] The feasibility of using a thin film of BCP as a self-assembling template was demonstrated by Chaikin and Register, et al., Science 276, 1401 (1997). Dense arrays of dots and holes with dimensions of 20 nm were transferred from a thin film of poly(styrene-block-isoprene) to a silicon nitride substrate.
[0008] A BCP comprises different blocks, each typically comprising one or more identical monomers, and arranged side-by side along the polymer chain. Each block may contain many monomers of its respective type. So, for instance, an A-B BCP may have a plurality of type A monomers in the (or each) A block and a plurality of type B monomers in the (or each) B block. An example of a suitable BCP is, for instance, a polymer having covalently linked blocks of polystyrene (PS) monomer (hydrophobic block) and polymethylmethacrylate (PMMA) monomer (hydrophilic block). Other BCPs with blocks of differing hydrophobicity/hydrophilicity may be useful. For instance a tri-block copolymer such as (A-B-C) BCP may be useful, as may an alternating or periodic BCP e.g. [-A-B-A-B-A-B-] n or [-A-B-C-A-B-C] m where n and m are integers. The blocks may be connected to each other by covalent links in a linear or branched fashion (e.g., a star or branched configuration).
[0009] A BCP may form many different phases upon self-assembly, dependent upon the volume fractions of the blocks, degree of polymerization within each block type (i.e. number of monomers of each respective type within each respective block), the optional use of a solvent and surface interactions. When applied in a thin film, geometric confinement may pose additional boundary conditions that may limit the phases formed. In general spherical (e.g. cubic), cylindrical (e.g. tetragonal or hexagonal) and lamellar phases (i.e. self-assembled phases with cubic, hexagonal or lamellar space-filling symmetry) are practically observed in thin films of self-assembled BCPs.
[0010] The phase type observed may depend upon the relative molecular volume fractions of the different polymer blocks. For instance, a molecular volume ratio of 80:20 will provide a cubic phase of discontinuous spherical domains of the low volume block arranged in a continuous domain of the higher volume block. As the volume ratio reduces to 70:30, a cylindrical phase will be formed with the discontinuous domains being cylinders of the lower volume block. At a 50:50 ratio, a lamellar phase is formed. With a ratio of 30:70 an inverted cylindrical phase may be formed and at a ratio of 20:80, an inverted cubic phase may be formed.
[0011] Suitable BCPs for use as a self-assemblable polymer include, but are not limited to, poly(styrene-b-methylmethacrylate), poly(styrene-b-2-vinylpyridone), poly(styrene-b-butadiene), poly(styrene-b-ferrocenyldimethylsilane), poly(styrene-b-ethyleneoxide), poly(ethyleneoxide-b-isoprene). The symbol “b” signifies “block” Although these are di-block copolymer examples, it will be apparent that self-assembly may also employ a tri-block, tetra-block or other multi-block copolymer.
[0012] One method used to guide or direct self-assembly of a polymer (such as a BCP) onto a substrate surface is known as graphoepitaxy. This method involves the self-organization of a BCP guided by topological pre-patterning on the substrate using one or more features constructed of resist (or one or more features transferred from resist onto a substrate surface, or one or more features transferred onto a film stack deposited on the substrate surface). The pre-patterning is used to form an enclosure or “recess” comprising a substrate base and a sidewall, e.g., a pair of opposing side-walls, of resist (or a side-wall formed in a film or a side-wall formed in the substrate).
[0013] Typically, the height of a feature of a graphoepitaxy template is of the order of the thickness of the BCP layer to be ordered, so may be, for instance, from about 20 nm to about 150 nm.
[0014] A lamellar self-assembled BCP can form a parallel linear pattern of lithography features with adjacent lines of the different polymer block domains in the recesses. For instance if the BCP is a di-block copolymer with A and B blocks within the polymer chain, the BCP may self-assemble into an ordered layer in each recess, the layer comprising regularly spaced first domains of A blocks, alternating with second domains of B blocks.
[0015] Similarly, a cylindrical self-assembled BCP can form an ordered pattern of lithography features comprising cylindrical discontinuous first domains surrounded by a second continuous domain. For instance, if the BCP is a di-block copolymer with A and B blocks within the polymer chain, the A block may assemble into a cylindrical discontinuous domain within a circular recess and surrounded by a continuous domain of B block. Alternatively, the A block may assemble into cylindrical discontinuous domains regularly spaced across a linear recess and surrounded by a continuous domain of B block.
[0016] Graphoepitaxy may be used, therefore, to guide the self-organization of lamellar or cylindrical phases such that the BCP pattern subdivides the spacing of the side wall(s) of a recess into domains of discrete copolymer patterns.
[0017] In a process to implement the use of BCP self-assembly in nanofabrication, a substrate may be modified with a neutral orientation control layer, as part of the graphoepitaxy template, to induce the preferred orientation of the self-assembly pattern in relation to the substrate. For some BCPs used in self-assemblable polymer layers, there may be a preferential interaction between one of the blocks and the substrate surface that may result in orientation. For instance, for a polystyrene(PS)-b-PMMA BCP, the PMMA block will preferentially wet (i.e. have a high chemical affinity with) an oxide surface and this may be used to induce the self-assembled pattern to lie oriented substantially parallel to the plane of the surface. Substantially normal orientation may be induced, for instance, by depositing a neutral orientation layer onto the surface rendering the substrate surface neutral to both blocks, in other words the neutral orientation layer has a similar chemical affinity for each block, such that both blocks wet the neutral orientation layer at the surface in a similar manner. By “normal orientation” it is meant that the domains of each block will be positioned side-by-side at the substrate surface, with the interfacial regions between adjacent domains of different blocks lying substantially perpendicular to the plane of the surface.
[0018] In a graphoepitaxy template for aligning a di-block copolymer having A and B blocks, where A is hydrophilic and B is hydrophobic in nature, the graphoepitaxy pattern may comprise hydrophobic resist side-wall features, with a neutral orientation base between the hydrophobic resist features. The B domain may preferentially assemble alongside the hydrophobic resist features, with several alternating domains of A and B blocks aligned over the neutral orientation region between the pinning resist features of the graphoepitaxy template.
[0019] A neutral orientation layer may, for instance, be created by use of random copolymer brushes which are covalently linked to the substrate by reaction of a hydroxyl terminal group, or some other reactive end group, to oxide at the substrate surface. In other arrangements for neutral orientation layer formation, a crosslinkable random copolymer or an appropriate silane (i.e. molecules with a substituted reactive silane, such as a (tri)chlorosilane or (tri)methoxysilane, also known as silyl, end group) may be used to render a surface neutral by acting as an intermediate layer between the substrate surface and the layer of self-assemblable polymer. Such a silane based neutral orientation layer will typically be present as a monolayer whereas a crosslinkable polymer is typically not present as a monolayer and may have a layer thickness of typically less than or equal to about 40 nm, or less than or equal to about 20 nm.
[0020] A thin layer of self-assemblable BCP may be deposited onto a substrate having a graphoepitaxy template as set out above. A suitable method for deposition of the self-assemblable polymer is spin-coating, as this process is capable of providing a well-defined, uniform, thin layer of self-assemblable polymer. A suitable layer thickness for a deposited self-assemblable polymer film is approximately 10 nm to 150 nm.
[0021] Following deposition of the BCP film, the film may still be disordered or only partially ordered and one or more additional steps may be needed to promote and/or complete self-assembly. For instance, the self-assemblable polymer may be deposited as a solution in a solvent, with solvent removal, for instance by evaporation, prior to self-assembly.
[0022] Self-assembly of a BCP is a process where the assembly of many small components (the BCP) results in the formation of a larger more complex structure (the nanometer sized features in the self-assembled pattern, referred to as domains in this specification). Defects arise naturally from the physics controlling the self-assembly of the polymer. Self-assembly is driven by the differences in interactions (i.e. differences in mutual chemical affinity) between A/A, B/B and A/B (or B/A) block pairs of an A-B BCP, with the driving force for phase separation described by Flory-Huggins theory for the system under consideration. The use of graphoepitaxy may greatly reduce defect formation. The Flory-Huggins interaction parameter (chi value), and the degree of polymerization of the BCP blocks (N value) are parameters of the BCP which affect the phase separation, and the dimensions with which self-assembly of a particular BCP occurs.
[0023] For a polymer which undergoes self-assembly, the self-assemblable polymer will exhibit an order-disorder temperature To/d. To/d may be measured by any suitable technique for assessing the ordered/disordered state of the polymer, such as differential scanning calorimetry (DSC). If layer formation takes place below this temperature, the molecules will be driven to self-assemble. Above the temperature To/d, a disordered layer will be formed with the entropy contribution from disordered A/B domains outweighing the enthalpy contribution arising from favorable interactions between neighboring A-A and B-B block pairs in the layer. The self-assemblable polymer may also exhibit a glass transition temperature Tg below which the polymer is effectively immobilized and above which the copolymer molecules may still reorient within a layer relative to neighboring copolymer molecules. The glass transition temperature is suitably measured by differential scanning calorimetry (DSC).
[0024] Defects formed during ordering as set out above may be partly removed by annealing. A defect such as a disclination (which is a line defect in which rotational symmetry is violated, e.g. where there is a defect in the orientation of a director) may be annihilated by pairing with other another defect or disclination of opposite sign. Chain mobility of the self-assemblable polymer may be a factor for determining defect migration and annihilation and so annealing may be carried out at a temperature where chain mobility is high but the self-assembled ordered pattern is not lost. This implies temperatures up to a few ° C. above or below the order/disorder temperature To/d for the polymer.
[0025] Ordering and defect annihilation may be combined into a single annealing process or a plurality of processes may be used in order to provide a layer of self-assembled polymer such as BCP, having an ordered pattern of domains of differing chemical type (of domains of different block types).
[0026] In order to transfer a pattern, such as a device architecture or topology, from the self-assembled polymer layer into the substrate upon which the self-assembled polymer is deposited, typically a first domain type will be removed by so-called breakthrough etching to provide a pattern of a second domain type on the surface of the substrate with the substrate laid bare between the features of the second domain type. A pattern having parallel cylindrical phase domains can be etched using a dry etching or reactive ion etching technique. A pattern having lamellar phase domains can utilize a wet etching technique in addition to or as an alternative to those suitable for the etching of parallel cylindrical phase domains.
[0027] Following the breakthrough etching, the pattern may be transferred by so-called transfer etching using an etching means which is resisted by the second domain type and so forms recesses in the substrate surface where the surface has been laid bare.
[0028] Spacing between lithography features is known as pitch—defined as the width of one repeat unit of the lithography feature (i.e. feature width plus inter-feature spacing). A self-assembly process using a BCP can be used to produce lithography features with particularly low pitch, typically less than 30-50 nm.
SUMMARY
[0029] FIGS. 1A and 1B show, in plan view and cross-section respectively, part of a substrate 1 to which a lithography process using self-assembly of a BCP is applied. An anti-reflection coating may be present on the surface of the substrate 1 . The anti-reflection coating (if present) may be an organic material, such as, for example, ARC 29 , from Brewer Science. Alternatively, the anti-reflection coating may be an inorganic material such as, for example, SiC or SiON. A layer of photo-resist 2 is applied to the substrate 1 . The layer of photo-resist 2 is patterned with a plurality of contact hole resist recesses 3 , 4 , 5 .
[0030] In FIG. 1C , a BCP layer 6 has been deposited onto the substrate 1 and the photo-resist 2 . The BCP layer 6 is shown with a uniform thickness within each of the photo-resist recesses 3 , 4 , 5 , and on top of the photo-resist 2 . In FIGS. 1D and 1E , which show cross-section and plan views respectively, the BCP layer 6 has been thermally annealed. The thermal annealing process causes a redistribution of the BCP material, with some BCP material being transported from the regions above photo-resist 2 into the photo-resist recesses 3 , 4 , 5 . As can be seen from FIGS. 1D and 1E , depletion regions 7 are formed where the BCP material has been removed from the photo-resist 2 in regions around the photo-resist recesses 3 , 4 , 5 . The BCP material removed from the depletion regions 7 has been redistributed to the photo-resist recesses 3 , 4 , 5 .
[0031] In FIG. 1D , it can also be seen that the isolated photo-resist recess 3 has a thicker layer of BCP than the layer which is formed in the group of photo-resist recesses 4 , 5 . Further, the photo-resist recess 5 , which is surrounded by the photo-resist recesses 4 has a thinner layer of BCP than the layer which is formed in the photo-resist recesses 4 , or the isolated photo-resist recess 3 .
[0032] It will be appreciated that if the separation between adjacent photo-resist recesses is greater than the size of the depletion regions (as is the case with photo-resist recess 3 ), then BCP material from the surrounding areas may be redistributed to within the photo-resist recess. However, if the separation between adjacent photo-resist recesses is smaller than the size of the depletion regions (as is the case with the photo-resist recess feature 5 ), then the photo-resist recesses will each receive less BCP from the top of surrounding photo-resist material.
[0033] The photo-resist recesses 4 are each closely adjacent to at least one other recess (the photo-resist recess 5 ). However, the photo-resist recesses 4 are not completely surrounded by photo-resist recesses, and so receive more BCP from the top of surrounding photo-resist 2 than is received by the photo-resist recess 5 .
[0034] The photo-resist recess 3 contains more BCP material than the photo-resist recesses 4 , which each contain more BCP material than the photo-resist recess 5 , in spite of an initial uniform layer 6 of BCP material being deposited over each of the photo-resist recesses 3 , 4 , 5 .
[0035] As is demonstrated above, the local density of lithography features on a substrate 1 can influence the thickness of the BCP layer which is formed during annealing and self-assembly. However, when creating BCP features on the surface of a substrate 1 , it may be desirable to maintain a substantially uniform thickness in all areas of the substrate 1 .
[0036] The use of BCP material may allow domains of component polymer materials to be self-assembled within a BCP feature. For example, the BCP deposited within photo-resist recess 5 can be seen to have formed distinct domains of polymer. A first type A polymer domain 8 is formed as a cylinder within a continuous type B polymer domain 9 .
[0037] To guide this self-assembly, lateral dimensions are controlled by the spacing of photo-resist wall portions, while the BCP material thickness also influences the self-assembly process. Therefore, while the thickness of the BCP layer within photo-resist recess 5 may be optimized for the formation of distinct domains of type A and type B polymers, the thickness within photo-resist recesses 3 and 4 may be too thick to allow the self-assembly of type A and type B domains. Similarly, if the BCP film 6 was too thin, then distinct type A and type B domains may not be formed.
[0038] As such, using a known method, it may not be possible to achieve a thickness of BCP material sufficiently uniform across a substrate which has a distribution of local feature densities to promote successful self-assembly. Therefore, it may not be possible to create a graphoepitaxy lithography feature using a known method which can accommodate a distribution in feature densities across a single substrate.
[0039] It would be useful, for example, to be able to construct multiple BCP features on a substrate with a substantially uniform thickness especially where there is some variation in the local density of BCP features in any particular region.
[0040] It is an object of the invention, for example, to obviate or mitigate a disadvantage described herein, or some other disadvantage associated with the art, past, present or future.
[0041] According to an aspect, there is provided a method of forming a lithography feature, the method comprising:
[0042] providing at least one lithography recess on a substrate, the or each lithography recess comprising a side-wall and a base, with portions of the side-wall having a width therebetween;
[0043] providing at least one dummy recess on the substrate, the or each dummy recess comprising a side-wall and a base, with portions of the side-wall having a width therebetween;
[0044] providing a self-assemblable block copolymer (BCP) having first and second blocks in the or each lithography recess, in the or each dummy recess and on the substrate beyond the or each lithography recess and the or each dummy recess;
[0045] causing the self-assemblable block copolymer to migrate from a region surrounding the or each lithography recess and the or each dummy recess to within the or each lithography recess and the or each dummy recess;
[0046] causing the self-assemblable block copolymer to self-assemble into an ordered layer within the or each lithography recess, the layer comprising at least a first domain of first block and a second domain of second block; and
[0047] selectively removing the first domain to form the lithography feature comprised of the second domain within the or each lithography recess,
[0048] wherein the or each lithography recess has a greater width than the width of the or each dummy recess,
[0049] wherein the width of the or each dummy recess is smaller than the minimum width required by the self-assemblable block copolymer to self-assemble, and
[0050] wherein the or each dummy recess is within the region of the substrate surrounding the or each lithography recess from which the self-assemblable block copolymer is caused to migrate.
[0051] In an embodiment, at least one dummy recess is provided close enough to the lithography recess to cause some of the self-assemblable block copolymer (BCP) to migrate into the dummy recess, rather than into the lithography recess. The migration of the BCP to the dummy recess, rather than the lithography recess, may reduce the final thickness of the BCP within the lithography recess. This provides an advantage of allowing the thickness of the BCP layer within the lithography recess to be maintained at a desired level, enabling self-assembly of a lithography feature within the lithography recess in a predictable manner. The use of a dummy recess, which is too small to allow self-assembly to occur within the dummy recess itself, enables adjustment of the effective recess density and hence BCP layer thickness, without having any substantial effect on the density of lithography features which appear on the final substrate.
[0052] The following features are applicable to all the embodiments of the invention where appropriate. When suitable, combinations of the following features may be employed as part of an embodiment of the invention, for instance as set out in the claims. An embodiment of the invention is suitable for use in device lithography. For instance, an embodiment of the invention may be of use in patterning a substrate which is used to form a device, or may be of use in patterning an imprint template for use in imprint lithography (which may then be used to form devices).
[0053] Two or more dummy recesses may be provided. The dummy recesses may be arranged symmetrically around the or each lithography recess.
[0054] A symmetrical arrangement of the dummy recess around the or each lithography recess provides an advantage of promoting a substantially uniform and symmetrical distribution of BCP within the or each lithography recess.
[0055] The or each lithography recess may be used to form a contact hole. A contact hole may be a circular opening which allows access between non-adjacent layers on a substrate. The use of self-assembly of a BCP in a lithography recess to form a contact hole may allow a hole to be formed having a smaller lateral dimension than the dimensions of the lithography recess. The application of this self-assembly technique to the formation of a contact hole provides an advantage of reducing the dimension of the contact hole.
[0056] The or each dummy recess may be circular. The provision of a circular dummy recess allows the dummy recess to be positioned between features of any geometry so as to adjust the local density of recesses, and consequently to adjust the thickness of BCP within a lithography recess.
[0057] The or each dummy recess may be linear. The provision of a linear dummy recess, or trench, may allow the dummy recess to closely follow the geometry of a linear lithography recess so as to adjust the thickness of BCP within that lithography recess.
[0058] The lithography feature may have a minimum lateral dimension of 40 nm or less. The lithography feature may have a minimum lateral dimension of 5 nm or more. The lithography feature formed by the self-assembly of BCP may allow the definition of a smaller lithography feature than would be defined by a conventional lithography method alone. The use of self-assembly of a BCP may allow the definition of a lithography feature with more uniformity than would be possible with a lithography feature defined by a conventional lithography technique at such small dimensions.
[0059] In order to direct self-assembly and reduce defects, the side-wall(s) may have a higher chemical affinity for one of the BCP domain types, such that, upon assembly, the BCP domain type having the higher chemical affinity with the side-wall is caused to assemble alongside that side-wall. Chemical affinity may be provided by utilizing a hydrophobic or hydrophilic side-wall feature.
[0060] Providing the layer of self-assemblable BCP in the recess may be carried out by spin coating of a solution of the BCP followed by removal of solvent.
[0061] The self-assemblable BCP may be caused to self-assemble by lowering the temperature to a temperature less than To/d for the BCP, to give an ordered layer of self-assembled BCP in the recess.
[0062] The substrate may be a semiconductor substrate, and may comprise a plurality of layers forming the substrate. For instance, the outermost layer of the substrate may be an ARC (anti-reflection coating) layer.
[0063] The outermost layer of the substrate may be neutral to the domains of the BCP, by which it is meant that it has a similar chemical affinity for each of the domain types of the BCP. The neutral orientation layer may, for example, be created by use of random copolymer brushes. Alternatively, an orientation control layer may be provided as an uppermost or outermost surface layer of the substrate to induce a desired orientation of the self-assembly pattern in relation to the substrate.
[0064] The recesses may be formed by photolithography, for instance with actinic radiation such as UV, EUV or DUV (deep UV) radiation.
[0065] The recesses may, for example, be formed in resist. The recesses may, for example, be formed on a substrate surface (e.g. having been transferred from resist onto the substrate). The recess may, for example, be formed in a film stack (e.g. having been transferred from resist onto the film stack).
[0066] The height of the recesses may be of the order of the thickness of the BCP layer to be ordered. The height of the recesses may for example be from about 20 nm to about 150 nm (e.g. about 100 nm).
[0067] The or each lithography recess may be circular. The self-assemblable block copolymer may be adapted to form an ordered layer having a cylindrical first domain of the first block in a cylindrical arrangement surrounded by a second continuous domain of the second block, the cylindrical first domain being oriented substantially perpendicular to the substrate. The use of a circular lithography recess allows the definition of a circular lithography feature.
[0068] The or each lithography recess may be linear. The self-assemblable block copolymer may be adapted to form a lamellar ordered layer wherein the first domains are lamellae alternating with second domains which are also lamellae, the lamellae of the first and second domains being orientated with their planar surfaces lying substantially perpendicular to the substrate and parallel to the lithography recess walls. The use of a linear lithography recess allows the definition of a linear lithography feature.
[0069] Selectively removing one of the domains may be achieved by etching, wherein the ordered layer of self-assembled BCP acts as a resist layer for etching a lithography feature within the recess on the substrate. Selective etching can be achieved by utilizing polymers having different etch resist properties and by selection of an etchant capable of selectively etching certain of the polymer domains. Selective removal may alternatively or additionally be achieved, for instance, by selective photo-degradation or photo-cleavage of a linking agent between blocks of the copolymer and subsequent solubilization of one of the blocks.
[0070] According to an aspect, there is provided a method of forming at least one lithography feature on a substrate, the substrate comprising at least one lithography recess, the or each lithography recess comprising a side-wall and a base, with portions of the side-wall having a width therebetween and at least one dummy recess, the or each dummy recess comprising a side-wall and a base, with the portions of the side-wall having a width therebetween, wherein the or each lithography recess has a greater width than the width of the or each dummy recess, the method comprising:
[0071] providing a self-assemblable block copolymer having first and second blocks in the or each lithography recess, in the or each dummy recess and on the substrate between and around the or each lithography recess and the or each dummy recess;
[0072] causing the self-assemblable block copolymer to migrate from the region surrounding the or each lithography recess and the or each dummy recess to within the or each lithography recess and the or each dummy recess;
[0073] causing the self-assemblable block copolymer to self-assemble into an ordered layer within the or each lithography recess, the layer comprising at least a first domain of first block and a second domain of second block; and
[0074] selectively removing the first domain to form the at least one lithography feature comprised of the second domain within the or each lithography recess,
[0075] wherein the width of the or each dummy recess is smaller than the minimum width required by the self-assemblable block copolymer to self-assemble, and
[0076] wherein the or each dummy recess is within the region of the substrate surrounding the or each lithography recess from which the self-assemblable block copolymer is caused to migrate.
[0077] According to an aspect, there is provided a substrate comprising at least one lithography recess, the or each lithography recess comprising a side-wall and a base, with portions of the side-wall having a width therebetween, and at least one dummy recess, the or each dummy recess comprising a side-wall and a base, with portions of the side-wall having a width therebetween, wherein the or each lithography recess has a greater width than the width of the or each dummy recess, wherein the width of the or each dummy recess is smaller than the minimum width required, in use, by a self-assemblable block copolymer having first and second blocks to self-assemble, and wherein the or each dummy recess is arranged within a region of the substrate surrounding the or each lithography recess from which, in use, the self-assemblable block copolymer may be caused to migrate.
[0078] An embodiment of the present invention relates to a lithography method. The method may be used in processes for the manufacture of devices, such as electronic devices and integrated circuits or other applications, such as the manufacture of integrated optical systems, guidance and detection patterns for magnetic domain memories, flat-panel displays, liquid-crystal displays (LCDs), thin film magnetic heads, organic light emitting diodes, etc. An embodiment of the invention is also of use to create regular nanostructures on a surface for use in the fabrication of integrated circuits, bit-patterned media and/or discrete track media for magnetic storage devices (e.g. for hard drives).
[0079] The methods described herein may be useful for forming a contact hole providing access between layers of a semiconductor device.
[0080] The self-assemblable BCP may be a BCP as set out herein comprising at least two different block types, referred to as first and second polymer blocks, which are self-assemblable into an ordered polymer layer having the different block types associated into first and second domain types. The BCP may comprise di-block copolymer, a tri-block copolymer, and/or a multi-block copolymer. Alternating or periodic BCPs may also be used in the self-assemblable BCP.
[0081] By “chemical affinity”, in this specification, is meant the tendency of two differing chemical species to associate together. For instance chemical species which are hydrophilic in nature have a high chemical affinity for water whereas hydrophobic compounds have a low chemical affinity for water but a high chemical affinity for an alkane. Chemical species which are polar in nature have a high chemical affinity for other polar compounds and for water whereas apolar, non-polar or hydrophobic compounds have a low chemical affinity for water and polar species but may exhibit high chemical affinity for other non-polar species such as an alkane or the like. The chemical affinity is related to the free energy associated with an interface between two chemical species: if the interfacial free energy is high, then the two species have a low chemical affinity for each other whereas if the interfacial free energy is low, then the two species have a high chemical affinity for each other. Chemical affinity may also be expressed in terms of “wetting”, where a liquid will wet a solid surface if the liquid and surface have a high chemical affinity for each other, whereas the liquid will not wet the surface if there is a low chemical affinity. Chemical affinities of surfaces may be measured, for instance, by means of contact angle measurements using various liquids, so that if one surface has the same contact angle for a liquid as another surface, the two surfaces may be said to have substantially the same chemical affinity for the liquid. If the contact angles differ for the two surfaces, the surface with the smaller contact angle has a higher chemical affinity for the liquid than the surface with the larger contact angle.
[0082] By “chemical species” in this specification is meant either a chemical compound such as a molecule, oligomer or polymer, or, in the case of an amphiphilic molecule (i.e. a molecule having at least two interconnected moieties having differing chemical affinities), the term “chemical species” may refer to the different moieties of such molecules. For instance, in the case of a di-block copolymer, the two different polymer blocks making up the block copolymer molecule are considered as two different chemical species having differing chemical affinities.
[0083] Throughout this specification, the term “comprising” or “comprises” means including the component(s) specified but not to the exclusion of the presence of others. The term “consisting essentially of” or “consists essentially of” means including the components specified but excluding other components except for materials present as impurities, unavoidable materials present as a result of processes used to provide the components, and components added for a purpose other than achieving the technical effect of the invention. Typically, a composition consisting essentially of a set of components will comprise less than 5% by weight, typically less than 3% by weight, more typically less than 1% by weight of non-specified components. The terms “consist of” or “consisting of” mean including the components specified but excluding the deliberate addition of other components.
[0084] Whenever appropriate, the use of the term “comprises” or “comprising” may also be taken to include the meaning “consist of” or “consisting of”, “consists essentially of” or “consisting essentially of”.
[0085] In this specification, when reference is made to the thickness of a feature, the thickness is suitably measured by an appropriate means along an axis substantially normal to the substrate surface and passing through the centroid of the feature. Thickness may suitably be measured by a technique such as interferometry or assessed through knowledge of etch rate.
[0086] Wherever mention is made of a “layer” in this specification, the layer referred to is to be taken to be layer of substantially uniform thickness, where present. By “substantially uniform thickness” is meant that the thickness does not vary by more than 10%, desirably not more than 5% of its average value across the layer.
[0087] In this specification “recess” is not intended to imply a particular shape. The term “recess” may be interpreted as meaning a lithography feature formed on the surface of a substrate, which has a depth and one or more side-walls. A recess may, for example, be circular in shape, for example defining a contact hole, having a diameter or width and having a side-wall which, in cross-section, appears vertical. A recess may be linear in shape, for example defining a trench, having side-walls which are separated by a width in a first direction, and extend in an elongate manner in a second direction. It will be appreciated that a recess may take any other convenient form, and may include linear or curved sections. A lithography feature may comprise one or more recesses. The term “lithography recess” may be interpreted as meaning a recess which is intended to result in the production of a lithography feature. The term “dummy recess” may be interpreted as meaning a recess which is not intended to result in the production of a lithography feature, but is instead intended to modify the local density of recesses.
[0088] In this specification, the term “substrate” is meant to include any surface layer forming part of the substrate, or being provided on a substrate, such as one or more planarization layers or anti-reflection coating layers which may be at, or form, the surface of the substrate, or may include one or more other layers such as those specifically mentioned herein.
[0089] In this specification, the term “lateral” may be interpreted as meaning in the plane of the surface of a substrate. For example, the width or diameter of a recess may be considered to be a lateral dimension of that recess. The length of a recess may be considered to be a lateral dimension of that recess. However, the depth of a recess would not be considered to be a lateral dimension of that recess.
[0090] One or more aspects of the invention may, where appropriate to one skilled in the art, be combined with any one or more other aspects described herein, and/or with any one or more features described herein.
BRIEF DESCRIPTION OF THE DRAWINGS
[0091] Specific embodiments of the invention will be described with reference to the accompanying Figures, in which:
[0092] FIG. 1 schematically depicts directed self-assembly of A-B block copolymer onto a substrate by graphoepitaxy;
[0093] FIG. 2 schematically depicts directed self-assembly of A-B block copolymer onto a substrate by graphoepitaxy using lithography and dummy recesses according to an embodiment of the invention;
[0094] FIG. 3 is a schematic representation of a substrate having lithography and dummy recesses according to an embodiment of the invention;
[0095] FIG. 4 is a schematic representation of a substrate having lithography and dummy recesses according to an embodiment of the invention;
[0096] FIG. 5 is a schematic representation of a substrate having lithography and dummy recesses according to an embodiment of the invention; and
[0097] FIG. 6 is a schematic representation of a substrate having lithography and dummy recesses according to an embodiment of the invention.
DETAILED DESCRIPTION
[0098] The described and illustrated embodiments are to be considered as illustrative and not restrictive in character, it being understood that only embodiments have been shown and/or described and that all changes and modifications that come within the scope of the inventions as defined in the claims are desired to be protected.
[0099] FIGS. 2A and 2B show, in plan view and cross-section respectively, a substrate 10 on which a layer of photo-resist 11 is provided. The layer of photo-resist 11 is patterned with a plurality of contact hole resist recesses 12 and a plurality of dummy recesses 13 . The contact hole resist recesses 12 and dummy recesses 13 appear as recesses in cross-section, as shown in FIG. 2B . The contact hole resist recesses 12 are examples of lithography recesses. The dummy recesses 13 are intended to modify the local density of recesses.
[0100] In FIG. 2C , a self-assemblable A-B block copolymer (BCP) layer 14 has been deposited onto the substrate 10 and the photo-resist 11 . The BCP layer 14 is shown with a uniform thickness within each of the photo-resist recesses 12 , 13 and on top of the photo-resist 11 . In FIGS. 2D and 2E , which show a cross-sectional and plan view respectively, the BCP layer 14 has been thermally annealed. The thermal annealing process causes redistribution and self-assembly of the BCP material. The redistribution of the BCP material results in some BCP material being transported from the regions above the photo-resist 11 into the photo-resist recesses 12 , 13 . A depletion region 15 is formed around each of the photo-resist recesses 12 , 13 , where BCP material is transported away from the photo-resist and into the photo-resist recesses. In FIGS. 2D and 2E , the depletion region 15 extends across the whole substrate 10 .
[0101] As can be seen in FIGS. 2D and 2E , both contact hole resist recesses 12 and dummy recesses 13 receive BCP material from the surrounding areas of photo-resist 11 , forming the depletion region 15 . However, the relatively small width of the dummy recesses 13 essentially prevents phase separation and self-assembly within the BCP material. As can be seen within the contact hole resist recesses 12 , the BCP material self-assembles to form domains of A block 16 (unhatched) and domains of B block 17 (hatched). Domains of A blocks 16 and B blocks domains 17 are formed within each of the contact hole resist recesses 12 . The A block domains 16 are in a cylindrical arrangement, each A block domain 16 being a cylinder surrounded by a continuous B block domain 17 . The cylindrical A block domains 16 are oriented substantially perpendicular to the substrate 10 .
[0102] The dimensions of resist recesses for use with directed self-assembly of BCP varies in dependence upon the particular BCP selected. For example, the length of the BCP polymer chains affects the recess dimensions at which phase separation and self-assembly occurs. A shorter length polymer chain is likely to result in a recess with a smaller dimension being suitable to direct self-assembly of that polymer chain.
[0103] For example, the BCP may comprise blocks of polystyrene (PS) wherein the total molecular weight of the PS is 68 kDa, and blocks of polymethylmethacrylate (PMMA) wherein the total molecular weight of the PMMA is 33 kDa. The use of this BCP (PS-PMMA: 68 kDa-33 kDa) may result in a threshold dimension for self-assembly in a circular contact hole resist recess of around 70 nm. For example, a dummy recess having a diameter of less than 70 nm (e.g. 65 nm) may not permit self-assembly, whereas a contact hole recess having a diameter of greater than 70 nm (e.g. 75 nm) may permit self-assembly.
[0104] A BCP system having a lower degree of polymerization (lower N value) and consequently having smaller molecular weight blocks (e.g. PS-PMMA: 26.8 kDa-12.2 kDa) may have a smaller self-assembly threshold dimension.
[0105] Alternatively, or additionally, the use of BCP material with a high chi value may allow self-assembly threshold dimensions to be reduced further. According to Flory-Huggins theory, it is expected that polymers will self-assemble if N*chi is greater than about 10.5, for a lamellar phase. For a cylindrical phase, it is estimated that N*chi should be above around 15 for self-assembly. For N*chi values below these thresholds BCPs will preferentially mix, rather than phase separate. Therefore, increasing the chi value allows the self-assembly threshold dimensions to be reduced.
[0106] Increasing the chi value of the BCP material allows the use of lower N values, and smaller (lower molecular weight) block copolymers, for a given self-assembly threshold dimension.
[0107] In more general terms, the self-assembly of BCP is governed by phase separation. The periodicity of phase separation in BCPs has been reported to range from about 10 nm to about 150 nm. For directed self-assembly use in conjunction with resist recesses formed in common photo-lithography resists, the dimensions of a lithography recess are typically about 1.2 to 2.1 times the periodicity of the phase separation of a particular PS-PMMA BCP. Therefore, the one or more dummy recesses should have a size which is below this range so as to avoid self-assembly in the dummy recess. In such a recess (i.e. with a size below this range) the PS-PMMA BCP would mix rather than phase separate. However, it will be appreciated that for other BCPs or other resists this ratio may be different.
[0108] The self-assemblable A-B block copolymer may have hydrophilic A block (unhatched) and hydrophobic B block (hatched). The hydrophobic B block has a high affinity for the sidewall of the recess, whereas the hydrophilic A block has a high affinity for other A block. Therefore, during the annealing process, the ordered layer of BCP has formed with cylindrical domains of hydrophilic A block, surrounded by domains of B block, which are in contact with the recess sidewall.
[0109] In subsequent processing steps (not shown) domains of A block 16 can be selectively removed by any technique. Such selective removal of A block domains 16 exposes the substrate 10 below the A block domains 16 . However, B block domains 17 will not be removed by the process which removed the A block domains 16 , due to the selectivity of the etching process. Further, the BCP material in the dummy recesses 13 , which has not formed discrete A and B block domains, will not be removed by the type A selective etch process. In this way, it is possible to remove only regions of type A polymer, with all other areas of the substrate 10 being covered by either B block domains 17 , mixed BCP material, or photo-resist 11 .
[0110] The remaining B block feature(s) may subsequently be used as a mask defining an opening which can be etched. For example, contact holes may subsequently be etched in the substrate 10 as defined by the relatively small opening presented by the removed A block domains. This process allows a higher resolution to be achieved than could be achieved by conventional photo-resist patterning techniques, the dimensions of the lithographically defined contact hole resist recesses 12 directing the self-assembly of the BCP to create a smaller region of A block domains 16 .
[0111] Selective etching is achieved due the relative susceptibility towards etching, with the A block being relatively prone to etching, while the B block is relatively resistant to etching. Selective removal may also be achieved, for instance, by selective photo-degradation or photo-cleavage of a linking agent between blocks of the copolymer and subsequent solubilization of one of the blocks. An embodiment of the invention allows for formation, onto a substrate, of a feature which has a critical dimension which is smaller than that of the recess which directs the self-assembly, allowing a feature of the order of a few nm to be created with a smallest lithographically defined recess of the order of a few tens of nm. For example, the use of a lithographically defined circular recess having a diameter of 70 nm may result in a contact hole feature having a diameter of the order of 15-30 nm. Features with a minimum dimension of 5 nm with a periodicity of 11 nm may be formed.
[0112] In an embodiment (not illustrated) the etching (or other removal process) may etch into the substrate. Following this the type A domains may be removed, leaving behind a regularly spaced array of lithography features formed in the substrate, with a critical dimension which is smaller than the minimum dimension which can be achieved by the photolithography feature which was used to define the recesses.
[0113] An embodiment of the present invention may overcome a problem which was illustrated in FIG. 1 . By way of contrast with the method illustrated in FIG. 2 , FIG. 1 shows a substrate 1 on which several contact hole resist recesses 3 , 4 , 5 are defined. However, as is described above, and can be seen in FIGS. 1D and 1E , the thickness of the BCP material varies between recesses 3 , 4 and 5 , depending on the local area density of lithography recesses. The self-assembly of BCP is highly sensitive to the thickness of the BCP material. Using the process of FIG. 1 , it may therefore not be possible to achieve a sufficiently uniform BCP layer thickness, to allow the directed self-assembly of polymer domains within each of the lithography recesses 3 , 4 and 5 . This problem may be overcome in the method illustrated by FIG. 2 , by the use of a dummy recess.
[0114] In a particular lithography process, if the BCP layer thickness varies with printed feature density it may not be possible to reliably create well defined domains of a particular polymer block as is required by the self-assembly process. Therefore one or more dummy recesses are added to the mask design to provide control over the BCP layer thickness.
[0115] An optimal BCP layer thickness may exist for each BCP material used. Any thickness which is significantly above, or below, this optimal layer thickness may result in imperfect self-assembly. For example, the optimal BCP layer thickness for self-assembly in an isolated resist trench may be 33 nm. However, a BCP layer thickness of 31 nm or 35 nm may result in defective self-assembly. In such cases, the BCP material may self-assemble, but with an alternative orientation to that which is desired, or which is achieved with a BCP thickness of 33 nm. Any such variation in the self-assembly process may result in the resulting lithography feature being improperly formed.
[0116] The use of one or more dummy recesses allows some control over the local density of recesses on a substrate, without having to adjust the density of features which appear on the final device. A dummy recess can thus enable directed self-assembly to be used to reduce a minimum feature size and improve critical dimension uniformity.
[0117] The distribution of the one or more dummy recesses can be determined to ensure that the or each lithography recess is surrounded with one or more other recesses, whether a dummy recess or otherwise. The aim is to ensure that the local recess density for each lithography recess is approximately equal to the local recess density of each other lithography recess on the substrate. Recesses which are surrounded by one or more other recesses (high density of recesses) may be less sensitive to BCP layer thickness variation than an isolated recess.
[0118] For proper control of self-assembly, it is expected that optimal BCP layer thickness will be related to the periodicity of the phase separation of a particular BCP. Suitable layer thicknesses and tolerances may be determined by the skilled person through routine experimentation. Achieving a BCP thickness within an acceptable range allows some degree of freedom in the placement of a dummy recess. In particular, this tolerance permits some degree of variation in the corrected local feature density.
[0119] To determine where a dummy recess can be successfully used, the local density of features on a substrate may be considered. Additionally the size of the depletion zone formed around each recess may have an effect on the extent to which the thickness of the BCP layer is altered during processing.
[0120] The redistribution of BCP material into the recesses and the formation of the depletion zone are related to the mobility of the block copolymer chains. It is therefore expected that the size of the depletion zone is dependent on the type and also length of the block copolymer. Small length polymers will have a higher mobility than longer polymers. Additionally the Flory-Huggins parameter chi will affect the mobility of the BCP chains. The annealing time will also have an effect on the size of the depletion zone. A longer annealing time will result in a larger depletion zone.
[0121] The thickness of the BCP layer after thermal annealing compared to the initial BCP layer thickness is defined as the relative layer thickness. The relative layer thickness may depend on the recess's size, the local recess density, the size of the depletion zone (which itself depends on several parameters as discussed above) and also on the thickness of both the BCP layer and the resist layer.
[0122] For example, considering a single isolated linear recess (or trench) on a substrate, the relative layer thickness of BCP within the trench can be calculated by Equation (1):
[0000]
RLT
=
w
DEPLETION
ZONE
w
TRENCH
(
1
)
[0123] where:
[0124] RLT is the relative layer thickness,
[0125] w DEPLETION ZONE is the width of the depletion zone (including the trench width), and
[0126] w TRENCH is the width of the trench.
[0127] It can be seen from Equation (1) that for a single isolated recess on a substrate the relative layer thickness is only influenced by the width of the recess (trench) and the width of the depletion zone (although the depletion zone width will depend on several other parameters, such as BCP mobility and BCP layer thickness). However, in a more complex layout, the relative layer thickness of the BCP layer will also depend on the spacing between adjacent recesses.
[0128] For example, in such a more complex layout, a recess which is a circular hole may form part of a dense hexagonal array of similar recesses (circular holes), where the spacing between adjacent holes (periodicity) is smaller than the depletion zone. The relative layer thickness may be calculated according to Equation (2):
[0000]
RLT
=
P
2
3
2
π
R
2
(
2
)
[0129] where:
[0130] P is the periodicity of the holes, and
[0131] R is the radius of each of the holes.
[0132] It can be seen from Equation (2) that for a circular hole which is part of a dense array of holes, the depletion zone width does not influence the relative layer thickness. However, the relative layer thickness of a hole which is at the perimeter of such a dense array of holes would be influenced by the depletion zone width.
[0133] It will be appreciated that the relative layer thickness for recesses within alternative layouts can be calculated according to simple geometrical relationships.
[0134] The placement and density of one or more dummy recesses should be sufficiently close to the one or more lithography recesses that it will have some effect on the relative layer thickness. However, the placement and density of the one or more dummy recesses should not be so close that relative layer thickness within the one or more lithography recesses becomes too thin. The one or more dummy recesses should be placed within the depletion zone around a lithography recess.
[0135] In practical applications, the relative layer thickness within a lithographically defined pattern for directed self-assembly may vary between 1 and 20. In most cases, the relative layer thickness varies between 1 and 5. It will be appreciated that this wide variation in relative layer thickness may prevent the effective self-assembly of discrete polymer block domains within a BCP layer. A substantially uniform and predictable BCP layer thickness is desired to help ensure predictable self-assembly of discrete polymer block domains.
[0136] The migration and self-assembly of a BCP material has been described above with reference to an annealing process, and in particular a thermal annealing process. However, other forms of annealing may facilitate the migration or self-assembly of BCP molecules. For example, solvent vapor annealing with an appropriate solvent may sufficiently increase the mobility of BCP molecules to allow a degree of migration or self-assembly.
[0137] Further, while the migration of BCP material has been described during an annealing process, this can also occur during spin-coating. When a BCP layer is applied by spin coating, a solution with approximately 2% BCP dissolved in a solvent is deposited on to a substrate. The solvent will subsequently evaporate, leaving a residue of BCP material on the surface of the substrate. However, as the solvent evaporates the BCP material may be relatively mobile on the surface of the substrate, enabling some migration of the BCP material from the surface of photo-resist, to the recesses. In this way non-uniform BCP layer thickness may be encountered without performing an annealing step. An embodiment of the present invention may be applied to solve the problem of non-uniform BCP layer thickness encountered in this way.
[0138] A complete depletion zone is not required for non-uniform thickness to occur across the surface of a substrate. For example, the thickness of BCP above a photo-resist layer may be significantly reduced, with BCP material being transported to recesses or other features, without the BCP material above the photo-resist layer being entirely removed.
[0139] FIG. 2 shows one possible layout of dummy recesses. However, it will be appreciated that other layouts are possible. Dummy recesses may be used around in any arrangement in which the dummy recesses provide some adjustment to the local lithography recess density on a substrate.
[0140] For example, FIG. 3 shows a substrate 20 with an array of lithography recesses 21 A, 21 B. Like features are again shown with like shading. A plurality of circular dummy recesses 22 are provided around the perimeter of the array of lithography recesses 21 A, 21 B. The central lithography recess 21 A is surrounded by peripheral lithography recesses 21 B. Without the addition of dummy recesses 22 , the central lithography recess 21 A would have a higher local recess density than each of the peripheral lithography recesses 21 B. The dummy recesses 22 have the effect of increasing the local recess density at each of the peripheral lithography recesses 21 B, resulting in a more uniform BCP layer thickness within the lithography recesses 21 A, 21 B. The BCP material within recesses 21 A, 21 B has self-assembled to form discrete A block domains 23 and B block domains 24 . There is no self-assembly of BCP within the dummy recesses 22 , due to their size being below the threshold at which self-assembly can occur.
[0141] In a further embodiment, FIG. 4 shows a substrate 30 having an array of lithography recesses 31 A, 31 B, in which dummy recesses 32 are arranged as trenches around the array of lithography recesses 31 A, 31 B. The central lithography recess 31 A is surrounded by peripheral lithography recesses 31 B. Without the addition of dummy recesses 32 , the central lithography recess 31 A would have a higher local recess density than each of the peripheral lithography recesses 31 B. The dummy recesses 32 have the effect of increasing the local recess density at each of the peripheral lithography recesses 31 B, resulting in a more uniform BCP layer thickness within the lithography recesses 31 A, 31 B. The BCP material within recesses 31 has self-assembled to form discrete A block domains 33 and B block domains 34 . There is no self-assembly of BCP within the dummy recesses 32 , due to their size being below the threshold at which self-assembly can occur.
[0142] While one or more dummy recesses may be used in proximity to lithography recesses on a device, a dummy recess is not necessarily required in all areas of a device. For example, FIG. 5 shows a lithography pattern 40 in which lithography recesses 41 are surrounded by dummy recesses 42 . The BCP material within recesses 41 has self-assembled to form discrete A block domains 43 and B block domains 44 . There is no self-assembly of BCP within the dummy recesses 42 , due to their size being below the threshold at which self-assembly can occur. However, in regions of the pattern in which there are no lithography recesses present, such as the region shown by dotted line 45 , no dummy recess is required. In the region shown by line 45 the BCP layer will not self-assemble, as there are no recesses to direct the self-assembly process. Therefore there is no reason to control the BCP layer thickness in this region.
[0143] FIG. 6 shows a substrate 50 with linear lithography recesses 51 A 51 B. Dummy recesses 52 surround the lithography recesses 51 A, 51 B. The BCP material within the recesses 51 A, 51 B has self-assembled to form discrete A block domains 53 and B block domains 54 . There is no self-assembly of BCP within the dummy recesses 52 , due to their size being below the threshold at which self-assembly can occur.
[0144] In contrast to the earlier embodiments, the A block domains 53 and B block domains 54 within lithography recesses 51 A, 51 B are shown in a lamellar arrangement. The elongate arrangement of recesses 51 A, 51 B guides the self-assembly of the BCP to form B-block domains 54 at the edges of the recesses 51 with a single A-block domain 53 running along the center of each of the elongate recesses 51 A, 51 B. The lamellae of the A-block and B-block domains 53 , 54 are orientated with their planar surfaces lying substantially perpendicular to the substrate and substantially parallel to the recess walls. The dummy recesses 52 have the effect of increasing the local recess density around the lithography recesses 51 , resulting in a more uniform BCP layer thickness within the lithography recesses 51 A, 51 B. Alternatively, there may be a plurality of A-block domains which are lamellae alternating with B-block domains which are also lamellae.
[0145] Without the dummy recesses 52 , the central lithography recess 51 A would have a higher local recess density than each of the outer lithography recesses 51 B. Consequently, the outer lithography recesses 51 B would have a thicker BCP layer than the central lithography recess 51 A. Therefore, the dummy recesses 52 result in a more uniform local recess density, and consequently a more uniform BCP layer thickness within the lithography recesses 51 A, 51 B.
[0146] Alternative lithography and dummy recess geometries are possible beyond the circular and elongate examples discussed above. For example, trenches may be used for both lithography recesses (as shown in FIG. 6 ) and for dummy recesses (as shown in FIG. 4 ). Any recess geometry which promotes self-assembly of BCP may be used for a lithography recess. Similarly, any recess geometry which does not allow self-assembly of BCP may be used for a dummy recess.
[0147] It will be appreciated that the use of resist (also known as photo-resist) to form the sidewall of the lithography and dummy recesses is intended to be an example, rather than a limiting feature. For example, recesses may be provided by patterning of the substrate itself, or patterning of a layer deposited or grown onto the substrate. The recesses may themselves be provided by the self-assembly of a BCP material. | Causing a self-assemblable block copolymer (BCP) having first and second blocks to migrate from a region surrounding a lithography recess of the substrate and a dummy recess on the substrate to within the lithography recess and the dummy recess, causing the BCP to self-assemble into an ordered layer within the lithography recess, the layer having a first block domain and a second block domain, and selectively removing the first domain to form a lithography feature having the second domain within the lithography recess, wherein a width of the dummy recess is smaller than the minimum width required by the BCP to self-assemble, the dummy recess is within the region of the substrate surrounding the lithography recess from which the BCP is caused to migrate, and the width between portions of a side-wall of the lithography recess is greater than the width between portions of a side-wall of the dummy recess. | 69,103 |
BACKGROUND OF THE INVENTION
The present invention relates to high DC current acyclic or homopolar generators and particularly to an improved liquid metal collector therefor.
A goal of present research and development efforts is to develop smaller, ultra-high current acyclic generators of dramatically increased power density. To this end, high current density field coils, such as supercooled or superconducting field coils, are utilized to provide the requisite high density magnetic field. This coupled with dramatic increases in the peripheral velocity of the rotor can develop DC current outputs in the megamp range. To accommodate such high DC current magnitudes and peripheral velocities, liquid metal collectors are a virtual necessity to reliably handle current transport between the rotor and stator of the generator.
At such high currents and peripheral velocities, control of the liquid metal, typically a sodium-potassium eutectic (NaK), becomes extremely difficult due to the myriad forces acting on the liquid metal. Obviously, the liquid metal must continuously wet the rotor and stator collector surfaces and completely fill the gaps therebetween to avoid arcing and undue losses. In addition, the current carried by the liquid metal, coupled with the physical agitation thereof during high current, high velocity generator operation, generates considerable heat in the liquid metal, which heat must be removed if it is not to raise the liquid metal's resistivity and thus increases losses. Thus, it is important that the liquid metal be continuously removed from the collector regions, cooled and returned thereto in recirculating fashion, all without creating voids in the gaps between collector surfaces.
Complicating these objectives is the force exerted on the liquid metal resulting from the interaction of the generator current flowing therethrough and the magnetic field associated therewith. This outwardly directed Lorentz force tends to drive the liquid metal out of the collector gaps and is a direct function of the current magnitude. Thus, as the generator current is increased, Lorentz expulsion forces become a significant factor. In addition, the gererator current coacts with the component of the generator magnetic field existing in the collector gap which is normal to the current path therethrough to develop forces driving the liquid metal in a circumferential direction opposite to the direction of rotor rotation.
In addition to the above-noted magnetochydrodynamic motoring forces acting on the liquid metal in the collector gaps, mechanical forces exerted on the liquid metal due to the high rotational velocity of the rotor must also be taken into consideration. First, there is a viscous pumping force which tends to drive the liquid metal in the same circumferential direction in which the rotor collector surface is moving. Thus, this torquing force acts in the opposite circumferential direction to the magnetohydrodynamic forces generated by the coaction of the generator current and the generator field in the collector gaps. At zero generator current, this viscous torquing or pumping force causes the liquid metal in the collector gaps to revolve circumferentially at velocity equal to one-half of the rotor peripheral velocity. As generator current is increased, so does the counteracting circumferential magnetohydrodynamic force. At some current value, circumferential motion of the liquid metal will be halted, and at higher values, the liquid metal will be driven in a direction opposite to the direction of rotor rotation. Such counter-rotation of the liquid metal significantly increase viscous drag on the rotor, resulting in higher losses.
Finally, there are the radially directed, viscous centrifugal pumping forces acting on the liquid metal due to the rotational motion of the rotor surfaces in contact therewith.
It is seen that these liquid metal pumping or motoring forces vary with generator current and rotor velocity. Thus, it becomes extremely difficult to develop a design capable of affording the requisite control of the liquid metal over a wide range of operating conditions from zero to rated generator current and zero to rated rotor velocity.
In addition to the foregoing considerations, it would be desirable to utilize these magnetohydrodynamic and mechanical forces to recirculate the liquid metal through the collector region and thus avoid the added complexity and cost of an external pump to move the liquid metal in a recirculating path through the collector gaps.
It is accordingly an object of the present invention to provide an improved liquid metal collector for an acyclic generator.
A further object is to provide a liquid metal collector of the above-character, wherein viscous drag on the generator rotor is minimized.
An additional object is to provide a liquid metal collector of the above-character, wherein the inherent forces acting on the liquid metal are advantageously harnessed to achieve recirculation of the liquid metal through the collector region.
Yet another object is to provide a liquid metal collector of the above-character, wherein recirculation of the liquid metal through the collector region pursuant to extracting heat therefrom is achieved without resort to an external recirculating pump.
A still further object is to provide a liquid metal collector of the above-character of improved efficiency and capable of handling extremely high power densities.
Another object is to provide a liquid metal collector of the above character which is efficient in design and reliable in operation over a wide range of operating conditions and over a long service life.
Other objects of the invention will in part be obvious and in part appear hereinafter.
SUMMARY OF THE INVENTION
In accordance with the present invention, there is provided an improved liquid metal collector for an acyclic generator wherein the circumferential forces acting on the liquid metal are controlled such as to minimize viscous rotor drag without jeopardizing the recirculation of the liquid metal through the collector gap pursuant to the extraction of heat therefrom. To this end, a plurality of circumferentially spaced, compliant, braided metal filament brushes are mounted by the stator for extension from the stator collector surface across the collector gap into virtual contact with the rotor collector surface. These brushes, of an axial length corresponding to the axial lengths of the stator and rotor conductive collector surfaces in the main generator current path are uniformly distributed about the circumference of the annular collector gap. As a consequence, these brushes, which serve with the liquid metal in the transport of generator current across the collector gap, are positioned to effectively block the magnetohydrodynamically induced, counter-rotational, circumferential flow of liquid metal in the collector gap and thus eliminate the component of viscous rotor drag otherwise occasioned thereby. Moreover, by virtue of the angular or circumferential spacing of the brushes, a multiplicity of axially directed passages are provided between adjacent brushes for the circulation therethrough of liquid metal motivated by the Lorentz pumping forces acting thereon.
The invention accordingly comprises the features of construction, combination of elements and arrangement of parts which will be exemplified in the construction hereinafter set forth, and the scope of the invention will be indicated in the claims
For a fuller understanding of the nature and objects of the invention, reference should be had to the following detailed description taken in conjunction with the accompanying drawings, in which:
FIG. 1 is a fragmentary, sectional view of an acyclic generator incorporating a liquid metal collector constructed in accordance with the present invention; and
FIG. 2 is a sectional view taken along line 2--2 of FIG. 1.
Corresponding reference numerals refer to like parts throughout the several views of the drawings.
DETAILED DESCRIPTION
Referring to FIG. 1, an acyclic or homopolar generator, generally indicated at 10, includes a stator, generally indicated at 12, having a bore 14 accommodating a rotor generally indicated at 16 and journalled for rotation about an axis 18 by suitable bearings (not shown). The stator includes a terminal member 20 of highly conductive metal, such as copper, which is provided with an annular collector surface 22. The rotor may be entirely made of a lightweight, highly conductive, solid cylinder of aluminium (or aluminium-beryllium alloy) or may include an iron core 24 for carrying the magnetic flux generated by field coils (not shown). Mounted on any such iron rotor core is a highly conductive metallic sleeve or cylinder 26 of copper or aluminium for carrying the main generator current. Integrally formed at each end of cylinder 26 (the right end being shown in FIG. 1) is an annular rotor collector member 28 which presents a cylindrical collector surface 30 in uniformly gapped relation with stator collector surface 22. To accommodate main generator current transport between collector surfaces 22 and 30, the collector gap therebetween is filled with a highly conductive liquid metal 32, such as a sodium-potassium eutectic (NaK). The surfaces of the stator and rotor to each side of this collector gap are fashioned in closely spaced stepped formation relation for purposes ascribed below. Except for the axial segments 34, the conforming collector surfaces of the stator aid rotor are covered with an insulative coating 36, which may take the form of sprayed alumina which is subsequently vacuum impregnated with epoxy. Consequently, current transport between the stator and rotor is limited to the welldefined axial segments 34 of the stator and rotor cylindrical collector surfaces 22 and 30, respectively, which are devoid of insulative coating 36, and the liquid metal 32 filling the annular collector gap therebetween.
In accordance with the present invention, a pherality of brushes 40 are uniformly angularly spaced about the circumference of this annular collector gap, as best seen in FIG. 2. These brushes are preferably formed of a compliant mesh of conductive metal filaments in an approximate L-shaped configuration with the radially outer legs 40a thereof mounted by stator terminal member 20. The free, radially inner legs 40b thereof are initially disposed in rubbing, tangential relation with the conductive rotor collector surface 30 over the axial segment 34 thereof. Brush legs 40b are seen to extend from brush legs 40b. in the direction of rotor collect surface movement indicated by arrow 66 in FIG. 2. Each brush may be comprised of flat copper braid which is flattened and folded over on itself to a double thickness before being formed in the illustrated L-shaped configuration. The brush filaments must be fully compatible with liquid metal 32 and wettable with the liquid metal so as to provide a very low resistivity. While tin plated copper braid is preferred, other braided (or otherwise compliant) conductive materials may be used. Also, various surface finishes, such as electroplated gold, silver, tin, nickel, etc., may be applied to the braided filaments to enhance wettability with the liquid metal.
While brushes 40 may be mounted to the stator terminal member 20 in several ways, such as by electron beam welding the legs 40a thereto while being lodged in radial slots formed in stator collector surface 22, FIG. 2 illustrates that the copper braid is folded about a conductive metal dowel 42 and captured in keyhole-shaped grooves 44 formed in the stator and opening into stator collector surface 22. It will be appreciated that the brushes may be mounted by the rotor instead.
Returning to FIG. 1, liquid metal 32 is supplied to the annular collector gap via one or more inlet passages 46 to the inboard side of the collector gap and withdrawn therefrom via one of more outlet passages 48 formed in stator 12 to the outboard side of the collector gap. These passages are connected in a liquid metal recirculating loop which includes a degasser 50 and a heat exchanger 52. Degasser 50 removes any inert cover gas, such as nitrogen, entrained in the liquid metal and returns the recovered gas, as indicated diagrammatically at 48a, to the gap between the stator and rotor where it exerts a pressure to prevent escape of the liquid metal axially beyond the stepped formation to each side of the collector region. The heat exchanger extracts heat from the liquid metal prior to its return to inlet passages 46 and the collector gap.
As is well understood in the art, while generator current is flowing radially through the collector gap, leading from a path in rotor 16 generally indicated by arrow 52, the interaction of this current and its (i.e. the circumferential magnetic field produced by this same current) magnetic field generates a force on the liquid metal 32 within the collector gap between the uninsulated collector surfaces 22, 30 which is to the right or in the outboard direction indicated by arrow 54 in FIG. 1. This Lorentz force is utilized to advantage to propel the liquid metal axially through the collector gap from the inlet passager 46 toward the outlet passages 48. This liquid metal flow is not impeded by brushes 40 since, as seen in FIG. 2, the spaces between the brushes provide a multiplicity of unobstructed, axially oriented channels 56. That this Lorentz pumping force increases with increasing generator current magnitude is used to advantage in providing enhance axial liquid metal flow through the collector gap when most needed to achieve a cool running liquid metal collector.
Acting in opposition to the Lorentz pumping forces are the viscous centrifugal pumping forces exerted on the liquid metal in the annular gaps between the complimenting stairstep formations 58 in the stator and rotor to the outboard or right side of the collector gap as seen in FIG. 1 during high velocity rotation of rotor 16. Supplementing these centrifugal viscous pumping forces is the cover gas pressure existing at liquid metal-gas interface 60.
It is desirable to achieve a balance point between these opposing dynamic pumping heads which is located approximately at the entries into outlet passages 48 and thus provide an effective hydrostatic pumping head propelling the liquid metal in the desired recirculating path through passages 48, degasser 50, heat exchanger 52 and inlet passages 46. To this end, insulative coating 36 is extended onto the marginal portions 22a and 30a of the stator and rotor collector surfaces, respectively, to an extent necessary to isolate the liquid metal proximate the entries into passages 48 from the highest level of generator current conducted across the collector gap, taking into account fringing current paths at the right edge of axial extent 34. Thus, this portion of the liquid metal is not subjected to Lorentz forces, and consequently the Lorentz dynamic head existing in the collector gap encompassed by axial segments 34 is converted to a hydrostatic head substantially at or somewhat to the inboard or left of the passage 48 entries.
It will be noted in FIG. 1 that the insulative coating 36 is also extended onto the inboard marginal surface portions 22b and 30b of the stator and rotor collector surfaces, respectively. As a consequence, brushes 40 are axially spaced from the exits of inlet passages 46. There is thus provided an unobstructed annular chamber 62 which serves as an inlet manifold affording inlet passages 46 fluid communication with the multiplicity of axial channels 56. It will be noted that the liquid metal in chamber 62 is essentially free of magnetohydrodynamic effects, i.e., the Lorentz pumping forces and the circumferential pumping forces generated by coaction of the generator current and the axial component of the generator field existing in the collector gap. Thus, the dominate pumping force acting on the liquid metal in chamber 62 is the viscous drag circumferential pumping force generated by the rapidly rotating rotor surface bounding the chamber. This pumping force is utilized to advantage in rapidly distributing the cooled liquid metal supplied via the inlet passages throughout annular chamber 62 prior to its flow into the collector gap.
The same is true at the outboard end of the collector region in that brushes 40 are axially spaced from the entries into outlet passages 48. Thus there is provided unobstructed annular chamber 64 which serves as an outlet manifold affording axial channels 56 open fluid communication with the outlet passages 48. Similarly, viscous circumferential pumping forces distribute the liquid metal exiting axial channels 56 throughout annular chamber 64 preparator to its being pumped out via outlet passages 48 by the hydrostatic pressure head therein.
Considering the circumferential liquid metal pumping forces to which the brushes 40 are addressed, rotation of the rotor 16 in the assumed counterclockwise direction indicated by arrow 66 in FIG. 2 produces viscous pumping forces on the liquid metal 32 also in the counterclockwise direction, as indicated by arrow 68. With the transport of generator current through the liquid metal in the collector gap encompassed by axial segments 34, the coaction of this current with the axial component of the generator magnetic field in the collector gap produces a magnetohydrodynamic pumping force in the clockwise direction, indicated by arrow 70. It is seen that these two liquid metal pumping forces are in opposition, and at high generator currents, the magnetohydrodynamic pumping forces will dominate, causing the liquid metal in the collector gap to revolve in the clockwise direction, counter to the direction of rotor rotation. As a consequence, viscous drag on the rotor increases significantly, which represents added generator losses.
It is seen in FIG. 2 that brushes 40 are positioned to radially span the collector gap and serve as barriers to impede significant counter-rotational flow of the liquid metal in the collector gap in response to losses associated therewith are substantially avoided. While, at high generator current levels, there may be some degree of counter rotational movement of the liquid metal, it is limited to the individual channels 56 where the opportunity to reach significant velocities does not exist. Since the brushes 40 afford effective control of the circumferential movement of the liquid metal in the conductive portion (axial segments 34) of the collector gap, variations in rotor speed and generator current, insofar as their influences on circumferential liquid metal motion are concerned, do not significantly influence axial circulation of the liquid metal through the collector gap. Thus, the liquid metal collector may be designed to take maximum advantage of the axial Lorentz pumping forces and the radial centrifugal pumping forces to achieve the requisite recirculation of the liquid metal through the collector region and thus a cool running liquid metal collector.
It is thus seen that the objects set forth above, including those made apparent from the preceding description, are efficiently attained, and, since certain changes may be made in the above construction without departing from the scope of the invention, it is intended that all matter contained in the above description or shown in the accompanying drawings shall be interpreted as illustrative and not in a limiting sense. | A plurality of circumferentially spaced, compliant, braided metal filament brushes are mounted by the stator of an acyclic generator for extension from the stator collector surface across the liquid metal collector gap into virtual contact with the rotor collector surface. These brushes are each of an axial length corresponding to the axially lengths of the stator and rotor conductive collector surfaces and serve to effectively block the magnetohydrodynamically induced, counter-rotational, circumferential flow of liquid metal in the collector gap, thus eliminating the component of viscous rotor drag otherwise occasioned thereby. | 19,782 |
BACKGROUND OF THE INVENTION
This invention relates to communication and collaboration tools which allow groups to share information across time and space using computer and other communication channels. The inventive method may be incorporated into the design of products such as groupware software and communications services.
The conventional approach to the design of communication and collaboration products, especially of groupware, is a centripetal method, i.e., group members are required to go to a central area in order to retrieve and exchange data and information. For example, in the Internet, group members need to converge on a server in order to communicate and collaborate.
The previous approaches taken in this field can be categorized in two different product groups:
(1) Centripetal method: This method is seen in all of the following products: IBM's Lotus Notes and Domino; Microsoft's Exchange and NetMeeting; Netscape's Virtual Office by Concentric; Radnet's Webshare; Novell's GroupWise; Thuridion's Crew; IntraACTIVE's In Tandem; Linkstar's HotOffice; Changepoint's Involv; Internet Media Inc.'s 3-2-1 Intranet; and others. All of these products require group members to remember to go to a central area (a server) in order to retrieve and exchange data and information. This centripetal design leads producers to develop products by increasing the speed of connection and facilitating access to the central site of communication and collaboration. Using the client-server infrastructure, products are either proprietary servers, enhanced software clients, or both.
(2) Narrowcasting method: This method is seen in all of the following products: PointCast's Client and Server; Marimba's Castanet; Progressive Network's Real Clients and Servers; Microsoft's NetShow; Netscape's Browser and Media Server; Wayfarer's INCISA; and all listserve products. All of these products use the narrowcasting model of one-to-many communication. Group members (many) have to remember to "tune-in" or attend the narrowcasted content served by a central site (one), without knowing whether or not new or relevant information is there.
Both the centripetal and narrowcasting approaches suffer from the disadvantage that group members have to report and remember to report to a central area for communication and collaboration. While they have not failed as models, they have failed to anticipate problems associated with the information age such as information glut and competition for attention. Prior art methods assume that value is added by improving the way group members go about retrieving information that updates at a central location. Collaborative value is stored in the central repository. Group members still must actively go to the central resource to get any information or value from the group. For example, in the Internet, a group member would need to remember to log into a server for a videoconferencing appointment at a designated time. It would be an improvement to such a system for appointments and reminders for appointments to be "pushed" to the group member's awareness via e-mail with a Web hyperlink to the videoconference, via a narrowcast of the appointment, or other technologies that drive the information outward to the group member.
In the digital era, the computer has increasingly become a substitute for physical presence and interaction. Designers, however, have focused on providing cheaper and quicker access and offering additional functionality such as manipulation of the data and information sought. In the attempt to mimic human interaction such as congregating in a town hall for a meeting (a centripetal method) via electronic means, the power of the electronic medium to conduct the meeting outside of the town hall has been ignored.
SUMMARY OF THE INVENTION
The invention, referred to in some of its aspects as a Centrifugal Communication and Collaboration Method (CCCM), reverses the established centralized design of communication and collaboration products especially of groupware software. CCCM "pushes" out to group members the data and information contained in a central area. This centrifugal flow is distinct from the current centripetal design of such products, and provides numerous advantages.
A centrifugal arrangement improves the ability of groups to communicate, collaborate, and exchange information because of its focus on the individual group members rather than a central meeting site. CCCM creates value in interactive group-oriented software applications by distributing the accumulated group knowledge and activity to the individual group members, rather than forcing the group members to go to the central source of data and information where the wealth of the group is stored. Previous applications focused on better, cheaper, and faster ways to bring group members together in a central location. CCCM focuses on using the interactive capabilities of networks to maintain value among the group members, not only at a central repository of information and data.
The active, centrifugal delivery to users of updated information relevant to the members, such as the actions of other group members, the status of their pending group activities, the status of their requested information, etc. simplifies the process by which group members use software programs to gain information over networks. Since the information is pushed, there is minimal need to converge at a central repository.
The prior art model is a centripetal model. Individual users are attracted to or pulled into that central place. The value added by previous software programs has been to make the access easier and cheaper and to improve the manipulation of data.
With CCCM, the dynamic is a centrifugal push, the opposite of the prior art model. The flow of information among members of a group using CCCM-enabled communication and collaboration software is outward in direction. CCCM takes the value of the central resource out to the individual users. The members must converge at the centrifugal core only briefly. They are notified when they must do so, and their convergence is facilitated by shortcuts that make it easier to converge. Collaborative activity is moved away from the central core out through the network to the user's peripheral location. For example, in the Internet, group members automatically receive from a server the data necessary to communicate and collaborate as a group.
CCCM is an integrative method. Using a computer network, it employs software code and servers to distribute content. In an internetworked environment, if group collaboration software resides together with an HTTP server, then pushing out the group-generated information by e-mail employs a mail server, a network connection of all group members, and software code within the group collaboration software that calls on the mail server to push content. Or, if the group-generated information is distributed by narrowcasting, then a narrowcasting server may be used from which narrowcasting clients of group members receive information feed. The group collaboration software, through added software code, then communicates with the narrowcasting server to deliver group-generated information to group members.
As distinguished from other group-oriented software, CCCM reverses the basic assumption about how group value is created and information is shared. Rather than focusing on bringing group members into a central location in a better, cheaper, and faster way, CCCM empowers the users by providing them information right where they are and leaves them to decide whether or not to go to the central site at all.
As distinguished from other uses of "push" technology, the content in CCCM is provided and continuously changed by the group members. The traditional push system is broadcasting, such as television and radio. In this traditional model, preset content is sent to all viewers who have means to receive it, such as TV or radio. Viewers must be there at the same time as the broadcast to receive the content they want, or they must record it at the time of broadcast.
The general Internet model of push is narrowcasting. As with broadcasting, the source(s) of content are decided by the narrowcaster, and filtered according to the users' predetermined criteria as to what will be received.
By contrast, the content of CCCM that is continually being "pushed out" is not a standard collection of information selected by a central narrowcaster, but is a custom mix of information that remains in flux. The information that is pushed is created and continuously modified by the group members themselves. Messages and other information are unique to and generated by group members, and are determined by the role of that member in the group.
Rather than substitute an electronic model for the physical model of a meeting place, CCCM enhances the model of group interaction by taking advantage of the possibilities of virtual and digital communication and collaboration. While all other models took the previous "real world" example of a meeting hall, substituted it in cyberspace, then improved upon the substitute, CCCM uses the power of electronic methods to provide centrifugal flow that enhances the physical model.
CCCM removes the need for individuals to gather at a central location to find out what is there, what has changed since they were last there, and what they can do there. All group value no longer resides in the central resource. CCCM takes the dynamic group information from the center as it is changing with the contributions of its diverse members and distributes it out to those members.
A system for communicating information among members of a group comprises for each group member, a peripheral device capable of transmitting and receiving information; and a central agent comprising two-way links to the peripheral devices capable of receiving and transmitting information, a notice generator triggered by an information input from an inputting member directed to a receiving member, the notice generator generating a notice for the receiving member, and pushing the notice to the peripheral device of the receiving member only if the member is one to whom the associated information input was directed, a central storage medium in which the information input is stored, and an access channel of the link by which the receiving member may receive the information input only if the receiving member responds to the notice.
The access channel is preferably a hyperlink URL in an e-mail embodiment of the invention.
The notice generator may push the notice immediately or at the end of a predetermined period, when all notices generated during the preceding period are pushed together. The notice preferably comprises a summary of the information input, and a link to the information input on the central database. The notice generator may push notices via e-mail, narrowcasting, or a combination. Access to the central agent preferably requires using a password, and information inputs and notices may be encrypted.
The links may form a computer network, a cable network, a telecommunications network, a wireless network, or a combination. The central agent may reside as a program operating on at least one of a network server, an internet, an intranet. The inputs are preferably retained in the central storage medium as a database archive for a predetermined period. The system may comprise a network server farm including a server selected from the group consisting of groupware, a video server, an audio server, a chat server, and a news server.
A method for communicating information among members of a group having peripheral devices capable of transmitting and receiving information comprises providing a central device capable of receiving information from the peripheral devices and transmitting information to the peripheral devices, linking the central device to the peripheral devices, when a first information input is transmitted from the peripheral device of a member of the group directed to at least one other member of the group, centrally receiving the first information input, associating the first information input with the at least one other member, preparing a notice of the first information input for the at least one other member, pushing the notice to the peripheral device of the at least one other member, and centrally storing the first input such that when the at least one other member receives the notice, the at least one other member can retrieve the first information input at the respective peripheral device, and can respond by transmitting a second information input, and minimizing the information transmitted to the peripheral devices by
(a) pushing a notice to a member only if the member is one to whom the associated information input was directed, and
(b) transmitting an information input to a member only if the member responds to a notice.
The first information input is typically directed to a plurality of other members, and the second information input may be directed to the first member, another member, or a plurality of members. The method may further comprise allowing a person to join as a member of the group by forming a link with the person, and inviting a person to join as a member of the group.
In another embodiment, a computer readable medium comprises a program for carrying out the method according to the invention.
Further objectives and advantages will become apparent from a consideration of the description and drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention is better understood by reading the following detailed description with reference to the accompanying figures, in which like reference numerals refer to like elements throughout, and in which:
FIG. 1 illustrates a prior art model for centripetal communication and collaboration in a group.
FIG. 2 illustrates the centrifugal communication and collaboration method of the invention.
FIGS. 3-A to 3-C show flow charts for the asynchronous events in a responsive, rapid interaction among three individual members of a group. FIG. 3-A shows the flow of information from the initial input by member P1. FIG. 3-B shows a response by member P2 directed to member P1. FIG. 3-C shows a response and comment by member P3, directed to members P1 and P2.
FIGS. 4-A and 4-B show flow charts for the events in a slower interaction among three individual members of a group. FIG. 4-A shows the flow of information received at separate times from each of the members P1-P3. FIG. 4-B shows the flow of information periodically pushed to the members.
FIG. 5 is a flow chart of information flow in a system according to the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
In describing preferred embodiments of the present invention illustrated in the drawings, specific terminology is employed for the sake of clarity. However, the invention is not intended to be limited to the specific terminology so selected, and it is to be understood that each specific element includes all technical equivalents which operate in a similar manner to accomplish a similar purpose.
In the prior art as shown in FIG. 1, an eight member group is depicted as circles 1-8, connected to central repository 10. Each user must converge on the central repository 10 to obtain information. If a member does not converge, the member has no access to information that is contained in central repository 10, and no knowledge of whether the information in repository 10 has been changed or updated, and has no way of knowing if any new information is relevant to that particular member. Convergence must be done on a "blind " basis, and is typically done periodically, such as every day or twice a day whether needed or not. Central repository 10 is essentially a database, presenting all information and making it available in a standardized fashion periodically, such as every day or twice a day whether needed or not. Central repository 10 is essentially a database, presenting all information and making it available in a standardized fashion to each member to access and review. The information may be filtered to the individual members, but it must all be stored centrally for such a system to operate effectively.
In a schematic depiction of the invention as shown in FIG. 2, an eight member group is shown oriented around central core 20. Each member has a unique flow of information sent to and received from the central core 20, depicted as individual curved arrows 11-18. Members are notified when relevant information is posted at the central core 20, and may then retrieve the information knowingly. They need not converge blindly on the central core. In addition, because information is tailored and directed to individual members, the arrangement of information at the central core does not need to be a standardized database available to all members.
Preferred embodiments of the invention include the following.
(1) Software intended for use by groups, enabled with CCCM by programmed code intended to push out group-generated information by e-mail, narrowcasting, and other such distribution methods. For example, a group discussion software contains software code that allows discussion content to be e-mailed to the entire set or a subset of participants. An additional program may run at a predefined interval to notify participants of what content is new, what has been read and what has not, or whether or not they have been requested to respond to a particular comment. The individualized e-mail contains the content plus a mouse-clickable Web hyperlink to the message itself from the central server and/or to the entire discussion. The Web hyperlink may in itself open a videoconference, or the Web hyperlink may open a window that contains channelized connections not only to the discussion and videoconference, but also to the schedule and address book of the group member. Another example is a group scheduling software linked to a narrowcasting system that activates a narrowcasting client which then narrowcasts, say, the events of the day or of the month, or that an appointment is about to become due, or that an Internet presentation is about to begin, or that someone has replied to a comment in a group discussion. Both e-mail and narrowcasting can be done in multimedia, such as text, audio, video, and images.
(2) CCCM can be used in non-computer-based networks, provided there is bi-directional exchange of information, including telecommunication systems, newer versions of cable-based networks, wireless networks and others. The invention does not much depend on how the network is linked. What is important is that each database record or field has a URL or similar "retrievable handle" that can be accessed for retrieval by the network, and that this URL or handle can be "pushed" in various ways (like e-mail) so that following (or clicking on) the link will retrieve the database record or field.
The variations occur in the technology used to distribute centrifugally group-generated information. Distribution may occur by e-mail, by narrowcasting, and by other electronic means. According to the invention, there is a method to distribute group-generated information to group members, without requiring them to converge at a central area, and the method is selective and deliberate as to what information is being delivered. Users need not remember to go to a central site for collaboration. CCCM makes participation among users more convenient and improves communication and collaboration products which are currently in existence and which may be developed in the future.
According to the invention, groups may be self-initiated. In other words, in an internet embodiment, one person can identify e-mail addresses for a desired group of colleagues, friends, or family, name the group, and provide a uniform resource locator (URL) for a group conference. The system pushes an e-mail notice to the desired group, with the URL. The recipients, by clicking on the URL, are brought to a conference area. In synchronous mode, they can communicate in streaming conversation, and can scroll through messages. In asynchronous mode the members may participate and return at any time. If a member has not returned for a predetermined time, a notice may be pushed to the member (a) reminding them that a response is desired, (b) indicating that a new message is there, or (c) providing a summary of recent activity.
An e-mail driven embodiment is shown in FIGS. 3-A to 3-C. These flow charts represent a responsive continuous interaction among three individual members of a group. Although the events are asynchronous, they may be relatively rapid. Throughout, the agent identifies and pushes the appropriate URLs to the appropriate people. In FIG. 3-A, member Person 1, identified as circle 31, initiates a session by providing an initial input A in a peripheral device such as a personal computer, as identified by box 34. In this example, input A is a question for members Person 2, identified as 32, and Person 3, identified as 33. The question could be "What is the status of Project X?" Intelligent agent 35 receives input A from member Person 1, selects the members to whom the input is relevant, in this case Person 2 and Person 3, and pushes and posts notice of activity with hyperlink at the peripheral computers 36 and 37 for members Person 2 and Person 3. In addition, the intelligent agent 35 stores input A on the central database 38 as database record A.
In FIG. 3-B, member Person 2 (box 32) receives notice A 36 as in the previous figure, and responds by clicking the hyperlink, box 40. This brings input A directly to member Person 2 from the central database, and displays the question "What is the status of Project X?" as shown in box 41. Member Person 2 provides a status report to Person 1, which may include text, graphics, video, and audio, and inputs the report as input Response B, shown as box 42. Agent 35 selects Person 1 as the relevant member, pushes and posts notice B with hyperlink shown as box 43 on the peripheral device of Person 1, and stores input B as database record B in central database 38.
In FIG. 3-C member Person 3 provides a response and comment directed to both of the other members. Person 3 responds to notice A by clicking the hyperlink, box 45. This brings input A directly to Person 3 from the central database, and displays the question "What is the status of Project X?" as shown in box 46. Member Person 3 provides a different status report, input C, directed to both members Person 1 and Person 2, shown as box 47. Agent 35 selects members Person 1 and Person 2 as the relevant members, pushes and posts notice C with hyperlink shown as box 48 and 49 on the peripheral device of Person 1 and Person 2, and stores input C as a database record in central database 38.
FIGS. 4-A and 4-B show flow charts for a more extended asynchronous interaction among three individual members of a group with a periodic push setting. In FIG. 4-A, at time T1, member Person 1 submits input comment D, shown as box 51. At time T2, Person 2 submits input comment E, shown as box 52. At time T3, Person 3 submits input comment F, shown as box 53. Inputs D, E, and F are each intended for the other group members. As each of the inputs is received, agent 35 selects the intended recipients, and stores the inputs in central database 37 as records D, E, and F for periodic push and notification. The push period can be any desirable period such as hourly, daily, or weekly. In some applications the push period may be minutes, seconds, or less.
In FIG. 4-B, after the elapsed predetermined period, at time T4, such as the next day if the system is set for daily notification, agent 35 pushes and posts individualized notices at the peripheral device of each member. Members do not receive notices of their own inputs. Notice 56 for Person 1 refers to inputs E and F by Persons 2 and 3. Notice 57 for Person 2 refers to inputs D and F by Persons 1 and 3. Notice 58 for Person 3 refers to inputs D and E by Persons 1 and 2. If there are eight members of the group in this example, members 4-8 receive no notification. Thus, in this approach, members 1-3 are notified that there is information, and provided with a direct link to the central database to retrieve it. Other members do not need to take any action because there is no relevant new information for them, and they know that by the absence of a notice. In addition, the members for whom there is relevant information are not burdened by a constant flow of information as with a list-server, and are shown only information relevant to them.
In FIG. 5, the software structure integral to the system is shown. Centrifugal access programming for intelligent agent 63 may be written according to conventional programming principles, and may be provided by a "middleware" product such as Radnet's Webshare (Cambridge, Mass.), Allaire's ColdFusion (Cambridge, Mass.), SilverStream's Web Application Platform (Irvine Calif.), or BlueStone's Sapphire/Web (Mount Laurel, N.J.). Internet-connected Web-browser(s) 61 accesses HTTP server(s) 62 and is allowed by means of centrifugal access software program 63 to access, for example, the database 64 to obtain a record of a comment 64' in a bulletin board-style Web discussion. The intelligent agent (63) retrieves the record 64' from database 64 and presents it in HTML format with URL 63' to SMTP mail server 65, and thence to mail client 66.
If the user clicks to respond to the record of the comment in database 64, and to notify the author who made the previous comment of this new response, the mail sent to notify this previous author must contain the URL 63' of the actual database record 64' of the response, as follows. Upon reading the e-mail in 66, following or clicking on the URL 63' will retrieve the new response record 64' automatically from the database 64, after clearing applicable authentication procedures such as password clearance. In a similar fashion, if software agent 63 were running overnight counting a user's number of unread messages in a bulletin board-style Web discussion from a database 64, the agent's 63 e-mail report to the user 66 must contain the URL of the actual database record of one or more of the unread messages so that following or clicking on the URL will retrieve one or more of the unread message records (1) automatically from the database (4) after clearing any authentication procedures.
In this embodiment, HTTP server 62, intelligent agent 63, database 64, and SMTP server 65 collectively establish the central agent. Intelligent agent 63 is the notice generator, and the SMTP engine 65 of a mail server is used as the notice sender if an e-mail push is used.
It is apparent from these examples that the intelligent agent is interposed between the member users and the central database, in contrast with conventional centripetal methods of collaboration. As a result the central database need not be complete. Indeed, once an input has been pushed to all intended recipients, the database could be purged, although in practice it may be preferable to keep a backup record of transactions in the group for at least a predetermined period (e.g. one month).
In a list-server, members sign up to join the group independently and can remove themselves at will. Thus, no member can control the presence of the others. The list is formed individually by the sign up of each recipient. According to a preferred embodiment of the invention, in contrast, each member can push a notice to any other person available on the internet via an e-mail message, to select an individualized and personalized group without requiring routing through a central list-server. Moreover, the central database according to the invention can be used to provide a threaded and scrollable record of relevant inputs, as opposed to the excessive number of individual e-mail messages in a list-server, which are not threaded or scrollable. The inventive system is a whole-loop database and network. Also, list servers generally do not use a database. A distinctive aspect of the invention is "pushing" the URL (or retrievable handle) of the database record or field that needs to be seen in order to present it to the user.
According to the invention, the pattern of pushing that is done may depend on the following factors.
(1) the list of people identified by the inputting person
(2) if the people identified are not already members of the group, whether they join the group,
(3) whether there has been new activity relevant to a particular member,
(4) whether there has been a response to a particular input.
(5) a predetermined update frequency
In a preferred commercially viable embodiment, a hypothetical group includes members 1, 2, 3 . . . n at n different locations. Each is given an e-mail notice of a group meeting, either asynchronous or scheduled at a particular time. At that time, or indidually, they each re-open the e-mail message and follow a hyperlink that fires up a web browser and takes them directly to an e-meeting center, in this case a web page where they may converge. They provide a password, and join.
For an on-demand conference, members can read and post messages, read and post files, and publish and attend presentations and lectures. For a live conference, members communicate and collaborate interactively in real time via video, audio, screen sharing, chat, wireboard, and so on.
The embodiments illustrated and discussed in this specification are intended only to teach those skilled in the art the best way known to the inventors to make and use the invention. Nothing in this specification should be considered as limiting the scope of the present invention. Modifications and variations of the above-described embodiments of the invention are possible without departing from the invention, as appreciated by those skilled in the art in light of the above teachings. It is therefore to be understood that, within the scope of the claims and their equivalents, the invention may be practiced otherwise than as specifically described. | A system and method for communicating information among members of a distributed discussion group having peripheral communication devices involves communication between the peripheral communication devices and a central agent. The central agent receives and stores messages intended for at least one other group member. It creates a notice informing the at least one other group member that such a message exists and containing a channel (e.g., a hyperlink) directly to the memory location of the message. The at least one other group member may then elect to retrieve the message and may also elect to reply to the message. Such replies are transmitted from the peripheral device of the at least one other group member to the central agent, where it is stored and associated with the original message. Messages are retained in memory, thereby causing discussions to be maintained. | 30,906 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to a variable drive current driver circuit.
[0003] 2. Description of the Prior Art
[0004] According to the conventional standards, such as IEEE 1394 standards, a drive current of a signal transmitted between electronic devices, such as personal computers, video movies, or mini-disc players, connected mutually via a cable or the like is determined so as to become either of two kinds. When a certain electronic device is connected to another electronic device via a cable, the former have the latter notify the former of the standard of a signal that can be received by the latter, and the former transmits data with a drive current determined on the basis of this notification.
[0005] [0005]FIG. 1 is a diagram showing a conventional driver circuit that is capable of varying a drive current of a signal. In the conventional technique, as shown in FIG. 1, either a driver circuit for a standard A or a driver circuit for a standard B is driven on the basis of, for example, a control signal of “0” or “1” so as to be able to cope with both a case where the electronic device of the opposite party receives a signal of one of two kinds of drive current defined by the standard and another case where the electronic device of the opposite party receives a signal of the other of the two kinds.
[0006] In other words, if a control signal of “1” is inputted to the standard A driver circuit and the standard B driver circuit, then the standard A driver circuit is enabled and the standard B driver circuit is disabled. If a control signal of “0” is inputted to the standard A driver circuit and the standard B driver circuit, then the standard A driver circuit is disabled and the standard B driver circuit is enabled.
[0007] In the conventional technique, however, it is necessary to prepare as many driver circuits as the number of kinds of the drive current defined by the standard. As a result, the circuit scale becomes large as the number of kinds of the drive current increases. Especially in such an electronic device that transmission and reception of a plurality of data are performed using one physical layer LSI, it is desired to prevent the circuit scale from becoming large.
SUMMARY OF THE INVENTION
[0008] Therefore, an object of the present invention is to provide a variable drive current driver circuit having a small circuit scale.
[0009] According to a first aspect of the present invention, there is provided a variable drive current driver circuit, comprising: a pair of push-pull circuits for driving a load circuit complementarily; a first current source circuit for having a bias current flow into the pair of push-pull circuits; a second current source circuit for having the bias current flow out of the pair of push-pull circuits; and a control circuit for varying both the bias current flowed by the first current source circuit and the bias current flowed by the second current source circuit according to a control signal.
[0010] In the variable drive current driver circuit, the first current source circuit may comprise a current mirror circuit, and the control circuit may control an input current of the current mirror circuit according to the control signal.
[0011] In the variable drive current driver circuit, the control circuit may control the input current by controlling a control terminal voltage of a transistor for flowing the input current.
[0012] In the variable drive current driver circuit, the control of the control terminal voltage may be performed by changing, by a transistor which turns on or off according to the control signal, a magnitude of a load in which a current flowing out of a third current source flows.
[0013] In the variable drive current driver circuit, the second current source circuit may comprise a transistor, and the control circuit may control a control terminal voltage of the transistor according to the control signal.
[0014] In the variable drive current driver circuit, the control of the control terminal voltage may be performed by changing, by a transistor which turns on or off according to the control signal, a magnitude of a load in which a current flowing out of a third current source flows.
[0015] According to a second aspect of the present invention, there is provided a variable drive current driver circuit, comprising: a pair of push-pull circuits for driving a load circuit complementarily; a first current source circuit for having a first bias current flow into the pair of push-pull circuits; a second current source circuit for having the first bias current flow out of the pair of push-pull circuits; a third current source circuit capable of having a second bias current flow into the pair of push-pull circuits; a fourth current source circuit capable of having the second bias current flow out of the pair of push-pull circuits; and a control circuit for varying both the second bias current flowed by the third current source circuit and the second bias current flowed by the fourth current source circuit according to a control signal.
[0016] In the variable drive current driver circuit, the control circuit mayhave the third current source circuit have the second bias current flow nor not flow into the pair of push-pull circuit, and the control circuit may have the fourth current source circuit have the second bias current flow or not flow out of the push-pull circuit.
BRIEF DESCRIPTION OF THE DRAWINGS
[0017] [0017]FIG. 1 is a diagram showing a variable drive current driver circuit according to a conventional technique;
[0018] [0018]FIG. 2 is a diagram showing such a state that electronic devices each incorporating a variable drive current driver circuit according to an embodiment of the present invention are connected to each other;
[0019] [0019]FIG. 3 is a circuit diagram showing the configuration of a variable drive current driver circuit according to a first embodiment of the present invention;
[0020] [0020]FIG. 4 is a circuit diagram showing the configuration of a variable drive current driver circuit according to a second embodiment of the present invention; and
[0021] [0021]FIG. 5 is a circuit diagram showing the configuration of a variable drive current driver circuit according to a third embodiment of the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0022] Hereinafter, embodiments of the present invention will be described with reference to the drawings.
[0023] [0023]FIG. 2 is a block diagram showing the configuration of a transmission system of the first embodiment according to the present invention. FIG. 2 shows a state that electronic devices 10 and 20 are connected to each other via a cable 30 . The electronic devices 10 and 20 include LSIs 12 and 22 , and instruction sections 11 and 21 for monitoring the operation of the LSIs 12 and 22 and instructing generation, transmission and reception of data mutually transmitted to the electronic devices 20 and 10 , respectively. The LSIs 12 and 22 incorporate variable drive current driver circuits 13 and 23 for transmitting data adjusted in drive current so that the data are received by the electronic devices 20 and 10 , and control circuits 14 and 24 for generating and outputting control signals to control drive currents of data transmitted by the variable drive current driver circuits 13 and 23 , respectively.
[0024] Each of the instruction sections 11 and 21 is controlled by a CPU, which operates according to software and which is not illustrated. The control circuits 14 and 24 are incorporated in the LSIs 12 and 22 together with the variable drive current driver circuits 13 and 23 , respectively.
[0025] [0025]FIG. 3 is a circuit diagram showing the first embodiment of the variable drive current driver circuit shown in FIG. 2.
[0026] With reference to FIG. 3, the variable drive current driver circuit according to the first embodiment is supplied with a constant current Ia from a constant current source 100 . On the basis of the constant current Ia, the variable drive current driver circuit generates an output current. First, a current Ic is generated by a current mirror formed of transistors NMOS 11 , NMOS 12 and NMOS 15 . From the current Ic, a constant current Id1 is further generated by a current mirror formed of transistors PMOS 11 and PMOS 12 . Concurrently with them, a constant current Id2 is generated by a current mirror formed of transistors NMOS 11 , NMOS 12 and NMOS 16 . In this case it is necessary to design the drive circuit so as to satisfy the relation Id1=Id2 in order to balance the output currents. The current Id1 is outputted from the driver circuit to the outside, passed through resistors R 11 and R 12 , and drawn in as the current Id2. The output voltage is determined by the value of the current Id1 and values of the resistors R 11 and R 12 . A node Ve between the resistor R 11 and the resistor R 12 is a node of a common level. This node is supplied with a constant potential from a constant voltage source mainly including an operational amplifier.
[0027] By the way, transistors PMOS 13 and NMOS 17 form a first push-pull circuit, whereas transistors PMOS 14 and NMOS 18 form a second push-pull circuit. Since a signal inputted to gates of the transistors PMOS 13 and NMOS 17 is complementary to a signal inputted to gates of the transistors PMOS 14 and NMOS 18 , the first push-pull circuit and the second push-pull circuit complementarily drive the resistors R 11 and R 12 serving as a load circuit.
[0028] In accordance with the present invention, transistors NMOS 13 and NMOS 14 and a control signal input terminal are further added. The logic values of a control corresponds to CMOS levels. According to the logic value, the value of the drive current changes. In a case where the logic value of the control signal is “ 1 ,” a current Ib flows and a voltage Va becomes Va1. On the other hand, in a case where the logic value of the control signal is “0,” the current Ib does not flow and the voltage Va becomes Va2, wherein Va2>Va1. The currents Ic, Id1 and Id2 when the logic value of the control signal is “0” are larger than those when the logic value of the control signal is “1”, respectively. As a result, two kinds of drive current according to the control signal can be implemented.
[0029] [0029]FIG. 4 is a circuit diagram showing a second embodiment of a variable drive current driver circuit shown in FIG. 2.
[0030] Comparing FIG. 4 with FIG. 3, it is apparent that the variable drive current driver circuit according to the second embodiment differs from the variable drive current driver circuit according to the first embodiment in that a control circuit is added to an output stage including transistors PMOS 24 , PMOS 25 , PMOS 26 , NMOS 25 , NMOS 26 and NMOS 27 . In the variable drive current driver circuit according to the first embodiment, the control circuit is added not to the output stage but to the constant current source side. In FIG. 4, the voltage Va is constant. In a case where the logic value of the control signal is “1,” currents Ic 1 and Ic 2 flow. In a case where the logic value of the control signal is “0,” currents Ic 1 and Ic 2 do not flow. When the logic value of the control signal is “1,” therefore, the sum of currents Ic 1 and Id1 or the sum of currents Ic 2 and Id2 becomes the drive current. When the logic value of the control signal is “0,” only the current Id1 or Id2 becomes the drive current. In the same way as the variable drive current driver circuit according to the first embodiment, the variable drive current driver circuit according to the second embodiment has two kinds of drive current controlled by the control signal.
[0031] [0031]FIG. 5 is a circuit diagram showing the third embodiment of a variable drive current driver circuit shown in FIG. 2.
[0032] Comparing FIG. 5 with FIG. 3, it is apparent that the variable drive current driver circuit according to the third embodiment is structured by preparing a plurality of sets of the transistors NMOS 13 and NMOS 14 of the variable drive current driver circuit according to the first embodiment and connecting the sets in parallel. Transistors NMOS 131 , NMOS 141 , NMOS 132 , NMOS 142 , . . . , NMOS 13 N and NMOS 14 N correspond to the plurality of sets of the transistors NMOS 13 and NMOS 14 . Gates of the transistors NMOS 141 , NMOS 142 , . . . , NMOS 14 N are supplied with their respective control signals. Therefore, the variable drive current driver circuit according to the third embodiment can drive its load with not only either of drive currents of two kinds but also any of drive currents of many kinds.
[0033] It is a matter of course that the variable drive current driver circuit according to the second embodiment can be expanded so as to be capable of corresponding to many kinds of drive current, in the same way as expanding the variable drive current driver circuit according to the first embodiment to obtain the variable drive current driver circuit according to the third embodiment. In this case, a plurality of sets of the transistors PMOS 22 , PMOS 23 and NMOS 28 are prepared. The plurality of sets are connected in parallel with the transistor PMOS 24 . A plurality of sets of the transistors NMOS 23 , NMOS 24 and PMOS 27 are prepared. The plurality of sets are connected in parallel with the transistor NMOS 25 . | Disclosed is a variable drive current driver circuit, comprising: a pair of push-pull circuits for driving a load circuit complementarily; a first current source circuit for having a bias current flow into the pair of push-pull circuits; a second current source circuit for having the bias current flow out of the pair of push-pull circuits; and a control circuit for varying both the bias current flowed by the first current source circuit and the bias current flowed by the second current source circuit according to a control signal. | 14,114 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] A Provisional Patent Application covering the invention described herein was filed on Jun. 10, 2014, and assigned Ser. No. 62/009,960.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0002] Research and development of this invention and Application have not been federally sponsored, and no rights are given under any Federal program.
REFERENCE TO A MICROFICHE APPENDIX
[0003] NOT APPLICABLE
BACKGROUND OF THE INVENTION
[0004] 1. Field of the Invention
[0005] This invention relates to drink identification apparatus, in general, and to a manner of distinguishing the drinking cup of one user from that of another through the inclusion of differently appearing elastic identification bands, in particular.
[0006] 2. Description of the Related Art
[0007] As will be appreciated, confusion oftentimes arises among participants at parties or other large gatherings as to who's drinking cup, glass, bottle or can is who's after their placement on table tops or resting surfaces upon the individuals returning after moving about. Especially prevalent with younger children and with the elderly, several solutions have been previously proposed. One such proposal for cups envisions writing the individual's name on a label placed on the outside surface of the cup. Another proposes issuing pattern indicia labels made to the individual that matches like indicia on the cup he/she will be using When not integral with the cup as part of an initial manufacture, labels of these types are typically provided with adhesive backings to provide the bond thus formed by the label with the cup.
[0008] Such identification methods, in order to be effective, however, obviously presupposes that one have an equal number of labels to service the cups being filled. Moreover, such operations can be more easily carried out where the individual cups, specifically, are to be reused, as contrasted with the situation where the cups are thereafter to be disposed of using paper or foam cups. The confusion follows in such instances when one cannot identify his/her cup from that of another's, may accidently drink from that cup previously used by another, partially still filled or otherwise, or abandons his/her cup for refill with another one that might otherwise be used later on by another. Obviously, the situation is similar where glasses, bottles and cans are being employed by the several participants concerned.
OBJECTS OF THE INVENTION
[0009] It is an object of the present invention, therefore, to provide an inexpensive, readily understandable solution for the identification of one's own disposable or non-disposable drinking cup, glass, bottle or can from that of another's in use.
[0010] It is an object of the present invention, also, to provide inexpensive and disposable identification bands for releasable securement to the individual drinking cup, and for discarding them along with the disposable cup, glass, bottle or can after their use.
[0011] It is another object of the invention to package the two together where desired, as where paper and foam cups are to be used, for retail shelf sale in quantities and sizes to meet the needs of the party or gathering occasion at hand.
[0012] It is a further object of the invention to provide such a package for a variety of occasion celebrations where the discardable bands themselves may coordinate the occasion with the utilization of disposable cups (yet still differ them one from another for identification purposes) or within a class of occasions that do not coordinate with the presentation of the disposable cup, glass, bottle or can itself.
SUMMARY OF THE INVENTION
[0013] As will become clear from the following description, the disposable/discardable identification bands are of a fabrication to be elastically stretchable around the peripheral outside surface of the cup, glass, bottle or can to which it secures. As a class, the bands may be of different colors, shadings, patterns and/or decorative design presentations, one from another—and where employed with a disposable cup, of a composition for intentional discarding with the disposable cup after the cup has been used, and while still on it. In a for-sale retail shelf assembly or for on-line sales of disposable cups, a preferable arrangement is one wherein a single sales container includes a plurality of bands in a first packaging at least equal in number to the number of disposable cups included in a second packaging of the container—and preferably, of a number greater than the cups.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] These and other features of the invention will be more clearly understood from a consideration of the following description, taken in connection with the accompanying Drawings in which:
[0015] FIG. 1 is a pictorial view of the identification bands for use with disposable individual drinking cups in accordance with the invention;
[0016] FIG. 2 is an illustration showing a packing of the identification bands with those individual drinking cups in a wrapper container enclosure; and
[0017] FIG. 3 is an illustration of how the identification bands may be utilized for individual identification of cups, glasses, bottles or cans, whether disposable or not.
DETAILED DESCRIPTION OF THE INVENTION
[0018] In FIG. 1 , a disposable cup of a cylindrical or substantially cylindrical configuration of predetermined volume is shown at 12 . Typically fabricated of paper, foam or plastic—and of a size to hold anywhere from 6-24 oz. of liquid—the cup may be dressed or unadorned, colored or white. As is usually the case, the cup 12 includes an open top 14 of outer diameter greater than the diameter of an included closed bottom 16 . When sold in an enclosing wrapper or container, a preferred arrangement may include 10-50, or more, of these disposable cups nestably received together in one packaging, or stacked alongside one another in multiple packagings. An elastic stretchable, inexpensively composed band is illustrated at 26 according to the invention, available in a second or additional packaging of the container to be emplaced below the rim 22 of the cup 12 . In accordance with one enhanced embodiment of the invention, a plurality of streamers 28 hang downwardly along an outside peripheral surface of the cup at 24 , for purposes of decoration, for any given occasion.
[0019] As will be appreciated, the bands 26 can take on their individual identifications by means of colors, shadings, patterns and/or decorative design presentations, one from another, the same as with the streamers 28 —all of which can be easily identified by fabricating the disposable cup 12 of a drab color (red, white, black, for example). When included in a wrapper container of disposable cups, a preferred construction would incorporate a plurality of bands, at least equal in number to the plurality of disposable cups, but preferably in excess thereof. To differentiate one band and/or streamer from another, they can each be of a different coloration or pattern, especially as consistent with a display occasion—such as for the holidays of Thanksgiving and Christmas, and for such party occasions as birthdays, bridal wedding parties, baby welcoming home parties and wedding anniversaries. But in so doing, whether packaged with the streamers or not, and whether packaged with the discardable cups separately or not, the identification bands will all be selected of an inexpensive, elastically stretchable material to be encircled about the peripheral wall surfaces of the cup, to be held there in place below the cup rim, and then to be discarded along with the disposable cup after use. The participant at the party or gathering will then be able to differentiate his/her disposable cup from that used by another when desirous of utilizing it once again for drinking purposes.
[0020] FIG. 2 illustrates a manner of this packaging of 48 plastic cups for cold drinks of 16 oz. capacity, red in color for example, and although semi-reusable if treated with care, are more often disposed of, in such manners as at catering affairs, parties and special occasions. Shown at 50 is an illustration of a packaging of the identification bands for use with these cups in accordance with the invention, the wrapper enclosure container for the cups and the bands being shown at 52 . Similar configurations for disposable paper or foam cups for drinking hot liquids would take on a similar appearance—and regardless of the cup composition employed. Depending upon needs and uses, cup sizes of smaller 4, 8, 10, 12 and 16 oz. capacities could be utilized, with package arrangements being available anywhere from 10 to 25, 50, 100 or more cup inclusions.
[0021] FIG. 3 similarly illustrates identification bands 54 stretched around the outside peripheral surfaces of glasses 60 , 61 and 62 , a bottle 63 , and cans 64 and 65 —as well as around cups 66 , 67 , 68 , 69 and 70 .
[0022] In any event, when employed, the differentiating set of bands are thus helpful in enabling the users to locate and identify those cups, glasses, bottles and cans that they had been previously using. For a paper, plastic or foam cup, this enables everything to be disposed thereafter simply and inexpensively, by a discarding of the cups and bands together as a unit. Testing has indicated that a band 26 of some ⅝″ width works extremely well, whether colored, patterned, glittered or otherwise, as long as it can be elastically stretched around the outside wall surface of the cup, glass, bottle or can with which it is utilized. The diameter of the band then depends upon the diameter or size capacity of the cup, glass, bottle or can to be encircled. In its simplest terms, the present invention then describes a container of elastic bands, at least 8 in number, each of which is of an inexpensive composition to manufacture and then discard after use, each of which is stretchable to encircle a cup, glass, bottle or can to which it is emplaced, and each of which is uniquely distinguishable one from another by color, pattern or other manner of indicia.
[0023] A simple, colorized rubber band, circular in cross-section as at 75 in FIG. 2 , would satisfy these needs, as well as one of a wider flat surface affording adequate room for inclusion of additional information content where desired, as an anniversary couples name, or newborn baby's name, a Happy New Years greeting, whatever. In all thee respects, however, each of the elastic identification bands will be understood to be of substantially the same length and width, and have the same stretchability characteristics, of the same cross-sectional shape and thickness. When arranged for sale they can be packaged within a container, along with a second package where desired, including a plurality of nestably received drinking cups. There, each of the elastic bands would be of an unstretched length less than a cross-section of each of the nestably received drinking cups, and of a stretchability characteristic for enlarged placement about the drinking cups when one of the bands and one of the cups are both removed from the container. In such manner, the elastic identification bands can be combined together for sale as a container separate from that of the cups, or together with them in a unitary container of both. As will be appreciated, having them contained separately enables the elastic bands to be used in identifying not only drinking cups, but glasses, bottles and/or cans to which the bands are stretched around. And, as will be appreciated, where used with drinking cups, the bands can serve their identification purpose both for drinking cups that are intended for discarding after use, as well as with the more permanent type of non-disposable cups.
[0024] While there have been described what are considered to be preferred embodiments of the present invention, it will be readily understood by those skilled in the art that modifications can be made without departing from the scope of the teachings herein. For at least such reason, therefore, resort should be had to the claims appended hereto for a true understanding of the invention. | The apparatus of the invention allows an identification of one's own disposable or non-disposable drinking cup, glass, bottle or can from that of another through the use of elastic identification bands all of substantially the same length, width and stretchability but with each having markedly different appearances one from another as to at least one of coloring, shading, patterning and design presentation. | 12,687 |
CROSS-REFERENCE
[0001] This application is a continuation of International PCT Application No. PCT/DE02/01566, filed Apr. 30, 2002.
SPECIFICATION
[0002] The patent application concerns a computer-managed deposit system for articles, in particular for disposable packaging articles, a return device for articles having a deposit thereon, in particular for disposable packaging articles, an originality seal for identifying articles, in particular disposable packaging articles, and a detection apparatus for use with the deposit system.
BACKGROUND OF THE INVENTION
[0003] Deposit systems for reusable packaging articles such as glass or PET bottles are in existence in Germany and other countries. In 1991 in Germany the legislators issued a Packaging Regulation (PackReg) which is intended to guarantee a minimum quota of 72% for the reusable packaging articles having a deposit thereon. That legally prescribed level has repeatedly not been reached since 1997. The PackReg provides that, if the minimum quota is not reached repeatedly, a deposit is also to be introduced for disposable packaging articles.
[0004] Previous deposit return systems form a closed circuit between the packaging filler, stores and the consumer. The deposit is a constituent part of the packaging article and can thus also change owner with the packaging article. Disposable packaging articles involve the problem that the packaging articles can no longer be used in a direct circuit as they are not used afresh by the packaging filler. Instead, the packaging articles with a deposit thereon are sent for disposal thereof. One way of guaranteeing this is for the disposable packaging articles which are taken back by the stores to be destroyed. That necessitates complex automatic systems involving different destruction mechanisms. Those automatic apparatuses are to be set up at large shopping centers and permit return.
[0005] Previous approaches to the aspect of implementing a deposit for disposable packaging articles are based on the notion of using tamper-proof identifications, for example in the form of holograms, that is to say providing copy protection for the deposit seal and destroying the returned packaging articles. Those systems are not only complicated and expensive but they are also susceptible to fraud.
SUMMARY OF THE INVENTION
[0006] The object of the present invention is to provide a simple and cost-effective deposit return system and the corresponding means for the implementation thereof.
[0007] In accordance with the invention that object is attained by a method comprising the following method steps: associating the article with a clear identification from a plurality of identifications managed in a database (linkage), associating the identification from the database with a deposit value, using the article in at least one intermediate step, detecting the identification of the article and identifying the article on the basis of the identification, and cancelling the linkage of the identification in the database upon return of the deposit on the article.
[0008] Herein the term identification is used to denote any manner of clearly indicating the disposable packaging article, for example by a deposit number. The deposit number can be in numerical, alphanumeric or graphic format. Combinations of the representation formats are also possible.
[0009] The deposit number is preferably arranged on the article on which the deposit is to be paid, wherein in particular direct application in the manner of integration into the surface appears desirable as that physically guarantees the connection of the article to the deposit number. In accordance with the system articles and in particular packaging articles are identified in the packaging filling procedure, by the application of a clear deposit number. That deposit number is stored in a deposit database with the associated deposit value and optionally with more extensive information.
[0010] Alternatively the deposit number can be subsequently printed on or can be applied to a sticker which can be joined to the article. It is however also possible for the deposit number to be applied on a separate carrier in the manner of a token.
[0011] Advantageously the identification of the article that is to say the deposit number applied thereto, is such that it is tamper-proof in order in that way to avoid abuse.
[0012] Management of the identifications and the association thereof with articles and deposit values respectively is implemented by a deposit database in the deposit system according to the invention. The database can be in the form of a central database or in the form of a distributed or segmented database. That manner of managing the identifications is particularly advantageous for the reason that, in an online procedure and thus as close to real time as possible, it permits direct checking on an asserted claim on the part of a person returning the article with a deposit thereon, to be given the monetary value corresponding to the deposit value.
[0013] By way of example a deposit is placed on a disposable packaging article in the packaging filler procedure and then, provided with the deposit, can pass through one or more stages in the course of trade therewith. When the disposable packaging article is given back the deposit thereon is returned. If the deposit number is applied to a separate carrier in the manner of a token, it is necessary to ensure when the article is returned that, upon return of the token, the packaging article corresponding to that group of packaging articles is also surrendered. In order to ensure that the prescribed or desired disposal process chain is followed for disposal of the disposable packaging articles, it can be provided in a further development that, when passing through the individual process steps, amounts of the deposit are credited to the operators of the recycling or disposal installations.
[0014] In the normal case the deposit numbers are called up from the deposit database before they are applied to the disposable packaging article in order to prevent possible multiple deposit implementation (the provision of a plurality of packaging articles with the same deposit number). Alternatively it is possible to allocate to the packaging filling operators sets of numbers which are determined by the deposit database and which are reserved for them, from the reservoir of deposit numbers.
[0015] In addition however the use of databases also permits other functions and the initiation of additional operating procedures upon the surrender of an article with a deposit thereon. Firstly this can involve a refund of the amount of money corresponding to the deposit value, to the person surrendering the article. In that case it is particularly advantageous to implement that refund as a cashless transaction, for example by credit to an account, a money card or the like as that means that there is no need to keep amounts of cash. In this connection however a cashless process can be a payment in kind, which is virtually convertible, for the person surrendering the packaging article. Thus it is also possible to envisage a credit to an organisation other than an account-holding bank, that is to say for example a telephone connection or an anonymous credit card. In regard to a credit card as just mentioned it may be provided for example that it is issued by appropriate organisations exclusively for the purposes of crediting deposit values in a method according to the invention.
[0016] It is particularly advantageous in this connection if, upon delivery of the article, additional data which can be associated with the person are recorded and processed. In this case the procedure involves so-to-speak personalisation of the credit amount to be paid out for the deposit value of the surrendered article, in regard to which the person can decide on the use of the amount to his or her benefit.
[0017] In accordance with the invention the identification of the article can be linked to further items of information. Thus it is possible inter alia for the identification, besides the deposit number, to be provided for example with a symbol expressing the deposit value, in particular a number, or in addition for an expiry date to be applied to the identification, which makes it clear to a consumer the date by which payment of the monetary value corresponding to the deposit is guaranteed on the part of the article-disposal organisation.
[0018] In the deposit return system according to the invention, it is provided that the article remains undamaged upon surrender, and destruction of the packaging articles is therefore not necessarily to occur. Electronic invalidation of the packaging articles with a deposit thereon replaces mechanical destruction of the deposit item. As the concept manages without the expensive procedure of destroying the packaging article when it is returned, the system, in comparison with the estimates published by the Ministry of the Environment, reduces the one-off investment figures of around 1 billion Euros to 141 million Euros. That cost saving is substantially implemented by the inexpensive and small invalidation units involved. Invalidation units can be used as mobile devices at kiosks, filling stations and naturally also quickly and easily in stores. There, the deposits can be returned on packaging articles and the articles can be disposed of, without any problem.
[0019] The return of disposable packaging articles can be effected at all existing acceptance locations for reusable packaging articles. Instead of some thousand central automatic installations, this involves a system which permits the return of the packaging articles at a hundred thousand kiosks and supermarkets over a widespread area.
[0020] The object of the invention is further attained by a return device for articles bearing a deposit, in particular for disposable packaging articles, which is provided for example for use with the above-indicated deposit system and has a receiving device and at least one detection apparatus. The detection apparatus clearly detects and identifies an article arranged in the receiving device, on the basis of an identification on the article. Therefore, arranged at the receiving device of the return device according to the invention are means for detecting an article intended to be returned so that the article can be detected and identified and after optionally possible release can be passed along for disposal.
[0021] In an advantageous development of the return device provided thereat is a deposit-removal device, by means of which the deposit can be removed from the article in a deposit-removal operation and a deposit value associated with the article can be passed to a settlement procedure. After detection and identification in the return device the article to be taken back subsequently undergoes a devaluation procedure in terms of its deposit by means of the deposit-removal device, in such a fashion that it loses its deposit value. Further use of that deposit value then takes place in a settlement procedure of any appropriate configuration, which for example is effected cashlessly in the course of a clearing process.
[0022] That can be implemented in a particularly advantageous fashion if the deposit-removal device, during the deposit-removal operation, is at least temporarily connected to at least one database in which the linkage of the identification is cancelled and in that way further use thereof is prevented. For that purpose, using an ordinary communication path such as for example a line-supported or radio-supported telecommunication path, the deposit-removal device forms a connection to a database which manages the associations of articles and identifications. Accordingly it is further advantageous if the deposit-removal device has communication means, by way of which it makes a connection to a data processing apparatus with access to a database.
[0023] Establishment of the connection to the database can in that respect be a one-off matter in the sense that the connection exists continuously once it has been formed, but it can also only be made at certain moments in time or in response to certain requirements. It is further possible to envisage in this connection that the deposit-removal device is provided with a local memory which for example then locally provides its own sub-database, for example with a given reserved set of identifications, and adaptation takes place by way of a connection to a further database only at fixed moments in time. In addition the above-mentioned local memory could also be used to provide a number of identifications which were used last, so that interrogation and testing thereof takes place even more quickly than by the interrogation of a remotely provided database.
[0024] In the deposit-removal operation, in the above-mentioned database, the linkage is cancelled for example by the preferably clear identification being taken out of the database. In addition it is also possible to envisage that identification only remaining in the database with a time-limited or definite blocking note. Cancellation of the linkage between identification, article and deposit value at any event provides that a possibly forged, identical identification could not be used once again in that manner and in that case the return device refuses to issue the deposit value so that this therefore prevents multiple use of the identification. It will be appreciated that the above-mentioned term telecommunication path also means any computer connection between two data processing installations. Thus for example the return station or the deposit-removal device thereof could communicate by way of a radio standard, such as for example Wireless LAN, with a so-called access point which then takes up the connection to the computer holding the database. It is also possible to envisage that the deposit-removal device itself functions as that access point for such deposit-removal devices which only have a radio interface provided for that kind of communication.
[0025] The communication means arranged at the deposit-removal device further also relate to means with which a user, whether the user is a person returning an article or a maintenance engineer, can identify himself in relation to the deposit-removal device. That can be done for example by the use of a code card carrying given items of information, for which a reading unit can be provided at the deposit-removal device. For that purpose the above-mentioned code card can contain any items of information which can be used for the system, thus for example the name of the user or an account connection. It is not necessary in that respect for the information to be personalised for it is also possible in that respect to consider an anonymised or provisional card with which person-related data are associated only at a later moment in time or also not at all, thus for example the code card can be envisaged in the form of a card associated with any payback system. For a maintenance engineer it is possible to envisage code cards containing either data which can be associated with the engineer or which can be associated with the return device to be maintained.
[0026] It is desirable in the sense of ease of handleability if the receiving device has at least one guide means, in particular a guide rail, for positioning of the inserted article. The arrangement of a guide means is appropriate for the reason that it permits a user of the receiving device to introduce the article to be taken back, in a simple and reliable fashion, and in addition permits the detection apparatus to quickly and reliably detect and identify the article and its identification. In addition the guide means can also be adapted to preselect the articles to be taken back, in such a way that it only permits the feed of articles of a given geometry, which can be desirable in the sense of providing for space-saving or pre-selected storage. As an additional aid it is possible for example to provide on the guide means an abutment which presets for the user a depth of insertion of the article for optimum detection thereof.
[0027] There is also the possibility, if the articles to be received are to be classified on the basis of their weight, to provide at the guide means a weighing mechanism which transmits the weight information that it ascertains.
[0028] In a development of the return device according to the invention, the receiving device can have a closure mechanism which is integrated or which can be arranged separately thereon. That mechanism can be for example in the nature of an automatic or manually actuable closure member which can be pivoted into a position in front of the opening of the receiving device. On the one hand, by means of that closure mechanism it is possible to prevent abuse of the return device if the return device should be used improperly unintentionally or intentionally, for example by the introduction of articles for which it is not intended, while on the other hand this affords a possible way of taking the return device out of further use when a receiving container provided for that purpose is in a full condition, until it can be emptied.
[0029] In order to be able to provide for proper use of the return device and use of the deposit system, in accordance with the invention provided at the detection apparatus are detection means in the form of a light barrier arrangement and/or a scanner and/or a camera. In this respect the detection means serves in the manner of a scanner for detecting and identifying the article itself introduced into the receiving means, for example on the basis of its identification or however also on the basis of its geometry. If the scanner detects the identification of the article, that identification can be subjected to further processing by the deposit-removal device while in the event of unsuccessful identification further steps in the deposit method can be refused.
[0030] A detection means designed in the form of a light barrier arrangement can be used on the return device in such a way that the operations related to the deposit-removal procedure by the deposit-removal device can be initiated only when the article has passed a point or a plane of the return device, which makes it impossible for it to be removed again from the return device. That ensures that the article from which the deposit is to be removed is also actually passed for disposal and the deposit which is to be paid back in that respect is requested with every justification on the part of the person returning the article. Optionally it would also be possible to consider for example an arrangement of reflectors in the viewing window of the scanner instead of a light barrier arrangement. Finally it is also possible to use a camera as the detection means, for example instead of the scanner, in which case the signal recorded on the part of the camera can also be optically transmitted and can serve in that way for the communication of information.
[0031] For user-friendly user guidance it is advantageous to arrange at the return device for providing information for a user a display device, in particular a viewing window and/or an optical and/or acoustic signalling means and/or a display. It is possible in that way to impart certain items of information to the user who is returning an article which has a deposit thereon, and thus to influence the behaviour of the user in the subsequent steps. Thus for example the signalling means which can be for example light emitting diodes or a simple loudspeaker can be provided to display to the user, by affording various signals, whether he has correctly arranged the article in the receiving device. A viewing window would give the user the option to observe the article which is disposed in the receiving device, and if necessary re-align it. The same thing could also be afforded by a display which shows a signal transmitted to the user by the above-mentioned camera. If the display for example is in the form of a touchsensitive screen, that gives the user a large number of further options in terms of interaction. In particular it is then possible with such a display to request items of information which are to be inputted directly by the user, for example for further use of the deposit amount to be paid. In addition the display can be used for example for communicating information to maintenance personnel on site, for example in regard to the filling condition, cleanliness, power supply or maintenance intervals.
[0032] For integration of a return device according to the invention into already existing collecting apparatuses, it is particularly advantageous if the return device can be arranged at a collecting container for the articles which are to be taken back. It is possible in that way for practically all collecting containers which are used at the present time and in future for receiving articles, for example the containers which are set up at many locations, to be equipped for use with the return device. For that purpose the return device only has to be arranged on the collecting container or introduced with regions intended for that purpose into the receiving opening of the corresponding collecting container and for example fixed and secured by means of a clamp and a lock. In that respect, for the various different forms of container, it is additionally possible to provide a coupling portion which is to be arranged for example in the form of a sleeve between the return device and the collecting container. To deal with a possible period when the return device is not in use, the collecting container can continue to be used as an ordinary refuse container, in spite of the return device remaining in place.
[0033] For operation of the return device it is provided that it has a mains-independent or mains-supported voltage supply. Depending on the respective local factors involved therefore the return device can be operated at locations at which a voltage supply is available by a mains system, but it is then also possible for the return device to be operated in a power-autonomous mode over a certain period of time, for example by the use of accumulators. That period of time can be additionally prolonged by the provision of a power-saving operating mode when the device is not in use.
[0034] As already mentioned hereinbefore, for influencing the procedures of the return device, it is desirable if it has a user interface which permits a user to interact with the return device, in particular permitting the implementation of a settlement process for redeeming the deposit value. In that respect the form of the interaction can go from simply starting up the return device, for example by inserting a code card into a card reader, to a complex transaction in respect of the deposit value or a plurality of deposit values on a settlement system of any kind.
[0035] The object of the invention is further attained by an originality seal for identifying the article for a computer-managed deposit system. The seal is fixed on the article by means of an adhesive layer, and it has a printable carrier layer which is arranged on the adhesive layer and which can be provided with an identification associated with the article. In that case the carrier layer is at least partially covered over by the seal layer which can only be detached from the carrier layer with accompanying destruction. Accordingly the originality seal according to the invention comprises a multi-layer sticker for the article to be identified, for example in the manner of a label, which can be applied to a location provided for that purpose on the article. An adhesive layer is arranged between a carrier layer which carries information and which was processed by a printing procedure for applying the information, and the article, to provide for adhesion of the originality seal. On the side of the originality seal which is towards a viewer, the seal is protected by a seal layer which at least partially covers the carrier layer. That seal layer serves on the one hand for mechanically protecting the identification, while on the other hand it can be so designed that only the detachment thereof makes it in any way possible to remove the deposit on the article by exposing the identification. In that situation the seal layer is destroyed.
[0036] In an advantageous development the adhesive layer is a non-detachable adhesive. That affords a non-releasable bond between the article and the identification on the carrier layer, and that bond can only be separated again by destroying at least the identification, with the result that the corresponding deposit value can no longer be redeemed.
[0037] In a further configuration the carrier layer of the originality seal has at least one incision. That incision has the result that, in the event of an attempt to detach the originality seal from the adhesive layer, the latter rips or tears in half along the incision so that further use is not possible.
[0038] In a particularly preferred feature the identification of an originality seal according to the invention includes a two-dimensional bar code. The use of such a code is already desirable for the simple reason that, in that way, while involving a relatively small amount of space, this affords a whole host of possible identifications which can be of the order of magnitude of about 10 18 or even greater. In addition this form of coding presents itself as it is highly suitable for including in the code additional items of information which can relate to the article, its material, producer or the like. In addition this form of coding also facilitates the settlement of deposit values. In addition, with this form of code, it is also easily possible to produce and associate sets of numbers for any use. They can for example in turn relate to certain kinds of goods or also marketing areas or the like.
[0039] Furthermore, in a development, the seal layer can be provided with an additional visual feature. This for example may involve a colored marking which, as part of the seal layer, in turn covers a part of the identification of the article. In the event of damage to or removal of that visual feature a user is immediately advised, due to the absence of the feature, that the identification has possibly already been subjected to a deposit-removal operation so that that indication tells him to refrain from a purchase of that article, in respect of which he will possibly no longer receive a recompense value for the deposit value upon returning the article.
[0040] Among the many possible options in regard to the configuration of the seal layer it is particularly preferably made from an adhesive, a wax or a rubber coating, which can all be easily removed to prepare for the deposit-removal operation.
[0041] Finally the object of the invention is also attained by a detection unit for automatically detecting an identification on an article having a deposit thereon, which is intended in particular for use with the described deposit system. The detection unit includes in particular a scanner for detecting the identification of a disposable packaging article and has detection means for reading off the identification, and means which ensure that detection of the identification takes place only when the packaging article is emptied. By virtue of the use of a small portable hand unit in the form of a scanner, it is in this case a matter for the organisation receiving the articles which are to be given back, to decide how the appropriate storage thereof is to be implemented, while the procedures involved with the deposit-removal operation can be effected by the detection unit. A user can use the components of this modular system separately or together.
[0042] A central problem in terms of practical implementation of the method according to the invention are the transmission times and transmission costs related thereto for connecting the scanner to a central data processing apparatus. Preferably for that reason processing is effected batch-wise in order to reduce the transaction costs. Thus a plurality of labels can be detected by a store owner for the deposit-removal operation and collected in one data file. That file is transmitted to the central processing apparatus upon exceeding a given size, when therefore a given number of labels has been detected. That procedure would present itself for example in relation to a sales or collection stage in a middleman situation.
[0043] In an alternative configuration it can be provided that upon the purchase of a disposable packaging article the trader issues a voucher which can be redeemed against the amount of the deposit upon return of the packaging article and in the deposit-removal procedure. The central computer credits the amount to the trader, and that can also be effected in a batch process. Non-redeemed vouchers are therefore to the benefit of the trader, which makes this arrangement particularly attractive to the trader.
[0044] By virtue of the coupling of given automatic apparatuses to specific traders, the central computer and the system knows what sums the store has paid out. The central computer can thus implement a central remittance so that it is not necessary to book in every voucher.
[0045] The invention further concerns a detection apparatus for automatically detecting a deposit mark on a packaging article or the like. In particular it concerns a scanner for detecting the deposit mark on a disposable packaging article. Preferably the scanner is in the form of a hand scanner.
[0046] Known detection apparatuses, in particular scanners, already permit relatively simple detection of the deposit marks for removal of the deposit on a packaging article when it is returned. In terms of implementing the method according to the invention however the problem also arises that a purchaser may attempt under some circumstances to directly remove the deposit from a packaging article before it is emptied, in order to obtain the deposit redemption value.
[0047] The invention is intended to provide a further development in a detection apparatus of the general kind set forth, in such a way that the detection of the label can take place only when the packaging article has actually been emptied. As packaging articles are made from various materials such as polyethylene (PET), metal sheet, aluminum, multi-component materials or the like, the choice of the means to ensure that fundamentally depends on the material of the packaging article.
[0048] For relatively rigid packaging articles such as cans, canisters or the like the detection apparatus can be provided with a receiving device for the packaging articles, which is so dimensioned that the packaging article can be received therein only in the emptied condition. That configuration is based on the notion that the packaging article in the closed condition, due to the medium contained therein, basically cannot be compressed. The rigid packaging article in contrast can be at least slightly compressed when it has been opened.
[0049] The receiving device can be of a substantially bridge-shaped configuration, with a free space extending between two limbs. The internal distance between the front ends of the limbs is slightly smaller than the outside diameter of the packaging article to be detected. As the reading unit is arranged substantially at the apex, that is to say the highest point of the bridge-shaped opening, detection can take place only when the label is disposed in the immediate region of the reading unit. That however in turn is only possible when the packaging article has been compressed in order to insert it into the receiving device.
[0050] In a further development it can be provided that the internal distance between the limbs of the receiving device is adjustable so that it can be used for various packaging articles involving different dimensions.
[0051] In another structure a loop or the like can be provided on the detection apparatus, the loop being so dimensioned that it is possible to read off the deposit mark only when the loop is introduced into the opening of the packaging article from which the deposit value is to be removed. The loop thus prevents the closed packaging article from being arranged in front of the reading unit of the detection apparatus. Reading can be effected only when the loop has been inserted into the opening of the packaging article. It will be appreciated that the packaging article will then also be empty. In order to prevent liquid from still nonetheless being present in the packaging article, the free end of the loop can additionally be provided with a moisture sensor.
[0052] The loop can be for example of a substantially U-shaped configuration which firstly extends laterally from the fixing point to the detection apparatus away therefrom and after a 180° curvature leads back in front of the reading unit of the detection apparatus. The loop can be retro-fitted to existing detection apparatuses such as for example a hand scanner.
[0053] For the purposes of adapting the loop to different packaging article sizes, it can be provided that the loop is adjustable in respect of its size. For example it can be telescopic in order to effect adaptation in respect of its size for detecting cans and bottles.
[0054] An alternative configuration provides that the detection apparatus is provided with a bar which in the detection operation passes into the packaging article. As in the case of the above-described structures this one is also based on the idea that the operation of reading the label is only possible in the immediate region of the detection unit.
[0055] Another structure provides that the detection apparatus is provided with sound generators for applying a sound pulse to the packaging article and sound detection means for detecting the sound pulse. The sound generator can be for example a simple loudspeaker. Preferably however lithotriptors are used, which produce a short, explosive sound wave. The sound detection means is preferably in the form of a microphone. The microphone detects the signal emitted by the sound-generating means. As the signal is propagated at different speeds in liquids than in air, it is possible to ascertain by means of the transit time delay or spectral analysis with decision criteria whether the packaging article is full or empty. Spectral analysis of the echo gives information about the filling condition of the packaging article.
BRIEF DESCRIPTION OF THE DRAWINGS
[0056] The deposit system according to the invention and the means for carrying it into effect are described by way of example with reference to the Figures in which:
[0057] [0057]FIG. 1 shows the basic system procedure in the form of the circuit of a deposit-bearing article in the form of a disposable packaging article,
[0058] [0058]FIG. 2 shows the diagram of possible forms of attack on deposit systems and measures for fending them off,
[0059] [0059]FIG. 3 shows graphic forms of representation of identifications, for example deposit numbers,
[0060] [0060]FIG. 4 shows the structure of an originality seal according to the invention,
[0061] [0061]FIG. 5 shows the principle of deposit redemption,
[0062] [0062]FIG. 6 shows a mobile hand scanner for use with a deposit system,
[0063] [0063]FIG. 7 shows a hand scanner with a receiving device according to the invention,
[0064] [0064]FIG. 8 shows a side view of a hand scanner with a loop according to the invention,
[0065] [0065]FIG. 9 shows a side view of an alternative embodiment of a hand scanner which operates by means of sound and resonance,
[0066] [0066]FIG. 10 shows a plan view of the side, towards the user, of an embodiment of the return device, and
[0067] [0067]FIG. 11 shows a view in cross-section through the view of the return device of FIG. 10 along line X-X.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0068] The basic system configuration with the deposit and material circuits is shown in FIG. 1. Accordingly it is possible to identify two circuits, the material circuit and the deposit circuit.
[0069] The material circuit is shown in FIG. 1 by wide arrows. The manufacturer produces packaging articles which during the filling operation are labelled with the deposit numbers obtained by the filling organisation as identifications. The products identified in that way are sold including the deposit costs to the stores. They sell on the products including deposit costs to the consumer. After consumption the consumer brings the empty packaging articles back to the store. The packaging articles returned at the store, after the deposit value has been removed therefrom, are prepared for the disposal organisation. No particular demands are made on the preparation procedure such as for example previous destruction or theft-proofing. The packaging articles can thus be prepared in containers, bags or drums to be taken away by the disposal organisation.
[0070] Recyclable materials, after recycling thereof, can be sold to the manufacturer as raw material for the production of fresh packaging articles.
[0071] The deposit circuit is identified in FIG. 1 by thin arrows. For each of its packaging articles, the filling organisation obtains an individual deposit number which it receives from the deposit database. The packaging article has a deposit placed thereon by virtue of applying the deposit number to the packaging article, as the deposit value of that packaging article is noted in the deposit database. The deposit value remains on the packaging article through all trading stages until the consumer returns the packaging article to the store. Upon return the deposit number is taken out of the deposit database in an online procedure and the deposit value is credited to the consumer. From that moment in time the applied deposit number is valueless and cannot be returned a second time. Thus the packaging articles can be prepared for collection, in open containers. The packaging articles, after removal of the deposit value therefrom, only involve value as raw material.
[0072] The system affords the following advantages:
[0073] The use of electronic value-removal apparatuses permits separation of the two circuits and makes it unnecessary to set up mechanical automatic equipment for destroying the packaging article.
[0074] The electronic value-removal apparatuses can be produced at considerably lower cost. They permit widespread use by virtue of their low costs and small dimensions. With portable value-removal apparatuses, packaging articles can be taken back at kiosks, restaurants, filling stations and the store where they are sold.
[0075] The use of individual deposit numbers means that the deposit can be selected as desired in terms of amount and currency. This means that the system can be used on an international scale.
[0076] The deposit system according to the invention is independent of packaging article shapes and sizes as well as the changes therein, in contrast to automatic return apparatuses which can recognise, process and sort only a limited number of types of packaging.
[0077] Security against abuse is a central problem for deposit systems. The deposit system according to the invention withstands inter alia the following attack scenarios:
[0078] a) Repeatedly bringing in packaging articles
[0079] Scenario: by repeatedly bringing in packaging articles for which the deposit has already been paid out, it is possible to obtain deposit payments by underhand means.
[0080] Measure: the use of clear deposit numbers and online checking in the deposit database upon return makes it possible to detect whether packaging articles from which value has already been taken are brought in again, at all return stations. That prevents repeated return of the deposit.
[0081] b) Bringing in packaging articles which are foreign to the system.
[0082] Scenario: bringing in packaging articles which are foreign to the system and for which no deposit was paid make it possible to obtain deposit payments by underhand means.
[0083] In the case of the deposit methods hitherto on the market for reusable packaging articles the deposit is 0.15 Euro for each packaging article. The production costs of the packaging articles however are about 0.17 Euro per packaging article. The deposit value is therefore less than the packaging article production price.
[0084] Due to the relatively high deposit value (for example 0.25 Euro to 0.50 Euro) planned for the disposable packaging articles, there is a high level of motivation to defraud the deposit system as the deposit value of the packaging article is higher than the production costs. The risk of fraud is considerable in particular in the case of cans involving production costs of a few cents of a Euro.
[0085] Measure: the unique deposit number in the deposit circuit excludes this attack. When the packaging article is returned, an online check is made in the deposit database to ascertain whether a deposit was previously paid in for that packaging article and that deposit has not yet been paid out. This therefore excludes packaging articles which are foreign to the system and which do not have a deposit number from being returned against redemption of a deposit.
[0086] c) Premature removal of value from packaging articles
[0087] Scenario 1: by virtue of removing value from packaging articles prior to sale to the consumer, for example by the store, the deposit can already have been removed from the packaging article when the article is sold. That means that the consumer is cheated by the amount of the deposit as, when the article is returned, the value-removal operation which has already been effected is found and the consumer does not get his deposit back.
[0088] Measure: this fraud situation can basically be detected by the deposit database as the deposit database automatically registers multiple return. If the consumer insists that he had paid a deposit, a process is initiated which transfers the case to fraud management (fraud detection: uncovering simple or organised service abuse). The purchase and address data of the consumer are taken down and the packaging articles kept separately. In the case of systematic fraud the defrauder can be identified in that way.
[0089] In order further to limit the fraud options in a further development the deposit numbers applied to the packaging articles are concealed (sealed). It is only when the concealing covering is rubbed or scratched off that it is possible to read the deposit number and thus pay out the deposit. A packaging article from which value has been prematurely removed can thereby be recognised by the consumer, by virtue of the uncovered deposit number.
[0090] Scenario 2: by virtue of value being removed from full packaging articles directly after purchase by the consumer the deposit is redeemed and paid back. Thus the customer has acquired a packaging article without deposit and must no longer return the packaging article.
[0091] Measure: in this fraud situation the sales person is circumventing the Packaging Regulations and is thus perpetrating a violation. To remove the deposit a deposit scanner and an agreement with the operator of the deposit database is required. In consideration of a contractual agreement a sale of products from which value has been removed can be linked to corresponding sanctions. In the case of larger (unsupervised) return stations, removal of the deposit can be linked to physical monitoring of the return of a packaging article.
[0092] d) Duplication of the deposit identifications
[0093] Scenario: as the deposit identification represents the actual value of the deposit manufacturers, filling organisations, stores and consumers could produce duplicates of the deposit numbers and thus try to obtain the deposit by underhand means.
[0094] Measure: the unique deposit number and the online checking thereof upon surrender excludes multiple payment of deposits for duplicated deposit identifications. The system recognises the fraud and notifies the attempted multiple surrenders to the fraud management department.
[0095] e) Guessing deposit numbers
[0096] Scenario: manufacturers, filling organisations, stores and consumers could try themselves to produce valid deposit numbers and to achieve a payback without actually paying a deposit.
[0097] Measure: by choosing a large set of numbers successfully guessing deposit numbers is in actual fact impossible. For example only one out of 10 millions of possible numbers is valid.
[0098] f) Altering deposit numbers
[0099] Scenario: manufacturers, filling organisations, stores and consumers can try to alter the existing deposit numbers and thus make it impossible for the deposit to be paid out.
[0100] Measure: the alteration to deposit numbers is detected upon online return as here too the large set of numbers detects the altered deposit numbers as being invalid. That then corresponds to guessing deposit numbers.
[0101] g) Modification of the return system
[0102] Scenario: if cashless credits are provided for paying back a deposit, stores could accept packaging articles from the consumer and by manipulation prevent cashless credits. A later genuine transaction would then be effected with the packaging articles, to their own benefit.
[0103] Measure: as in that case the store defrauds not the deposit system but the consumer, it is highly probable that the consumer notes this fraud. Complaints in this respect from consumers are passed to the fraud management team. It is also possible that, in each cashless deposit return, a receipt document is printed for the customer. If accounting for the deposit payback is effected exclusively on a cashless basis, the transaction can possibly be attributed to the storekeeper to his own advantage.
[0104] [0104]FIG. 2 compares once again the previously identified attacks and measures for preventing them.
[0105] The representation of the possible forms of attack shows that all attacks can be detected. That affords the possibility of pursuing these in the context of fraud management.
[0106] The transparency of the attacks permits any scaling of the prosecution of fraud. The uses necessary for that purpose for the security of the system can thus be adapted to the real security needs of the system.
[0107] As the packaging articles are not destroyed and a deposit is only paid out once in each case, evidence can be certainly secured in suspicious circumstances.
[0108] The system participants consisting of filling organisations and stores are identified in relation to the central system. Systematic manipulation involves a considerable risk of being detected and convicted.
[0109] Without electronic implementation by way of an online database fraud is possible to an unknown level and due to the system involved cannot be detected. The advantage of the online system therefore lies not only in the possible prevention of attacks but in particular in the detection thereof.
[0110] There are various alternative implementations in regard to the deposit identification. It is assumed that in general the deposit number is already applied to the disposable packaging articles in the packaging filling process. The identification with the deposit does not necessarily have to be implemented upon production. It is also possible to provide for later or earlier application of the deposit number, for example on imported goods in the retail trade.
[0111] In accordance with the system each deposit number must be unique and each packaging article receives its unmistakably associated deposit number. Production or issue of the deposit numbers is centrally managed and controlled in order to exclude manipulation procedures and forgeries.
[0112] The deposit numbering can be designed for example for 100 billions (10 11 ) of packaging articles which can be simultaneously processed with the system. This involves the packaging articles over several years as the consumer can have the packaging articles over a long time before return thereof.
[0113] A safeguard against forgery is ensured by the selection of a suitably large set of numbers which is preferably 10 millions (10 7 ) times larger than the numbers actually used. This means that the chance of being able to produce a correct number by fraud is also 1 to 10 millions for each packaging article. That gives a deposit number to be represented from the range of 10 18 .
[0114] There are many different possible ways of representing the deposit number. The representation of the information depends on the area required and the legibility involved in the deposit-removal operation. Some alternative configurations will be set forth by way of example here.
[0115] The representation of the deposit number can be represented as a numerical FIGURE by 18 digits, for example 428912592927402856. Combing numerical and alphabetical characters means that the deposit number can be represented as a 12-character alphanumeric number, for example A2ED5GTZ45BB or in the form of mutually separately arranged character groups ADED, 5GTZ, 45BB. Alternatively the deposit identification can also be represented graphically with the same level of security in various ways as shown in FIG. 3, for example with smileys.
[0116] The size of the deposit number is preferably in the range between ¼ cm 2 and 4 cm 2 in area. Depending on the respective choice of the representation other sizes are also a possibility, depending on the packaging article.
[0117] The deposit numbers can be applied in various ways. Basically, this is possible with the labelling systems which are already involved in the filling processes. For that purpose, the deposit number is applied similarly to a variable batch number or like the best-before date. The corresponding deposit numbers are electronically transmitted from the deposit database to the filling organisation. They cannot be guessed by virtue of the large set of numbers for the filling organisation. Deposit numbers which are used in duplicate are detected by means of the fraud management procedures and can be proven by impounding the packaging articles.
[0118] The deposit numbers can also be supplied by the deposit database in the form of stickers. That improves the uniformity and legibility of the deposit numbers. Visibility and in particular recognition of the deposit numbers by the consumer also affords a higher level of acceptance. In addition the supply of stickers produced by the system affords possible ways of detecting forgery on the material and thus improving fraud management.
[0119] Finally it is also possible for the deposit number to be printed on a carrier provided separately from the article, in the manner of a token, which the purchaser receives together with the packaging article and which he must give back when returning the article or the disposable packaging article. In that case however redemption of the deposit is actually only possible when a packaging article corresponding to the value of the token is returned. Accordingly, in this alternative embodiment, return is not limited to the individual packaging article but to a class of articles.
[0120] In a further development it can be provided that the consumer upon making the purchase can see that there is a deposit on a packaging article. The deposit number can be concealed for example under a seal. The deposit can be redeemed only when the seal has been removed and thus destroyed. Conversely, an undamaged seal means that the packaging article has not yet had the deposit redeemed thereon. The seal thus serves as an originality seal. The structure of such a seal is shown in FIG. 4.
[0121] Layer 1 of the seal is an adhesive which firmly joins the sticker to the packaging article. In contrast to reusable labels the adhesive is preferably not water-soluble.
[0122] Layer 2 is a paper which is cut into or a film or sheet on which the deposit number is printed. This means that the deposit number cannot be detached from the packaging article without involving destruction.
[0123] Layer 3 is a seal film or sheet or rubber coating which covers the deposit number and which allows the deposit number to be visible only after having been rubbed or scratched off.
[0124] Accordingly the invention also concerns an originality seal on which, at each stage in the method, it is directly possible for a consumer to see whether deposit removal has taken place as the seal is destroyed when that happens. The third layer does not necessarily have to be in the form of a rubber coating. The change in condition of the seal could also be effected by a change in color or other irreversible alterations.
[0125] The system for deposit removal is shown in FIG. 5. When the consumer returns the packaging article to the shop the deposit number is transmitted to the database with the deposit numbers and stored as cancelled. The deposit number is admittedly still on the empty packaging article but it no longer has any deposit value. From that moment in time the empty packaging articles can be logistically easily collected and disposed of. The deposit number identified in the database excludes a deposit being paid back again for the packaging article.
[0126] The operation of recognising the deposit number can be effected in particular in a store for example by a mobile or a stationary recognition system. The mobile deposit scanner shown in FIG. 6 in the form of a detection unit is a small light hand device which can be used at kiosks, funfairs, leisure parks and so forth. The scanner has a recognition unit with which the deposit numbers can be read off the packaging articles, and a data transfer unit. Data transfer can be by cable or by radio. The design configuration involving a bidirectionally operational Bluetooth radio interface is particularly compact. Bluetooth is the wireless connection of various communication devices. A line-of-sight connection between the terminals is no longer required by virtue of the radio transmission procedure. If deposit numbers with images are used an image recognition unit can also be provided in the scanner.
[0127] The data received by the scanner are communicated to the deposit database for example by way of data networks. In this respect there are various intermediate stations in which the data are collected and passed on. One or more scanners can communicate with a base station (this can be a cellular radio tower or a desktop device). The base station then forms the communication with the deposit database. This can be line oriented (ISDN, PSTN, GSM or the like) or packet oriented (IP, GPRS or the like).
[0128] From the deposit database the acknowledgement about the redeemed deposit is sent back to the deposit scanner so that, after the complete return of all packaging articles, the entire deposit amount can be read off at the scanner. To conclude the return procedure, the hand scanner prints out a receipt document for the consumer.
[0129] On the basis of the mobile deposit scanner, it is possible to provide self-service stations which can be used as return apparatuses in a store, for example in the form of a deposit scanner involving simple wall mounting. The consumer there redeems his deposit from his packaging articles and then throws them into a container.
[0130] In order to prevent the consumer from prematurely cancelling the deposit on full packaging articles, a mechanism checks the discarding of a packaging article before the amount of the deposit is credited. In order to prevent immediate cancellation of the deposit on new packaging articles prior to use thereof, the receiving device of the station can be so designed that it non-removably receives the article and optionally counts it.
[0131] So that the deposit redemption procedure is of a simple nature from the point of view of a store the deposit can be cashlessly credited to the consumer. For that purpose the consumer identifies himself in relation to the system. The deposit is then credited for example to his bank account or to his telephone bill.
[0132] As an additional incentive for consumers and stores it is further possible, depending on the place at which the packaging articles are returned, to implement the respective bonus system on the market (Payback®, Miles and More®, Webmiles® etc). Besides the redemption of the deposit the customer can then also collect discount points.
[0133] The first deposit redemption operation can be implemented in about 20 seconds: subsequent transactions then require in the region of 1-2 seconds. That is afforded by virtue of the fact that the system is in the form of an online system in which establishing the connection to the deposit database generally takes more time than the actual transaction process. At locations involving numerous deposit returns however the time for making the connection can almost disappear as all transactions are assessed as subsequent transactions.
[0134] The transaction costs for deposit redemption are at the present time about 1.25 cents of a Euro.
[0135] In a further development it can be provided that the deposit number can additionally be compared to other databases. That can afford for example an additional incentive, insofar as for example each millionth deposit is rewarded with a prize.
[0136] It will be apparent to the man skilled in the art that the deposit system according to the invention can be used not only for disposable packaging articles but also for other articles, for which well-ordered return is to be ensured, for example for batteries, dangerous chemicals or the like.
[0137] [0137]FIG. 7 shows a detection unit which is in the form of a hand scanner and which is provided with a receiving device 20 according to the invention, as a plan view. The receiving device 20 is of a substantially bridge-shaped configuration with a free space extending between two limbs, wherein the internal distance between the front ends of the limbs, that is to say the insertion opening for the packaging article, is slightly smaller than the outside diameter of the packaging article 30 to be detected. The reading unit 12 of the hand scanner is arranged at the apex of the bridge-shaped opening. Detection of the label of a can or the like is possible only when the can is slightly compressed and can be inserted into the insertion opening in order to move the label into the immediate region of the reading unit 12 . Naturally this is only possible when the packaging article has been opened and emptied. Instead of a mobile hand scanner, the receiving device according to the invention can also be provided on stationary scanners. Existing scanners can be retro-fitted therewith.
[0138] [0138]FIG. 8 shows a perspective view of a further embodiment of a detection unit which is also in the form of a hand scanner 10 . Fixed on the top side of the scanner housing 10 is a U-shaped loop 40 which initially extends laterally away from the hand scanner 10 and after a 180°-curvature projects back in front of the reading unit 14 of the hand scanner 10 . The end of the loop 40 is provided with a rectangular plate 42 . As the plate 42 is arranged immediately in front of the reading unit, a packaging article from which the deposit is to be removed cannot be moved in a closed condition into the detection region of the reading unit 14 . If in contrast the packaging article is empty, the free end of the loop 40 and the plate 42 can be inserted into the opening of the packaging article so that the label of the packaging article can be moved directly into the region of the reading unit 14 , to cancel the deposit on the packaging article. The loop 40 is telescopic in the longitudinal portions 43 .
[0139] [0139]FIG. 9 shows a perspective view of a further embodiment of a hand scanner 50 which operates not by means of optical detection means but by way of sound detection. For that purpose arranged at the front end of the hand scanner 50 at a spacing from each other are a lithotriptor 52 and a microphone 54 . When a can from which the deposit is to be taken or another packaging article for deposit removal is arranged in front of the reading unit 56 of the hand scanner 50 the lithotriptor 52 emits a sound pulse which can be detected by the microphone 54 . By way of the transit time delay for the sound in an empty can in comparison with a filled can, it is possible to establish whether the can is or is not empty. The deposit is redeemed only if the packaging article is actually empty.
[0140] [0140]FIG. 10 shows a plan view on to the front side of a return device 60 according to the invention. It firstly comprises a substantially circular base plate 62 which for example can be made from a metal. On its side remote from the person viewing the drawing the base plate 62 is fixed at two fixing elements 64 arranged at the periphery of the base plate 62 to a collecting container 72 (not shown), for example a container for collecting disposable packaging articles. In the present case the fixing elements are in the form of substantially trapezoidal screw clamps. In a bottom left region of the return device 60 , as viewed from the point of view of the person viewing the drawing, the circular shape is interrupted by a part of the circular arc having been removed. At one of the interruption points of the arc the base plate is continued straight tangentially with respect to the circular arc, wherein the resulting rectangular region rises from the base plate towards the viewer. That raised region accommodates a card reading unit 66 (shown in broken line) of the deposit-removal device, in which for example a code card can be inserted substantially in the direction A and can be used there for bringing into operation the deposit-removal device or as an auxiliary means in a settlement procedure. Arranged around the center point of the base plate 62 is a feed opening 68 of the return device 60 , the center point of the base plate 62 not coinciding with the center of the feed opening 68 which is radially displaced. The feed opening 68 has a circular region, at the ends of which are arranged two straight leg-like portions which converge towards a trough-shaped portion joining the limbs. Overall the return device 60 is of a substantially annular configuration for the person viewing FIG. 10. When a user passes an article from which the deposit value is to be removed into the return device 60 , he can observe it through a viewing window 70 which is arranged at the surface of the base plate and which is provided with a glass panel, and possibly re-align it, so that the article can be detected, identified and the deposit thereon redeemed.
[0141] [0141]FIG. 11 shows a view in section through the return device 60 in FIG. 10 along line X-X. In this case the return device 60 is arranged on a collecting container 72 and covers over the receiving opening thereof. It is also possible clearly to see the region which is raised from the base plate 62 and which accommodates the card reading unit 66 . A leg 74 extends from the edge region of the base plate 62 , in the direction of the interior of the collecting container. Mounted to the leg 74 is a detection apparatus 76 which in the present case has a scanner. When an article from which the deposit is to be redeemed is pushed through the feed opening 68 , it can be arranged in front of the detection apparatus 76 in such a way that the scanner can detect the identification disposed thereon, and identify it. To facilitate proper alignment of the article, the arrangement has a leg projecting also from the edge region of the base plate 62 into the interior of the container, acting as a guide rail 78 ; at its free end which is towards the interior of the container, in opposite relationship to the detection apparatus, the guide rail 78 has a viewing panel 80 . By means of the guide rail 78 and the viewing panel 80 the article can be easily aligned in such a way that its identification can be detected by the beam from the scanner. The guide rail 78 thus serves as an orientation aid for aligning the article on which the deposit is to be redeemed, in order to reduce the number of translatory directions of movement and thus to permit simpler and correct alignment of the label in relation to the detection apparatus 76 .
[0142] The deposit-removal operation which takes place in response to identification of the article is implemented by means of electronic components (not shown) which can be easily arranged (not shown) in the internal region of the return device. In this case, both the communication means for affording a communication with the database and also for example the voltage supply means are of a modular nature in such a fashion that, without involving major complication or expenditure, they can at any time be arranged on and removed again from the return device 60 . Arranged further in the direction of the interior of the container, at a free end of the leg 74 , is the lighting means 82 of a light barrier arrangement 84 . The light thereof impinges on a reflector 88 arranged on a further, oppositely disposed leg 86 which projects into the interior of the container from the base plate 62 . In this arrangement the deposit-removal operation for the article to be returned is such that a settlement procedure for the deposit value of the article is started only when the article has passed the light barrier arrangement 84 . This therefore ensures that the article cannot be subsequently removed from the return device again and the claim for the deposit value is rightly made. | The invention concerns a computer-managed deposit system for articles, in particular for disposable packaging articles, a return device for articles having a deposit thereon, in particular for disposable packaging articles, an originality seal for identifying articles, in particular disposable packaging articles, and a detection apparatus for use with the deposit system. To prevent fraud caused by multiple returns in accordance with the invention there is proposed a method having the following method steps: associating the article with a unique identification from a plurality of identifications managed in a database (linkage), associating the identification from the database with a deposit value, using the article in at least one intermediate step, detecting the identification of the article and identifying the article on the basis of the identification, and cancelling the linkage of the identification in the database when removing the deposit from the article. | 68,198 |
RELATED APPLICATIONS
This present application is a Continuation Application of and claims priority to U.S. patent application Ser. No. 10/189,776, now U.S. Pat. No. 7,792,053, entitled “System for Accessing End-to-End Broadband Network Via Network Access Server Platform”, filed on Jul. 8, 2002, and is herein incorporated by reference in its entirety. This present application is related to U.S. patent application Ser. No. 10/163,500, entitled “Providing Mobility in a Distributed End-to-End Packet/Cell/Frame Network”, by Albert Chow et al., which was filed on Jun. 7, 2002, and is now abandoned and U.S. Pat. No. 7,496,102, entitled “Broadband Telecommunication Service with Personalized Service Capability for Mobile Terminals”, by Albert Chow, which was filed on Jun. 7, 2002, each of which is herein incorporated by reference in its entirety.
FIELD OF THE INVENTION
The present invention relates generally to the field of telecommunications and specifically to a personalized system and method for accessing a broadband network via a network access server platform (NASP).
BACKGROUND OF THE INVENTION
Telecommunications have evolved from plain old telephone service (POTS) using a conventional wired line telephone and keypad. Circuit switched telecommunications have evolved from circuit-switched to end-to-end broadband packet/cell/frame networks. This evolution has enabled new services and new means of communication. In a true end-to-end broadband packet/cell/frame network environment, the use of traditional circuit-switch facilitated dial tone and numbering scheme (i.e., Directory Number (DN), E.164) as a method for establishing a link to someone is no longer applicable. Users/customers/subscribers now expect easier telecommunications access as well as substantially more services. Users will have voice prompted greetings from an access network based system/service after a telephone/telecommunication device goes “off-hook”, where users will utilize unique personal identifiers comparable to the email address format (e.g., [email protected]).
SUMMARY OF THE INVENTION
The present invention is applicable to current and future subscribers and integrates a service provider's residential and business services and a service provider's broadband transport network to provide personalized end-to-end packet/cell/frame based services.
The system and method described herein provides enhanced end-to-end packet telephony and conventional telecommunication services with distributed end-to-end packet network environments. Since the broadband transport methodology is irrelevant to the overall NASP service concepts, the Asynchronous Transfer Mode (ATM) with cell based transport, frame relay network and all transport methodology from the resident, business and small office/home office (SOHO) environments are all examples of underlying transport technologies and should be considered as exemplary broadband transport networks.
The emerging broadband (i.e., up to T1+rate) access from the home/business (via for example, cable/hybrid fiber coax (HFC) and generic digital subscriber line (xDSL)) environments facilitates a variety of new services including integrated packet voice, data, and multimedia applications. These advanced multimedia services/applications require a sophisticated user-to-network interaction to fulfill and communicate all the service criteria, and the simplicity of the conventional telephone keypad cannot fulfill these needs. New multi-modal user interfaces, such as speech/voice recognition, will enable the user/consumer to interact with the network in a more human/natural and sophisticated manner.
Personalized network access to a broadband network is achieved through the use of a NASP, which is a network centric service element that interfaces between a network access entity (e.g., BAA), a content service provider and service providers network. End users are enabled to access network services though procedures other than via conventional telephone access methods such as a keypad, etc. The NASP controls many access procedures such as voice access, network signaling, integrating various generations of services and procedures and the integration of various network technologies. Examples of personalized network access include a voice greeting to a user after a telephone/telecommunication device goes “off-hook”, asking what service the user needs, adding/modifying/removing and generally maintaining a personal address book for the user's contacts, maintaining various user-specific databases such as preferred calling plans, placing calls to contacts maintained in the user's personal address book, forwarding calls, screening calls and locating the most inexpensive calling plan for placing a call. All interactions with the network are via voice communications.
It is, therefore, an object of the present invention to provide personalized network access to an end-to-end broadband packet/cell/frame network using the Network Access Server Platform.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention is best described with reference to the detailed description and the following FIGURE, where:
FIG. 1 shows an exemplary embodiment of an end-to-end broadband network including the NASP of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The Network Access Server Platform (NASP) is a network centric service element that provides interworking functions between a network access entity(s), a content services provider(s) and a service provider's broadband packet/cell/frame network to facilitate services and applications. The NASP provides end users, in either residential, small office/home office (SOHO), business or public environments, the means to access the network centric services, the procedures that locate and deliver services, and the methodologies that allow the introduction of advanced services in a distributed intelligent manner by a service provider. Subscribers can customize their telecommunication needs, such as service and feature selections, maintenance of personal address books and directories, profiles and databases, and service preferences, etc. simply by programming the NASP anywhere and anytime. The NASP assists the subscriber in accessing telecommunication services via a service provider's broadband packet/cell/frame network, and the NASP replaces the conventional dial tone and telephone keypad with technologies such as speech coding, interactive voice, voice recognition and text-to-speech conversion. When the user wishes to request a telecommunication service, he/she picks up the telephone/telecommunications device, or turns on a laptop/PC, or initiates the NASP application. The user will interact with the NASP instantaneously/directly via the premises-based Broadband Access Agent (BAA) to fulfill, initiate and terminate the service requests in multi-session and multi-application scenarios. The NASP, based on the behavior of the user, interacts with the service provider's broadband packet/cell/frame network and the BAA to deliver network centric or content service provider's services to the end-users.
Each user can program the NASP via a web-based service management dialogue or through an interactive voice session supported by the NASP via BAA, and the NASP provides personalized services to the user on demand. In an exemplary embodiment, the NASP can be programmed via a web-based dialogue box or pull-down manual after the user logs onto the service (i.e., turn on the laptop, PDA etc.). The dialogue box or pull-down manual can be installed as part of a service initialization process, for instance from a CD issued by the service provider to the broadband service user/subscriber. In turn, the user will install the dialogue software onto their choice of communications devices including stationary PC, laptop, PDA etc. The pull-down manual/dialogue will allow the user/subscriber to program their service preferences and personal profile, which will, in turn, be transmitted to the NASP via the BAA. NASP also eliminates the necessity of consumers programming each of their communication devices with their preferences.
For a service provider, the NASP provides network access control functions and acts as a broker-agent to provide the bridge that links a service provider broadband packet/cell/frame network and its network centric services to the end user. In addition, the NASP supports network related security management including services such as the subscriber authentication; services authorization; call session control; billing and accounting; subscriber identity related naming and directory services; and mobility management (e.g., terminal, session, personal, service, and number portability) for the end-users. For example, a user may carry their telecommunication device to another location and connect to a telecommunication jack at the new location. Once connected to the telecommunication jack powering the telecommunication device on the BAA at the new location will recognize the telecommunication device and signal the NASP accordingly to retrieve the personalized databases and provide the user with their personalized services. For network simplicity and distribution of network intelligence, the NASP partitions services from network control/transport and in turn, reduces deployment costs effectively. Furthermore, the distributed network intelligence that NASP promotes provides flexible and efficient network centric service creation, services upgrades, and optimally provides best quality of service (QoS) to the users.
An exemplary embodiment depicted in FIG. 1 comprises a distributed network centric network where a user operating from a business, home or SOHO 105 is connected to a premises-based BAA 110 . The BAA 110 provides the intelligence and forms a part of the service provider's media specific equipment at the customer site. In an exemplary embodiment, the BAA 110 would form a part of a cable or xDSL modem provided to a user by the service provider. BAA 110 is connected to a switch 120 via any one of a number of underlying network control/transport technologies. Depicted in FIG. 1 is xDSL 115 using an IP DSL switch 120 . The underlying network control/transport services may be provided by ATM, HFC, etc. using a corresponding compatible switch. Switch 120 (which may be, for example, an IP DSL switch) is connected to NASP 125 which acts as an agent/broker for services and features requested and subscribed to by a user. Switch 120 is a soft switch, which, for example, is using an xDSL media and separates voice from data. NASP 125 interworks with broadband transport network 130 . NASP 125 interworks with BAA 110 to establish the call with a previous caller designated network Call Connection Agent (CCA) 135 to complete the call via broadband transport network 130 . The CCA 135 is responsible for authentication, authorization and accounting, and may be integrated with the NASP 125 . The NASP 125 is connected to the user via the premises based BAA 110 , a switch 120 and the broadband transport network 130 via the internet. The NASP 125 is like a 5ESS switch but is packet switched rather than circuit switched and is intended to provide similar but enhanced services, as will be described herein. The NASP 125 functions above the network control/transport layer and provides the personalized services described herein via an interface to the broadband transport network 130 . The NASP 125 provides services users are already familiar with and want such as call forwarding, caller identification, etc. Multiple content service providers (CSPs) (not shown) are also connected to and in communication with the distributed end-to-end broadband transport network 130 and provide personalized services to a user via the NASP 125 .
Examples of the NASP 125 Usage:
1. John picks up his telephone (e.g., POTS, ISDN, and Internet telephony protocol) or turns on his laptop/PDA, etc.
2. John's BAA 110 initiates signaling communication to John's designated NASP 125 , which sends a voice greeting to John; “AT&T, John, may I help you?”
3. John voices his request to his designated NASP 125 to call his friend Mary, and John's designated NASP 125 responds with “Thank you and please wait.”
4. John's designated NASP 125 will retrieve Mary's destination address from John's personal directory database (e.g., John's address book) maintained by John's designated NASP 125 . Mary's destination address may be in the form of [email protected], or 555 1212@, verizon.com. John's designated NASP 125 places a call to Mary.
5. John's designated NASP 125 will interwork with John's BAA 110 to establish the call with a previous caller designated network Call Connection Agent 135 to complete the call to Mary. John instructs NASP 125 to forward all calls from Mary to his wireless telephone.
6. Mary's NASP 125 will interwork with Mary's BAA 110 to decide how to terminate the incoming call, for instance:
a. Switch call to voicemail b. Route call to Mary's remote location c. Answer the call, etc.
7. Upon call termination, both NASPs 125 generate call detail records and send copies to the CCA 135 and/or a designated billing center/clearinghouse.
Additionally, the following are also possible instructions John may give his designated NASP 125 . John instructs his designated NASP 125 to add/remove entries from his address book. John instructs his designated NASP 125 to place an international call using the most inexpensive calling plan that is currently offered by the service providers. John's designated NASP 125 will screen all incoming calls to check disposition status based on John's instructions, e.g., complete the call, forward the call to voicemail, or reject the call.
The key features of the NASP 125 of the present invention are to provide a distributed network centric service architecture within a broadband packet/cell/frame network; to provide the procedures and methods to manage mobility for terminal, personal, session and services and numbering; to provide the signaling and messages necessary for services between the NASP 125 and the user end-equipment (e.g., telephone, laptop, PDA etc.); to provide the signaling and messages necessary for services between a service provider network and the NASP 125 ; to support the services and call features among the NASP 125 , user end equipment, and the service provider network; to provide the procedures and methods to integrate 2nd, 3d, and 4th generation wireless access technologies and services via the NASP 125 ; and to provide the procedures and methods that integrate wired broadband network access technologies including cable, xDSL etc. via the NASP 125 .
It should be clear from the foregoing that the objectives of the invention have been met. While particular embodiments of the present invention have been described and illustrated, it should be noted that the invention is not limited thereto since modifications may be made by persons skilled in the art. The present application contemplates any and all modifications within the spirit and scope of the underlying invention disclosed and claimed herein. | A system is described for providing personalized network access and services in a distributed end-to-end broadband transport network having a telecommunication device used by a user having a unique personal identifier, a premises-based broadband access agent (BAA), the BAA connected to and in communication with the telecommunication device, a switch specific to an underlying transport medium, the switch connected to and in communication with the distributed end-to-end broadband transport network, a network access server platform (NASP), the NASP connected to and in communication with the BAA and the switch, the NASP provides personalized network access and services on demand and a call connection agent (CCA) to complete a call placed by the user to a terminating user. | 15,686 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the priority of Korean Patent Application No. 2008-32640 filed on Apr. 8, 2008, and Korean Patent Application No. 2008-37297 filed on Apr. 22, 2008, in the Korean Intellectual Property Office, the disclosure of which is incorporated herein by reference.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates to a high voltage power supply, and more particularly, to a high voltage power supply capable of reducing voltage stress of a voltage multiplying device and supplying a voltage applied to an inductor as a bias voltage of a switching device according to a turn ratio without employing a power converting transformer.
[0004] 2. Description of the Related Art
[0005] Recently, a high voltage power supply has found very broad applications in overall industrial fields and is being necessarily utilized in an increasing number of areas. This high voltage power supply is applied in various fields covering industrial purposes such as new material developments and plasma applications, civil purposes, medical appliances,
[0006] A printer is easily accessible equipment at home or in the office and employs a high voltage power supply with stable multiple functions, which are most essential in forming an image. Also, there is an increasing demand for such a high voltage power supply.
[0007] FIG. 1 is a configuration view illustrating a conventional high voltage power supply.
[0008] Referring to FIG. 1 , the conventional high voltage power supply 10 includes a power converter 11 converting a voltage level of an input direct current (DC) power according to a preset turn ratio, and a multiplier 12 multiplying a DC voltage level converted from the power converter 11 .
[0009] In the conventional high voltage power supply 10 , the current converter 11 employs a power converting high voltage transformer 11 a having primary and secondary windings Np, Ns and an accessory winding Nb wound around a magnetic device to multiply a high voltage DC power. Also, multiplying cells 12 a , 12 b , and 12 c including diodes D 1 , D 2 , and D 3 and capacitors C 1 , C 2 , and C 3 , respectively receive the high voltage DC power to multiply at a preset ratio.
[0010] In the conventional high voltage power supply 10 , the voltage level of the high voltage DC power from the power converter 11 is applied to the diodes D 1 , D 2 , and D 3 of the multiplying cells 12 a , 12 b , and 12 c and the capacitors C 1 , C 2 , and C 3 , respectively.
[0011] Accordingly, the conventional high voltage power supply 10 needs to employ high voltage devices with high withstanding voltages in the respective multiplying cells 12 a , 12 b , and 12 c , thereby increasing manufacturing costs. As described above, since the power converter 11 utilizes a current converting high voltage transformer 11 a to enable the primary and secondary windings Np and Ns and the accessory winding Nb to be wound around a magnetic device, the number of turns of the primary, secondary, and accessory windings Np, Ns, and Nb and the winding method are complicated when the high voltage DC power is outputted, which accordingly leads to an increase in the bulk and size of the magnetic device.
SUMMARY OF THE INVENTION
[0012] An aspect of the present invention provides a high voltage power supply capable of reducing voltage stress of a voltage multiplying device and supplying a voltage applied to an inductor as a bias voltage of a switching device according to a turn ratio without employing a power converting transformer.
[0013] An aspect of the present invention also provides a high voltage power supply including: a power converter switching on/off and converting an input direct current power into a direct current power having a preset voltage level; and a voltage multiplier including a first multiplying cell multiplying the voltage level of the direct current power from the power converter, wherein the first multiplying cell includes: first and second capacitors charging the direct current power from the power converter, respectively; a first diode providing a path for transferring the direct current power when the power converter is switched off; and a second diode providing a path for transferring the direct current power when the power converter is switched on.
[0014] The first diode of the first multiplying cell may include a cathode electrically connected to the power converter and an anode electrically connected to the second diode.
[0015] The second diode may include a cathode electrically connected to the first diode and an anode electrically connected to the second capacitor, the first capacitor has one end electrically connected to a junction between the first and second diodes and another end electrically connected to an input direct current power terminal, and the second capacitor has one end electrically connected to the cathode of the first diode and another end electrically connected to the anode of the second diode.
[0016] The high voltage power supply may further include an output stabilizer stabilizing an output direct current power from the voltage multiplier.
[0017] The voltage multiplier may further include at least another multiplying cell electrically connected in series between the first multiplying cell and the output stabilizer, wherein the at least another multiplying cell includes: a pair of charging capacitors charging the direct current power of the power converter, respectively; a switching off path diode providing a path for transferring the direct current power when the power converter is switched off; and a switching on path diode providing a path for transferring the direct current power when the power converter is switched on.
[0018] The output stabilizer may include: an output diode providing a path for transferring the output direct current power from the voltage multiplier; and an output capacitor charging the output direct current power from the voltage multiplier.
[0019] The output direct current power may include the input direct current power having a polarity inversed.
[0020] The power converter may convert the input direct current power into a switching bias power according to a preset turn ratio, and switch on the input direct current power in response to the switching bias power and convert the voltage level of the direct current power.
[0021] The power converter may include: a switch switching on the input direct current power; a first inductor having a preset number of turns and charging energy of the input direct current power; and a second inductor having a preset number of turns and supplying the switching bias power to the switch according to the turn ratio with respect to the first inductor.
[0022] The high voltage power supply may further include a protective circuit blocking an overvoltage higher than a preset voltage level from being applied between an emitter and a base of the switch.
[0023] The power converter may further include a current source supplying the switching bias power to the switch during initial driving.
[0024] The high voltage power supply may further include a stabilizer stabilizing an output power from the voltage multiplier, wherein the stabilizer provides a path for transferring the output power; and a capacitor charging the output power.
[0025] The power converter may operate in a current continuous conduction mode.
[0026] The power converter may operate in a current discontinuous conduction mode.
BRIEF DESCRIPTION OF THE DRAWINGS
[0027] The above and other aspects, features and other advantages of the present invention will be more clearly understood from the following detailed description taken in conjunction with the accompanying drawings, in which:
[0028] FIG. 1 is a configuration view illustrating a conventional high voltage power supply; conventional high voltage power supply;
[0029] FIG. 2 is a configuration view illustrating a high voltage power supply according to an exemplary embodiment of the invention;
[0030] FIG. 3A to 3F illustrates operation of a power converter employed in a high voltage power supply according to an exemplary embodiment of the invention;
[0031] FIG. 4 is a waveform diagram of major signals of a power converter employed in a high voltage power supply according to an exemplary embodiment of the invention;
[0032] FIGS. 5A and B sequentially illustrate voltage multiplication of a high voltage power supply operating in a current continuous mode;
[0033] FIG. 6 is an operational waveform diagram of the high voltage power supply shown in FIG. 5 ;
[0034] FIGS. 7A to 7C sequentially illustrate voltage multiplication of a high voltage power supply operating in a current discontinuous mode;
[0035] FIG. 8 is an operational waveform diagram of the high voltage power supply shown in FIG. 7 ; and
[0036] FIG. 9 is a simulation waveform diagram of a high voltage power supply according to an exemplary embodiment of the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0037] be described in detail with reference to the accompanying drawings.
[0038] FIG. 2 is a configuration view illustrating a high voltage power supplier according to an exemplary embodiment of the invention.
[0039] Referring to FIG. 2 , the high voltage power supply 100 includes a power converter 110 , a voltage multiplier 120 and an output stabilizer 130 .
[0040] The power converter 110 switches on/off and converts an input direct current (DC) power Vin into a DC power having a preset voltage level. This power converter 110 may adopt various configurations such as a current source or a power converting transformer. In the present embodiment, the power converter 110 includes a switch Q connected to an input DC power Vin terminal, a first inductor L 1 receiving a power switched from the switch Q, and a second inductor L 2 receiving energy from the first inductor L 1 and supplying a switching bias power to the switch Q.
[0041] The switch Q can be configured as a PNP transistor including an emitter receiving the input DC power Vin, a base receiving the switching bias power and a collector outputting the switched on/off DC power.
[0042] The first inductor L 1 has a preset number of turns, and charges and discharges the DC power switched on/off by the switch Q.
[0043] The second inductor L 2 has a preset number of turns, and supplies the DC power from the first inductor to the base of the switch Q as the switching bias voltage according to a turn ratio with respect to the first inductor L 1 .
[0044] Moreover, the power converter 110 may further include a current source Vx supplying a switching bias power when initially operated.
[0045] FIG. 3 illustrates operation of a power converter employed in a high voltage power supply according to an exemplary embodiment of the invention. FIG. 4 is a waveform diagram of major signals of a power converter employed in a high voltage power supply according to an exemplary embodiment of the invention.
[0046] Referring to FIG. 3 , the operation of the power converter employed in the high voltage power of the present invention will be described except for the voltage multiplier 120 .
[0047] Referring to FIGS. 3 and 4 , as shown in FIG. 3A , when the switch Q is switched on, a current path occurs as indicated with a dotted arrow, and thus the input DC voltage Vin is applied as a both-end voltage V L1 of the first inductor L 1 . A voltage Ns/Np*Vin is combined with a voltage of the current source Vx in the second inductor L 2 according to a turn ratio with respect to the first inductor L 1 and then is supplied as a voltage V EC between the emitter and base of the switch Q to turn on the switch Q continuously. This allows a base Ib current to flow. At this time, a collector current Ic of the switch Q, i.e., current flowing to the first inductor L 1 is increased with an inclination of Vin/L 1 (see an internal T 0 to T 1 of FIG. 4 ).
[0048] Next, with the collector current Ic of the switch Q gradually increasing, the switch Q in stable operation enters a saturation region (see an interval T 1 and T 2 of FIG. 3B and FIG. 4 ). This increases a voltage V EC between the emitter and collector of the switch Q. With an increase in the voltage V EC between the emitter and collector of the switch Q, the voltage V L1 applied to both ends of the first inductor L 1 is decreased commensurately since the switch Q is on the same current path as the first inductor as illustrated. With a decrease in the voltage V L1 applied to the both ends of the first inductor L 1 , a voltage Vb between the emitter and base of the switch Q is decreased and the base current Ib is decreased, thus allowing the switch Q to be switched off. When the voltage V L1 applied to the both ends of the first inductor L 1 is 0V, the first inductor L 1 and the capacitor Cr resonate (see an interval T 2 to T 3 of FIG. 3C and FIG. 4 ).
[0049] Subsequently, the voltage V L1 applied to the both ends of the first inductor L 1 drops to −Vo, an output diode Do of the stabilizer 130 is in an ON state and thus energy stored in the first inductor L 1 is released to an output side (see an interval T 3 to T 4 of FIG. 3D and FIG. 4 ).
[0050] Thereafter, with the energy of the first inductor L 1 released completely, that is, the first inductor current I L1 becomes 0, the capacitor Cr and the first inductor L 1 resonate again, thus decreasing the voltage V EC between the emitter and collector of the switch Q. Accordingly, this increases the both-end voltage V L1 of the first inductor L 1 (see an interval T 4 and T 5 of FIG. 3E and FIG. 4 ).
[0051] Finally, when the both-end voltage V L1 of the first inductor L 1 rises to 0V or higher, the switching bias power is supplied to the switch Q through the second inductor L 2 according to a turn ratio with respect to the first inductor L 1 . This allows the switch Q to be switched on (see an interval T 5 and T 6 of FIG. 3F and FIG. 4 ).
[0052] As described above, the power converter 110 employed in the high voltage power supply of the present embodiment receives the both-end voltage of the first inductor L 1 according to a turn ratio to be applied between the emitter and base of the switch Q, thereby self-oscillating. The high voltage power supply of the present embodiment employs the inductors, in place of a high voltage transformer for generating a high voltage DC power as in the conventional high voltage power supply. Accordingly, this reduces the size and price of the magnetic device and precludes a need for complicated windings for generating a high voltage, thereby ensuring more reliable products.
[0053] Referring back to FIG. 2 , the voltage multiplier 120 employed in the high voltage power supply 100 of the present embodiment may include at least one multiplying cell. The voltage multiplier 120 may include a plurality of multiplying cells according to a desired multiplying ratio.
[0054] The multiplying cells 121 to 12 N of the voltage multiplier 120 each include respective two capacitors C 1 to C 2 N and respective two diodes D 1 to D 2 N.
[0055] For example, in the case of a first multiplying cell 121 , a first diode D 1 includes a cathode electrically connected to the first inductor L 1 and an anode electrically connected to a second diode D 2 . A second diode D 2 includes a cathode electrically connected to the anode of the first diode D 1 and an anode electrically connected to the second capacitor C 2 . A first capacitor C 1 has one end electrically connected to a junction between the first and second diodes D 1 and D 2 and another end electrically connected to the input DC power Vin terminal. A second capacitor C 2 has one end electrically connected to the cathode of the first diode D 1 and another end electrically connected to the anode of the second diode D 2 .
[0056] In a case where the voltage multiplier 120 includes a plurality of multiplying cells, the second and Nth multiplying cells 122 to 12 N may be connected in series between the first multiplying cell 121 and the output stabilizer 130 .
[0057] The second and Nth multiplying cells 122 and 12 N include 2 N- 1 and 2 N capacitors C 3 and C 2 N, respectively and 2 N- 1 and 2 N diodes D 3 and D 2 N, respectively, where N is a natural number of at least two. In the second multiplying cell 122 , a third diode D 3 includes a cathode electrically connected to the anode of the second diode D 2 of the first multiplying cell 121 and an anode electrically connected to a fourth diode D 4 . The fourth diode D 4 includes a cathode electrically connected to the anode of the third diode D 3 and an anode electrically connected to a fourth capacitor C 4 and the following multiplying cell. A third capacitor C 3 has one end electrically connected to a junction between the third and fourth diodes D 3 and D 4 and another end electrically connected to the input DC power Vin terminal. A fourth capacitor C 4 has one end electrically connected to the cathode of the third diode D 3 and another end electrically connected to the anode of the fourth diode D 4 . In the same manner as described above, a third multiplying cell (not shown) to an Nth multiplying cell 12 N may be connected in series between the second multiplying cell and the output stabilizer 130 . Also, as described above, the third multiplying cell to the Nth multiplying cell 12 N may include 2 N- 1 and 2 M diodes, respectively and 2 N- 1 and 2 N capacitors, respectively, where N is a natural number of at least 3.
[0058] The multiplying cells 121 to 12 N can multiply the converted DC power from the power converter 110 according to a preset amplifying ratio. For example, in a case where the voltage multiplier 120 includes the first multiplying cell 121 , the converted DC power can have a voltage level multiplied two times. In a case where the voltage multiplier 120 includes the first and second multiplying cells 121 and 122 , the converted DC power can have a voltage level multiplied three times. In this fashion, when the voltage multiplier 120 includes first to Nth multiplying cell 121 to 12 N, the converted DC power can have a voltage level multiplied by N+1 times, where N is a natural number of at least two.
[0059] The output stabilizer 130 includes an output capacitor Co and an output diode Do. The output diode Do provides a cycle path of an output DC power Vo from the voltage multiplier 120 . The output capacitor Do charges the output DC power Vo to supply to a load RL. Here, the output DC power Vo has a polarity that is an inversed polarity of the input DC power Vin.
[0060] The high voltage power supply 100 of the present embodiment may further include a protective circuit 140 protecting a switch Q of the power converter 110 from an overvoltage.
[0061] The protective circuit 140 protects the switch Q from being damaged in a case where the switching bias voltage supplied from the current source Vx during initial operation or the switching bias voltage from the second inductor L 2 has a voltage level higher than a preset voltage level. To this end, a zenor diode Dz may be electrically connected between the emitter and base of the switch Q.
[0062] The power converter 110 can be operated in a current continuous mode or current discontinuous mode. Hereinafter, the high voltage power supply 100 of the present embodiment will be described in detail according to the operation mode of the power converter 110 .
[0063] FIGS. 5A and B sequentially illustrate voltage multiplication of a high voltage power supply operating in a current continuous mode. FIG. 6 is an operational waveform diagram illustrating the high voltage power supply shown in FIG. 5 .
[0064] Referring to FIGS. 5 and 6 , the power converter 110 employed in the high voltage power supply 100 of the present embodiment can operate in a current continuous conduction mode (CCM). Moreover, for the convenient description of the operation, the voltage multiplier 120 is assumed to include the first multiplying cell 121 and the power converter 110 has only portions of elements illustrated to describe voltage multiplication of the voltage multiplier 120 .
[0065] When the switch Q is turned off at t=T 0 , the first diode D 1 and the output diode Do are in an ON state and energy stored in the first inductor L 1 is discharged through a path defined by the first inductor L 1 —the input DC power terminal Vin—the first capacitor C 1 —the first diode D 1 , and through a path defined by the first inductor L 1 —the output capacitor C 0 —the output diode D 0 —the second diode D 2 . Therefore, a current i L (t) flowing in the first inductor L 1 is expressed as following Equation 1;
[0000]
i
L
(
t
)
=
i
L
(
T
0
)
+
V
i
n
-
V
x
L
(
t
-
T
0
)
=
i
L
(
T
0
)
+
V
x
-
V
0
L
(
t
-
T
0
,
Equation
1
[0066] Accordingly, a current i L (T 1 ) at t=T 1 is expressed as following Equation 2;
[0000]
i
L
(
T
1
)
=
i
L
(
T
0
)
+
V
i
n
-
V
x
L
(
1
-
D
)
T
s
=
i
L
(
T
0
)
+
V
x
-
V
0
L
(
1
-
,
Equation
2
[0067] where D is a duty ratio of on/off of the switch Q and Ts is a switching frequency.
[0068] In the operation interval described above, Vx is applied as an inverse voltage of the second diode D 2 and a drain-to-source voltage Vds of the switch Q, respectively.
[0069] Next, when the switch Q in an ON state at t=T 1 , the first diode D 1 and the output diode Do are in an OFF state and the second diode D 2 is in an ON state. Energy is stored in the first inductor L 1 through a path defined by the input DC power terminal Vin—the switch Q—the first inductor L 1 . Therefore, the current i L (t) flowing through the first inductor L 1 is expressed as following Equation 3;
[0000]
i
L
(
t
)
=
i
L
(
T
1
)
+
V
i
n
L
(
t
-
T
1
)
,
Equation
3
[0070] Accordingly, a current i L (T 2 ) at t=T 2 is expressed as following Equation 4,
[0000]
i
L
(
T
2
)
=
i
L
(
T
1
)
+
V
i
n
L
DT
s
=
i
L
(
T
0
)
,
Equation
4
[0071] In the operation interval described above, when the second diode D 2 is in an ON state, a path defined by the capacitor C 1 —the switch Q—the second capacitor C 2 —the second diode D 2 is formed, and both-end voltages of the first and second capacitors C 1 and C 2 are Vx, respectively. Vx is applied as the inverse voltage of the first diode D 1 and Vin+Vo−Vx is applied as the inverse voltage of the output diode Do. When the switch Q is in an OFF state at t=T 2 , the operation mode in this interval ends and operations in the interval T 0 to T 2 are repeated periodically.
[0072] When the Equations 2 and 4 are combined, the voltage Vx applied to both ends of the first and second capacitors C 1 and C 2 is calculated according to following Equation 5 and an input/output voltage conversion ratio Vo/Vin is calculated according to following Equation 6,
[0000]
V
x
=
V
i
n
1
-
D
,
Equation
5
V
o
V
i
n
=
1
+
D
1
-
D
,
Equation
6
[0073] Here, the duty ratio D ranges from 0 to 1, and thus Vin<Vx<Vo is satisfied. Accordingly, the input/output voltage conversion ratio is expressed as following Equation 7;
[0000]
V
o
V
i
n
CCM
=
N
-
1
1
-
D
+
D
1
-
D
,
Equation
7
[0074] where D is a duty ratio of on/off of the switch Q and N is a multiplying integer of the voltage multiplier 120 . That is, when the voltage multiplier 120 includes the first multiplying cell 121 , N becomes 2, and when the voltage multiplier 120 includes the first and second multiplying cells 121 and 122 , N becomes 3.
[0075] FIGS. 7A to 7C sequentially illustrate voltage multiplication of a high voltage power supply operating in a current discontinuous mode. FIG. 8 is an operational waveform diagram of the high voltage power supply shown in FIG. 7 .
[0076] Referring to FIGS. 7 and 8 , the power converter 110 employed in the high voltage power supply 100 of the present embodiment can operate in a current discontinuous conduction mode (DCM).
[0077] When the switch Q is in an ON state at t=T 0 , the first diode D 1 and the output diode Do are in an OFF state and the second diode D 2 is in an ON state. Energy is stored in the first inductor L 1 through a path defined by the input DC power terminal Vin—the switch Q—the first inductor L 1 . Therefore, the current i L (t) flowing through the first inductor L 1 is expressed as following Equation 8,
[0000]
i
L
(
t
)
=
V
i
n
L
(
t
-
T
0
)
,
Equation
8
[0078] Accordingly, the current i L (T 1 ) at t=T 1 is expressed as following Equation 9,
[0000]
i
L
(
T
1
)
=
V
i
n
L
DT
s
,
Equation
9
[0079] In the operation interval described above, when the second diode D 2 is an ON state, a path defined by the first capacitor C 1 —the switch Q—the second capacitor C 2 —the second diode D 2 is formed, and both-end voltages of the first and second capacitors C 1 and C 2 are Vx, respectively. Thus, Vx is applied as the inverse voltage of the first diode D 1 and Vi+Vo−Vx is applied as the inverse voltage Vdo of the output diode.
[0080] When the switch is in an OFF state at t=T 1 , the first diode D 1 and the output diode Do are in an ON state, and energy stored in the first inductor L 1 is discharged through a path defined by the first inductor L 1 —the input DC power terminal Vin—the first capacitor C 1 —the first diode D 1 , and through a path defined by the first inductor L 1 —the output capacitor Co—the output diode Do—the second capacitor C 2 . Therefore, the current i L (T) flowing through the first inductor L 1 is expressed as following Equation 10.
[0000]
i
L
(
t
)
=
i
L
(
T
1
)
+
V
i
n
-
V
x
L
(
t
-
T
1
)
=
i
L
(
T
1
)
+
V
x
-
V
o
L
(
t
-
T
1
)
Equation
10
[0081] During the operation interval described above, Vx is applied as the inverse voltage of the second diode D 2 and the drain-source voltage Vds of the switch Q, respectively. Accordingly, at t=T 2 , the current i L (T 2 ) of the first inductor becomes zero and following Equation 11 is satisfied according to the Equations 9 and 10.
[0000] DI′ 1 =D 2 ( I′ N −I′ in )= D 2 ( I′ O −I′ N ) Equation 11,
[0082] where D 2 is defined as (T 2 −T 1 )/Ts.
[0083] At t=T 2 , all of the diodes are in an OFF state, and a both-end voltage of an inductive device L and the current flowing through the first inductor L 1 become zero (0). During the operation interval described above, voltages of Vds (Q), VDo, VD 1 , and VD 2 are Vi, Vo−Vx, Vx−Vi, and Vin, respectively. At t=T 3 , with the switch Q in an ON state, the operation mode in the interval T 0 to T 3 is repeated periodically.
[0084] A both-end voltage Vx of the first and second capacitors C 1 and C 2 and an input/output voltage conversion ratio Vo/Vin during the discontinuous conduction mode satisfy following Equations 12 and 13, respectively according to Equation 11.
[0000]
V
x
=
D
+
D
2
D
2
V
i
n
,
Equation
12
V
o
=
2
D
+
D
2
D
2
V
i
n
,
Equation
13
[0085] Referring to graphs of FIGS. 7 and 8 , an output load current (Io) is a mean value of the current of the output diode (Do), and thus satisfies following Equation 14,
[0000]
I
o
=
V
o
R
L
=
D
2
i
L
(
T
1
)
4
,
Equation
14
[0086] When the Equation 9 is applied to Equation 14, D 2 can be obtained according to following Equation 15,
[0000]
D
2
=
2
K
D
·
V
o
V
i
n
,
Equation
15
[0087] where K=2 L/(RLTs).
[0088] When Equation 15 is applied to Equation 13, an input/output voltage conversion ration Vo/Vin of a circuit of the present invention operating in the discontinuous conduction mode can be derived according to Equation 16;
[0000]
V
o
V
i
n
=
1
+
1
+
4
D
2
K
2
,
Equation
16
[0089] Accordingly, the input/output voltage conversion ratio can be obtained according to following Equation 17;
[0000]
V
o
V
i
n
DCM
=
N
-
1
+
(
N
-
1
)
2
+
4
D
2
/
K
2
Equation
17
[0090] Electrical properties of the high voltage power supply of the present invention will be compared with those of the conventional high voltage power supply with reference to the Table below.
[0000]
TABLE
Conventional
Present invention
Input/output voltage conversion ratio
M
=
3
-
2
D
*
1
-
D
*
M
=
2
+
D
1
-
D
Duty ratio
D
*
=
M
-
3
M
-
2
D
=
M
-
2
M
+
1
Maximum inverse voltage of diode
Vin
1
-
D
*
Vin
1
-
D
Capacitor voltage
Vin
,
Vin
1
-
D
*
,
Vin
1
-
D
*
+
Vin
Vin
1
-
D
,
2
Vin
1
-
D
Maximum drain-source voltage of switch
Vin
+
D
*
1
-
D
*
Vin
Vin
+
1
1
-
D
Vin
[0091] In the Table noted above, as shown in FIG. 1 , the conventional high voltage power supply was set to multiply the converted DC power three times. The high voltage power supply of the present invention was set to include the first and second voltage multiplying cells 121 and 122 to multiply the DC power three times as in the conventional high voltage power supply. Also, the input DC power Vin was set to 24V and the output DC power Vo was set to 1200V. The switching frequency was set to 50 KHz and an operation mode was set to the current continuous conduction mode.
[0092] Accordingly, the input/output voltage conversion ratio of the high voltage power supply of the conventional art and the present invention is set to 50, respectively. When the above voltage level is applied to Equations in the Table, the duty ratio of the conventional art and the present invention are set to 0.979 and 0.941, respectively.
[0093] In the conventional high voltage power supply, the maximum inverse voltage applied to each of the diodes D 1 , D 2 , and D 3 is about 1152V. Meanwhile, the maximum inverse voltage applied to the first and second diodes D 1 , D 2 , D 3 , and D 4 and the output diode Do of the present invention can be as low as 408V.
[0094] Moreover, in the conventional high voltage power supply, voltages of 24V, 1152V, and 1176V are applied to the capacitors C 1 , C 2 , and C 3 , respectively. On the other hand, in the present invention, a voltage of 408V is applied to the first and second capacitors C 1 and C 2 of the first multiplying cell 121 and the first capacitor C 3 of the second multiplying cell 122 , respectively and a voltage of 816V is applied to the second capacitor C 4 of the second multiplying cell.
[0095] Furthermore, in the conventional high voltage power supply, a voltage of 1152V is applied to the switch Q. On the other hand, in the high voltage power supply of the present invention, a voltage of 432V is applied to the switch Q.
[0096] FIG. 9 is a simulation waveform diagram of a high voltage power supply according to an exemplary embodiment of the invention.
[0097] Referring to FIG. 9 , the high voltage power supply of self oscillation according to the present embodiment includes the voltage multiplier 120 set to multiply the input DC power three times. When a voltage level of the DC power applied to the switch Q is about 384V and a voltage level of the DC power applied to the first inductor L 1 is about −360V, the output DC power is −1410V according to a multiplying ratio of the voltage multiplier 120 .
[0098] As described above, the voltage applied to each of devices employed in the high voltage power supply of the present embodiment is much lower compared with the conventional high voltage power supply. This may lead to a slight increase in the number of devices added, but devices with relatively low withstanding voltages may be adopted to reduce manufacturing costs over the conventional high voltage power supply.
[0099] As set forth above, according to exemplary embodiments of the invention, unlike a conventional high voltage power supply in which a converted DC power is applied to a diode regardless of switching on/off when a power is converted, a DC power is converted and applied through different paths according to switching on/off. Moreover, a power converting transformer is not employed and a voltage applied to an inductor is applied as a bias voltage of a switching device according to a turn ratio. As a result, the power is transferred by self oscillation to allow low voltage devices to be utilized, thereby reducing manufacturing costs.
[0100] While the present invention has been shown and described in connection with the exemplary embodiments, it will be apparent to those skilled in the art that modifications and variations can be made without departing from the spirit and scope of the invention as defined by the appended claims. | There is provided a high voltage power supply capable of reducing voltage stress of a voltage multiplying device. The high voltage power supply includes: a power converter switching on/off and converting an input direct current power into a direct current power having a preset voltage level; and a voltage multiplier including a first multiplying cell multiplying the voltage level of the direct current power from the power converter, wherein the first multiplying cell includes: first and second capacitors charging the direct current power from the power converter, respectively; a first diode providing a path for transferring the direct current power when the power converter is switched off; and a second diode providing a path for transferring the direct current power when the power converter is switched on. | 76,677 |
This is a continuation-in-part of co-pending Ser. No. 07/276,578 filed Nov. 28, 1988, now abandoned.
BACKGROUND OF THE INVENTION
This invention relates to an electrophotographic sensitive material useful advantageously in an image-forming apparatus such as the copying machine.
In recent years, as electrophotographic sensitive materials for use in such image-forming apparatuses as copying machines, sensitive materials of the kind permitting a wide freedom in design of functions have been proposed.
Particularly, electrophotographic sensitive materials possessed of a photosensitive layer of the separate function type containing an electric charge generating material capable of generating electric charge upon exposure to light and an electric charge transferring material capable of transferring generated electric charge in one or two layers have been proposed. For example, electrophotographic sensitive materials possessed of a single-layer type photosensitive layer containing an electric charge generating material, an electric charge transferring material, and a binding resin in one layer and electrophotographic sensitive materials possessed of a laminate type photosensitive layer formed by superposition of an electric charge generating layer containing an electric charge generating material on an electric charge transferring layer containing an electric charge transferring material and a binding resin have been proposed.
In the formation of a copied image by the use of an electrophotographic sensitive material, the Carlson process is popularly utilized. The Carlson process basically comprises a charging step for uniformly charging a sensitive material by corona discharge, an exposing step for exposing the charged sensitive material through a given original image to light thereby forming on the sensitive material an electrostatic latent image conforming to the original image, a developing step for developing the electrostatic latent image with a developer containing a toner thereby forming a toner image, a transferring step for causing the toner image to be transferred onto a substrate such as paper, a fixing step for fixing the toner image transferred on the substrate, and a cleaning step for removing the toner remaining on the sensitive material after the transferring step. For the image to be produced with high quality in the Carlson process, the electrophotographic sensitive material is required to excel in the charging property and the photosensitive property and, at the same time, to be low in residual potential after the exposure to light.
The electrophotographic properties of the electrophotographic sensitive material of the separate function type mentioned above are affected in a large measure by the combination of an electric charge generating material and an electric charge transferring material. For example, an electrophotographic sensitive material possessed of a photosensitive layer using a pyrrolopyrrole type compound proposed as an electric charge generating material U.S. Pat. No. 4,632,893 in combination with a hydrazone type compound such as N-ethyl-3-carbazolylaldehyde-N,N-diphenyl hydrazone which depends heavily for drift mobility upon the intensity of electric field is high in residual potential and is deficient in sensitivity. The hydrazone type compound has no sufficient stability to resist light because it is liable to be isomerized and dimerized on exposure to light. The sensitive material, therefore, has a disadvantage that it suffers from gradual decrease of sensitivity and gradual increase of residual potential through repeated rounds of printing.
A sensitive material which uses a phthalocyanine type compound as an electric charge generating material in combination with a styryl triphenylamine type compound represented by 4-styryl-4'-methoxy triphenylamine, 4-(4-methylstyryl)-4'-methyl triphenylamine, or 4-(3,5-dimethylstyryl)-4'-methyl triphenylamine as an electric charge transferring material has been proposed (Publication for unexamined Japanese Patent Application Disclosure No. 115,167/1987).
The sensitive material possessed of a photosensitive layer containing a styryl triphenylamine type compound generally excels in electrical properties and sensitive properties as compared with the sensitive material containing other electric charge transferring material.
The styryl triphenylamine type compound, however, exhibits no sufficient compatibility with a binding resin, possesses a small capacity for electron donation, and betrays its deficiency in the electric charge transferring property. The sensitive material which is produced by using the styryl triphenylamine type compound, therefore, has a disadvantage that the charging property and the sensitivity are short of sufficiency and the residual potential is unduly high.
SUMMARY OF THE INVENTION
This invention aims to provide an electrophotographic sensitive material which excels in stability to resist light, charging property, and photosensitive property.
The electrophotographic sensitive material contemplated by the present invention is a sensitive material having a photosensitive layer formed on an electroconductive substrate and is characterized by the fact that the sensitive material contains a pyrrolopyrrole type compound represented by the following general formula (1) and a benzidine derivative represented by the following general formula (2). ##STR2## (wherein R 1 and R 2 independently stand for an aryl group which may contain a substituent, an aralkyl group which may contain a substituent, or a heterocyclic group and R 3 and R 4 independently stand for a hydrogen atom, an alkyl group, or an aryl group which may contain a substituent). ##STR3## (wherein R 5 , R 6 , R 7 , R 8 , R 9 and R 10 independently stand for a hydrogen atom, a lower alkyl group, a lower alkoxy group, or a halogen atom, l, m, n, and o each stand for an integer in the range of 1 to 3, and p and q each stand for 1 or 2).
The electrophotographic sensitive material contemplated by the present invention has a photosensitive layer formed on an electroconductive substrate. This photosensitive layer contains a pyrrolopyrrole type compound represented by the aforementioned general formula (1) and a benzidine derivative represented by the aforementioned general formula (2).
The electroconductive substrate may be in the form of a sheet or in the form of a drum. As regards the material of the electroconductive substrate, the substrate itself may be made of a material possessed of electroconductivity or the substrate made of a material not possessed of electroconductivity may be endowed on the surface thereof with electroconductivity. The electroconductive substrate is desired to manifest high mechanical strength at the time of its use. Various materials possessed of electroconductivity are available for the production of the electroconductive substrate meeting the description given above. Simple metals such as aluminum, copper, tin, platinum, gold, silver, vanadium, molybdenum, chromium, cadmium, titanium, nickel, palladium, indium, stainless steel, and brass; plastic materials having these metals vacuum deposited or superposed thereon; and glass sheets coated with aluminum iodide, tin oxide, or indium oxide may be cited as concrete examples. In these materials which are available for the electroconductive substrate, aluminum is used desirably for the purpose of preventing occurrence of black spots and pinholes in a copied image and, at the same time, enhancing the tightness of adhesion between the photosensitive layer and the substrate. The aluminum which has undergone electrolysis in an oxalic acid solution and which consequently has no crystal particles of aluminum retained on the surface thereof is used especially desirably for this purpose. The aluminum which, in consequence of the electrolysis, has been provided with an oxide coating 5 to 12 μm in thickness and no more than 1.5 μm in surface roughness is used most advantageously for the purpose.
As concrete examples of the aryl group of R 1 and R 2 in the general formula (1) of the pyrrolopyrrole type compound to be contained in the photosensitive layer, phenyl group, naphthyl group, anthryl group, phenanthryl group, fluorenyl group, and 1-pyrenyl group may be cited. Among other aryl groups mentioned above, the phenyl group or the naphthyl group is particularly desirable. The phenyl group is most desirable.
As concrete examples of the aralkyl group, there may be cited benzyl group (phenylmethyl group), phenylethyl group, and naphthylmethyl group.
The substituent in the aryl group or the aralkyl group may be selected from the class consisting of halogen atoms, lower alkyl groups containing a halogen atom, a cyano group, alkyl groups, alkoxy groups, and dialkylamino group, for example.
The halogen atoms include fluorine, chlorine, bromine, and iodine, for example. Among other halogen atoms mentioned, chlorine or bromine atom is desirable.
As concrete examples of the alkyl group containing a halogen atom, there may be cited chloromethyl group, dichloromethyl group, trichloromethyl group, 2-chloroethyl group, 2,2-trichloroethyl group, 2,2,2-trichloroethyl group, and trifluoromethyl group.
As concrete examples of the alkyl group, there may be cited such alkyl groups as methyl group, ethyl group, propyl group, isopropyl group, butyl group, isobutyl group, tert-butyl group, pentyl group, hexyl group, heptyl group, octyl group, nonyl group, decyl group, undecyl group, dodecyl group, and stearyl group which have 1 to 18 carbon atoms. In the alkyl groups mentioned above, linear or branched alkyl groups having 1 to 12 carbon atoms are desirable, linear or branched lower alkyl groups having 1 to 6 carbon atoms are more desirable, and linear or branched lower alkyl groups having 1 to 4 carbon atoms are most desirable.
As concrete examples of the alkoxy group, there may be cited methoxy group, ethoxy group, propoxy group, isopropoxy group, butoxy group, isobutoxy group, tertbutoxy group, pentyloxy group hexyloxy group heptyloxy group, octyloxy group, nonyloxy group, decyloxy group, undecyloxy group, dodecyloxy group, and stearyloxy group. In the alkoxy groups mentioned above, linear or branched alkoxy groups having 1 to 12 carbon atoms are desirable, linear or branched lower alkoxy groups having 1 to 6 carbon atoms are more desirable, and linear or branched lower alkoxy groups having 1 to 4 carbon atoms are most desirable.
As concrete examples of the dialkylamino group, there may be cited such dialkylamino groups as dimethylamino, diethylamino, methylethylamino, dipropylamino, diisopropylamino, dibutylamino, diisobutylamino, di-tert-butylamino, dipentylamino, and dihexylamino groups which have an alkyl moiety of 1 to 6 carbon atoms.
As concrete examples of the heterocyclic group, there may be cited thienyl, thianthrenyl, furyl, pyranyl, isobenzofuranyl, chromenyl, xanthenyl, phenoxazinyl, pyrrolyl, imidazolyl, pyrazolyl, isothiazolyl, isooxazolyl, indolysinyl, isoindolyl, indolyl, indazolyl, purinyl, pyridyl, pyrazinyl, pyrimidyl, pyridazinyl, quinolidinyl, isoquinolyl, quinolyl, phthalazinyl, naphthylidinyl, quinoxalinyl, quinazolinyl, cinnolinyl, pteridinyl, carbazolyl, carbonylyl, phenanthridinyl, acridinyl, perimidinyl, phenanthrolinyl, phenazinyl, phenarsazinyl, phenothiazinyl, furazanyl, phenoxazinyl, isochromanyl, chromanyl, pyrrolidinyl, pyrrolinyl, imidazolidinyl, imidazolinyl, pyrazolidinyl, pyrazolinyl, piperidyl, piperidino, piperazinyl, indolinyl, isoindolinyl, quinuclidinyl, morpholinyl, and morpholino groups, and the condensed heterocyclic groups of the condensed heterocyclic type compounds by the ortho-condensation or peri-condensation of compounds containing the heterocyclic groups mentioned above with an aryl compound. As concrete examples of the alkyl group of R 3 and R 4 in the general formula (1) of the pyrrolopyrrole type compound to be contained in the photosensitive layer, there may be cited, in the lower alkyl groups cited above with respect to the substituents R 1 and R 2 , those lower alkyl groups having 1 to 6 carbon atoms, preferably the alkyl groups of 1 to 4 carbon atoms.
The aryl groups containing a substituent are desired to be substituted phenyl groups. The substituent is desired to be selected from the class consisting of halogen atoms, lower alkyl groups containing a halogen atom, alkyl groups, alkoxy groups, alkylthio groups, and nitro groups. As concrete examples of the halogen atoms, the lower alkyl groups containing a halogen atom, the alkyl groups, and the alkoxy groups, there may be cited the same substituents as cited above with respect to R 1 and R 2 . As concrete examples of the alkylthio group, there may be cited methylthio group, ethylthio group, propylthio group, isopropylthio group, butylthio group, isobutylthio group, tert-butylthio group, pentylthio group, hexylthio group, heptylthio group, octylthio group, nonylthio group, decylthio group, undecylthio group, dodecylthio group, and stearylthio group. In the alkylthio groups mentioned above, linear or branched alkylthio groups having 1 to 12 carbon atoms are desirable, linear or branched lower alkylthio groups having 1 to 6 carbon atoms are more desirable, and linear or branched lower alkylthio groups having 1 to 4 carbon atoms are most desirable.
It is especially desirable that the substituents R 3 and R 4 are both a hydrogen atom.
In the pyrrolopyrrole type compounds of the description given above, those which are desirable herein include 1,4-dithioketo-3,6-diphenylpyrrolo[3,4-c]pyrrole, 1,4-dithioketo-3,6-di(4-tolyl)pyrrolo[3,4-c]pyrrole, 1,4-dithioketo-3,6-di(4-ethylphenyl)pyrrolo[3,4-c]pyrrole, 1-4-dithioketo-3,6-di(4-propylphenyl)pyrrolo[3,4-c]pyrrole, 1,4-dithioketo-3,6-di(4-isopropylphenyl)pyrrolo[3,4-c]-pyrrole, 1,4-dithioketo-3,6-di(4-butylphenyl)pyrrolo[3,4-c]pyrrole, 1,4-dithioketo-3,6-di(4-isobutylphenyl)pyrrolo-[3,4-c]pyrrole, 1,4-dithioketo-3,6-di(4-tert-butylphenyl)pyrrolo[3,4-c]pyrrole, 1,4-dithioketo-3,6-di(4-pentylphenyl)pyrrolo[3,4-c]pyrrole, 1,4-dithioketo-3,6-di4-hexylphenyl)pyrrolo[3,4-c]pyrrole, 1,4-dithioketo-3,6-di(3,5-dimethylphenyl)pyrrolo[3,4-c]pyrrole, 1,4-dithioketo-3,6-di(3,4,5-trimethylphenyl)pyrrolo[3,4-c]pyrrole, 1,4-dithioketo-3,6-di(4-methoxyphenyl)pyrrolo-[3,4-c]pyrrole, 1,4-dithioketo-3,6-di(4-ethoxyphenyl)pyrrolo[3,4-c]pyrrole, 1,4-dithioketo-3,6-di(4-propoxyphenyl)pyrrolo[3,4-c]pyrrole, 1,4-dithioketo-3,6-di(4-isopropoxyphenyl)pyrrolo[3,4-c]pyrrole, 1,4-dithioketo-3,6-di(4-butoxyphenylpyrrolo[3,4-c]pyrrole, 1,4-dithioketo-3,6-di(4-isobutoxyphenyl)pyrrolo[3,4-c]pyrrole, 1,4-dithioketo-3,6-di(4-tert-butoxyphenyl)pyrrolo[3,4-c]pyrrole, 1,4-dithioketo-3,6-di(4-pentyloxyphenyl)pyrrolo[3,4-c]pyrrole, 1,4-dithioketo-3,6-di(4-hexyloxyphenyl)pyrrolo[3,4-c]pyrrole, 1,4-dithioketo-3,6-di(3,5-dimethoxyphenyl)pyrrolo[3,4-c]pyrrole, 1,4-dithioketo-3,6-di(3,4,5-trimethoxyphenyl)pyrrolo[3,4-c]pyrrole, 1,4-dithioketo-3,6-dibenzylpyrrolo[3,4-c]pyrrole, 1,4-dithioketo-3,6-dinaphthylpyrrolo[3,4-c]pyrrole, 1,4-dithioketo-3,6-di(4 -cyanophenyl)pyrrolo[3,4-c]pyrrole, 1,4-dithioketo-3,6-di(4-chlorophenyl)pyrrolo[3,4-c]pyrrole, 1,4-dithioketo-3,6-di(2-bromophenyl)pyrrolo[3,4-c]pyrrole, 1,4-dithioketo-3,6-di(4-trifluoromethylphenyl)pyrrolo[3,4-c]pyrrole, 1,4-dithioketo-3,6-di(4-dimethylaminophenyl)pyrrolo[3,4-c]pyrrole, 1,4-dithioketo-3,6-di(4-diethylaminophenyl)pyrrolo[3,4-c]pyrrole, N,N'-dimethyl-1,4-dithioketo-3,6-diphenylpyrrolo[3,4-c]pyrrole, N,N'-dimethyl-1,4-dithioketo-3,6-ditolylpyrrolo[3,4-c]pyrrole, N,N'-dimethyl-1,4-ditioketo-3,6-di(4-ethylphenyl)pyrrolo[3,4-c]pyrrole, N,N'-dimethyl-1,4-dithioketo-3,6-di(4-isopropylphenyl)pyrrolo[3,4-c]pyrrole, N,N'-dimethyl-1,4-dithioketo-3,6-di(4-tert-butylphenyl)pyrrolo[3,4-c]pyrrole, N,N'-dimethyl-1,4-dithioketo-3,6-di(3,4,5-trimethylphenyl)pyrrolo[3,4-c]pyrrole, N,N'-dimethyl-1,4-dithioketo-3,6-di(4-methoxyphenyl)pyrrolo[3,4-c]pyrrole, N,N'-dimethyl-1,4-dithioketo-3,6-di(4-ethoxyphenyl)pyrrolo[3,4-c]pyrrole, N,N'-dimethyl-1,4-dithioketo-3,6-di(4-isopropoxyphenyl)pyrrolo[3,4-c]-pyrrole, N,N'-dimethyl-1,4-dithioketo-3,6-di(4-tert-butoxyphenyl)pyrrolo[3,4-c]pyrrole, N,N'-dimethyl-1,4-dithioketo-3,6-di(3,4,5-trimethoxyphenyl)pyrrolo[3,4-c]-pyrrole, 1,4-dithioketo-3,6-di(3-pyrrolyl)pyrrolo[3,4-c]pyrrole, 1,4-dithioketo-3,6-di(4-oxazolyl)pyrrolo[3,4-c]pyrrole, 1,4-dithioketo-3,6-di(4-thiazol)pyrrolo[3,4-c]pyrrole, 1,4-dithioketo-3,6-diimidazolylpyrrolo[3,4-c]pyrrole, 1,4-dithioketo-3,6-di(2-imidazolyl)pyrrolo[ 3,4-c]pyrrole, 1,4-dithioketo-3,6-di(4-imiazolyl)pyrrolo[3,4-c]pyrrole, 1,4-dithioketo-3,6-di(4-pyridylpyrrolo[3,4-c]pyrrole, 1,4-dithioketo-3,6-di(2-pyrimidinyl)pyrrolo[3,4-c]pyrrole, 1,4-dithioketo-3,6-dipiperidinopyrolo[3,4-c]pyrrole, 1,4-dithioketo-3,6-di(4-piperidinyl)pyrrolo[3,4-c]pyrrole, 1,4-dithioketo-3,6-dimorpholinopyrrolo[3,4-c]pyrrole, 1,4-dithioketo-3,6-di(2-quinolyl)pyrrolo[3,4-c]pyrrole, 1,4-dithioketo-3,6-di(3-benzo[b]thiophenyl)pyrrolo[3,4-c]pyrrole, 1,4-dithioketo-3,6-di(2-quinolyl)pyrrolo[3,4-c]-pyrrole, N'-dimethyl-1,4-dithioketo-3,6-di(4-imidazolyl)pyrrolo[3,4-c]pyrrole, N,N'-dimethyl-1,4-dithioketo-3,6-dimorpholinopyrrolo[3,4-c]pyrrole, and N,N'-dimethyl-1,4-dithioketo-3,6-di(4-pyridyl)pyrrolo[3,4-c]pyrrole, for example.
The pyrrolopyrrole type compounds represented by the aforementioned general formula (1) are used either single or jointly in the form of a mixture of two or more members.
Optionally, the pyrrolopyrrole type compounds represented by the aforementioned general formula (1) may be used as combined with a varying electric charge generating material in a ratio incapable of impeding the photosensitive property, for example. As concrete examples of the electric charge generating material usable in this case, there may be cited selenium, seleniumtellurium, amorphous silicon, pyrylium salts, azo type compounds, adizo type compounds, phthalocyanine type compounds, anthanthrone type compounds, perylene type compounds, indigo type compounds, triphenylmethane type compounds, threne type compounds, toluidine type compounds, pyrazoline type compounds, and quinacridone type compounds. The electric charge generating materials mentioned above are used either single or jointly in the form of a mixture of two or more members.
As concrete examples of the lower alkyl group, the lower alkoxy group, and the halogen atom of the substituents R 5 , R 6 , R 7 , R 8 , R 9 , and R 10 in the general formula (2) representing the benzidine derivative to be contained in the photosensitive layer, there may be cited those substituents cited above with respect to the substituents R 1 and R 2 . In the substituents R 5 , R 6 , R 7 , R 8 , R 9 , and R 10 mentioned above, hydrogen atom, alkyl groups of 1 to 4 carbon atoms, alkoxy groups of 1 to 4 carbon atoms, and halogen atoms are desirable.
The substituents R 5 , R 6 , R 7 , R 8 , R 9 , and R 10 may be attached to suitable positions in a benzene ring or a biphenyl backbone.
In the benzidine derivatives represented by the aforementioned general formula (2), the compounds shown in the following table may be cited as desirable examples.
__________________________________________________________________________ ##STR4##Compound No. R.sup.5 R.sup.6 R.sup.7 R.sup.8 R.sup.9 R.sup.10__________________________________________________________________________1 H H H H H H2 3-CH.sub.3 H 3-CH.sub.3 H H H3 3-CH.sub.3 3-CH.sub.3 3-CH.sub.3 3-CH.sub.3 H H4 4-CH.sub.3 H 4-CH.sub.3 H H H5 4-CH.sub.3 4-CH.sub.3 4-CH.sub.3 4-CH.sub.3 H H6 3,5- H 3,5- H H H di CH.sub.3 di CH.sub.37 3,5- 3,5- 3,5- 3,5- H H di CH.sub.3 di CH.sub.3 di CH.sub.3 di CH.sub.38 3-CH.sub.3 3,5- 3-CH.sub.3 3,5- H H di CH.sub.3 di CH.sub.39 4-CH.sub.3 3,5- 4-CH.sub.3 3,5- H H di CH.sub.3 di CH.sub.310 2,6- H 2,6- H H H di CH.sub.3 di CH.sub.311 2,6- 2,6- 2,6- 2,6- H H di CH.sub.3 di CH.sub.3 di CH.sub.3 di CH.sub.312 3-CH.sub.3 2,6- 3-CH.sub.3 2,6- H H di CH.sub.3 di CH.sub.313 4-CH.sub.3 2,6- 4-CH.sub.3 2,6- H H di CH.sub.3 di CH.sub.314 3,4,5- H 3,4,5- H H H tri CH.sub.3 tri CH.sub.315 3,4,5- 3,4,5- 3,4,5- 3,4,5- H H tri CH.sub.3 tri CH.sub.3 tri CH.sub.3 tri CH.sub.316 3-CH.sub.3 3,4,5- 3-CH.sub.3 3,4,5- H H tri CH.sub.3 tri CH.sub.317 4-CH.sub.3 3,4,5- 4-CH.sub.3 3,4,5- H H tri CH.sub.3 tri CH.sub.318 3,5- 3,4,5- 3,5- 3,4,5- H H di CH.sub.3 tri CH.sub.3 di CH.sub.3 tri CH.sub.319 H H H H 2-CH.sub.3 2'-CH.sub.320 3-CH.sub.3 H 3-CH.sub.3 H 2-CH.sub.3 2'-CH.sub.321 3-CH.sub.3 3-CH.sub.3 3-CH.sub.3 3-CH.sub.3 2-CH.sub.3 2'-CH.sub.322 4-CH.sub.3 H 4-CH.sub.3 H 2-CH.sub.3 2'-CH.sub.323 4-CH.sub.3 4-CH.sub.3 4-CH.sub.3 4-CH.sub.3 2-CH.sub.3 2'-CH.sub.324 3,5- H 3,5- H 2-CH.sub.3 2'-CH.sub.3 di CH.sub.3 di CH.sub.325 3,5- 3,5- 3,5- 3,5- 2-CH.sub.3 2'-CH.sub.3 di CH.sub.3 di CH.sub.3 di CH.sub.3 di CH.sub.326 3-CH.sub.3 3,5- 3-CH.sub.3 3,5- 2-CH.sub.3 2'-CH.sub.3 di CH.sub.3 di CH.sub.327 4-CH.sub.3 3,5- 4-CH.sub.3 3,5- 2-CH.sub.3 2'-CH.sub.3 di CH.sub.3 di CH.sub.328 2,6- H 2,6- H 2-CH.sub.3 2'-CH.sub.3 di CH.sub.3 di CH.sub.329 2,6- 2,6- 2,6- 2,6- 2-CH.sub.3 2'-CH.sub.3 di CH.sub.3 di CH.sub.3 di CH.sub.3 di CH.sub.330 3-CH.sub.3 2,6- 3-CH.sub.3 2,6- 2-CH.sub.3 2'-CH.sub.3 di CH.sub.3 di CH.sub.331 4-CH.sub.3 2,6- 4-CH.sub.3 2,6- 2-CH.sub.3 2'-CH.sub.3 di CH.sub.3 di CH.sub.332 3,4,5- H 3,4,5- H 2-CH.sub.3 2'-CH.sub.3 tri CH.sub.3 tri CH.sub.333 3,4,5- 3,4,5- 3,4,5- 3,4,5- 2-CH.sub.3 2'-CH.sub.3 tri CH.sub.3 tri CH.sub.3 tri CH.sub.3 tri CH.sub.334 3-CH.sub.3 3,4,5- 3-CH.sub.3 3,4,5- 2-CH.sub.3 2'-CH.sub.3 tri CH.sub.3 tri CH.sub.335 4-CH.sub.3 3,4,5- 4-CH.sub.3 3,4,5- 2-CH.sub.3 2'-CH.sub.3 tri CH.sub.3 tri CH.sub.336 3,5- 3,4,5- 3,5- 3,4,5- 2-CH.sub.3 2'-CH.sub.3 di CH.sub.3 tri CH.sub.3 di CH.sub.3 tri CH.sub.337 H H H H 3-CH.sub.3 3'-CH.sub.338 3-CH.sub.3 H 3-CH.sub.3 H 3-CH.sub.3 3' -CH.sub.339 3-CH.sub.3 3-CH.sub.3 3-CH.sub.3 3-CH.sub.3 3-CH.sub.3 3'-CH.sub.340 4-CH.sub.3 H 4-CH.sub.3 H 3-CH.sub.3 3'-CH.sub.341 4-CH.sub.3 4-CH.sub.3 4-CH.sub.3 4-CH.sub.3 3-CH.sub.3 3'-CH.sub.342 3,5- H 3,5- H 3-CH.sub.3 3'-CH.sub.3 di CH.sub.3 di CH.sub.343 3,5- 3,5- 3,5- 3,5- 3-CH.sub.3 3'-CH.sub.3 di CH.sub.3 di CH.sub.3 di CH.sub.3 di CH.sub.344 3-CH.sub.3 3,5- 3-CH.sub.3 3,5- 3-CH.sub.3 3'-CH.sub.3 di CH.sub.3 di CH.sub.345 4-CH.sub.3 3,5- 4-CH.sub.3 3,5- 3-CH.sub.3 3'-CH.sub.3 di CH.sub.3 di CH.sub.346 2,6- H 2,6- H 3-CH.sub.3 3'-CH.sub.3 di CH.sub.3 di CH.sub.347 2,6- 2,6- 2,6- 2,6- 3-CH.sub.3 3'-CH.sub.3 di CH.sub.3 di CH.sub.3 di CH.sub.3 di CH.sub.348 3-CH.sub.3 2,6- 3-CH.sub.3 2,6- 3-CH.sub.3 3'-CH.sub.3 di CH.sub.3 di CH.sub.349 4-CH.sub.3 2,6- 4-CH.sub.3 2,6- 3-CH.sub.3 3'-CH.sub.3 di CH.sub.3 di CH.sub.350 3,4,5- H 3,4,5- H 3-CH.sub.3 3'-CH.sub.3 tri CH.sub.3 tri CH.sub.351 3,4,5- 3,4,5- 3,4,5- 3,4,5- 3-CH.sub.3 3'-CH.sub.3 tri CH.sub.3 tri CH.sub.3 tri CH.sub.3 tri CH.sub.352 3-CH.sub.3 3,4,5- 3-CH.sub.3 3,4,5- 3-CH.sub.3 3'-CH.sub.3 tri CH.sub.3 tri CH.sub.353 4-CH.sub.3 3,4,5- 4-CH.sub.3 3,4,5- 3-CH.sub.3 3'-CH.sub.3 tri CH.sub.3 tri CH.sub.354 3,5- 3,4,5- 3,5- 3,4,5- 3-CH.sub.3 3'-CH.sub.3 di CH.sub.3 tri CH.sub.3 di CH.sub.3 tri CH.sub.355 H H H H 2,5- 2',5'- di CH.sub.3 di CH.sub.356 3-CH.sub.3 H 3-CH.sub.3 H 2,5- 2',5'- di CH.sub.3 di CH.sub.357 3-CH.sub.3 3-CH.sub.3 3-CH.sub.3 3-CH.sub.3 2,5- 2',5'- di CH.sub.3 di CH.sub.358 4-CH.sub.3 H 4-CH.sub.3 H 2,5- 2',5'- di CH.sub.3 di CH.sub. 359 4-CH.sub.3 4-CH.sub.3 4-CH.sub.3 4-CH.sub.3 2,5,- 2',5'- di CH.sub.3 di CH.sub.360 3,5- H 3,5- H 2,5,- 2',5'- di CH.sub.3 di CH.sub.3 di CH.sub.3 di CH.sub.361 3,5- 3,5- 3,5- 3,5- 2,5,- 2',5'- di CH.sub.3 di CH.sub.3 di CH.sub.3 di CH.sub.3 di CH.sub.3 di CH.sub.362 3-CH.sub.3 3,5- 3-CH.sub.3 3,5- 2,5- 2',5'- di CH.sub.3 di CH.sub.3 di CH.sub.3 di CH.sub.363 4-CH.sub.3 3,5- 4-CH.sub.3 3,5- 2,5,- 2',5'- di CH.sub.3 di CH.sub.3 di CH.sub.3 di CH.sub.364 2,6- H 2,6- H 2,5- 2',5'- di CH.sub.3 di CH.sub.3 di CH.sub.3 di CH.sub.365 2,6- 2,6- 2,6- 2,6- 2,5- 2',5'- di CH.sub.3 di CH.sub.3 di CH.sub.3 di CH.sub.3 di CH.sub.3 di CH.sub.366 3-CH.sub.3 2,6- 3-CH.sub.3 2,6- 2,5- 2',5'- di CH.sub.3 di CH.sub. 3 di CH.sub.3 di CH.sub.367 4-CH.sub.3 2,6- 4-CH.sub.3 2,6- 2,5- 2',5'- di CH.sub.3 di CH.sub.3 di CH.sub.3 di CH.sub.368 3,4,5- H 3,4,5- H 2,5- 2',5'- tri CH.sub.3 tri CH.sub.3 di CH.sub.3 di CH.sub.369 3,4,5- 3,4,5- 3,4,5- 3,4,5- 2,5- 2',5'- tri CH.sub.3 tri CH.sub.3 tri CH.sub.3 tri CH.sub.3 di CH.sub.3 di CH.sub.370 3-CH.sub.3 3,4,5- 3-CH.sub.3 3,4,5- 2,5- 2',5'- tri CH.sub.3 tri CH.sub.3 di CH.sub.3 di CH.sub.371 4-CH.sub.3 3,4,5- 4-CH.sub.3 3,4,5- 2,5- 2',5'- tri CH.sub.3 tri CH.sub.3 di CH.sub.3 di CH.sub.372 3,5- 3,4,5- 3,5- 3,4,5- 2,5- 2',5'- di CH.sub.3 tri CH.sub.3 di CH.sub.3 tri CH.sub.3 di CH.sub.3 di CH.sub.373 4-CH.sub.3 H 4-CH.sub.3 H 3,5- 3'-5'- di CH.sub.3 di CH.sub.374 4-CH.sub.3 4-CH.sub.3 4-CH.sub.3 4-CH.sub.3 3,5- 3'-5'- di CH.sub.3 di CH.sub.375 3,5- H 3,5- H 3,5- 3'-5'- di CH.sub.3 di CH.sub.3 di CH.sub.3 di CH.sub.376 3,5- 3,5- 3,5- 3,5- 3,5- 3'-5'- di CH.sub.3 di CH.sub.3 di CH.sub.3 di CH.sub.3 di CH.sub.3 di CH.sub.377 3,4,5- H 3,4,5- H 3,5- 3'-5'- tri CH.sub.3 tri CH.sub.3 di CH.sub.3 di CH.sub.378 3,4,5- 3,4,5- 3,4,5- 3,4,5- 3,5- 3'-5'- tri CH.sub.3 tri CH.sub.3 tri CH.sub.3 tri CH.sub.3 di CH.sub.3 di CH.sub.379 3-OCH.sub.3 H 3-OCH.sub.3 H H H80 3-OCH.sub.3 3-OCH.sub.3 3-OCH.sub.3 3-OCH.sub.3 H H81 4-OCH.sub.3 H 4-OCH.sub.3 H H H82 4-OCH.sub.3 4-OCH.sub.3 4-OCH.sub.3 4-OCH.sub.3 H H83 3,5- H 3,5- H H H di OCH.sub.3 di OCH.sub.384 3,5- 3,5- 3,5- 3,5- H H di OCH.sub.3 di OCH.sub.3 di OCH.sub.3 di OCH.sub.385 3-OCH.sub.3 3,5- 3-OCH.sub.3 3,5- H H di OCH.sub.3 di OCH.sub.386 4-OCH.sub.3 3,5- 4-OCH.sub.3 3,5- H H di OCH.sub.3 di OCH.sub.387 2,6- H 2,6- H H H di OCH.sub.3 di OCH.sub.388 2,6- 2,6- 2,6- 2,6- H H di OCH.sub.3 di OCH.sub.3 di OCH.sub.3 di OCH.sub.389 3-OCH.sub.3 2,6- 3-OCH.sub.3 2,6- H H di OCH.sub.3 di OCH.sub.390 4-OCH.sub.3 2,6- 4-OCH.sub.3 2,6- H H di OCH.sub.3 di OCH.sub.391 3,4,5- H 3,4,5- H H H tri OCH.sub.3 tri OCH.sub.392 3,4,5- 3,4,5- 3,4,5- 3,4,5- H H tri OCH.sub.3 tri OCH.sub.3 tri OCH.sub.3 tri OCH.sub.393 3-OCH.sub.3 3,4,5- 3-OCH.sub.3 3,4,5- H H tri OCH.sub.3 tri OCH.sub.394 4-OCH.sub.3 3,4,5- 4-OCH.sub.3 3,4,5- H H tri OCH.sub.3 tri OCH.sub.395 3,5- 3,4,5- 3,5- 3,4,5- H H di OCH.sub.3 tri OCH.sub.3 tri OCH.sub.3 tri OCH.sub.396 H H H H 2-OCH.sub.3 2'-OCH.sub.397 3-OCH.sub. 3 H 3-OCH.sub.3 H 2-OCH.sub.3 2'-OCH.sub.398 3-OCH.sub.3 3-OCH.sub.3 3-OCH.sub.3 3-OCH.sub.3 2-OCH.sub.3 2'-OCH.sub.399 4-OCH.sub.3 H 4-OCH.sub.3 H 2-OCH.sub.3 2'-OCH.sub.3100 4-OCH.sub.3 4-OCH.sub.3 4-OCH.sub.3 4-OCH.sub.3 2-OCH.sub.3 2'-OCH.sub.3101 3,5- H 3,5- H 2-OCH.sub.3 2'-OCH.sub.3 di OCH.sub.3 di OCH.sub.3102 3,5- 3,5- 3,5- 3,5- 2-OCH.sub.3 2'-OCH.sub.3 di OCH.sub.3 di OCH.sub.3 di OCH.sub.3 di OCH.sub.3103 3-OCH.sub.3 3,5- 3-OCH.sub.3 3,5- 2-OCH.sub.3 2'-OCH.sub.3 di OCH.sub.3 di OCH.sub.3104 4-OCH.sub.3 3,5- 4-OCH.sub.3 3,5- 2-OCH.sub.3 2'-OCH.sub.3 di OCH.sub.3 di OCH.sub.3105 2,6- H 2,6- H 2-OCH.sub.3 2'-OCH.sub.3 di OCH.sub.3 di OCH.sub.3106 2,6- 2,6- 2,6- 2,6- 2-OCH.sub.3 2'-OCH.sub.3 di OCH.sub.3 di OCH.sub.3 di OCH.sub.3 di OCH.sub.3107 3-OCH.sub.3 2,6- 3-OCH.sub.3 2,6- 2-OCH.sub.3 2'-OCH.sub.3 di OCH.sub.3 di OCH.sub.3108 4-OCH.sub.3 2,6- 4-OCH.sub. 3 2,6- 2-OCH.sub.3 2'-OCH.sub.3 di OCH.sub.3 di OCH.sub.3109 3,4,5- H 3,4,5- H 2-OCH.sub.3 2'-OCH.sub.3 tri OCH.sub.3 tri OCH.sub.3110 3,4,5- 3,4,5- 3,4,5- 3,4,5- 2-OCH.sub.3 2'-OCH.sub.3 tri OCH.sub.3 tri OCH.sub.3 tri OCH.sub.3 tri OCH.sub.3111 3-OCH.sub.3 3,4,5- 3-OCH.sub.3 3,4,5- 2-OCH.sub.3 2'-OCH.sub.3 tri OCH.sub.3 tri OCH.sub.3112 4-OCH.sub.3 3,4,5- 4-OCH.sub.3 3,4,5- 2-OCH.sub.3 2'-OCH.sub.3 tri OCH.sub.3 tri OCH.sub.3113 3,5- 3,4,5- 3,5- 3,4,5- 2-OCH.sub.3 2'-OCH.sub.3 di OCH.sub.3 tri OCH.sub.3 di OCH.sub.3 tri OCH.sub.3114 H H H H 3-OCH.sub.3 3'-OCH.sub.3115 3-OCH.sub.3 H 3-OCH.sub.3 H 3-OCH.sub.3 3'-OCH.sub.3116 3-OCH.sub.3 3-OCH.sub.3 3-OCH.sub.3 3-OCH.sub.3 3-OCH.sub.3 3'-OCH.sub.3117 4-OCH.sub.3 H 4-OCH.sub.3 H 3-OCH.sub.3 3'-OCH.sub.3118 4-OCH.sub.3 4-OCH.sub.3 4-OCH.sub.3 4-OCH.sub.3 3-OCH.sub.3 3'-OCH.sub.3119 3,5- H 3,5- H 3-OCH.sub.3 3'-OCH.sub.3 di OCH.sub.3 di OCH.sub.3120 3,5- 3,5- 3,5- 3,5- 3-OCH.sub.3 3'-OCH.sub.3 di OCH.sub.3 di OCH.sub.3 di OCH.sub.3 di OCH.sub.3121 3-OCH.sub.3 3,5- 3-OCH.sub.3 3,5- 3-OCH.sub.3 3'-OCH.sub.3 di OCH.sub.3 di OCH.sub.3122 4-OCH.sub.3 3,5- 4-OCH.sub.3 3,5- 3-OCH.sub.3 3'-OCH.sub.3 di OCH.sub.3 di OCH.sub.3123 2,6- H 2,6- H 3-OCH.sub.3 3'-OCH.sub.3 di OCH.sub.3 di OCH.sub.3124 2,6- 2,6- 2,6- 2,6- 3-OCH.sub.3 3'-OCH.sub.3 di OCH.sub.3 di OCH.sub.3 di OCH.sub.3 di OCH.sub.3125 3-OCH.sub.3 2,6- 3-OCH.sub.3 2,6- 3-OCH.sub.3 3'-OCH.sub.3 di OCH.sub.3 di OCH.sub.3126 4-OCH.sub.3 2,6- 4-OCH.sub.3 2,6- 3-OCH.sub.3 3'-OCH.sub.3 di OCH.sub.3 di OCH.sub.3127 3,4,5- H 3,4,5- H 3-OCH.sub.3 3'-OCH.sub.3 tri OCH.sub.3 tri OCH.sub.3128 3,4,5- 3,4,5- 3,4,5- 3,4,5- 3-OCH.sub.3 3-OCH.sub.3 tri OCH.sub.3 tri OCH.sub.3 tri OCH.sub.3 tri OCH.sub.3129 3-OCH.sub.3 3,4,5- 3-OCH.sub.3 3,4,5- 3-OCH.sub.3 3' -OCH.sub.3 tri OCH.sub.3 tri OCH.sub.3130 4-OCH.sub.3 3,4,5- 4-OCH.sub.3 3,4,5- 3-OCH.sub.3 3'-OCH.sub.3 tri OCH.sub.3 tri OCH.sub.3131 3,5- 3,4,5- 3,5- 3,4,5- 3-OCH.sub.3 3'-OCH.sub.3 tri OCH.sub.3 tri OCH.sub.3 tri OCH.sub.3 tri OCH.sub.3132 H H H H 2,5- 2',5'- di OCH.sub.3 di OCH.sub.3133 3-OCH.sub.3 H 3-OCH.sub.3 H 2,5- 2',5'- di OCH.sub.3 di OCH.sub.3134 3-OCH.sub.3 3-OCH.sub.3 3-OCH.sub.3 3-OCH.sub.3 2,5,- 2',5'- di OCH.sub.3 di OCH.sub.3135 4-OCH.sub.3 H 4-OCH.sub.3 H 2,5,- 2',5'- di OCH.sub.3 di OCH.sub.3136 4-OCH.sub.3 4-OCH.sub.3 4-OCH.sub.3 4-OCH.sub.3 2,5,- 2',5'- di OCH.sub.3 di OCH.sub.3137 3,5- H 3,5- H 2,5,- 2',5'- di OCH.sub.3 di OCH.sub.3 di OCH.sub.3 di OCH.sub.3138 3,5- 3,5- 3,5- 3,5- 2,5- 2',5'- di OCH.sub.3 di OCH.sub.3 di OCH.sub.3 di OCH.sub.3 di OCH.sub.3 di OCH.sub.3139 3-OCH.sub.3 3,5- 3-OCH.sub.3 3,5- 2,5,- 2',5'- di OCH.sub.3 di OCH.sub.3 di OCH.sub.3 di OCH.sub.3140 4-OCH.sub.3 3,5- 4-OCH.sub.3 3,5- 2,5,- 2',5'- di OCH.sub.3 di OCH.sub.3 di OCH.sub.3 di OCH.sub.3141 2,6- H 2,6- H 2,5- 2',5'- di OCH.sub.3 di OCH.sub.3 di OCH.sub.3 di OCH.sub.3142 2,6- 2,6- 2,6- 2,6- 2,5- 2',5'- di OCH.sub.3 di OCH.sub.3 di OCH.sub.3 di OCH.sub.3 di OCH.sub.3 di OCH.sub.3143 3-OCH.sub.3 2,6- 3-OCH.sub.3 2,6- 2,5- 2',5'- di OCH.sub.3 di OCH.sub.3 di OCH.sub.3 di OCH.sub.3144 4-OCH.sub.3 2,6- 4-OCH.sub.3 2,6- 2,5- 2',5'- di OCH.sub.3 di OCH.sub.3 di OCH.sub.3 di OCH.sub.3145 3,4,5- H 3,4,5- H 2,5- 2',5'- tri OCH.sub.3 tri OCH.sub.3 di OCH.sub.3 di OCH.sub.3146 3,4,5- 3,4,5- 3,4,5- 3,4,5- 2,5- 2',5'- tri OCH.sub.3 tri OCH.sub.3 tri OCH.sub.3 tri OCH.sub.3 di OCH.sub.3 di OCH.sub.3147 3-OCH.sub.3 3,4,5- 3-OCH.sub.3 3,4,5- 2,5- 2',5'- tri OCH.sub.3 tri OCH.sub.3 di OCH.sub.3 di OCH.sub.3148 4-OCH.sub.3 3,4,5- 4-OCH.sub.3 3,4,5- 2,5- 2',5'- tri OCH.sub.3 tri OCH.sub.3 di OCH.sub.3 di OCH.sub.3149 3,5- 3,4,5- 3,5- 3,4,5- 2,5- 2',5'- di OCH.sub.3 tri OCH.sub.3 di OCH.sub.3 tri OCH.sub.3 di OCH.sub.3 di OCH.sub.3150 4-OCH.sub.3 H 4-OCH.sub.3 H 3,5- 3'-5'- di OCH.sub.3 di OCH.sub.3151 4-OCH.sub.3 4-OCH.sub.3 4-OCH.sub.3 4-OCH.sub.3 3,5- 3'-5'- di OCH.sub.3 di OCH.sub.3152 3,5- H 3,5- H 3,5- 3'-5'- di OCH.sub.3 di OCH.sub.3 di OCH.sub.3 di OCH.sub.3153 3,5- 3,5- 3,5- 3,5- 3,5- 3'-5'- di OCH.sub.3 di OCH.sub.3 di OCH.sub.3 di OCH.sub.3 di OCH.sub.3 di OCH.sub.3154 3,4,5- H 3,4,5- H 3,5- 3',5'- tri OCH.sub.3 tri OCH.sub.3 di OCH.sub.3 di OCH.sub.3155 3,4,5- 3,4,5- 3,4,5- 3,4,5- 3,5- 3',5'- tri OCH.sub.3 tri OCH.sub.3 tri OCH.sub.3 tri OCH.sub.3 di OCH.sub.3 di OCH.sub.3156 3-Cl H 3-Cl H H H157 3-Cl 3-Cl 3-Cl 3-Cl H H158 4-Cl H 4-Cl H H H159 4-Cl 4-Cl 4-Cl 4-Cl H H160 3,5- H 3,5- H H H di Cl di Cl161 3,5- 3,5- 3,5- 3,5- H H di Cl di Cl di Cl di Cl162 3-Cl 3,5- 3-Cl 3,5- H H di Cl di Cl163 4-Cl 3,5- 4-Cl 3,5- H H di Cl di Cl164 2,6- H 2,6- H H H di Cl di Cl165 2,6- 2,6- 2,6- 2,6- H H di Cl di Cl di Cl di Cl166 3-Cl 2,6- 3-Cl 2,6- H H di Cl di Cl167 4-Cl 2,6- 4-Cl 2,6- H H di Cl di Cl168 3,4,5- H 3,4,5- H H H tri Cl tri Cl169 3,4,5- 3,4,5- 3,4,5- 3,4,5- H H tri Cl tri Cl tri Cl tri Cl170 3-Cl 3,4,5- 3-Cl 3,4,5- H H tri Cl tri Cl171 4-Cl 3,4,5- 4-Cl 3,4,5- H H tri Cl tri Cl172 3,5- 3,4,5- 3,5- 3,4,5- H H di Cl tri Cl di Cl tri Cl173 H H H H 2-Cl 2'-Cl174 3-Cl H 3-Cl H 2-Cl 2'-Cl175 3-Cl 3-Cl 3-Cl 3-Cl 2-Cl 2'-Cl176 4-Cl H 4-Cl H 2-Cl 2'-Cl177 4-Cl 4-Cl 4-Cl 4-Cl 2-Cl 2'-Cl178 3,5- H 3,5- H 2-Cl 2'-Cl di Cl di Cl179 3,5- 3,5- 3,5- 3,5- 2-Cl 2'-Cl di Cl di Cl di Cl di Cl180 3-Cl 3,5- 3-Cl 3,5- 2-Cl 2'-Cl di Cl di Cl181 4-Cl 3,5- 4-Cl 3,5- 2-Cl 2'-Cl di Cl di Cl182 2,6- H 2,6- H 2-Cl 2'-Cl di Cl di Cl183 2,6- 2,6- 2,6- 2,6- 2-Cl 2'-Cl di Cl di Cl di Cl di Cl184 3-Cl 2,6- 3-Cl 2,6- 2-Cl 2'-Cl di Cl di Cl185 4-Cl 2,6- 4-Cl 2,6- 2-Cl 2'-Cl di Cl di Cl186 3,4,5- H 3,4,5- H 2-Cl 2'-Cl tri Cl tri Cl187 3,4,5- 3,4,5- 3,4,5- 3,4,5- 2-Cl 2'-Cl tri Cl tri Cl tri Cl tri Cl188 3-Cl 3,4,5- 3-Cl 3,4,5- 2-Cl 2'-Cl tri Cl tri Cl189 4-Cl 3,4,5- 4-Cl 3,4,5- 2-Cl 2'-Cl tri Cl tri Cl190 3,5- 3,4,5- 3,5- 3,4,5- 2-Cl 2'-Cl di Cl tri Cl di Cl tri Cl191 H H H H 3-Cl 3'-Cl192 3-Cl H 3-Cl H 3-Cl 3'-Cl193 3-Cl 3-Cl 3-Cl 3-Cl 3-Cl 3'-Cl194 4-Cl H 4-Cl H 3-Cl 3'-Cl195 4-Cl 4-Cl 4-Cl 4-Cl 3-Cl 3'-Cl196 3,5- H 3,5- H 3-Cl 3'-Cl di Cl di Cl197 3,5- 3,5- 3,5- 3,5- 3-Cl 3'-Cl di Cl di Cl di Cl di Cl198 3-Cl 3,5- 3-Cl 3,5- 3-Cl 3'-Cl di Cl di Cl199 4-Cl 3,5- 4-Cl 3,5- 3-Cl 3'-Cl di Cl di Cl200 2,6- H 2,6- H 3-Cl 3'-Cl di Cl di Cl201 2,6- 2,6- 2,6- 2,6- 3-Cl 3'-Cl di Cl di Cl di Cl di Cl202 3-Cl 2,6- 3-Cl 2,6- 3-Cl 3'-Cl di Cl di Cl203 4-Cl 2,6- 4-Cl 2,6- 3-Cl 3'-Cl di Cl di Cl204 3,4,5- H 3,4,5- H 3-Cl 3'-Cl tri Cl tri Cl205 3,4,5- 3,4,5- 3,4,5- 3,4,5- 3-Cl 3'-Cl tri Cl tri Cl tri Cl tri Cl206 3-Cl 3,4,5- 3-Cl 3,4,5- 3-Cl 3'-Cl tri Cl tri Cl207 4-Cl 3,4,5- 4-Cl 3,4,5- 3-Cl 3'-Cl tri Cl tri Cl208 3,5- 3,4,5- 3,5- 3,4,5- 3-Cl 3'-Cl di Cl tri Cl di Cl tri Cl209 H H H H 2,5- 2',5'- di Cl di Cl210 3-Cl H 3-Cl H 2,5- 2',5'- di Cl di Cl211 3-Cl 3-Cl 3-Cl 3-Cl 2,5- 2',5'- di Cl di Cl212 4-Cl H 4-Cl H 2,5- 2',5'- di Cl di Cl213 4-Cl 4-Cl 4-Cl 4-Cl 2,5- 2',5'- di Cl di Cl214 3,5- H 3,5- H 2,5- 2',5'- di Cl di Cl di Cl di Cl215 3,5- 3,5- 3,5- 3,5- 2,5- 2',5'- di Cl di Cl di Cl di Cl di Cl di Cl216 3-Cl 3,5- 3-Cl 3,5- 2,5- 2',5'- di Cl di Cl di Cl di Cl217 4-Cl 3,5- 4-Cl 3,5- 2,5- 2',5'- di Cl di Cl di Cl di Cl218 2,6- H 2,6- H 2,5- 2',5'- di Cl di Cl di Cl di Cl219 2,6- 2,6- 2,6- 2,6- 2,5- 2',5'- di Cl di Cl di Cl di Cl di Cl di Cl220 3-Cl 2,6- 3-Cl 2,6- 2,5- 2',5'- di Cl di Cl di Cl di Cl221 4-Cl 2,6- 4-Cl 2,6- 2,5- 2',5'- di Cl di Cl di Cl di Cl222 3,4,5- H 3,4,5- H 2,5- 2',5'- tri Cl tri Cl di Cl di Cl223 3,4,5- 3,4,5- 3,4,5- 3,4,5- 2,5- 2',5'- tri Cl tri Cl tri Cl tri Cl di Cl di Cl224 3-Cl 3,4,5- 3-Cl 3,4,5- 2,5- 2',5'- tri Cl tri Cl di Cl di Cl225 4-Cl 3,4,5- 4-Cl 3,4,5- 2,5- 2',5'- tri Cl tri Cl di Cl di Cl226 3,5- 3,4,5- 3,5- 3,4,5- 2,5- 2',5'- di Cl tri Cl di Cl tri Cl di Cl di Cl227 4-Cl H 4-Cl H 3,5- 3',5'- di Cl di Cl228 4-Cl 4-Cl 4-Cl 4-Cl 3,5- 3',5'- di Cl di Cl229 3,5- H 3,5- H 3,5- 3',5'- di Cl di Cl di Cl di Cl230 3,5- 3,5- 3,5- 3,5- 3,5- 3',5'- di Cl di Cl di Cl di Cl di Cl di Cl231 3,4,5- H 3,4,5- H 3,5- 3',5'- tri Cl tri Cl di Cl di Cl232 3,4,5- 3,4,5- 3,4,5- 3,4,5- 3,5- 3',5'- tri Cl tri Cl tri Cl tri Cl di Cl di Cl233 H 2,4- H 2,4- H H di CH.sub.3 di CH.sub.3__________________________________________________________________________
The benzidine derivatives represented by the aforementioned general formula (2) are used either singly or jointly in the form of a mixture of two or more members. The benzidine derivatives represented by the aforementioned general formula (2) are excellent in stability to resist light and do not yield to such reactions as isomerization on exposure to light. The benzidine derivatives possess high degrees of drift mobility and have small dependency for drift mobility upon the intensity of an electric field.
The sensitive material of high sensitivity and low residual potential is obtained by producing a photosensitive layer using a benzidine derivative represented by the aforementioned general formula (2) in combination with a pyrrolopyrrole type compound represented by the aforementioned general formula (1). This sensitive material produces images of high quality free from fogging.
The compounds represented by the aforementioned general formula (2) can be produced by using any of various methods. They may be produced, for example, by causing a compound represented by the following general formula (3) to react with compounds represented by the following general formulas (4) to (7) simultaneously or sequentially. ##STR5## (wherein R 5 , R 6 , R 7 , R 8 , R 9 , R 10 , l, m, n, o, p, and q have the same meanings as defined above and X stands for a halogen atoms such as iodine).
The reaction of the compound represented by the aforementioned general formula (3) with the compounds represented by the aforementioned general formulas (4) to (7) is generally carried out in an organic solvent. Any of the organic solvents available at all may be used for this reaction on the sole condition that the solvent to be used in incapable of adversely affecting the solution. As concrete examples of the organic solvent, there may be cited nitrobenzene, dichlorobenzene, quinoline, N,N-dimethylformamide, N-methylpyrrolidone, and dimethylsulfoxide. The reaction is generally carried out at a temperature in the range of 150° to 250° C. in the presence of a metal or metal oxide catalyst such as copper powder, copper oxide, or a copper halogenide or a basic catalist such as sodium hydroxide, potassium hydroxide, sodium carbonate, potassium carbonate, sodium hydrogen carbonate, or potassium hydrogen carbonate.
Of the benzidine derivative compounds represented by the aforementioned general formula (2), those which have the substituents R 5 , R 6 , R 7 , R 8 , R 9 and R 10 attached at regulated positions can be produced, for example, by causing a compound represented by the following general formula (8) to react with compounds represented by the general formulas (4) and (6) thereby producing a compound represented by the general formula (9), then deacylating the compound represented by the general formula (9) by means of hydrolysis thereby producing a compound represented by the general formula (10), and further causing the compound of the general formula (10) to react with compounds represented by the general formulas (5) and (7). ##STR6## (wherein R 1 and R 2 each stand for a lower alkyl group and R 5 , R 6 , R 7 , R 8 , R 9 , R 10 , l, m, n, o, p, q and X have the same meanings as defined above).
The reaction of the compound represented by the aforementioned general formula (8) with the compounds represented by the aforementioned general formulas (4) and (6) can be carried out in the same manner as the reaction of the compound represented by the aforementioned general formula (3) with the compounds represented by the aforementioned general formulas (4) to (7). The reaction for the deacylation of the compound represented by the general formula (9) can be carried out by the conventional method in the presence of a basic catalyst. The reaction of the compound represented by the aforementioned general formula (10) with the compounds represented by the general formulas (5) and (7) can be carried out in the same manner as the reaction of the compound represented by the aforementioned general formula (3) with the compounds represented by the general formulas (4) to (7).
Of the benzidine derivatives represented by the aforementioned general formula (2), those compounds whose substituents R 5 , R 6 , R 7 , R 8 , R 9 and R 10 are invariable halogen atoms may be produced by causing a compound represented by the aforementioned general formula (10) to react with compounds represented by the general formulas (5) and (7) and subsequently halogenating the resultant reaction product.
After the reaction is completed, the reaction mixture is concentrated. Optionally, the concentrated reaction mixture may be further separated and purified by any of the conventional means such as recrystallization, extraction from a solvent, and column chromatography.
The sensitive material is produced with high sensitivity and low residual potential by preparing a photosensitive layer using a benzidine derivative represented by the aforementioned general formula (2) in combination with a pyrrolopyrrole type compound represented by the aforementioned general formula (1). These reactants, when necessary, may be used further in combination with other electric charge transferring material in a ratio incapable of impairing the charging property and the photosensitive property. As concrete examples of the other electric charge transferring material usable herein, there may be cited tetracyanoethylene, fluorenone type compounds such as 2,4,7-trinitro-9-fluorenone, nitrated compounds such as 2,4,8-trinitrothioxanthone and dinitroanthracene, succinic anhydride, maleic anhydride, dibromomaleic anhydride, oxadiazole type compounds such as 2,5-di(4-dimethylaminophenyl)-1,3,4-oxadiazole, styryl type compounds such as 9-(4-diethylaminostyryl)anthracene, carbazole type compounds such as polyvinyl carbazole, pyrazoline type compounds such as 1-phenyl-3-(p-dimethylaminophenyl)pyrazoline, amine derivatives such as 4,4',4"-tris(4-diethylaminophenyl)triphenylamine, conjugate type compounds such as 1,1-diphenyl-4,4-bis(4-dimethylaminophenyl)-1,3-butadiene, hydrazone type compounds such as 4-(N,N-diethylamino)benzaldehyde-N,N-diphenyl hydrazone, nitrogen-containing cyclic compounds such as indole type compounds, oxazole type compounds, isooxazole type compounds, thiazole type compounds, thiadiazole type compounds, imidazole type compounds, pyrazole type compounds, and triazole type compounds, and condensed polycyclic compounds. In the photoconductive polymers cited as electric charge transferring materials above, poly-N-vinyl carbazole, for example, may be used as a binding resin.
The photosensitive layer may incorporate therein various additives such as the conventional sensitizes represented by terphenyl, halonaphthoquinones, and acenaphtylene, quenchers represented by fluorene type compounds like 9-(N,N-diphenylhydrazino)fluorene and 9-carbazolyliminofluorene, plasticizer, and deterioration inhibitors represented by antioxidant and ultraviolet absorbent.
The photosensitive layer containing a pyrrolopyrrole type compound as an electric charge generating material represented by the aforementioned general formula (1) and a benzidine derivative as electric charge transferring material represented by the aforementioned general formula (2) may be either a single layer type photosensitive layer containing the pyrrolopyrrole type compound represented by the aforementioned general formula (1), the benzidine derivative represented by the aforementioned general formula (2), and a binding resin or a laminate type photosensitive layer composed of an electric charge generating layer containing the pyrrolopyrrole type compound represented by the aforementioned general formula (1) and an electric charge transferring layer containing the benzidine derivative represented by the aforementioned general formula (2) and a binding resin. The construction of the laminate type photosensitive layer is either such that the electric charge transferring layer is superposed on the electric charge generating layer or such that the electric charge generating layer is superposed on the electric charge transferring layer.
A wide variety of binding resins are available for the use mentioned above. The binding resins useful herein include styrene type polymers, acryl type polymers, styrene-acryl type copolymers, olefin type polymers such as polyethylene, ethylene-vinyl acetate copolymers, chlorinated polyethylene, polypropylene, and ionomers, polyvinyl chloride, vinyl chloride-vinyl acetate copolymers, polyesters, alkyd resins, polyamides, polyurethanes, epoxy resins, polycarbonates, polyallylates, polysulfones, diallylphthalate resins, silicone resins, ketone resins, polyvinyl butyral resins, polyether resins, phenol resins, photosetting resins such as epoxy acrylates, and various polymers, for example. These binding resins may be used either singly or jointly in the form of a mixture of two or more members.
In the formation of the single layer type photosensitive layer, the mixing ratio of the pyrrolopyrrole type compounds represented by the general formula (1) and the benzidine derivative represented by the general formula (2) is not specifically restricted but may be suitably selected to fit the properties the electrophotographic selective material is desired to possess. The proportion of the pyrrolopyrrole type compound is desired to be in the range of 2 to 20 parts by weight, preferably 3 to 15 parts by weight, and that of the benzidine derivative in the range of 40 to 200 parts by weight, preferably 50 to 100 parts by weight, based on 100 parts by weight of the binding resin. If the amounts of the pyrrolopyrrole type compound and the benzidine derivative are less than the lower limits of their ranges mentioned above, the sensitive material suffers from insufficient sensitivity and unduly high residual potential. If these amounts exceed the upper limits of their range, the sensitive material is deficient in wear resistance.
The single layer type photosensitive layer may be formed in a suitable thickness. This thickness is desired to be in the range of 10 to 50 μm, preferably 15 to 25 μm.
The electric charge generating layer of the laminate type photosensitive layer may be formed of a film obtained by vacuum depositing or spattering a pyrrolopyrrole type compound represented by the aforementioned general formula (1). In the case of the electric charge generating layer which is formed in combination with a binding resin, the mixing ratio of the pyrrolopyrrole type compound and the binding resin in the electric charge generating layer may be suitably selected. Generally the proportion of the pyrrolopyrrole type compound is desired to be in the range of 5 to 500 parts by weight, preferably 10 to 250 parts by weight, based on 100 parts by weight of the binding resin. If the amount of the pyrrolopyrrole type compound is less than 5 parts by weight, there ensues a disadvantage that the electric charge generating layer is deficient in electric charging capacity. If this amount exceeds 500 parts by weight, there arises a disadvantage that the electric charge generating layer suffers from inferior tightness of adhesion.
The electric charge generating layer may be formed in a suitable thickness. This thickness is desired to be approximately in the range of 0.01 to 3 μm, preferably 0.1 to 2 μm.
In the formation of the electric charge transferring layer, the mixing ratio of the binding resin and the benzidine derivative represented by the general formula (2) may be suitably selected. The proportion of the benzidine derivative is desired to be in the range of 10 to 500 parts by weight, preferably 25 to 200 parts by weight, based on 100 parts by weight of the binding resin. If the amount of the benzidine derivative is less than 10 parts by weight, the electric charge transferring layer is deficient in electric charge transferring capacity. If this amount exceeds 500 parts by weight, the electric charge transferring layer suffers from poor mechanical strength.
The electric charge transferring layer may be formed in a suitable thickness. This thickness is desired to be approximately in the range of 2 to 100 μm, preferably 5 to 30 μm.
The electric charge generating layer may contain the aforementioned benzidine derivative as an electric charge transferring material in addition to the pyrrolopyrrole type compound as an electric charge generating material. In this case, the mixing ratio of the pyrrolopyrrole type compound, the benzidine derivative, and the binding resin may be suitable selected. This mixing ratio is desired to be similar to that of the pyrrolopyrrole type compound, the benzidine derivative, and the binding resin in the aforementioned single layer type photosensitive layer. The electric charge generating layer may be formed in a suitable thickness. Generally, this thickness is approximately in the range of 0.1 to 50 μm.
The single layer type photosensitive layer can be formed by preparing a photosensitive layer coating liquid containing the aforementioned pyrrolopyrrole type compound, the aforementioned benzidine derivative, and the aforementioned binding resin, applying this coating liquid to the aforementioned electroconductive substrate, and drying or setting the applied layer of the coating liquid.
The laminate type photosensitive layer can be formed by preparing an electric charge generating layer coating liquid containing the aforementioned pyrrolopyrrole type compound, the aforementioned binding resin, etc. and an electric charge transferring layer coating liquid containing the aforementioned benzidine derivative, the aforementioned binding resin, etc., applying the coating liquids sequentially to the electroconductive substrate, and drying or setting the applied layers of the coating liquids.
In the preparation of the coating liquids mentioned above, a varying kind of organic solvent selected to suit the particular kind of binding resin to be adopted may be used. The organic solvents useful herein include aliphatic hydrocarbons such as n-hexane, octane, and cyclohexane; aromatic hydrocarbons such as benzene, toluene, and xylene; halogenated hydrocarbons such as dichloromethane, dichloroethane, carbon tetrachloride, and chlorobenzene; ethers such as dimethyl ether, diethyl ether, tetrahydrofuran, ethylene glycol dimethyl ether, ethylene glycol diethyl ether, and diethylene glycol dimethyl ether; ketones such as acetone, methylethyl ketone and cyclohexanone; esters such as ethyl acetate and methyl acetate; dimethyl formamide; and dimethyl sulfoxide, for example. These organic solvents may be used either singly or jointly in the form of one or more members. Further in the preparation of the coating liquids mentioned above, a surfactant, a leveling agent, etc. may be added for the purpose of enhancing dispersibility and coating property.
The coating liquids can be prepared by the conventional method using a mixing device such as, for example, a mixer, a ball mill, a paint shaker, a sand mill, an attriter, or an ultrasonic dispersion device. The electrophotographic sensitive material contemplated by the present invention can be obtained by sequentially applying the coating liquids to the aforementioned electroconductive substrate and thereafter heating the applied layers of the coating liquid to expel the solvent.
Optionally, for the purpose of enhancing the tightness of adhesion between the aforementioned electroconductive substrate and the photosensitive layer, an undercoating layer may be formed between the electroconductive substrate and the photosensitive layer. In this case, the undercoating layer is formed by applying to a given surface a solution containing a natural or synthetic macromolecule in an amount calculated to form a dry film approximately 0.01 to 1 μm in thickness.
For the purpose of enhancing the tightness of adhesion between the electroconductive substrate and the photosensitive layer, the electroconductive substrate may be treated with a surface treating agent such as, for example, a silane coupling agent or a titanium coupling agent.
Then, for the purpose of protecting the aforementioned photosensitive layer, a surface protecting layer may be formed on the photosensitive layer. The surface protecting layer is formed by preparing a mixed liquid consisting of various binding resins mentioned above or of a binding resin and additives such as a deterioration preventing agent and applying to a given surface this mixed liquid in an amount calculated to produce a dry layer 0.1 to 10 μm in thickness. Preferably, this thickness is approximately in the range of 0.2 to 5 μm.
The electrophotographic sensitive material of the present invention excels in stability to withstand light and in sensitivity and enjoys high surface potential because the photosensitive layer thereof contains a pyrrolopyrrole type compound represented by the aforementioned general formula (1) and a benzidine derivative represented by the aforementioned general formula (2). The electrophotographic sensitive material of the present invention, therefore, can be used advantageously in a copying machine, a laser beam printer, etc.
DETAILED DESCRIPTION OF THE EMBODIMENTS
Now, the present invention will be described more specifically below with reference to working examples.
Electrophotographic sensitive materials possessed of a laminated type photosensitive layer were produced as follows, using various pyrrolopyrrole type compounds and various benzidine derivatives shown in the foregoing table.
Pyrrolopyrrole type compounds
The pyrrolopyrrole type compounds mentioned above are identified by the following symbols in Tables 1 to 3.
A: 1,4-Dithioketo-3,6-diphenylpyrrolo[3,4-c]pyrrole
B: 1,4-Dithioketo-3,6-di(4-tolyl)pyrrolo[3,4-c]pyrrole
C: 1,4-Dithioketo-3,6-di(4-methoxyphenyl)pyrrolo[3,4-c]pyrrole
D: 1,4-Diketo-3,6-diethylpyrrolo[3,4-c]pyrrole
E: N,N'-Diethyl-1,4-dithioketo-3,6-di-tert-butylpyrrolo[3,4-c]pyrrole
F: 1,4-Dithioketo-3,6-distearylpyrrolo[3,4-c]pyrrole
G: N,N'-Dimethyl-1,4-dithioketo-3,6-dibenzylpyrrolo[3,4-c]pyrrole
M: 1,4-Dithioketo-3,6-dinaphthylpyrrolo[3,4-c]pyrrole
I: 1,4-Dithioketo-3,6-di(4-pyridyl)pyrrolo[3,4-c]pyrrole
J: N,N'-Diethyl-1,4-dithioketo-3,6-di(2-quinolyl)pyrrolo[3,4-c]pyrrole
K: N,N'-Diethyl-1,4-dithioketo-3,6-di(4-chlorophenyl)pyrrolo[3,4-c]pyrrole
L: 1,4-Dithioketo-3,6-di[4-(2,2,2-trifluoroethyl)phenyl]pyrrolo[3,4-c]pyrrole
M: 1,4-Dithioketo-3,6-di(4-diethylaminophenyl)pyrrolo[3,4-c]pyrrole
N: N,N'-Dimethyl-1,4-dithioketo-3,6-di(4-hexyloxyphenyl)pyrrolo[3,4-c]pyrrole
C: 1,4-Dithioketo-3,6-di(4-cyanophenyl)pyrrolo[3,4-c]pyrrole
P: 1,4-Dithioketo-3,6-di(2-bromophenyl)pyrrolo[3,4-c]pyrrole
Q: N,N'-Diethyl-1,4-dithioketo-3,6-di(4-dodecylphenyl)pyrrolo[3,4-c]pyrrole
EXAMPLE 1 to 22
An electric charge generating layer coating liquid consisting of 2parts by weight of a varying pyrrolo-pyrrole type compound indicated above, 1 part by weight of a vinyl chloride-vinyl acetate copolymer (produced by Sekisui Chemical Co., Ltd. and marketed under trademark designation of "S-lec C"), and 10.7 parts by weight of tetrahydrofuran was prepared, applied to an aluminum sheet, and heated at a temperature of 100° C. for 30 minutes to produce an electric charge generating layer about 0.5 μm in thickness.
Then, an electric charge transferring layer was formed using a varying benzidine derivative identified by Compound No. in the preceding table as an electric charge transferring material. Specifically, an electric charge transferring layer coating liquid was prepared by mixing and dissolving 8 parts by weight of a varying compound indicated in Tables 1 to 3, 10 parts by weight of a bisphenol Z type polycarbonate (produced by Mitsubishi Gas Chemical Industries Ltd. and marketed under product code of "PCZ"), and 90 parts by weight of benzene. The coating liquid was applied to the aforementioned electric charge generating layer and dried by heating to form an electric charge transferring layer about 25 μm in thickness. Thus, there was produced an electrophotographic sensitive material possessed of a laminate type photosensitive layer.
COMPARATIVE EXAMPLE 1
An electrophotographic sensitive material possessed of a laminate type photosensitive layer was obtained by following the procedure of Example 1, except that N-ethyl-3-carbazolylaldehyde-N,N-diphenyl hydrazone (described as Compound I hereinafter) was used in the place of the benzidine derivative.
COMPARATIVE EXAMPLE 2
An electrophotographic sensitive material possessed of a laminate type photosensitive layer was obtained by following the procedure of Example 2, except that β type metal-free phtalocyanine (produced by BASF and marketed under trademark designation of "Heliogen Blue-7800") and 4-styryl-4'-methoxytriphenylamine (described as Compound II hereinafter) were used in the place of the pyrrolopyrrole type compound and the benzidine derivative.
COMPARATIVE EXAMPLE 3
An electrophotographic sensitive material possessed of a laminate type photosensitive layer was obtained by following the procedure of Example 3, except that β type metal-free phthalocyanine (produced by BASF and marketed under trademark designation of "Heliogen Blue-7800") and 4-(3,5-dimethylstyryl-4'-methyltriphenylamine (described as Compound III hereinafter) were used in the place of the pyrrolopyrrole type compound and the benzidine derivative.
COMPARATIVE EXAMPLES 4-10
An electrophotographic sensitive material possessed of a laminate type sensitive layer was obtained by following the procedure of Example 1, except that each aromatic amine indicated by the following IV-X was used in the place of the benzidine derivative of Example 1.
______________________________________Compound______________________________________IV 4-(N,N-diethylamino)benzaldehyde-N, N-diphenylhydrazonV di[2-methyl-4-(diethylamino)phenyl]-phenyl-methaneVI 1-phenyl-3-(p-diethylaminophenylvinylene)-5-(p- diethylaminophenyl)pyrazolineVII 4,4'-(N-phenyl-N-ethylamino)biphenylVIII triphenylamineIX 2,5-di(4-diethylaminophenyl)-1,3,4-oxadiazoleX polyvinylcarbazole.______________________________________
To test for charging property and sensitive property, the electrophotographic sensitive materials obtained in Examples 1 to 22 and Comparative Examples 1-10 were each negatively charged by exposure to corona discharge generated under the condition of -6.0 KV in an electrostatic test copier (produced by Kawaguchi Denki K. K. and marketed under product code of "SP-428"). The initial surface potential, V s.p. (V), of each electrophotographic sensitive material was measured and, at the same time, the surface of the sensitive material was exposed to the light from a tungsten lamp of 10 luxes to clock the time required for the aforementioned surface potential, V s.p., to decrease to 1/2 the initial magnitude and calculated the half-life exposure, E 1/2 (uJ/cm 2 ). The surface potential measured on elapse of 0.15 second following the exposure was reported as residual potential, V r.p. (V).
The results of the test of the electrophotographic sensitive materials of Examples 1 to 22 and Comparative Examples 1-10 for charging property and sensitive property are shown in Tables 1 to 3.
TABLE 1______________________________________ Com-Pyrrolo-pyrrole pound E 1/2 Vs. p. Vr. p.type compound No. (μJ/cm.sup.2) (V) (V)______________________________________Example 1 A 2 9.75 -689 -23Example 2 A 10 7.24 -680 -18Example 3 A 22 7.45 -678 -26Example 4 A 80 7.31 -773 -16Example 5 A 158 7.45 -670 -26Example 6 B 3 8.32 -695 -20Example 7 C 6 9.81 -688 -22Example 8 D 9 8.27 -678 -18Example 9 E 12 8.51 -692 -24Example 10 F 15 9.71 -703 -22______________________________________
TABLE 2______________________________________ Com-Pyrrolo-pyrrole pound E 1/2 Vs. p. Vr. p.type compound No. (μJ/cm.sup.2) (V) (V)______________________________________Example 11 G 19 9.27 -710 -19Example 12 H 30 8.67 -682 -20Example 13 I 38 9.85 -679 -18Example 14 J 50 8.12 -684 -17Example 15 K 74 8.76 -692 -21Example 16 L 77 9.81 -680 -18Example 17 M 82 9.67 -669 -17Example 18 N 148 8.92 -682 -25Example 19 O 154 8.60 -690 -23Example 20 P 156 7.52 -684 -18______________________________________
TABLE 3______________________________________ Pyrrolo- pyrrole Com- type pound E 1/2 Vs. p. Vr. p. compound No. (μJ/cm.sup.2) (V) (V)______________________________________Example 21 Q 198 8.09 -698 -24Example 22 A 233 6.73 -782 -13Comparative A I 15.33 -736 -52Example 1Comparative -- II 19.81 -693 -62Example 2Comparative -- III 18.63 -684 -52Example 3Comparative A IV 17.23 -725 -68Example 4Comparative A V 16.84 -713 -72Example 5Comparative A VI 20.51 -729 -75Example 6Comparative A VII 26.33 -698 -98Example 7Comparative A VIII 30.28 -707 -120Example 8Comparative A IX 23.16 -716 -76Example 9Comparative A X 25.47 -710 -103Example 10______________________________________
It is noted from Tables 1 to 3, the electrophotographic sensitive materials of Comparative Examples 1-10 were invariably low in sensitivity and high in residual potential. In contrast, the electrophotographic sensitive materials of Examples 1 to 22 were invariably high in sensitivity and low in residual potential.
The test has demonstrated that the electrophotographic sensitive material of Example 22 particularly excelled in charging property and sensitivity and, at the same time, possessed very low residual potential.
The high sensitivity of the electrophotographic sensitive material of Example 22 may be explained by the following reasons (1) to (3).
(1) Since the ionization potential (IP) of No. 233 (4,4-bis[N-(2,4-dimethylphenyl-N-phenylamino]diphenyl) which is 5.43 eV is smaller that of A (1,4-dithioketo-3,6-diphenylpyrrolo[3,4-c]pyrrole) which is 5.46 eV, the injection of holes from A into No. 233 encounters no energy barrier. As the result, the injection of holes is carried out efficiently.
(2) Since the difference between the IP of A and that of No. 233 is as small as 0.03 eV, the possibility of A's IP surface level existing between the IP of A and that of No. 233 is very low even if A has an IP surface level (the IP level originating in the irregularity of molecular configuration on the surface of A existing as microcrystals). As the result, the holes are quickly injected from A into No. 233 without being trapped in route.
(3) Since the difference between the IP of A and that of No. 233 is very slight as mentioned above, the energy (Gibbs free energy difference, ΔG) radiated from A during the injection of holes from A into No. 233 is small. Otherwise, the surrounding binding resin, for example, generates electric dipoles on exposure to the radiated energy. The electric dipoles are oriented in the holes (cationic radicals) injected into No. 233 to help stabilize the holes. Thus, the possibility of the intermolecular transfer of holes in No. 233 being impeded by the stabilization of holes is extremely low.
EXAMPLES 23-33
A photosensitive layer coating liquid was prepared by mixing and dispersing with ball mill for 24 hours 8 parts by weight of a varying pyrrolopyrrole type compound indicated above, 100 parts by weight of benzidine derivative described as Compound No. in Tables aforementioned, 100 parts by weight of a bisphenol Z type polycarbonate (produced by Mitsubishi Gas Chemical Industries Ltd. and marketed under product code of "PCZ"), and 900 parts by weight of dichrolomethane. The coating liquid was applied to an aluminum sheet and dried by heating at a temperature of 100° C. for 30 minutes to produce a single type photosensitive layer of about 18 μm in thickness. Thus, there was produced an electrophotographic sensitive material.
COMPARATIVE EXAMPLES 11-12
An electrophotographic sensitive material possessed of a single layer type photosensitive layer was obtained by following the procedure of Example 23, except that Compounds IV and V aforementioned respectively were used in the place of the benzidine derivative.
The electrophotographic sensitive materials obtained in Examples 23-33 and Comparative Examples 11-12 for charging property and sensitive property are examined by following the procedure of Examples 1-22. The results of the test are shown in Table 4.
TABLE 4______________________________________ Pyrrolo- pyrrole Com- type pound E 1/2 Vs. p. Vr. p. compound No. (μJ/cm.sup.2) (V) (V)______________________________________Example 23 A 233 7.33 +726 +47Example 24 A 2 8.77 +716 +55Example 25 A 4 9.12 +730 +63Example 26 A 23 8.98 +718 +58Example 27 A 38 9.26 +700 +68Example 28 A 79 9.45 +698 +72Example 29 B 233 7.92 +710 +53Example 30 C 2 8.69 +720 +57Example 31 D 23 9.61 +731 +67Example 32 E 79 8.84 +725 +65Example 33 F 233 8.22 +705 +69Comparative A IV 16.57 +701 +85Example 11Comparative A V 17.21 +729 +93Example 12______________________________________
It is noted from Table 4 that the electrophotographic sensitive materials of Comparative Examples 11-12 were invariably low in sensitivity and high in residual potential. In contrast, the electrophotographic sensitive materials of Examples 23-33 were invariably high in sensitivity and low in residual potential.
As described above, the electrophotographic sensitive material of the present invention enjoys high sensitivity and low residual potential because the photosensitive layer thereof contains a pyrrolopyrrole type compound represented by the aforementioned general formula (1) and a benzidine derivative represented by the aforementioned general formula (2). | An electrophotographic sensitive material is provided which has a photosensitive layer formed on an electroconductive substrate, the photosensitive layer containing a pyrrolopyrrole type compound represented by the following genral formula (1) and a benzidine derivative represented by the following general formula (2) ##STR1## In the general formulas (1) and (2), R 1 , R 2 , R 3 , R 4 , R 5 , R 6 , R 7 , R 8 , R 9 , R 10 , l, m, n, o, p and q have the same meanings as defined in the text of the specification. | 84,683 |
FIELD OF THE INVENTION
[0001] The invention relates to a method and to an apparatus for encoding and decoding an audio signal using transform coding and adaptive switching of the temporal resolution in the spectral domain.
BACKGROUND OF THE INVENTION
[0002] Perceptual audio codecs make use of filter banks and MDCT (modified discrete cosine transform, a forward transform) in order to achieve a compact representation of the audio signal, i.e. a redundancy reduction, and to be able to reduce irrelevancy from the original audio signal. During quasi-stationary parts of the audio signal a high frequency or spectral resolution of the filter bank is advantageous in order to achieve a high coding gain, but this high frequency resolution is coupled to a coarse temporal resolution that becomes a problem during transient signal parts. A well-know consequence are audible pre-echo effects.
[0003] B. Edler, “Codierung von Audiosignalen mit ütberlappender Transformation und adaptiven Fensterfunktionen”, Frequenz, Vol. 43, No. 9, p. 252-256, September 1989, discloses adaptive window switching in the time domain and/or transform length switching, which is a switching between two resolutions by alternatively using two window functions with different length.
[0004] U.S. Pat. No. 6,029,126 describes a long transform, whereby the temporal resolution is increased by combining spectral bands using a matrix multiplication. Switching between different fixed resolutions is carried out in order to avoid window switching in the time domain. This can be used to create non-uniform filter-banks having two different resolutions.
[0005] WO-A-03/019532 discloses sub-band merging in cosine modulated filter-banks, which is a very complex way of filter design suited for poly-phase filter bank construction.
SUMMARY OF THE INVENTION
[0006] The above-mentioned window and/or transform length switching disclosed by Edler is sub-optimum because of long delay due to long look-ahead and low frequency resolution of short blocks, which prevents providing a sufficient resolution for optimum irrelevancy reduction.
[0007] A problem to be solved by the invention is to provide an improved coding/decoding gain by applying a high frequency resolution as well as high temporal resolution for transient audio signal parts.
[0008] The invention achieves improved coding/decoding quality by applying on top of the output of a first filter bank a second non-uniform filter bank, i.e. a cascaded MDCT. The inventive codec uses switching to an additional extension filter bank (or multi-resolution filter bank) in order to re-group the time-frequency representation during transient or fast changing audio signal sections.
[0009] By applying a corresponding switching control, pre-echo effects are avoided and a high coding gain is achieved. Advantageously, the inventive codec has a low coding delay (no look-ahead).
[0010] In principle, the inventive encoding method is suited for encoding an input signal, e.g. an audio signal, using a first forward transform into the frequency domain being applied to first-length sections of said input signal, and using adaptive switching of the temporal resolution, followed by quantization and entropy encoding of the values of the resulting frequency domain bins, wherein control of said switching, quantization and/or entropy encoding is derived from a psycho-acoustic analysis of said input signal, including the steps of:
adaptively controlling said temporal resolution is achieved by performing a second forward transform following said first forward transform and being applied to second-length sections of said transformed first-length sections, wherein said second length is smaller than said first length and either the output values of said first forward transform or the output values of said second forward transform are processed in said quantization and entropy encoding; attaching to the encoding output signal corresponding temporal resolution control information as side information.
[0013] In principle the inventive encoding apparatus is suited for encoding an input signal, e.g. an audio signal, said apparatus including:
first forward transform means being adapted for trans-forming first-length sections of said input signal into the frequency domain; second forward transform means being adapted for trans-forming second-length sections of said transformed first-length sections, wherein said second length is smaller than said first length; means being adapted for quantizing and entropy encoding the output values of said first forward transform means or the output values of said second forward transform means; means being adapted for controlling said quantization and/or entropy encoding and for controlling adaptively whether said output values of said first forward transform means or the output values of said second forward transform means are processed in said quantizing and entropy encoding means, wherein said controlling is derived from a psycho-acoustic analysis of said input signal; means being adapted for attaching to the encoding apparatus output signal corresponding temporal resolution control information as side information.
[0019] In principle, the inventive decoding method is suited for decoding an encoded signal, e.g. an audio signal, that was encoded using a first forward transform into the frequency domain being applied to first-length sections of said input signal, wherein the temporal resolution was adaptively switched by performing a second forward transform following said first forward transform and being applied to second-length sections of said transformed first-length sections, wherein said second length is smaller than said first length and either the output values of said first forward transform or the output values of said second forward transform were processed in a quantization and entropy encoding, and wherein control of said switching, quantization and/or entropy encoding was derived from a psycho-acoustic analysis of said input signal and corresponding temporal resolution control information was attached to the encoding output signal as side information, said decoding method including the steps of:
providing from said encoded signal said side information; inversely quantizing and entropy decoding said encoded signal; corresponding to said side information, either performing a first forward inverse transform into the time domain, said first forward inverse transform operating on first-length signal sections of said inversely quantized and entropy decoded signal and said first forward inverse transform providing the decoded signal,
or processing second-length sections of said inversely quantized and entropy decoded signal in a second forward inverse transform before performing said first forward inverse transform.
[0023] In principle, the inventive decoding apparatus is suited for decoding an encoded signal, e.g. an audio signal, that was encoded using a first forward transform into the frequency domain being applied to first-length sections of said input signal, wherein the temporal resolution was adaptively switched by performing a second forward transform following said first forward transform and being applied to second-length sections of said transformed first-length sections, wherein said second length is smaller than said first length and either the output values of said first forward transform or the output values of said second forward transform were processed in a quantization and entropy encoding, and wherein control of said switching, quantization and/or entropy encoding was derived from a psycho-acoustic analysis of said input signal and corresponding temporal resolution control information was attached to the encoding output signal as side information, said apparatus including:
means being adapted for providing from said side information and for inversely quantizing and entropy decoding said encoded signal; means being adapted for, corresponding to said side information, either performing a first forward inverse transform into the time domain, said first forward inverse trans-form operating on first-length signal sections of said inversely quantized and entropy decoded signal and said first forward inverse transform providing the decoded signal, or processing second-length sections of said inversely quantized and entropy decoded signal in a second forward inverse transform before performing said first forward inverse transform.
BRIEF DESCRIPTION OF THE DRAWINGS
[0026] Exemplary embodiments of the invention are described with reference to the accompanying drawings, which show in:
[0027] FIG. 1 inventive encoder;
[0028] FIG. 2 inventive decoder;
[0029] FIG. 3 a block of audio samples that is windowed and trans-formed with a long MDCT, and series of non-uniform MDCTs applied to the frequency data;
[0030] FIG. 4 changing the time-frequency resolution by changing the block length of the MDCT;
[0031] FIG. 5 transition windows;
[0032] FIG. 6 window sequence example for second-stage MDCTs;
[0033] FIG. 7 start and stop windows for first and last MDCT;
[0034] FIG. 8 time domain signal of a transient, T/F plot of first MDCT stage and T/F plot of second-stage MDCTs with an 8-fold temporal resolution topology;
[0035] FIG. 9 time domain signal of a transient, second-stage filter bank T/F plot of a single, 2-fold, 4-fold and 8-fold temporal resolution topology;
[0036] FIG. 10 more detail for the window processing according to FIG. 6 .
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0037] In FIG. 1 , the magnitude values of each successive overlapping block or segment or section of samples of a coder input audio signal CIS are weighted by a window function and transformed in a long (i.e. a high frequency resolution) MDCT filter bank or transform stage or step MDCT-1, providing corresponding transform coefficients or frequency bins. During transient audio signal sections a second MDCT filter bank or transform stage or step MDCT-2, either with shorter fixed transform length or preferably a multi-resolution MDCT filter bank having different shorter transform lengths, is applied to the frequency bins of the first forward transform (i.e. on the same block) in order to change the frequency and temporal filter resolutions, i.e. a series of non-uniform MDCTs is applied to the frequency data, whereby a non-uniform time/frequency representation is generated. The amplitude values of each successive overlapping section of frequency bins of the first forward transform are weighted by a window function prior to the second-stage transform. The window functions used for the weighting are explained in connection with FIGS. 4 to 7 and equations (3) and (4). In case of MDCT or integer MDCT transforms, the sections are 50% overlapping. In case a different transform is used the degree of overlapping can be different.
[0038] In case only two different transform lengths are used for stage or step MDCT-2, that step or stage when considered alone is similar to the above-mentioned Edler codec.
[0039] The switching on or off of the second MDCT filter bank MDCT-2 can be performed using first and second switches SW 1 and SW 2 and is controlled by a filter bank control unit or step FBCTL that is integrated into, or is operating in parallel to, a psycho-acoustic analyzer stage or step PSYM, which both receive signal CIS. Stage or step PSYM uses temporal and spectral information from the input signal CIS. The topology or status of the 2nd stage filter MDCT-2 is coded as side information into the coder output bit stream COS. The frequency data output from switch SW 2 is quantized and entropy encoded in a quantiser and entropy encoding stage or step QUCOD that is controlled by psycho-acoustic analyzer PSYM, in particular the quantization step sizes. The output from stages QUCOD (encoded frequency bins) and FBCTL (topology or status information or temporal resolution control information or switching information SW 1 or side information) is combined in a stream packer step or stage STRPCK and forms the output bit stream COS.
[0040] The quantizing can be replaced by inserting a distortion signal.
[0041] In FIG. 2 , at decoder side, the decoder input bit stream DIS is de-packed and correspondingly decoded and inversely ‘quantized’ (or re-quantized) in a depacking, decoding and re-quantizing stage or step DPCRQU, which provides correspondingly decoded frequency bins and switching information SW 1 . A correspondingly inverse non-uniform MDCT step or stage iMDCT-2 is applied to these decoded frequency bins using e.g. switches SW 3 and SW 4 , if so signaled by the bit stream via switching information SW 1 . The amplitude values of each successive section of inversely transformed values are weighted by a window function following the transform in step or stage iMDCT-2, which weighting is followed by an overlap-add processing. The signal is reconstructed by applying either to the decoded frequency bins or to the output of step or stage iMDCT-2 a correspondingly inverse high-resolution MDCT step or stage iMDCT-1. The amplitude values of each successive section of inversely transformed values are weighted by a window function following the transform in step or stage iMDCT-1, which weighting is followed by an overlap-add processing. Thereafter, the PCM audio decoder output signal DOS. The transform lengths applied at decoding side mirror the corresponding transport lengths applied at encoding side, i.e. the same block of received values is inverse transformed twice.
[0042] The window functions used for the weighting are explained in connection with FIGS. 4 to 7 and equations (3) and (4). In case of inverse MDCT or inverse integer MDCT transforms, the sections are 50% overlapping. In case a different inverse transform is used the degree of overlapping can be different.
[0043] FIG. 3 depicts the above-mentioned processing, i.e. applying first and second stage filter banks. On the left side a block of time domain samples is windowed and transformed in a long MDCT to the frequency domain. During transient audio signal sections a series of non-uniform MDCTs is applied to the frequency data to generate a non-uniform time/frequency representation shown at the right side of FIG. 3 . The time/frequency representations are displayed in grey or hatched.
[0044] The time/frequency representation (on the left side) of the first stage transform or filter bank MDCT-1 offers a high frequency or spectral resolution that is optimum for encoding stationary signal sections. Filter banks MDCT-1 and iMDCT-1 represent a constant-size MDCT and iMDCT pair with 50% overlapping blocks. Overlay-and-add (OLA) is used in filter bank iMDCT-1 to cancel the time domain alias. Therefore the filter bank pair MDCT-1 and iMDCT-1 is capable of theoretical perfect reconstruction.
[0045] Fast changing signal sections, especially transient signals, are better represented in time/frequency with resolutions matching the human perception or representing a maximum signal compaction tuned to time/frequency. This is achieved by applying the second transform filter bank MDCT-2 onto a block of selected frequency bins of the first forward trans-form filter bank MDCT-1.
[0046] The second forward transform is characterized by using 50% overlapping windows of different sizes, using transition window functions (i.e. ‘Edler window functions’ each of which having asymmetric slopes) when switching from one size to another, as shown in the medium section of FIG. 3 . Window sizes start from length 4 to length 2 n , wherein n is an integer number greater 2 . A window size of ‘4’ combines two frequency bins and doubled time resolution, a window size of 2 n combines 2 (n−1) frequency bins and increases the temporal resolution by factor 2 (n−1) . Special start and stop window functions (transition windows) are used at the beginning and at the end of the series of MDCTs. At decoding side, filter bank iMDCT-2 applies the inverse transform including OLA. Thereby the filter bank pair MDCT-2/iMDCT-2 is capable of theoretical perfect reconstruction.
[0047] The output data of filter bank MDCT-2 is combined with single-resolution bins of filter bank MDCT-1 which were not included when applying filter bank MDCT-2.
[0048] The output of each transform or MDCT of filter bank MDCT-2 can be interpreted as time-reversed temporal samples of the combined frequency bins of the first forward transform. Advantageously, a construction of a non-uniform time/frequency representation as depicted at the right side of FIG. 3 now becomes feasible.
[0049] The filter bank control unit or step FBCTL performs a signal analysis of the actual processing block using time data and excitation patterns from the psycho-acoustic model in psycho-acoustic analyzer stage or step PSYM. In a simplified embodiment it switches during transient signal sections to fixed-filter topologies of filter bank MDCT-2, which filter bank may make use of a time/frequency resolution of human perception. Advantageously, only few bits of side information are required for signaling to the decoding side, as a code-book entry, the desired topology of filter bank iMDCT-2.
[0050] In a more complex embodiment, the filter bank control unit or step FBCTL evaluates the spectral and temporal flatness of input signal CIS and determines a flexible filter topology of filter bank MDCT-2. In this embodiment it is sufficient to transmit to the decoder the coded starting locations of the start window, transition window and stop window positions in order to enable the construction of filter bank iMDCT-2.
[0051] The psycho-acoustic model makes use of the high spectral resolution equivalent to the resolution of filter bank MDCT-1 and, at the same time, of a coarse spectral but high temporal resolution signal analysis. This second resolution can match the coarsest frequency resolution of filter bank MDCT-2.
[0052] As an alternative, the psycho-acoustic model can also be driven directly by the output of filter bank MDCT-1, and during transient signal sections by the time/frequency representation as depicted at the right side of FIG. 3 following applying filter bank MDCT-2.
[0053] In the following, a more detailed system description is provided.
The MDCT
[0054] The Modified Discrete Cosine Transformation (MDCT) and the inverse MDCT (iMDCT) can be considered as representing a critically sampled filter bank. The MDCT was first named “Oddly-stacked time domain alias cancellation transform” by J. P. Princen and A. B. Bradley in “Analysis/synthesis filter bank design based on time domain aliasing cancellation”, IEEE Transactions on Acoust. Speech Sig. Proc. ASSP-34 (5), pp. 1153-1161, 1986.
[0055] H. S. Malvar, “Signal processing with lapped transform”, Artech House Inc., Norwood, 1992, and M. Temerinac, B. Edler, “A unified approach to lapped orthogonal transforms”, IEEE Transactions on Image Processing, Vol. 1, No. 1, pp. 111-116, January 1992, have called it “Modulated Lapped Trans-form (MLT)” and have shown its relations to lapped orthogonal transforms in general and have also proved it to be a special case of a QMF filter bank.
[0056] The equations of the transform and the inverse transform are given in equations (1) and (2):
[0000]
X
(
k
)
=
2
N
∑
n
=
0
N
-
1
h
(
n
)
·
x
(
n
)
·
cos
[
π
K
·
(
n
+
K
+
1
2
)
·
(
k
+
1
2
)
]
,
k
=
0
,
1
…
,
K
-
1
;
K
=
N
/
2
(
1
)
x
(
n
)
=
2
N
∑
k
=
0
K
-
1
h
(
n
)
·
X
(
k
)
·
cos
[
π
K
·
(
n
+
K
+
1
2
)
·
(
k
+
1
2
)
]
,
n
=
0
,
1
…
,
N
-
1
(
2
)
[0057] In these transforms, 50% overlaying blocks are processed. At encoding side, in each case, a block of N samples is windowed and the magnitude values are weighted by window function h(n) and is thereafter transformed to K=N/2 frequency bins, wherein N is an integer number. At decoding side, the inverse transform converts in each case M frequency bins to N time samples and thereafter the magnitude values are weighted by window function h(n), wherein N and M are integer numbers. A following overlay-add procedure cancels out the time alias. The window function h(n) must fulfill some constraints to enable perfect reconstruction, see equations (3) and (4):
[0000] h 2 ( n+N/ 2)+ h 2 ( n )=1 (3)
[0000] h ( n )= h ( N−n− 1) (4)
[0058] Analysis and synthesis window functions can also be different but the inverse transform lengths used in the decoding correspond to the transform lengths used in the encoding.
[0059] However, this option is not considered here. A suitable window function is the sine window function given in (5):
[0000]
h
sin
(
n
)
=
sin
(
π
·
n
+
0.5
N
)
,
n
=
0
…
N
-
1
(
5
)
[0060] In the above-mentioned article, Edler has shown switching the MDCT time-frequency resolution using transition windows.
[0061] An example of switching (caused by transient conditions) using transition windows 1 , 10 from a long transform to eight short transforms is depicted in the bottom part of FIG. 4 , which shows the gain G of the window functions in vertical direction and the time, i.e. the input signal samples, in horizontal direction. In the upper part of this figure three successive basic window functions A, B and C as applied in steady state conditions are shown.
[0062] The transition window functions have the length N L Of the long transform. At the smaller-window side end there are r zero-amplitude window function samples. Towards the window function centre located at N L /2, a mirrored half-window function for the small transform (having a length of N short samples) is following, further followed by r window function samples having a value of ‘one’ (or a ‘unity’ constant). The principle is depicted for a transition to short window at the left side of FIG. 5 and for a transition from short window at the right side of FIG. 5 . Value r is given by
[0000] r =( N L −N short )/ 4 (6)
Multi-Resolution Filter Bank
[0063] The first-stage filter bank MDCT-1, iMDCT-1 is a high resolution MDCT filter bank having a sub-band filter bandwidth of e.g. 15-25 Hz. For audio sampling rates of e.g. 32-48 kHz a typical length of N L is 2048 samples. The window function h(n) satisfies equations (3) and (4). Following application of filter MDCT-1 there are 1024 frequency bins in the preferred embodiment. For stationary input signal sections, these bins are quantized according to psycho-acoustic considerations.
[0064] Fast changing, transient input signal sections are processed by the additional MDCT applied to the bins of the first MDCT. This additional step or stage merges two, four, eight, sixteen or more sub-bands and thereby increases the temporal resolution, as depicted in the right part of FIG. 3 .
[0065] FIG. 6 shows an example sequence of applied windowing for the second-stage MDCTs within the frequency domain. Therefore the horizontal axis is related to f/bins. The transition window functions are designed according to FIG. 5 and equation (6), like in the time domain. Special start window functions STW and stop window functions SPW handle the start and end sections of the transformed signal, i.e. the first and the last MDCT. The design principle of these start and stop window functions is shown in FIG. 7 . One half of these window functions mirrors a half-window function of a normal or regular window function NW, e.g. a sine window function according to equation (5). Of other half of these window functions, the adjacent half has a continuous gain of ‘one’ (or a ‘unity’ constant) and the other half has the gain zero.
[0066] Due to the properties of MDCT, performing MDCT-2 can also be regarded as a partial inverse transformation. When applying the forward MDCTs of the second stage MDCTs, each one of such new MDCT (MDCT-2) can be regarded as a new frequency line (bin) that has combined the original windowed bins, and the time reversed output of that new MDCT can be regarded as the new temporal blocks. The presentation in FIGS. 8 and 9 is based on this assumption or condition.
[0067] Indices ki in FIG. 6 indicate the regions of changing temporal resolution. Frequency bins starting from position zero up to position k1−1 are copied from (i.e. represent) the first forward transform (MDCT-1), which corresponds to a single temporal resolution.
[0068] Bins from index k1−1 to index k2 are transformed to g1 frequency lines. g1 is equal to the number of transforms performed (that number corresponds to the number of overlapping windows and can be considered as the number of frequency bins in the second or upper transform level MDCT-2). The start index is bin k1−1 because index k1 is selected as the second sample in the first forward transform in FIG. 6 (the first sample has a zero amplitude, see also FIG. 10 a ). g1=(number_of_windowed_bins)/(N/2)−1=(k2−k1+1)/2−1, with a regular window size N of e.g. 4 bins, which size creates a section with doubled temporal resolution.
[0069] Bins from index k2−3 to index k3+4 are combined to g2 frequency lines (transforms), i.e. g2=(k3−k2+2)/4−1. The regular window size is e.g. 8 bins, which size results in a section with quadrupled temporal resolution.
[0070] The next section in FIG. 6 is transformed by windows (trans-form length) spanning e.g. 16 bins, which size results in sections having eightfold temporal resolution. Windowing starts at bin k3−5. If this is the last resolution selected (as is true for FIG. 6 ), then it ends at bin k4+4, otherwise at bin k4.
[0071] Where the order (i.e. the length) of the second-stage trans-form is variable over successive transform blocks, starting from frequency bins corresponding to low frequency lines, the first second-stage MDCTs will start with a small order and the following second-stage MDCTs will have a higher order. Transition windows fulfilling the characteristics for perfect reconstruction are used.
[0072] The processing according to FIG. 6 is further explained in FIG. 10 , which shows a sample-accurate assignment of frequency indices that mark areas of a second (i.e. cascaded) transform (MDCT-2), which second transform achieves a better temporal resolution. The circles represent bin positions, i.e. frequency lines of the first or initial transform (MDCT-1).
[0073] FIG. 10 a shows the area of 4-point second-stage MDCTs that are used to provide doubled temporal resolution. The five MDCT sections depicted create five new spectral lines. FIG. 10 b shows the area of 8-point second-stage MDCTs that are used to provide fourfold temporal resolution. Three MDCT sections are depicted. FIG. 10 c shows the area of 16-point second-stage MDCTs that are used to provide eightfold temporal resolution. Four MDCT sections are depicted.
[0074] At decoder side, stationary signals are restored using filter bank iMDCT-1, the iMDCT of the long transform blocks including the overlay-add procedure (OLA) to cancel the time alias.
[0075] When so signaled in the bitstream, the decoding or the decoder, respectively, switches to the multi-resolution filter bank iMDCT-2 by applying a sequence of iMDCTs according to the signaled topology (including OLA) before applying filter bank iMDCT-1.
Signaling the Filter Bank Topology to the Decoder
[0076] The simplest embodiment makes use of a single fixed topology for filter bank MDCT-2/iMDCT-2 and signals this with a single bit in the transferred bitstream. In case more fixed sets of topologies are used, a corresponding number of bits is used for signaling the currently used one of the topologies. More advanced embodiments pick the best out of a set of fixed code-book topologies and signal a corresponding code-book entry inside the bitstream.
[0077] In embodiments were the filter topology of the second-stage transforms is not fixed, a corresponding side information is transmitted in the encoding output bitstream. Preferably, indices k1, k2, k3, k4, . . . , kend are transmitted.
[0078] Starting with quadrupled resolution, k2 is transmitted with the same value as in k1 equal to bin zero. In topologies ending with temporal resolutions coarser than the maximum temporal resolution, the value transmitted in kend is copied to k4, k3, . . . .
[0079] The following table illustrates this with some examples. bi is a place holder for a frequency bin as a value.
[0000]
Indices signaling topology
Topology
k1
k2
k3
k4
kend
Topology with 1x, 2x, 4x,
b1 > 1
b2
b3
b4
b5
8x, 16x temporal
resolutions
Topology with 1x, 2x, 4x,
b1 > 1
b2
b3
b4
b4
8x temporal resolutions
(like in FIG. 6)
Topology with 8x temporal
0
0
0
bmax
bmax
resolution only
Topology with 4x, 8x and
0
0
b2
b3
bmax
16x temporal resolution
[0080] Due to temporal psycho-acoustic properties of the human auditory system it is sufficient to restrict this to topologies with temporal resolution increasing with frequency.
Filter Bank Topology Examples
[0081] FIGS. 8 and 9 depict two examples of multi-resolution T/F (time/frequency) energy plots of a second-stage filter bank. FIG. 8 shows an ‘8× temporal resolution only’ topology. A time domain signal transient in FIG. 8 a is depicted as amplitude over time (time expressed in samples). FIG. 8 b shows the corresponding T/F energy plot of the first-stage MDCT (frequency in bins over normalized time corresponding to one transform block), and FIG. 8 c shows the corresponding T/F plot of the second-stage MDCTs (8*128 time-frequency tiles). FIG. 9 shows a ‘1×, 2×, 4×, 8× topology’. A time domain signal transient in FIG. 9 a is depicted as amplitude over time (time expressed in samples). FIG. 9 b shows the corresponding T/F plot of the second-stage MDCTs, whereby the frequency resolution for the lower band part is selected proportional to the bandwidths of perception of the human auditory system (critical bands), with bN 1 = 16 , bN 2 =16, bN 4 =16, bN 8 =114, for 1024 coefficients in total (these numbers have the following meaning: 16 frequency lines having single temporal resolution, 16 frequency lines having double, 16 frequency lines having 4 times, and 114 frequency lines having 8 times temporal resolution). For the low frequencies there is a single partition, followed by two and four partitions and, above about f=50, eight partitions.
Filter Bank Control
[0082] The simplest embodiment can use any state-of-the-art transient detector to switch to a fixed topology matching, or for coming close to, the T/F resolution of human perception. The preferred embodiment uses a more advanced control processing:
Calculate a spectral flatness measure SFM, e.g. according to equation (7), over selected bands of M frequency lines (f bin ) of the power spectral density Pm by using a discrete Fourier transform (DFT) of a windowed signal of a long transform block with N L samples, i.e. the length of MDCT-1 (the selected bands are proportional to critical bands); Divide the analysis block of N L samples into S>8 overlapping blocks and apply S windowed DFTs on the sub-blocks. Arrange the result as a matrix having S columns (temporal resolution, t block ) and a number of rows according the number of frequency lines of each DFT, S being an integer; Calculate S spectrograms Ps, e.g. general power spectral densities or psycho-acoustically shaped spectrograms (or excitation patterns); For each frequency line determine a temporal flatness measure (TFM) according to equation (8); Use the SFM vector to determine tonal or noisy bands, and use the TFM vector to recognize the temporal variations within this bands. Use threshold values to decide whether or not to switch to the multi-resolution filter bank and what topology to pick.
[0000]
S
F
M
=
arithmetic
mean
value
[
fbin
]
/
geometric
mean
value
[
fbin
]
=
1
M
·
∑
m
Pm
/
(
∏
M
Pm
)
1
M
(
7
)
T
F
M
=
arithmetic
mean
value
[
tblock
]
/
geometric
mean
value
[
tblock
]
=
1
S
·
∑
s
Ps
/
(
∏
S
Ps
)
1
S
(
8
)
[0088] In a different embodiment, the topology is determined by the following steps:
performing a spectral flatness measure SFM using said first forward transform, by determining for selected frequency bands the spectral power of transform bins and dividing the arithmetic mean value of said spectral power values by their geometric mean value; sub-segmenting an un-weighted input signal section, performing weighting and short transforms on m sub-sections where the frequency resolution of these transforms corresponds to said selected frequency bands; for each frequency line consisting of m transform segments, determining the spectral power and calculating a temporal flatness measure TFM by determining the arithmetic mean divided by the geometric mean of the m segments; determining tonal or noisy bands by using the SFM values; using the TFM values for recognizing the temporal variations in these bands. Threshold values are used for switching to finer temporal resolution for said indicated noisy frequency bands.
[0094] The MDCT can be replaced by a DCT, in particular a DCT-4. Instead of applying the invention to audio signals, it also be applied in a corresponding way to video signals, in which case the psycho-acoustic analyzer PSYM is replaced by an analyzer taking into account the human visual system properties.
[0095] The invention can be use in a watermark embedder. The advantage of embedding digital watermark information into an audio or video signal using the inventive multi-resolution filter bank, when compared to a direct embedding, is an increased robustness of watermark information transmission and watermark information detection at receiver side. In one embodiment of the invention the cascaded filter bank is used with a audio watermarking system. In the watermarking encoder a first (integer) MDCT is performed. A first watermark is inserted into bins 0 to k1−1 using a psycho-acoustic controlled embedding process. The purpose of this watermark can be frame synchronization at the watermark decoder. Second-stage variable size (integer) MDCTs are applied to bins starting from bin index k1 as described before. The output of this second stage is resorted to gain a time-frequency expression by interpreting the output as time-reversed temporal blocks and each second-stage MDCT as a new frequency line (bin). A second watermark signal is added onto each one of these new frequency lines by using an attenuation factor that is controlled by psycho-acoustic considerations. The data is resorted and the inverse (integer) MDCT (related to the above-mentioned second-stage MDCT) is performed as described for the above embodiments (decoder), including windowing and overlay/add. The full spectrum related to the first forward transform is restored. The full-size inverse (integer) MDCT performed onto that data, windowing and overlay/add restores a time signal with a watermark embedded.
[0096] The multi-resolution filter bank is also used within the watermark decoder. Here the topology of the second-stage MDCTs is fixed by the application. | Perceptual audio codecs make use of filter banks and MDCT in order to achieve a compact representation of the audio signal, by removing redundancy and irrelevancy from the original audio signal. During quasi-stationary parts of the audio signal a high frequency resolution of the filter bank is advantageous in order to achieve a high coding gain, but this high frequency resolution is coupled to a coarse temporal resolution that becomes a problem during transient signal parts by producing audible pre-echo effects. The invention achieves improved coding/decoding quality by applying on top of the output of a first filter bank a second non-uniform filter bank, i.e. a cascaded MDCT. The inventive codec uses switching to an additional extension filter bank (or multi-resolution filter bank) in order to re-group the time-frequency representation during transient or fast changing audio signal sections. By applying a corresponding switching control, pre-echo effects are avoided and a high coding gain and a low coding delay are achieved. | 56,875 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority to U.S. provisional application No. 61/934,341, filed Jan. 31, 2014, U.S. provisional application No. 62/038,589, filed Aug. 18, 2014, and U.S. provisional application No. 62/090,632, filed Dec. 11, 2014 all of which are incorporated herein by reference.
BACKGROUND
[0002] Data security is of paramount importance as more and more data is collected and maintained in network based systems. An important component of security is secure communications between devices. Specifically, a large amount of data is exchanged between network connected devices every minute. The exchange can take the form of messages, documents and other data communicated between devices, including as emails, attachments, instant messages, files and others.
[0003] Today, a large volume of data including emails and documents are communicated with minimal security, meaning that such communications can be readily intercepted and misappropriated by malicious third party devices. Although mechanisms exist for securing such communications, they are typically cumbersome to use and relatively easy to defeat. For example, most existing systems for securing communications rely on asymmetric encryption methods where a publicly available key is used to encrypt data and a private key is used to decrypt it. Asymmetric encryption methods are problematic in that they do not offer as strong a protection as symmetric ones. Moreover, since the public/private key pair remain unchanged, once a key pair is compromised, a vast amount of communications can be deciphered.
[0004] Symmetric encryption methods also exist for securing communications that offer stronger protection than asymmetric methods. However, such methods are cumbersome to use. For example, they typically involve exchanging keys out of band, making the setting or renewal of keys cumbersome and thus infrequent. Accordingly, there is a need for a system and method for a secure communications that affords strong protection and is convenient to use.
SUMMARY
[0005] It is an objective to provide a novel server and method for secure communications that obviates and mitigates at least one of the above-identified disadvantages of the prior art.
[0006] Aspects and advantages will be subsequently apparent, and reside in the details of construction and operation as more fully hereinafter described and claimed, reference being had to the accompanying drawings forming a part hereof, wherein like numerals refer to like parts throughout.
BRIEF DESCRIPTION OF DRAWINGS
[0007] FIG. 1 shows a block diagram of an implementation of a system for secure communications in accordance with an implementation;
[0008] FIG. 2 shows a method of providing an enhanced public key for securing communications of the system of FIG. 1 in accordance with an implementation;
[0009] FIG. 3 shows a block diagram of the system of FIG. 1 in the process of performing the method of FIG. 2 in accordance with an implementation;
[0010] FIG. 4 shows a block diagram of the system of FIG. 1 in the process of performing the method of FIG. 2 in accordance with an implementation;
[0011] FIG. 5 shows a block diagram of the system of FIG. 1 in the process of performing the method of FIG. 2 in accordance with an implementation;
[0012] FIG. 6 shows a block diagram of the system of FIG. 1 in the process of performing the method of FIG. 2 in accordance with an implementation;
[0013] FIG. 7 shows a block diagram of the system of FIG. 1 in the process of performing the method of FIG. 2 in accordance with an implementation;
[0014] FIG. 8 shows a block diagram of the system of FIG. 1 in the process of performing the method of FIG. 2 in accordance with an implementation;
[0015] FIG. 9 shows a block diagram of an enhanced public key in the process of being normalized in accordance with an implementation
[0016] FIG. 10 shows a block diagram of the system of FIG. 1 in the process of performing the method of FIG. 2 in accordance with an implementation;
[0017] FIG. 11 shows a method of public key addition by the system of FIG. 1 in accordance with an implementation;
[0018] FIG. 12 shows a block diagram of the system of FIG. 1 in the process of performing the method of FIG. 11 in accordance with an implementation;
[0019] FIG. 13 shows a block diagram of the system of FIG. 1 in the process of performing the method of FIG. 11 in accordance with an implementation;
[0020] FIG. 14 shows a block diagram of the system of FIG. 1 in the process of performing the method of FIG. 11 in accordance with an implementation;
[0021] FIG. 15 shows a block diagram of the system of FIG. 1 in the process of performing the method of FIG. 11 in accordance with an implementation;
[0022] FIG. 16 shows a block diagram of the system of FIG. 1 in the process of performing the method of FIG. 11 in accordance with an implementation;
[0023] FIG. 17 shows a block diagram of the system of FIG. 1 in the process of performing the method of FIG. 11 in accordance with an implementation;
[0024] FIG. 18 shows a block diagram of the system of FIG. 1 including an example message in accordance with an implementation;
[0025] FIG. 19 shows a method of receiving secure communications by the system of FIG. 1 in accordance with an implementation;
[0026] FIG. 20 shows a block diagram of the system of FIG. 1 in the process of performing the method of FIG. 19 in accordance with an implementation;
[0027] FIG. 21 shows a block diagram of the system of FIG. 1 in the process of performing the method of FIG. 19 in accordance with an implementation;
[0028] FIG. 22 shows a block diagram of the system of FIG. 1 in the process of performing the method of FIG. 19 in accordance with an implementation;
[0029] FIG. 23 shows a block diagram of the system of FIG. 1 in the process of performing the method of FIG. 19 in accordance with an implementation;
[0030] FIG. 24 shows a block diagram of the system of FIG. 1 in the process of performing the method of FIG. 19 in accordance with an implementation;
[0031] FIG. 25 shows a method of sending secure communications by the system of FIG. 1 in accordance with an implementation;
[0032] FIG. 26 shows a block diagram of the system of FIG. 1 in the process of performing the method of FIG. 25 in accordance with an implementation;
[0033] FIG. 27 shows a block diagram of the system of FIG. 1 in the process of performing the method of FIG. 25 in accordance with an implementation;
[0034] FIG. 28 shows a block diagram of the system of FIG. 1 in the process of performing the method of FIG. 25 in accordance with an implementation; and
[0035] FIG. 29 shows a block diagram of the system of FIG. 1 in the process of performing the method of FIG. 25 in accordance with an implementation.
DETAILED DESCRIPTION
[0036] FIG. 1 shows a diagram of a system 100 for secure communications. At least one secure communications terminal (the secure communications terminals 104 - 1 and 104 - 2 ) can be connected, via the network 108 , to a public key server 112 . Collectively, the secure communications terminals 104 - 1 and 104 - 2 are referred to as the secure communications terminals 104 , and generically as the secure communications terminal 104 . This nomenclature is used elsewhere herein. The secure communications terminals 104 can be based on any suitable computing environment, and the type is not particularly limited so long as each secure communications terminal 104 is capable of receiving, processing and sending secured communications. In a present implementation, the secure communications terminals 104 are configured to at least execute instructions that can interact with the network services hosted by the public key server 112 for establishing secure communications. Although in the illustrative example of FIG. 1 only two secure communications terminals are shown, it is to be understood that in other implementations more or fewer secure communications terminals 104 can be present.
[0037] Each secure communications terminal 104 includes at least one processor connected to a non-transitory computer-readable storage medium such as a memory. The processor runs or executes operating instructions or applications that are stored in the memory to perform various functions for the secure communications terminal 104 . The processor includes one or more microprocessors, microcontrollers, digital signal processors (DSP), state machines, logic circuitry, or any device or devices that process information based on operational or programming instructions stored in the memory. In accordance with the embodiments, the processor processes various functions and data associated with carrying out data encryption, decryption and secure communications.
[0038] Memory can be any suitable combination of volatile (e.g. Random Access Memory (“RAM”)) and non-volatile (e.g. read only memory (“ROM”), Electrically Erasable Programmable Read Only Memory (“EEPROM”), flash memory, magnetic computer storage device, or optical disc) memory. In one implementation, memory includes both a non-volatile memory for persistent storage of computer-readable instructions and other data, and a non-volatile memory for short-term storage of such computer-readable instructions and other data during the execution of the computer-readable instructions. Other types of computer readable storage medium, which in some implementations may be removable or external to a secure communications terminal 104 are also contemplated, such as secure digital (SD) cards and variants thereof. Other examples of external or removable computer readable storage media include compact discs (CD-ROM, CD-RW) and digital video discs (DVD).
[0039] Each secure communications terminal 104 can also include a communications interface operably connected to the processor. The communications interface can allow a secure communications terminal 104 to communicate with other computing devices, for example via the network 108 . The communications interface can therefore be selected for compatibility with the network 108 . In some implementations of the system 100 , the secure communications terminals 104 may be connected to the public key server 112 and/or each other directly, without an intervening network 108 such as where a secure communications terminal 104 is connected to the public key server 112 and/or another secure communications terminal 104 through a wired universal serial bus (USB) connection or a wireless Bluetooth connection. These connections can be established in addition to or in place of a connection through the network 108 .
[0040] The network 108 can comprise any network capable of linking the public key server 112 with the secure communications terminals 104 and can include any suitable combination of wired and/or wireless networks, including but not limited to a Wide Area Network (WAN) such as the Internet, a Local Area Network (LAN), cell phone networks, Wi-Fi™ networks, WiMAX™ networks and the like.
[0041] In general terms, the public key server 112 can comprise any platform capable of assisting with the performance of secured communications. In a present embodiment, the public key server 112 is a server configured for receiving, maintain and providing public keys. The public key server 112 can be based on a server-type computing environment including appropriate configurations of one or more central processing units (CPUs) configured to control and interact with non-transitory computer readable media in the form of computer memory or a storage device. Computer memory or storage device can include volatile memory such as Random Access Memory (RAM), and non-volatile memory such as hard disk drives or FLASH drives, or a Redundant Array of Inexpensive Disks (RAID) or cloud-based storage. The public key server 112 can also include one or more network or communication interfaces, to connect to the network 108 or the secure communications terminals 104 . The public key server 112 can also be configured to include input devices such as a keyboard or pointing device or output devices such as a monitor or a display or any of or all of them, to permit local interaction.
[0042] Other types of hardware configurations for the public key server 112 are contemplated. For example, the public key server 112 can be implemented as part of a cloud-based computing solution, whereby the functionality of the public key server 112 is implemented as one or more virtual machines executing at a single data center or across a plurality of data centers. The public key server 112 can also be implemented as a distributed server, distributed across multiple computing devices operably connected across a network, for example, the network 108 . The software aspect of the computing environment of the public key server 112 can also include remote access capabilities in lieu of, or in addition to, any local input devices or local output devices.
[0043] Any desired or suitable operating environment can be used in the computing environment of the public key server 112 . The computing environment can be accordingly configured with appropriate operating systems and applications to effect the functionality discussed herein. Those of skill in the art will now recognize that the public key server 112 need not necessarily be implemented as a stand-alone device and can be integrated as part of a multi-purpose server or implemented as a virtual machine.
[0044] The public key server 112 is operable to receive, store and send public keys associated with one or more client accounts. The public key server 112 can be further operable to determine that the uploaded keys are not duplicates of previously uploaded keys. Moreover, the public key server 112 can be operable to confirm the client account providing the keys and verify that the uploaded keys were indeed generated by that client account. In variations, there may be more than one public key server 112 .
[0045] In some implementations, the secure communications terminals 104 are configured to be associated with a client account. For example, as shown in FIG. 1 , the secure communications terminal 104 - 1 is associated with a client account A, whereas secure communications terminal 104 - 2 is associated with a client account B. Access to a client account is typically obtained based on supplied credentials, such as a user name, an email address, a password and/or other credentials that will now occur to a person of skill. In some variations, more than one account can be associated with a secure communications terminal 104 . In further variations, an account can be associated with more than one secure communications terminal 104 . In other variations, accounts may not be used, and instead, credentials may be unique credentials associated with a secure communications terminal 104 that are not known by others, such as a unique serial number associated with the device. In these variations, secure communications described below are performed based on device credentials as opposed to client account credentials associated with a secure communications terminal 104 .
[0046] Based on the client account maintained, a secure communications terminal can be can be configured, in association with a client account, to generate symmetric and asymmetric keys, generate messages, encrypt the generated messages and other data, send generated messages to other secure communications terminals 104 , receive messages from other secure communications terminals 104 and decrypt received messages. Encryption performed by the secure communications terminals 104 in association with a client account can be based on keys or key identifiers that are previously generated by that client account and communicated to another client account as part of a previously sent message. For example, in some implementations, a shared symmetric key SSK and a shared symmetric key identifier SSKID may be generated by a client account and included as part of a message sent to another client account. The shared symmetric key SSK can be generated based on any desired key generation method. Accordingly, when the client account receives a subsequent message, which includes the shared symmetric key identifier SSKID, the client account can determine, based on the inclusion of the SSKID, that the message, at least in part, was encrypted by the other client account composing the message, using the shared symmetric key SSK. Thus to decrypt at least portions of the received message, the client account can identify the shared symmetric key SSK, based on the shared symmetric key identifier SSKID, and use the identified shared symmetric key SSK to decrypt portions of the received message. In this manner, each message sent between two client accounts can be encrypted by a different symmetric key that is shared between the two client accounts exchanging the messages. In variations, SSK and SSKID can be used to encrypt a set of messages. Thus, even if a shared symmetric key is compromised by a third party, only one or a set messages can be decrypted.
[0047] In variations, the client account can encrypt the shared symmetric key identifier SSKID using another symmetric key that is unique to that client account (unique client key UCK), which is not shared with other client accounts, to reduce the chance of the shared symmetric key identifier SSKID being intercepted and decoded by third party client accounts that are not the sender or the receiver of the messages. In some variations, the unique client key UCK may be generated using a random number generator, with a client account credential, such as the password being the seed. In this manner, the unique client key UCK can be consistently generated across various devices on which a client account exists. Although the unique client key UCK is unique to a client account, in variations it may vary in time or based on changes to the client account credentials, for example.
[0048] In order to be able to use different shared symmetric keys with different messages or sets of messages, a method is provided for generating and sharing shared keys between two client accounts. Accordingly, a shared symmetric key SSK once generated by a client account is shared with just one other client account and used for encrypting messages keys sent from that other account to the client account that generated the symmetric shared key SSK. In variations, the shared symmetric key can be shared with a set of other client accounts.
[0049] In some implementations, a public key PuK associated with a recipient client account can also be used, by another client account, to encrypt at least portions of a message destined to the recipient client account, in addition to the use of a shared symmetric key. Moreover, the public key PuK can be included, by the other client account, as part of the message prior to sending the message to the recipient client account. In these implementations, the other client account can receive the public key PuK from the public key server 112 , which is described in greater detail below. The public key PuK can be encrypted, for example with the previously received shared symmetric key SSK, by the other client account, prior to inclusion in the message. Accordingly, when the recipient client account receives the message, it can decrypt the public key PuK using the shared symmetric key SSK, and identify the private key PrK corresponding to the public key PuK. In some variations and enhanced public key may be used such that the private key PrK corresponding to the public key PuK may be included as part of the enhanced public key, in an encrypted form, as described below in greater detail. Subsequently, the portions of the message encrypted with the public key PuK can be decrypted using the corresponding private key PrK. In variations at least some portions of the message may be encrypted using both the shared symmetric key SSK and the public key PuK. In variations, a different public key PuK may be obtained for encrypting each new message or a set of new messages created based on the use of an enhanced public key. Limiting the use of a public key PuK to the encryption of one or a set of messages limits any compromises due to the breach of a public/private key pair to one or a set of messages encrypted by that breached public key. Moreover, use of both a changing shared symmetric key and a changing asymmetric key also increases the security of message exchange and addresses issues such as the-man-in-the-middle problem.
[0050] In order to be able to use different public keys with different messages, a method is provided for generating and sharing multiple enhanced public keys associated with each client account. Accordingly, in variations, each client account can generate more than one public/private asymmetric key pair. The enhanced public keys generated by a client account can be uploaded to the public key server 112 and stored there in association with that client account. Subsequently, any client account can request an enhanced public key associated with a client account as new messages are being exchanged. In variations, the generated enhanced public keys can include a portion of data such that the public key server can verify that an enhanced public key being provided to it and to be associated with a client account is indeed generated by that client account. Moreover, the enhanced public key can also include a second data portion such that a client account uploading a new enhanced public key to a public key server 112 can verify that the public key server 112 is authentic (as opposed to, for example an interceptor attempting to compromise the public keys).
[0051] In some further implementations, at least a portion of a message can be encrypted by a symmetric message key MK. The portion encrypted by the MK can be, for example, the message content or other message data. MK can be generated by the client account sending the message, and included in the message. MK can be encrypted by the SSK and/or PuK of the client account to which the message is being sent.
[0052] Referring now to FIG. 2 , a method of providing an enhanced public key for securing system communication is indicated generally at 200 . In order to assist in the explanation of the method, it will be assumed that method 200 is operated using system 100 as shown in FIG. 1 . Additionally, the following discussion of method 200 leads to further understanding of system 100 . However, it is to be understood that system 100 , and method 200 can be varied, and need not work exactly as discussed herein in conjunction with each other, and that such variations are within scope.
[0053] Beginning at 205 , a set of public/private key pairs are generated by a client account at a secure communications terminal 104 . In the present example of FIG. 1 , the client account A generates one public/private key pair comprising an asymmetric public key PK 1 and an asymmetric private key PKR 1 respectively as shown in FIG. 3 in accordance with known methods of asymmetric key generation. Moreover, the secure communications terminal 104 - 1 maintains a previously generated unique client key UCKA unique to client A. The unique client key UCKA can be generated based on a random number generator using a credential of the client account A, such as its password.
[0054] Continuing with the method 200 at 210 , as well as FIG. 3 , an account confirmation code is also generated and encrypted. For example, a random number generator can be used to generate the account confirmation code ACC 1 . The account confirmation code ACC 1 can be used by the public key server 112 to verify that the client account sending a new public key is indeed the client account that the public key is to be associated with. The account confirmation code ACC 1 can be encrypted by itself, resulting in a first encrypted form of the account confirmation code ACC 1 (EACC 1 ). Moreover, as shown in FIG. 4 , the account generation code ACC 1 can also be encrypted with the unique client key UCKA resulting in a second encrypted form of the account authentication code ACC 1 (EACC 2 ). Subsequently the first encrypted account authentication code EACC 1 and the second encrypted account authentication code EACC 2 can be combined with asymmetric public key PK 1 as part of forming an enhanced version of the public key, the enhanced public key PuK 1 . The process of combining can take various forms, such as concatenation, for example.
[0055] Referring back to FIG. 2 , at 215 , a server authentication code (SAC 1 ) is generated using, for example, a random number generator, and encrypted. The server authentication code SAC 1 can be used by the client account A, for example, to confirm that the public key server is authentic. The server authentication code SAC 1 can be encrypted by the account authentication code ACC 1 , resulting in a first encrypted form of the server authentication code SAC 1 (ESAC 1 ). Moreover, SAC 1 can also be encrypted with the unique client key UCKA resulting in a second encrypted form of the SAC 1 (ESAC 2 ). Subsequently the first encrypted form of the SAC 1 , ESAC 1 and the second encrypted form of the SAC 1 , ESAC 2 can be combined with the rest of the contents of the enhanced public key PuK 1 as shown in FIG. 5 . The act of combining can take various forms, such as concatenation, for example.
[0056] Continuing the method 200 , at 220 , client account credentials are added to the enhanced public key. For example, an email address (emailA) that was used to create client account A can be added to the enhanced public key PuK 1 , as shown in FIG. 6 . In some variations, the credentials can be encrypted.
[0057] Continuing with the method 200 , at 225 , the private key PKR 1 corresponding to the public key PK 1 , generated at 205 is encrypted using the unique client code UCKA, to generate an encrypted form of the private key (EPKR 1 ). The encrypted form of the private key EPKR 1 is subsequently added to the enhanced public key PuK 1 as shown in FIG. 7 . By including the encrypted version of the private key PKR 1 , a client account can be relieved from maintaining the private key on a secure communications terminal 104 .
[0058] Referring back to FIG. 2 , at 230 , additional information can be added to the enhanced public key PuK 1 . For example, a version number of the public key generator used to generate the enhanced public key can be appended to the enhanced public key Puk 1 . Alternatively, or in addition, a date of generation on the enhanced public key PuK 1 , and an expiration date of the enhanced public key PuK 1 can also be appended. Moreover, the size SizeP, in bits for example, of the asymmetric public key PK 1 can also be included in the enhanced public key PUK 1 , as shown in FIG. 8 , which in this case is 512 bits.
[0059] Continuing with the method 200 , at 235 the enhanced public key is normalized. The normalization allows the enhanced public key to be utilized in accordance with existing asymmetric public key standards. To perform the normalization, the data combined to from the enhanced public key PuK 1 is split into rows having a bit length equal to the sizeP field in the PuK 1 , which in this example is 512 bits. In this example, the enhanced public key is split into three rows, R 1 , R 2 , and R 4 . The row R 1 includes the size of the asymmetric public key SizeP, the encrypted private key EPKR 1 corresponding to the asymmetric public key PK 1 and the email address emailA for the client account A. The row R 2 , on the other hand includes the second encrypted server authentication code ESAC 2 , the first encrypted server authentication code ESAC 1 , the second encrypted account confirmation code EACC 2 and the first encrypted account confirmation code EACC 1 . The row R 4 includes the asymmetric public key PK 1 . Row one is reserved for the normalization process which is discussed next. It should be noted that although in this example, the information thus far included in PuK 1 formed exactly three rows of 512 bits, in variations, they may form more or fewer than two rows. Moreover, in further variations, there may be at least one row which has fewer than 512 bits. In such cases, the row with fewer than 512 bits may be padded to 512 bits using zeros. It should also be noted that the exact order of the information included in the enhanced public key PuK 1 as well as the rows is not material and in different implementations, the order can vary.
[0060] To perform the normalization the three rows R 1 , R 2 and R 4 are combined with an adjustment row R 3 to form a matrix 900 . Row R 3 , includes an adjustment value AdjustP. The adjustment value AdjustP is determined on the basis of the information included in the enhanced public key PuK 1 , including the asymmetric public key PK 1 . For example, in this example, the adjustment value AdjustP can be calculated by determining the exclusive-or of the rows R 1 and R 2 , the result of which is exclusive-ored with the row R 4 . The determined adjustment value AdjustP is then added to the enhanced public key PuK 1 , as shown in FIG. 10 . In some variations, a hash of the enhanced public key can be generated and included in the enhanced public key providing an additional error checking mechanism.
[0061] In subsequent use of the enhanced pubic key PuK 1 , to encrypt any data based on it, the asymmetric public key PK 1 can be determined based on the adjustment value AdjustP and the rest of the information included in the enhanced public key PuK 1 . For example, in this case, referring back to FIG. 9 , to encrypt data with the enhanced public key PuK 1 , a matrix 900 can be once again constructed from the enhanced public key PuK 1 , and the rows R 1 and R 2 exclusive-ored, and the result further exclusive-ored with the adjustment value AdjustP to obtain the asymmetric public key PK 1 , which is subsequently used to encrypt the data. Moreover, to decrypt data encrypted with the asymmetric public key PK 1 , obtained from the enhanced public key PuK 1 , the corresponding private key PKR 1 does not have to be stored at client account A as long as the enhanced public key PuK 1 is communicated to the client account A along with the encrypted data. This is because the enhanced public key PuK 1 includes corresponding private key PKR 1 .
[0062] Once the enhanced public key PuK 1 is generated at a secure communications terminal 104 , it is communicated to the public key server 112 so that it can be made available to other client accounts such as client account B. Referring now to FIG. 11 , a method of public key addition is indicated generally at 1100 . In order to assist in the explanation of the method, it will be assumed that method 1100 is operated using system 100 as shown in FIG. 1 . Additionally, the following discussion of method 1100 leads to further understanding of system 100 . However, it is to be understood that system 100 , and method 1100 can be varied, and need not work exactly as discussed herein in conjunction with each other, and that such variations are within scope.
[0063] Beginning at 1105 , the client account A, through secure communications terminal 104 - 2 , accesses public key server 112 using the communications interface of the secure communications terminal 104 - 2 , and requests a current enhanced public key associated with the client account A. Upon receiving the current enhanced public key PuK 2 , which was generated previously in accordance with the method 200 and uploaded to the public key server 112 through a previous performance of the method 1100 , the server authentication code SAC 2 and the account confirmation code ACC 2 are obtained from the current enhanced public key PuK 2 . Specifically, as shown in FIG. 12 , the second encrypted server authentication code ESAC 22 and the second encrypted account confirmation code EACC 22 are extracted from the enhanced public key PuK 2 and decrypted to obtain the server authentication code SAC 2 and the account confirmation code ACC 2 respectively using the unique client key UCKA of the client account A. It will now be understood by those of skill that only client account A is equipped to perform this decryption since the unique client key UCKA of the client account A is not shared with any other client accounts.
[0064] Once the server authentication code SAC 2 and the account confirmation code ACC 2 are obtained from the enhanced public key PuK 2 , they are stored in secure communications client 104 - 1 , as shown in FIG. 13 . Continuing with the method 1100 , at 1120 the account confirmation code ACC 2 is transmitted to the public key server 112 along with the new enhanced public key PuK 1 , as shown in FIG. 14 . At 1125 , the public key server 112 verifies the client account. For example, as shown in FIG. 15 , the public key server 112 extracts from the current enhanced public key PuK 2 , information comprising the first encrypted account confirmation code EACC 2 and decrypts the extracted information using the received account confirmation code ACC 2 . It will now occur to those of skill that since the received account confirmation code ACC 2 was originally first encrypted using the account confirmation code ACC 2 itself as a key, only when the client account supplying the comparison key at 1120 is the same as the client account that supplied the current enhanced public key will the decryption of the first encrypted account confirmation code EACC 2 be successful. Accordingly, when the account confirmation code obtained by decrypting EACC 2 matches the received account confirmation ACC 2 , the client account is verified and the new public key is accepted. Thus the method 1100 moves to 1130 . When, on the other hand, the account confirmation code obtained by decrypting EACC 1 does not match the received account confirmation ACC 1 , then the method 1100 moves to 1135 rejecting the new enhanced public key PuK 2 .
[0065] Continuing with FIG. 11 , at 1135 the authentication of the public key server 112 by a secure communications terminal 104 is initiated, at the public key server 112 , by obtaining the server authentication code from the enhanced public key that was provided to the secure communications terminal 104 - 1 . Specifically, as shown in FIG. 16 , the public key server 112 obtains the server authentication code SAC 2 by extracting the first encrypted server authentication code ESAC 2 from the current enhanced public key PuK 2 and decrypting the first encrypted server authentication code ESAC 2 using the account confirmation code ACC 2 .
[0066] At 1140 , the server authentication code SAC 2 extracted from the current enhanced public key PuK 2 is sent to the secure communications terminal 104 - 1 , through a communication interface of the public key server 112 , as shown in FIG. 17 . At 1145 , the authenticity of the public key server 112 is verified based on the received server authentication code. Specifically, the received server authentication code SAC 2 is compared to the server authentication code SAC 2 that was obtained at 1110 . When the compared codes match, then the authenticity of the server is verified and further action is not taken. When, on the other hand, the compared codes do not match, then it is determined that the public key server 112 is not authentic and warnings are generated at 1150 . In variations, the server authentication code SAC 2 can be obtained from the current enhanced public key PuK 2 at this point rather than at 1110 .
[0067] In variations, the method of public key addition can be repeated as many times as desired, and the multiple enhanced public keys thus added to the public key server 112 can be buffered at the server 112 . The size of the buffer may vary. Moreover, the public key server 112 may provide each enhanced public key once, or a limited number of times, before deleting it or otherwise marking it as unavailable for public provision. In some variations, an enhanced public key may expire if not used after a predetermined period of time. The expiration date or period may be included in each enhanced public key, or may be determined as a policy of the public key server 112 . In further variations, where for example, only one enhanced public key is maintained by the public key server 112 , method 1100 can be used to change that enhanced public key as opposed to adding to it.
[0068] Once enhanced public keys for a client account are generated and made available through the public key server 112 , a client account can engage in secure communications with other client accounts. For example secure communications can be sent and received from a secure communications terminal 104 . In some variations, the communications can be in the form of sending and receiving messages. A message can include a number of different components. FIG. 18 , shows a non-limiting illustrative example message including various components. The components of a message, the message MSG 1 , are assembled by client account B at secure communications terminal 104 - 2 .
[0069] The example message MSG 1 of FIG. 18 includes ESSKID 1 , an encrypted form of the symmetric shared key identifier SSKIDA 1 that is the identifier for shared symmetric key SSKA 1 . The symmetric shared key identifier SSKIDA 1 , along with shared symmetric key SSKA 1 are previously generated as a key pair by a secure communications terminal 104 associated with the client account A, the symmetric shared key identifier SSKIDA 1 being encrypted using the unique client key UCKA for the client account A. The symmetric shared key can be generated based on any desired symmetric key generation method. The key pair (SSKA 1 and ESSKIDA 1 ) are then transmitted to the client account B as part of a previous message sent to the client account B, as an encrypted form of the symmetric shared key identifier SSKIDA 2 and shared symmetric key SSKA 2 in the manner described below in relation to the method 2500 . By providing the key pair to the client account B, the client account A enables the client account B to subsequently encrypt a message to the client account A using the provided key pair. Accordingly, in this example message MSG 1 of FIG. 18 , the secure communications terminal 104 - 2 , having received the key pair, encrypts a portion of the message MSG 1 using the shared symmetric key SSKA 1 and includes the encrypted symmetric shared key identifier ESSKIDA 1 to identify that it was the shared symmetric key SSKA 1 that was used to encrypt a portion of the message MSG 1 . It is to be noted that the key pair SSKIDA 1 and SSKA 1 were not necessarily generated at secure communications terminal 104 - 1 , and thus could have been generated at any secure communications terminal 104 associated with the client account A. It is to be further noted that because the symmetric shared key identifier SSKIDA 1 was encrypted using the unique client key UCKA, only the client account A has access to its unencrypted form, thus making it unlikely that any third party interceptor of the message MSG 1 can gain access to the shared symmetric key SSKA 1 . Moreover, since only the client account A has the ability to decrypt the encrypted symmetric shared key identifier ESSKIDA 1 , and further, since the shared symmetric key SSKA 1 is not included in the message MSG 1 encrypted with the shared symmetric key SSKA 1 , the key pair ESSKIDA 1 and SSKIDA 1 can only be used to encrypt messages to the client account A, such as the message MSG 1 .
[0070] The example message MSG 1 of FIG. 18 further includes the key pair ESSKB 2 and ESSKIDB 2 , which are the encrypted form of the shared symmetric key SSKB 1 and the symmetric shared key identifier SSKIDB 1 for shared symmetric key SSKB 1 . The key pair is generated by the secure communications terminal 104 - 2 , and is to be used by client account A for encrypting at least part of a message that will be send from the client account A to the client account B subsequent to the reception of the message MSG 1 . The encrypted shared symmetric key ESSKB 1 is generated by the secure communications terminal 104 - 2 by encrypting the shared symmetric key SSKB 1 using the shared symmetric key SSKA 1 and the public key PuKA 1 of the client account A. The symmetric shared key identifier SSKIDB 1 is encrypted by the secure communications terminal 104 - 2 using the unique client key UCKB of the client account B to generate the encrypted symmetric shared key identifier ESSKIDB 1 . In variations, the encrypted symmetric shared key identifier ESSKIDB 1 can be further encrypted with the public key PuKA 1 and the shared symmetric key SSKIDA 1 key.
[0071] The example message MSG 1 of FIG. 18 additionally includes an encrypted message key EMK 1 . The message key MK 1 is used by secure communications terminal 104 - 2 to encrypt the message data, such as the message content, to generate the encrypted data EData. The message key MK 1 is encrypted by the secure communications terminal 104 - 2 using the shared symmetric key SSKA 1 and the public key PuKA 1 of the client account A.
[0072] The example message MSG 1 of FIG. 18 also includes an encrypted public key EPuKA 1 of client account A. In this example, the client account B acquires an enhanced public key PuKA 1 , generated by the client account A at a secure communications terminal 104 as described above, from the public key server 112 . The enhanced public key PuKA 1 is used to encrypt portions of the message MSG 1 as described above. The enhanced public key PuKA 1 is encrypted using the shared symmetric key SSKA 1 . In variations, a different enhanced public key is obtained for each message (unique to that message) or set of messages to be sent to client account A. In such variations, the public key server 112 may delete or otherwise mark the provided public key PuKA 1 as unavailable, so as to prevent the provision of the same public key multiple times. In further variations, a public key may not be used as part encrypting a message at all, relying on the shared symmetric key, the unique client key and the message key instead. In other alternatives, the public key used may not be enhanced, (and for example changing for each message or set of messages) but instead may be the same public key for all messages destined to a client account, until that public key expires. In such variations, the public key may not be included in the message MSG 1 .
[0073] Referring now to FIG. 19 , a method of receiving secure communications is indicated generally at 1900 . In order to assist in the explanation of the method, it will be assumed that method 1900 is operated using system 100 as shown in FIG. 1 . Additionally, the following discussion of method 1900 leads to further understanding of system 100 . However, it is to be understood that system 100 , and method 1800 can be varied, and need not work exactly as discussed herein in conjunction with each other, and that such variations are within scope.
[0074] Beginning at 1905 , and as shown in FIG. 20 , a message MSG 1 is received from the client account B at terminal 104 - 1 associated with the client account A. Once a message is received, it is decrypted. Accordingly, at 1910 , the encrypted symmetric shared key identifier ESSKIDA 1 is decrypted using the unique client key UCKA for the client account A, as shown in FIG. 21 . At 1915 , the symmetric shared key identifier SSKIDA 1 is used to identify the shared symmetric key SSKA 1 that was used to encrypt the message MSG 1 . It is to be understood that the SSKIDA 1 can be identified in various ways. For example, all of the key pairs previously generated may be stored in a table and a particular symmetric shared key obtained based on a lookup with the corresponding identifier. Alternatively, the particular symmetric shared key can be generated based on the identifier. Other methods will now occur to a person of skill and are contemplated.
[0075] Referring back to FIG. 19 and continuing with the method 1900 at 1920 the public key included in the received message is decrypted. Specifically, as shown in FIG. 22 , the encrypted public key EPuKA 1 is decrypted using the shared symmetric key SSKA 1 to obtain the public key PuKA 1 . At 1925 , the private key PKRA 1 is identified based on the corresponding public key PuKA 1 . In some variations, the private keys may be stored at the secure communications terminals 114 associated with the client account A. In variations, the public key received can be an enhanced public key as described above, and the private key PKRA 1 , can actually be stored within the enhanced public key received.
[0076] Continuing with FIG. 19 , at 1930 , the additional keys included in the received message are decrypted. In this example, as shown in FIG. 23 , the encrypted form of the shared symmetric key SSKB 1 and the message key EMK 1 are decrypted using the shared symmetric key SSKA 1 and the public key PuKA 1 of the client account A. The encrypted symmetric shared key identifier SSKIDB 1 was encrypted by client B using the unique client key UCKB of client account B and thus is extracted from the message MSG 1 without decrypting it. The key pair was generated by client account B at secure communications terminal 104 - 2 , as described above and is to be used by client account A for encrypting at least part of a message that will be sent from client account A to client account B at a future point in time.
[0077] Referring back to FIG. 19 , at 1935 , the encrypted data portion of the received message is decrypted. In this example, as shown in FIG. 24 , the encrypted data EData is decrypted using the previously decrypted message key MK 1 which is unique to the message MSG 1 , since it was only used to encrypt the data for the message MSG 1 .
[0078] Referring now to FIG. 25 , a method of sending secure communications is indicated generally at 2500 . In order to assist in the explanation of the method, it will be assumed that method 2500 is operated using system 100 as shown in FIG. 1 . Additionally, the following discussion of method 2500 leads to further understanding of system 100 . However, it is to be understood that system 100 , and method 2500 can be varied, and need not work exactly as discussed herein in conjunction with each other, and that such variations are within scope.
[0079] At the beginning of the method 2500 , the secure communications terminal 104 - 1 maintains several encrypted and unencrypted keys as a result of performing the method 1800 to receive a secure communication in the form of message MSG 1 , relevant ones of which are shown in FIG. 26 . To prepare a new secure message MSG 2 to send to the client account B, a new message key MK 2 , unique to the message MSG 2 is generated at 2505 . In variations, the key can be used for multiple messages. The message key can be generated using known methods based on a random number generator for example. The data to be sent as part of the communications is obtained and encrypted using the message key MK 2 , and placed into the message MSG 2 as Edata 2 as shown in FIG. 26 .
[0080] Continuing with the method 2500 , at 2510 secure communications terminal 104 - 1 requests and receives a new public key PuKB 1 associated with the client account B and encrypts it using the previously received shared symmetric key SSKB 1 for client account B, as shown in FIG. 27 , adding the encrypted public key EPuKB 1 to the message MSG 2 .
[0081] At 2515 , the secure communications terminal 104 - 2 generates the next key pair to be used by the client account B for encrypting at least a portion of a subsequent message to be sent to the client account A. The key pair comprises the symmetric shared key identifier SSKIDA 2 , along with the corresponding shared symmetric key SSKA 2 . At 2520 , the symmetric shared key identifier SSKIDA 2 is encrypted using the unique client key UCKA to generate ESSKIDA 2 , which is in turn included in the message MSG 2 as shown in FIG. 28 .
[0082] Referring back to FIG. 25 , at 2525 the shared symmetric key SSKA 2 and the message key MK 2 are encrypted using the shared symmetric key SSKB 1 and the public key PuKB 1 and added to the message MSG 2 as shown in FIG. 29 . At 2530 , the previously encrypted ESSKIDB 1 is also added to the message MSG 2 to indicate the shared symmetric key used for encrypting portions of the message MSG 2 . At 2535 the message MSG 2 is transmitted to secure communications terminal 104 - 2 .
[0083] In some variations, prior to performing any of the above described methods, a client account is created. Accordingly, when the client account is created, user credentials to be associated with the client account are obtained by a secure communications terminal 104 , on the basis of which the unique client key for the newly created account is generated. For example, the unique client key can be generated on the basis of the password. Moreover, when the newly created attempts to upload the first enhanced public key to the public key server 112 , the public key server 112 can request confirmation from the account by sending a confirmation request to the account credentials which can be included in the enhanced public key. The confirmation is satisfied when a reply is received for the request.
[0084] The above-described embodiments are intended to be examples and alterations and modifications may be effected thereto, by those of skill in the art, without departing from the scope which is defined solely by the claims appended hereto. For example, methods and systems discussed can be varied and combined, in full or in part. | A server and method for providing a content selection is provided. The server receives content targeting parameters and obtains content items from at least one content site based on the content targeting parameters. The server can further identify content descriptors for the content items and generate a first content cluster from a subset of the content items based on the content descriptors. The server can further generate a second content cluster from a second subset of the content items based on the content descriptors and rank the first and the second content clusters in an order of usefulness. The ranking of the content clusters can be based on at least one of an importance of content, a recentness of the content items and a size of the content cluster. | 51,694 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority to U.S. Provisional Application No. 61/697,025, filed Sep. 5, 2012, and entitled “TREATMENT OF NEOPLASIA USING AUTOLOGOUS ACTIVATED IMMUNOCYTES”, which is hereby expressly incorporated by reference in its entirety.
FIELD OF THE INVENTION
[0002] The invention pertains to the area of immune modulation, specifically to the area of treating cancer using the immune system of the patient. More specifically, the invention pertains to the area of adoptive immunotherapy.
BACKGROUND
[0003] Surgery, radiation therapy, and chemotherapy have been the standard accepted approaches for treatment of cancers including leukemia, solid tumors, and metastases. Unfortunately, these approaches are associated with extremely high toxicity and adverse effects. Immunotherapy which uses the body's immune system, either directly or indirectly, to shrink or eradicate cancer has been studied for many years as an adjunct to conventional cancer therapy. It is believed that the human immune system is an untapped resource for cancer therapy and that effective treatment can be developed once the components of the immune system are properly harnessed. As key immunoregulatory molecules and signals of immunity are identified and prepared as therapeutic reagents, the clinical effectiveness of such reagents can be tested using established cancer models. Immunotherapeutic strategies include administration of vaccines, activated cells, antibodies, cytokines, chemokines, as well as small molecular inhibitors, anti-sense oligonucleotides, and gene therapy. It is believed by many that immunotherapy offers the potential for treatment of cancer without the toxicities associated with current approaches to cancer therapy.
[0004] The current focus of cancer research in general is the creation of therapies that not only destroy, inhibit, or block progression of primary tumors, but also suppress micrometastatic and metastatic progeny of the primary tumor from seeding the patient. Despite extensive research into the disease, effective means of treating the majoring of cancers at present have not been developed by the medical community. Although limited success is achieved using the current standard therapies: chemotherapy, radiation therapy, and surgery; each therapy has its own inherent limitations. Chemotherapy and radiation therapy have devastating consequences causing extensive damage to normal, healthy tissue such as bone marrow, intestinal cells, and neuronal cells, despite efforts to target such therapy to abnormal tissue (e.g., tumors). Surgery is in many cases effective in removing masses of cancerous cells; however, it cannot always ensure complete removal of affected tissue nor are all tumors in an anatomical location amenable to surgical removal. Furthermore seeding of distant tissues by the excised tumor during the process of removal or beforehand are significant problems.
[0005] Immunological control of neoplasia, specifically the ability of the immune system to control cancer, is suggested by evidence of longer survival of patients with a variety of cancers who possess a high population of tumor infiltrating lymphocytes [1-3]. Additionally, the observation has been made that immune suppressed patients, either as a result of transplant immune suppression or genetic conditions, develop cancer at a much higher frequency in comparison to non-immune suppressed individuals [4, 5]. Additionally, some data supports the notion that in some situations immunotherapy of cancer is effective [6]. While cancer immunotherapy offers the possibility of inducing remission and control of both the primary tumor mass, as well as micrometastasis, several drawbacks exist. The most significant one is that in many situations immunotherapy is either not powerful enough to cause a significant reduction of tumors, or is associated with a variety of toxicities.
[0006] Various types of immunotherapies for cancer have been tried, including: a) systemic cytokine administration; b) gene therapy; c) allogeneic vaccines; d) autologous vaccine; e) heat shock protein vaccines; f) dendritic cell vaccines; g) tumor infiltrating lymphocytes; h) administration of T cells in a lymphodepleted environment; and i) nutritional interventions. Although each of the approaches contains significant advantages and drawbacks, none of them simultaneously meet the criteria of reproducible efficacy, availability to the mass population, or specificity. The one exception to this is autologous PAP-GM-CSF pulsed dendritic cells developed by the company Dendreon.
[0007] Another type of immunotherapy is the use of systemically acting immune stimulants such as interleukin-2 (IL-2). The precursor of such therapies actually began with the work of William Coley who induced a systemic inflammatory/immune activation through administration of killed S pyogenes and Serratia marcescens bacteria in patients with soft tissue sarcoma [7]. The advent of molecular biology allowed for assessment of molecular signals associated with systemic immune activation. The cytokine tumor necrosis factor (TNF)-alpha was one of the molecular signals associated with anticancer efficacy of innate immune activators such as the Coley vaccine [8]. Studies have demonstrated that TNF-alpha has the ability to induce profound death of cancer cells in vitro and in vivo in animal models, however human studies demonstrated unacceptable levels of toxicity [9-11]. IL-2 was the next cytokine associated with immune activation that was tested. Originally termed T Cell Growth Factor (TCGF) [12], IL-2 was demonstrated in early studies to endow human lymphocytes with ability to selectively kill tumor but not healthy control cells [13]. Subsequent studies have demonstrated that cytotoxic activity was mediated through T cell and natural killer (NK) cells, whose activation requires stimulation of the IL-2 receptor [14, 15], which can be accomplished in vivo with high doses of IL-2 [16-18]. Animal studies suggested that IL-2 has a short half-life of approximately 2 minutes after intravenous injection [19, 20], and human half life was reported to be approximately an hour [21]. Thus it was apparent that clinical use of IL-2 would be requiring repeated administration at high doses. Despite this pitfall, preclinical studies demonstrated highly potent anti-tumor effect. In 1985 Steven Rosenberg reported regression of established pulmonary metastasis, as well as various subcutaneous tumors by administration of IL-2 [22]. These data were highly promising due to the fact that tumor killing could be achieved systemically, and by activation of specific immune cells that could be identified in vivo as interacting with and inducing death of the tumor.
[0008] Early studies of IL-2 demonstrated impressive results in a subset of melanoma and renal cell cancer patients. These studies were expanded and eventually IL-2 received approval as the first recombinant immunotherapeutic drug by the FDA. There appears to be a dose response with IL-2 in that the doses that seem to be most effective are also associated with significant toxicity. The most significant cause of toxicity is vascular leak syndrome (VSL), manifested as fluid loss into the interstitial space, which is a result of increase vessel permeability. Additional effects include thrombocytopenia, elevated hepatic serum transaminases, hepatocyte necrosis, hypoalbuminemia, tissue and peripheral eosinophilia, and prerenal azotemia [23].
[0009] Thus it is apparent that the limitations of many immunotherapeutic approaches to cancer is that tumor antigens are either not clearly defined, or in situations where they are defined, the tumor either mutates to lose expression of such antigens, or the antigen-specific vaccine is only applicable to patients with a certain major histocompatibility complex haplotype. The circumvention of this problem has been attempted using autologous vaccines, however in many cases this is an expensive and difficult procedure.
SUMMARY
[0010] Embodiments herein are directed to methods of treating cancer comprising: a) culturing autologous mononuclear cells derived from an autologous source; b) treating said mononuclear cells with an agent activating innate immune cells found in said mononuclear cell population; and c) re-administering activated immune cells into the same patient.
DETAILED DESCRIPTION
[0011] In one embodiment the invention provides a means of generating a population of cells with tumoricidal ability. Peripheral blood is extracted from a cancer patient and peripheral blood monoclear cells (PBMC) are isolated using the Ficoll Method. PBMC are subsequently resuspended in 10 ml STEM-34 media and allowed to adhere onto a plastic surface for 2-4 hours. The adherent cells are then cultured at 37° C. in STEM-34 media supplemented with 1,000 U/mL granulocyte-monocyte colony-stimulating factor and 500 U/mL IL-4 after non-adherent cells are removed by gentle washing in Hanks Buffered Saline Solution (HBSS). Half of the volume of the GM-CSF and IL-4 supplemented media is changed every other day. Immature DCs are harvested on day 7. In one embodiment said generated DC are used to stimulate T cell and NK cell tumoricidal activity. Incubation with interferon gamma may be performed for the period of 2 hours to the period of 7 days. Preferably, incubation is performed for approximately 24 hours, after which T cells and/or NK cells are stimulated via the CD3 and CD28 receptors. One means of accomplishing this is by addition of antibodies capable of activating these receptors. In one embodiment approximately, 2 ug/ml of anti-CD3 antibody is added, together with approximately 1 ug/ml anti-CD28. In order to promote survival of T cells and NK cells, was well as to stimulate proliferation, a T cell/NK mitogen may be used. In one embodiment the cytokine IL-2 is utilized. Specific concentrations of IL-2 useful for the practice of the invention are approximately 500 u/mL IL-2. Media containing IL-2 and antibodies may be changed every 48 hours for approximately 8-14 days. In one particular embodiment DC are included to said T cells and/or NK cells in order to endow cytotoxic activity towards tumor cells. In a particular embodiment, inhibitors of caspases are added in the culture so as to reduce rate of apoptosis of T cells and/or NK cells. Generated cells can be administered to a subject intradermally, intramuscularly, subcutaneously, intraperitoneally, intraarterially, intravenously (including a method performed by an indwelling catheter), intratumorally, or into an afferent lymph vessel.
[0012] In some embodiments, the culture of the cells is performed by starting with purified lymphocyte populations, for example, The step of separating the cell population and cell sub-population containing a T cell can be performed, for example, by fractionation of a mononuclear cell fraction by density gradient centrifugation, or a separation means using the surface marker of the T cell as an index. Subsequently, isolation based on surface markers may be performed. Examples of the surface marker include CD3, CD8 and CD4, and separation methods depending on these surface markers are known in the art. For example, the step can be performed by mixing a carrier such as beads or a culturing container on which an anti-CD8 antibody has been immobilized, with a cell population containing a T cell, and recovering a CD8-positive T cell bound to the carrier. As the beads on which an anti-CD8 antibody has been immobilized, for example, CD8 MicroBeads), Dynabeads M450 CD8, and Eligix anti-CD8 mAb coated nickel particles can be suitably used. This is also the same as in implementation using CD4 as an index and, for example, CD4 MicroBeads, Dynabeads M-450 CD4 can also be used. In some embodiments of the invention, T regulatory cells are depleted before initiation of the culture. Depletion of T regulatory cells may be performed by negative selection by removing cells that express makers such as neuropilin, CD25, CD4, CTLA4, and membrane bound TGF-beta. Experimentation by one of skill in the art may be performed with different culture conditions in order to generate effector lymphocytes, or cytotoxic cells, that possess both maximal activity in terms of tumor killing, as well as migration to the site of the tumor. For example, the step of culturing the cell population and cell sub-population containing a T cell can be performed by selecting suitable known culturing conditions depending on the cell population. In addition, in the step of stimulating the cell population, known proteins and chemical ingredients, etc., may be added to the medium to perform culturing. For example, cytokines, chemokines or other ingredients may be added to the medium. Herein, the cytokine is not particularly limited as far as it can act on the T cell, and examples thereof include IL-2, IFN-.gamma., transforming growth factor (TGF)-.beta., IL-15, IL-7, IFN-.alpha., IL-12, CD40L, and IL-27. From the viewpoint of enhancing cellular immunity, particularly suitably, IL-2, IFN-.gamma., or IL-12 is used and, from the viewpoint of improvement in survival of a transferred T cell in vivo, IL-7, IL-15 or IL-21 is suitably used. In addition, the chemokine is not particularly limited as far as it acts on the T cell and exhibits migration activity, and examples thereof include RANTES, CCL21, MIP1.alpha., MIP1.beta., CCL19, CXCL12, IP-10 and MIG. The stimulation of the cell population can be performed by the presence of a ligand for a molecule present on the surface of the T cell, for example, CD3, CD28, or CD44 and/or an antibody to the molecule. Further, the cell population can be stimulated by contacting with other lymphocytes such as antigen presenting cells (dendritic cell) presenting a target peptide such as a peptide derived from a cancer antigen on the surface of a cell. In addition to assessing cytotoxicity and migration as end points, it is within the scope of the current invention to optimize the cellular product based on other means of assessing T cell activity, for example, the function enhancement of the T cell in the method of the present invention can be assessed at a plurality of time points before and after each step using a cytokine assay, an antigen-specific cell assay (tetramer assay), a proliferation assay, a cytolytic cell assay, or an in vivo delayed hypersensitivity test using a recombinant tumor-associated antigen or an immunogenic fragment or an antigen-derived peptide. Examples of an additional method for measuring an increase in an immune response include a delayed hypersensitivity test, flow cytometry using a peptide major histocompatibility gene complex tetramer. a lymphocyte proliferation assay, an enzyme-linked immunosorbent assay, an enzyme-linked immunospot assay, cytokine flow cytometry, a direct cytotoxity assay, measurement of cytokine mRNA by a quantitative reverse transcriptase polymerase chain reaction, or an assay which is currently used for measuring a T cell response such as a limiting dilution method. In vivo assessment of the efficacy of the generated cells using the invention may be assessed in a living body before first administration of the T cell with enhanced function of the present invention, or at various time points after initiation of treatment, using an antigen-specific cell assay, a proliferation assay, a cytolytic cell assay, or an in vivo delayed hypersensitivity test using a recombinant tumor-associated antigen or an immunogenic fragment or an antigen-derived peptide. Examples of an additional method for measuring an increase in an immune response include a delayed hypersensitivity test, flow cytometry using a peptide major histocompatibility gene complex tetramer. a lymphocyte proliferation assay, an enzyme-linked immunosorbent assay, an enzyme-linked immunospot assay, cytokine flow cytometry, a direct cytotoxity assay, measurement of cytokine mRNA by a quantitative reverse transcriptase polymerase chain reaction, or an assay which is currently used for measuring a T cell response such as a limiting dilution method. Further, an immune response can be assessed by a weight, diameter or malignant degree of a tumor possessed by a living body, or the survival rate or survival term of a subject or group of subjects.
[0013] In one embodiment of the invention, ascorbic acid is administered intravenously together with activated lymphocytes which possess tumor inhibitory/killing activity. In a preferred embodiment the intravenous vitamin C is administered once every two days at a concentration of 10 g per injection. The rational for use of intravenous vitamin C comes from observations of a scurvy-like condition in a renal cell carcinoma patient treated with IL-2. The patient presented with acute signs and symptoms of scurvy (perifollicular petechiae, erythema, gingivitis and bleeding). Serum ascorbate levels were significantly reduced to almost undetectable levels [24]. Although the role of ascorbic acid (AA) hypersupplementation in stimulation of immunity in healthy subjects is controversial, it is well established that AA deficiency is associated with impaired cell mediated immunity. This has been demonstrated in numerous studies showing deficiency suppresses T cytotoxic responses, delayed type hypersensitivity, and bacterial clearance [25]. Additionally, it is well-known that NK activity, which IL-2 is anti-tumor activity is highly dependent on, is suppressed during conditions of AA deficiency [26]. Thus it may be that while IL-2 therapy on the one hand is stimulating T and NK function, the systemic inflammatory syndrome-like effects of this treatment may actually be suppressed by induction of a negative feedback loop. Such a negative feedback loop with IL-2 therapy was successfully overcome by work using low dose histamine to inhibit IL-2 mediated immune suppression, which led to the “drug” Ceplene (histamine dichloride) receiving approval as an IL-2 adjuvant for treatment of AML [27].
[0014] The concept of AA deficiency subsequent to IL-2 therapy (as an example of an immune stimulatant) was reported previously by another group. Marcus et al evaluated 11 advanced cancer patients suffering from melanoma, renal cell carcinoma and colon cancer being on a 3 phase immunotherapeutic program consisting of: a) 5 days of i.v. high-dose (10(5) units/kg every 8 h) interleukin 2, (b) 6½ days of rest plus leukapheresis; and (c) 4 days of high-dose interleukin 2 plus three infusions of autologous lymphokine-activated killer cells. Mean plasma ascorbic acid levels were normal (0.64+/−0.25 mg/dl) before therapy. Mean levels dropped by 80% after the first phase of treatment with high-dose interleukin 2 alone (0.13+/−0.08 mg/dl). Subsequently plasma ascorbic acid levels remained severely depleted (0.08 to 0.13 mg/dl) throughout the remainder of the treatment, becoming undetectable (less than 0.05 mg/dl) in eight of 11 patients during this time. Importantly, blood pantothenate and plasma vitamin E remained within normal limits in all 11 patients throughout the phases of therapy, suggesting the hypovitaminosis was specific AA. Strikingly, Responders (n=3) differed from nonresponders (n=8) in that plasma ascorbate levels in the former recovered to at least 0.1 mg/dl (frank clinical scurvy) during Phases 2 and 3, whereas levels in the latter fell below this level [28]. Similar results were reported in another study by the same group examining an additional 15 patients [29]. The possibility that prognosis was related to AA levels is strongly suggested.
[0015] One skilled in the art will appreciate that these methods and devices are and can be adapted to carry out the objects and obtain the ends and advantages mentioned, as well as those inherent therein. The methods, procedures, and devices described herein are presently representative of preferred embodiments and are exemplary and are not intended as limitations on the scope of the invention. Changes therein and other uses will occur to those skilled in the art which are encompassed within the spirit of the invention and are defined by the scope of the disclosure.
[0016] It is apparent to one skilled in the art that varying substitutions and modifications can be made to the invention disclosed herein without departing from the scope and spirit of the invention. Furthermore, those skilled in the art recognize that the aspects and embodiments of the invention set forth herein can be practiced separate from each other or in conjunction with each other. Therefore, combinations of separate embodiments are within the scope of the invention as disclosed herein.
BIBLIOGRAPHY
[0000]
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3. Chiba, T., et al., Intraepithelial CD8+ T-cell-count becomes a prognostic factor after a longer follow-up period in human colorectal carcinoma: possible association with suppression of micrometastasis. Br J Cancer, 2004. 91(9): p. 1711-7.
4. Astigiano, S., et al., Eosinophil granulocytes account for indoleamine 2,3-dioxygenase-mediated immune escape in human non-small cell lung cancer. Neoplasia, 2005. 7(4): p. 390-6.
5. Whiteside, T. L., Down-regulation of zeta-chain expression in T cells: a biomarker of prognosis in cancer? Cancer Immunol Immunother, 2004. 53(10): p. 865-78.
6. Rosenberg, S. A. and M. E. Dudley, Cancer regression in patients with metastatic melanoma after the transfer of autologous antitumor lymphocytes. Proc Natl Acad Sci USA, 2004. 101 Suppl 2: p. 14639-45.
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12. Ruscetti, F. W. and R. C. Gallo, Human T-lymphocyte growth factor: regulation of growth and function of T lymphocytes. Blood, 1981. 57(3): p. 379-94.
13. Lotze, M. T., et al., Lysis of fresh and cultured autologous tumor by human lymphocytes cultured in T-cell growth factor. Cancer Res, 1981. 41(11 Pt 1): p. 4420-5.
14. Robb, R. J., A. Munck, and K. A. Smith, T cell growth factor receptors. Quantitation, specificity, and biological relevance. J Exp Med, 1981. 154(5): p. 1455-74.
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16. Eberlein, T. J., et al., Immunomodulatory effects of systemic low-dose recombinant interleukin-2 and lymphokine-activated killer cells in humans. Cancer Immunol Immunother, 1989. 30(3): p. 145-50.
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22. Rosenberg, S. A., et al., Regression of established pulmonary metastases and subcutaneous tumor mediated by the systemic administration of high-dose recombinant interleukin 2. J Exp Med, 1985. 161(5): p. 1169-88.
23. Mier, J. W., et al., Toxicity of immunotherapy with interleukin-2 and lymphokine-activated killer cells. Pathol Immunopathol Res, 1988. 7(6): p. 459-76.
24. Alexandrescu, D. T., C. A. Dasanu, and C. L. Kauffman, Acute scurvy during treatment with interleukin-2. Clin Exp Dermatol, 2009. 34(7): p. 811-4.
25. Anthony, H. M. and C. J. Schorah, Severe hypovitaminosis C in lung-cancer patients: the utilization of vitamin C in surgical repair and lymphocyte-related host resistance. Br J Cancer, 1982. 46(3): p. 354-67.
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27. http://www.highbeam.com/doc/1G1-186526887.html.
28. Marcus, S. L., et al., Severe hypovitaminosis C occurring as the result of adoptive immunotherapy with high-dose interleukin 2 and lymphokine-activated killer cells. Cancer Res, 1987. 47(15): p. 4208-12.
29. Marcus, S. L., et al., Hypovitaminosis C in patients treated with high-dose interleukin 2 and lymphokine-activated killer cells. Am J Clin Nutr, 1991. 54(6 Suppl): p. 1292S-1297S. | Disclosed are therapeutic methods for ex-vivo activation of immune cells from a cancer patient for the purpose of inducing tumor regression and/or suppressing metastasis and/or tumor recurrence. In one embodiment mononuclear cells of a patient are isolated from peripheral blood and activated by a combination of innate immune system activators together with means allowing for T cell activation. | 26,140 |
PRIORITY APPLICATIONS
[0001] This application is a continuation of co-pending U.S. application Ser. No. 12/165,525 filed on Jun. 30, 2008 which claims priority to U.S. Provisional Application No. 61/033,775 filed on Mar. 4, 2008 and U.S. Provisional Application No. 61/034,129 filed on Mar. 5, 2008, the contents of both of which are incorporated by reference.
RELATED APPLICATIONS
[0002] This patent application is related to John Louch et al., U.S. patent application Ser. No. 11/145,577, Widget Authoring and Editing Environment, which is incorporated herein by reference.
[0003] This patent application is related to Chris Rudolph et al., U.S. patent application Ser. No. 11/834,578, Web Widgets, which is incorporated herein by reference.
BACKGROUND
[0004] Widgets are known in the art and may be found for example as part of Mac OS X in Dashboard. An application such as Apple Inc.'s Dashcode 1.0 (described in an Appendix) may be used to assist in the creation of Widgets. Web applications are known in the art and may run on mobile devices such as the Apple iPhone. Often it is desirable to create content that may alternatively run as a widget or as a web application. There are often common aspects to widget creation and web application creation.
[0005] The invention relates to content design.
[0006] In a first aspect, a method includes providing a user interface allowing the insertion of elements into a document flow comprising static and dynamic elements, the user interface presenting a graphical depiction of the document that is dynamically altered by the insertion of the element, wherein the dynamically altered appearance of the document correctly reflects the position and type of the inserted element and rearranges all existing static and flow elements of the document around the inserted element.
[0007] Implementations can include any, all or none of the following features. The user interface can be configured to insert into the document flow any element from a predefined library containing at least a box element, a browser element, a button element, an input control element, a gauge element, and combinations thereof. The user interface can be configured to insert into the document flow elements and non-flow elements. The user interface can provide that an underlying code of the document flow is modified based on the inserted element and the rearranged static and dynamic elements.
[0008] In a second aspect, a method includes detecting the movement of an element of a layout of a document outside a boundary of a first level of hierarchy; and visually and in the underlying code, placing that element in a level of hierarchy that is a parent of the first level of hierarchy.
[0009] Implementations can include any, all or none of the following features. The movement can begin in another element at the first level that is configured to contain the element at the first level, and the movement outside the boundary can include that the element is placed at the parent of the first level instead of being placed at the first level. A user can graphically move the element by dragging the element using a pointing device.
[0010] In a third aspect, a method includes refactoring an interface for content editing based on a project type.
[0011] Implementations can include any, all or none of the following features. The project type can be defined using a property list for the project type. The method can further include providing at least one of templates, attributes, library parts, views, icons, variable elements based on the project type. The method can further include choosing a deployment behavior based on the project type. The refactoring can be performed in a tool that includes templates for web applications and for web widgets, and a user can select one of the templates in the tool and the property list is provided from the selected template. The tool can provide a list view and at least one template row, and the method can further include receiving a modification of the template row and applying the modification to any other row that relates to the template row. The method can further include adding an element to the list view, adding the element to the template row, and updating all rows of the list relating to the template row.
[0012] In a fourth aspect, a method includes generating a replicated element based on the editing of a canonical element and mapping corresponding subcomponents of the canonical element to corresponding subcomponents of the replicated elements. The method can further include maintaining a dictionary to map identifiers of a subcomponent of a replicated element to an identifier of a subcomponent of the canonical element. The method can further include invoking a function that receives a cloned row relating to a template row, the cloned row having an attribute that contains a reference to each element in the cloned row, wherein the function changes an aspect of the cloned row based on the attribute.
[0013] In a fifth aspect, a method includes: running a debug plug in in a mobile device to monitor a web application and reporting data to a web application development tool.
[0014] Implementations can include any, all or none of the following features. The method can further include presenting a resource logging interface for the web application, the resource logging interface configured to be filtered. The method can further include providing graphical representations of memory, CPU and network use to indicate CPU usage or memory.
[0015] In a sixth aspect, a method includes: running a debug plug in a simulator of a mobile device to monitor a web application and reporting data to a web application development tool.
[0016] Implementations can include any, all or none of the following features. The method can further include monitoring a web application on both a mobile device and on a simulation of a mobile device connected to a debugging interface using plug-ins in a browser of the mobile device and a browser of the simulation of the mobile device. The method can further include presenting a resource logging interface for the web application, the resource logging interface configured to be filtered. The method can further include providing graphical representations of memory, CPU and network use to indicate CPU usage or memory.
[0017] In a seventh aspect, a method includes: depicting content intended for a mobile device at a scale related to the pixel resolution of the device in a simulation of the device.
[0018] Implementations can include any, all or none of the following features. The depicted content can be a pixel-to-pixel analog of the mobile device. The method can further include resealing to a 1:1 dimensionally accurate analog of a view on the mobile device.
[0019] In an eighth aspect, a method includes: depicting content intended for a mobile device at a scale related to the physical dimensions the device in a simulation of the device.
[0020] Implementations can include any, all or none of the following features. The method can further include simulating a rotation to be performed on the mobile device. Simulating the rotation can include determining, before simulating the rotation, each aspect of the depicted content; determining how each aspect should appear after rotation on the mobile device; and performing the rotation based on at least on the two determinations.
[0021] In a ninth aspect, a method to allow a visualization of content intended for a mobile device at a first scale related to the pixel resolution of the device in a simulation of the device or at a second scale related to the physical dimensions the device in the simulation of the device in response to a user input.
[0022] Implementations can include any, all or none of the following features. The method can further include selectively performing the visualization at at least one of the first scale or the second scale. The visualization can be performed at one of the first and second scales based on a user input.
[0023] In a tenth aspect, a method includes: listing all resources accessed by a web application or a web widget and filtering them based on one or more of network location and resource type.
[0024] Implementations can include any, all or none of the following features. A user can select one of the resources, and the method can further include displaying information regarding the selected resource. The method can further include toggling to display the resource instead of the displayed information.
[0025] In an eleventh aspect, a method includes displaying information comprising CPU, memory and network bandwidth usage of only those processes required to display or run a particular web application or widget.
[0026] Implementations can include any, all or none of the following features. The information can be displayed in a debug plug in in a mobile device that monitors a web application and reports data to a web application development tool. The information can be displayed in a debug plug in in a simulator of a mobile device that monitors a web application and reports data to a web application development tool.
DESCRIPTION OF DRAWINGS
[0027] In this application, the drawings are listed in the order in which the described figures appear in the description below.
[0028] FIGS. 3A and 3B depict refactoring of a user interface for a content creation tool in an implementation.
[0029] FIGS. 4A and 4B depict a user interface for web application creation in an implementation.
[0030] FIGS. 5A and 5B depict a user interface for widget creation in an implementation
[0031] FIGS. 1.1 through 1 . 8 depict a user interaction with a content creation tool to insert elements into a document in one implementation.
[0032] FIGS. 2.1 through 2 . 7 depict a user interaction with a content creation tool to insert elements into a document in an implementation.
[0033] FIGS. 12A-12C depict automatic replication of sub-components and sub-structure based on editing a canonical component
[0034] FIGS. 9A and 9B depict switching from pixel based scaling to dimension based scaling in one embodiment.
[0035] FIGS. 28A-28E depict rotation of content for a fixed size window in an implementation
[0036] FIGS. 26A and 26B depict a stacked layout in a document creation process in an implementation.
[0037] FIGS. 27A and 27B depict the running of a stacked layout in an implementation.
[0038] FIG. 11 is a diagram of a tool user interface to record and view local and network resources used by a web application or a widget.
[0039] FIG. 10 is a diagram of the software architecture of a web application and widget authoring system.
[0040] FIG. 7 is an example software stack for implementing the features and processes described herein.
[0041] FIG. 8 is an example system for implementing the features and processes described herein.
[0042] FIGS. 25A and 25B is a user interface for mobile device that can implement the invention.
[0043] FIG. 30 is a hardware architecture of the mobile device of FIGS. 25A & 25B for implementing the invention.
DETAILED DESCRIPTION
FIGS. 3A, 4 A, 4 B, 5 A, 5 B
Refactoring UI Based on Project Type
[0044] Generally, in FIGS. 3A , 3 B, 4 A and 4 B, aspects of a user interface of a web content creation, editing, test and debug tool are depicted. In the sequel references are made to various embodiments of such a tool by use of the terms “web content editing tool,” “content creation tool,” “content editing tool,” “content creation, editing, test and debug tool,” and variations thereof.
[0045] Specifically the figures depict at a high level the features found in a tool such as Dashcode 2.0, available from Apple Inc., and operable on computers that run the Mac OS X operating systems.
[0046] In one implementation, FIGS. 3A , 3 B, 4 A and 4 B each represent the refactoring of a user interface used to create web content for different types of final target presentations or documents. In one implementation, the content creation tool uses a set of properties presented as a p-list, to present attributes and controls for the selected type of content.
[0047] In FIG. 3A , a project type panel or template chooser panel 325 is used to select a document category out of the available categories, in this implementation, web applications 305 and widgets, 301 . In FIG. 3A , the user has selected the web application project type. in this case, the web application templates “custom,” “browser” and “RSS” as shown in the figure at 310 , 315 and 320 in panel 335 . Information about selected template “Custom” is depicted in information panel 330 .
[0048] A similar view for the other project type in this implementation, the “widget” type is depicted in FIG. 3B . In FIG. 3B , the templates for a widget type made available via the tool are depicted in template area 335 .
[0049] Once a template has been chosen, attributes for the project type can then be selected. In FIG. 4A , the attributes available for a web application are shown. In this case, the web application is targeted to a mobile device such as an iPhone and may have settings relating to device orientation and zoom. In other implementations, the target device may differ.
[0050] In FIG. 4B , the web application design user interface is shown.
[0051] A similar pair of figures is provided for widget design. In FIG. 5A , a set of widget attributes may be selected. As may be seen, these are significantly different from the attributes available for a web application as in FIG. 4A . identifier, access permissions and localization Furthermore, in FIG. 5B , a widget content editing interface is shown. Widget authoring in some embodiments has been discussed in related application Ser. No. 11/145,577 referenced above.
[0052] For each specific project type, templates, attributes, library parts, views, icons and other variable elements of the interface can be provided. For example, scaling and rotation are relevant for web applications for a mobile device, whereas they are not for widgets. On the other hand, the concept of a front and back side of a widget are not relevant to a web application.
[0053] Deployment behavior may also differ between the two project types. For example, widgets can deploy directly to a Mac OS Dashboard or generate a widget in a directory. In web applications the tool may upload the application directly to a web server or generate a folder with a web page and resources.
[0054] As may be appreciated, there may be other document types for which other interface versions and attributes may be presented. For example, an extension of this interface to generalized web pages or other types of content may be provided with modifications to the attributes and user interface as needed.
FIGS. 1 . 1 - 1 . 8
[0055] Dynamic WYSIWYG UI for Editing of a Document with Flow and Static Elements
[0056] In an implementation of a content creation interface as depicted in FIGS. 1.1 through 1 . 8 , addition of elements to a document flow is depicted. In one implementation the document comprises web content, that is content created using various web technologies including, for example, a markup language (e.g., HTML, XHTML), Cascading Style Sheets (CSS), JavaScript®, etc.). As is known in the art, elements in the document may be part of a document flow, that is, they may move relative to the boundaries of a view or a page as additional content is added or changed around them; or they may be statically fixed in various ways.
[0057] In FIG. 1.1 a box element 110 is added to a document in a document editor or creator. This box may be resized or changed and the underlying markup language and content may then be automatically modified based on user input to reflect the changes as made by the user in this implementation. In FIG. 1.2 a “browser” part is added which includes a fixed Home button 115 . This Home button may be specified as a fixed element of the document flow by, for example, its CSS properties. As before, all the underlying code corresponding to the browser part may be added at the same time. In FIG. 1.3 , a Back button 120 is added, and moved by the user to a location beneath the home button. The Back button 120 is a movable element of the document flow If the user attempts to move the Back button up further, as in FIG. 1.4 , the content creation implementation may automatically reposition the button 120 to a location above the fixed Home button 115 , and modify the underlying code, in this implementation, in CSS and HTML, to reflect the new relative position of the Back button. It may be noted that no user modification of the underlying code for the document is necessary to achieve the movement of the Back button 120 “around” the Home button 115 .
[0058] In FIG. 1.5 the user adds a Gauge element 125 to the document. In one implementation, selection from a predefined library of elements (not shown in the figure) may be performed to add an element such as a Gauge 125 . This Gauge element may be moved like the Back button and positioned as shown in FIG. 1.6 In FIG. 1.7 , a list element 130 also selected from a library is depicted, and this list element 130 is added below the Gauge element 125 . The Gauge element 125 is not fixed and therefore it may be moved up by the content creation tool in this implementation to accommodate the list element 130 . If the List element 130 is moved further up by the user, the Gauge element may slide under the List element as shown in FIG. 1.8
[0059] Thus this implementation allows a content creator to have a live, dynamic view of a document, implemented in this example by CSS and HTML elements, and to move the visual versions of those elements directly using a user interface without having to actually rewrite the underlying code. Furthermore, the implementation allows the mixture of flow and non-flow elements such as the Home button and the Back button in the same content and may appropriately move flow elements “around” the non-flow elements by altering the CSS appropriately as the user moves them on the interface.
[0060] As may be appreciated by one in the art, this technique may in general be applied to any document or content having flowing and non-flowing elements and is not limited merely to web based content. Thus for example, a sheet music composition system, layout editor for CAD, or any other application where user interacts with a visual version of an underlying coded representation are all candidates for this technique of making a dynamic live version of the underlying representation available for manipulation by the user.
[0000] FIGS. 2 . 1 - 2 . 7 UI for Insertion of Elements into a Parent Container in a Hierarchical Document
[0061] FIGS. 2 . 1 - 2 . 7 depict one specific aspect of an implementation. In web-based content, there may a Document Object Model (DOM) that may describe a hierarchy of containers made up by elements such as, for example, DIV elements. When a new object is introduced onto a visual dynamic representation of the web content, in a web content creation tool, the tool may locate it at one level of the hierarchy. Thus for example, in FIG. 2.1 , a basic browser element 205 is depicted. In FIG. 2.2 , a new element, Button 210 is added. As Button 210 is added, it is moved off the top of the view by the user ( FIG. 2.2 ). In one implementation, the content editing tool may create a top level sibling to the browser element as showing FIG. 2.3 and add the button 210 as a sibling of the browser element 205 . In a similar manner, in FIG. 2.4 , a table row 215 is depicted. A rectangle 220 is added as a child of the table cell enclosing it in FIG. 2.5 However, if the user moves the rectangle 220 outside the table cell, as in FIG. 2.6 , the rectangle is placed at a different level in the hierarchy and becomes a sibling of the table row 215 in FIG. 2.7 As before the changes on the screen view of the implementation are reflected in the underlying implementation of the document, in this case, in CSS and HTML.
[0062] Thus in general the implementation allows movement in a hierarchical document from one level to a parent level by a user movement of a representation over a boundary of the lower level.
FIGS. 12A-12C
Automatic Replication of Sub-Components and Sub-Structure Based on Editing a Canonical Component
[0063] FIG. 12A depicts a list creation process in one example of web application creation in a content creation tool 1200 , such as Dashcode 2.0. In this figure, a list 1215 is shown. This may be available as a standardized list part in a library. As indicated in the navigator frame, a list row template 1210 has been selected. In the document view the list 1215 shows the elements of the template, which are the label 1225 and the arrow 1220 . It may be noted that those elements are also present in the navigator pane on the left. Template row 1215 is the only row that the user can modify by adding and deleting elements, positioning them, etc. All other rows are grayed out because they are related to the first one and cannot be modified directly. As the item 1215 is edited by a user, the template is modified. This then may cause all the remaining rows in the list, 1245 , to be modified in accordance with the modification of the template.
[0064] In FIG. 12B , a modification of the template is depicted for the list described above with reference to FIG. 12A . A button element 1230 has been added to the list by the user. As may be seen in the navigator on the left, a button has been also added to the listRowTemplate element, to which the first row of the list in the document view corresponds. The tool automatically then may update all other rows in the list 1240 with the addition of a button in accordance with the addition of the button 1230 to the template. In this implementation the update to other rows or elements occurs very shortly after the update of the template row or element, appearing to the user as virtually immediate.
[0065] FIG. 12C shows a runtime view of the document view of FIG. 12B . In this view, a web application with content based on the document design of FIG. 12 B is shown running in a window. As may be seen, a list 1275 corresponding to the template and list of FIG. 12 B is present with text 1255 , button 1260 and arrow 1265 in each row
[0066] In general, implementations such as the content creation tool may automatically replicate in an intelligent manner, all the components and subcomponents of a repeated element. One important aspect of this replication is that while elements of each replicated piece may be similar, e.g. each list element may have components such as an icon, a text field, a button, an arrow among other myriad possibilities, their actual identifiers in the underlying document structure, e.g. in a DOM, will be different. That is, elements in the template row have an identifier that must be unique in the scope of the document. Because of this, when creating a cloned or similar element based on the template row or element, these identifiers are stripped out, but the cloned row may need to keep a reference to them in a dictionary. This way, the developer's code may then customize each row individually such as by adding specific text or values to a text field or button, in this example, by accessing the relevant internal elements through this dictionary and inserting data into them. A dictionary call back may be used in each duplicated element to construct the new copy based on the template. At runtime, the template element may be used to perform error checking.
[0067] As an example of how the list row template may be used, note that in FIG. 12C , there are 3 elements: “label”, “arrow” and “button”. A use may implement a function called, for example prepareRow(clone) that receives the cloned row. This clone has a “templateElements” attribute with a reference to each element inside it. In that function, the developer may have the following code:
[0068] clone.templateElements.label.innerText=“text of the cloned row”
[0000] to change the label of the row being processed
[0069] A list is only one example of this type of templating and replication of sub elements. In other examples, cells in a grid or even pages in a stacked view may be replicated using this technique of editing a canonical representative and modifying duplicative replicated versions with unique identifiers but a common dictionary of elements. Of course, this is not an exhaustive list of the types of replicated structures for which this technique may be employed. Furthermore, the sub elements of the canonical element, e.g. a button or text or an arrow, may also be various and different and include a myriad of sub elements such as geometrical shapes, text fields, active text, and many others as is known. Furthermore, such templating may be recursively employed in some implementations.
[0000] FIGS. 9A and 9B Depict Switching from Pixel Based Scaling to Dimension Based Scaling in One Embodiment; FIGS. 28A-28E Depict Rotation of Content for a Fixed Size Window in an Implementation
[0070] FIGS. 9A-B depicts one element of the user interface that includes an implementation to visualize scaling of the view in the content creation tool. In FIG. 9A , the view is a pixel to pixel analog of the view on the mobile device. Activating button 915 begins a process of the tool simulating how the document may appear on a mobile device like an iPhone Button 915 causes a resealing to a 1:1 dimensionally accurate analog of the view on the mobile device, as shown in FIG. 9B . This may be necessary for an accurate visualization of a web application executing on a mobile device such as an iPhone because pixel sizes on a mobile device differ from the pixel sizes on a development platform.
[0071] FIGS. 28A-28D depict the visual appearance of a web application in a simulation of a rotation of a mobile device. Thus, the user selection of button 2815 in FIG. 28A causes the content creation tool to display a rotation to show the user what the content which starts in a vertical configuration in 28 A will appear when rotated to the configuration in 28 D. FIGS. 28B and 28C depict an animation indicating what a user of a mobile device may see when a rotation of the view occurs on the device. This may e.g. be caused by an accelerometer based detection of a change of orientation on a device such as an iPhone.
FIGS. 26A and 26B Depict a Stacked Layout in a Document Creation Process in an Implementation.
[0072] FIGS. 26A and 26B depict the stacked layout view in a web application development scenario. In FIG. 26A , a list element 2610 in a stack of views is created, termed a list view. In FIG. 26B , a detail level, a text view, is created. It may be noted that the navigator panel on the left of document panel 2605 , the list view and detail view are shown as siblings.
[0073] To switch between the two views, which in the underlying code are sections of a single document, it is only necessary to select the appropriate icon in the navigator. In existing art, it may be necessary to manually edit the document code to make only one of the levels visible while hiding the other.
[0074] When the content produced in FIGS. 26A and 26B is viewed, the appearance on the mobile device is simulated as in FIG. 27A and FIG. 27B at 2620 and 2625 .
[0075] In other implementations, other types of hierarchical views may be presented in a similar or analogous manner using a representation of a tree. Clicking or selecting a single or a set of nodes in the navigation tree could then produce on a viewing panel a view including only those elements of the hierarchical structure that are selected.
FIG. 11 is a Diagram of the User Interface of a Tool to Record and View Local and Network Resources Used by a Web Application or a Widget.
[0076] FIG. 11 depicts a monitoring element of an application to create web applications and widgets such as Dashcode. Each web application or widget may access resources or consume resources. These may include system resources such as disk, system memory, or network bandwidth; alternatively the web application or widget may access specific data locations on the network such as a URI or networked file. When a user of the content creation application runs a widget or web application in a debug mode, the application may bring up a resource logging interface for that application. A sample screen from such a resource logging interface is depicted at a logical level in the figure. The output of the resource logger may be unfiltered as indicated by selecting the “All” button 1110 , filtered to include only local resources by selecting the “Local” button 1115 , or only resources from the network by selecting “Network” button 1120 . Clicking on or otherwise selecting a specific item in the list 1125 any column brings up a detail pane 1130 that provides detail on the item selected. The detail pane may switch between information about the content as shown in FIG. 11 , or the content itself, e.g. a bitmap or text, based on the info-content selectors 1135 - 1140 .
[0077] In addition to the resource logger interface, the content creation and debug tool may also provide graphical representations of memory, CPU and network use via representations such as a needle-and-dial or pie-chart with different colors to indicate CPU usage or used v/s available memory, respectively.
[0078] It is to be noted that the resource log and performance parameters are specific to the particular web application or widget. Thus a user of the content creation application and debug system may see exactly what level and type of resource use is being required for a specific application or widget.
FIG. 10 is a Diagram of the Software Architecture of a Web Application and Widget Authoring System.
[0079] FIG. 10 depicts a software architecture of a system implementing the content editing and runtime environment described. Content creation, test and debug tool 1009 such as e.g. Dashcode 2.0 executes on platform 1000 such as a Mac OS X system. Dashcode uses Webkit, 1012 , described below, to perform various functions including rendering, transforms, animation, etc. Daschcode may use templates and parts 1010 and 1011 . Furthermore, widgets 1006 created with Dashcode may be used in Dashboard 1008 . Web applications created in Dashcode may be run for test and debug on a mobile device simulator such as iPhone simulator 1007 which may incorporate a mobile version of Webkit or similar framework, 1005 . Dashcode may also run web applications for test and debug on an actual mobile device such as iPhone 1013 over a USB or other network connection, including a wireless connection, accessed at a software level as a socket 1017 in one implementation, and the web application may execute on mobile device 1013 on a mobile webkit instance 1014 .
[0080] It should be noted that the web apps running in simulator 1005 and on phone 1013 or device 1013 may have debugging plugins to allow Dashcode developers to debug, instrument and monitor such applications, using technologies such as gdb, inspector, instruments and others.
FIG. 7 is an Example Software Stack for Implementing the Features and Processes Described Herein.
[0081] FIG. 7 is a screen shot of example software stack 700 for implementing a content creation, editing, and debug tool such as Dashcode 2.0 for widgets and web applications. The software stack 700 is based on the Mac OS® software stack. It should be noted, however, that any software stack can be used to implement the features and processes described in reference to FIGS. 1-6 .
[0082] The software stack 700 can include an application layer and operating system layers. In this Mac OS® example, the application layer can include Dashcode 2.0 710 , Widgets 705 , or Web Applications 715 . In some embodiments Widgets may live in a separate Dashboard layer. The Dashcode 2.0 application may include code to facilitate functionality such as widget creation, web application creation, WYSIWYG editing of web content, debug and test of web content, among others.
[0083] Web application or widget code can include HTML 720 , CSS 725 , JavaScript® 730 and other resources 735 . CSS is a stylesheet language used to describe the presentation of a document written in a markup language (e.g., style web pages written in HTML, XHTML). CSS may be used by authors and readers of web content to define colors, fonts, layout, and other aspects of document presentation. JavaScript® is a scripting language which may be used to write functions that are embedded in or included from HTML pages and interact with a Document Object Model (DOM) of the page.
[0084] In some implementations, a web application 715 , a widget 705 or web content creation and debug tool such as Dashcode 2.0, 710, in the application layer uses WebKit® services 740 . WebKit® 740 is an application framework included, in one implementation, with Mac OS X. The framework allows third party developers to easily include web functionality in custom applications. WebKit® includes an Objective-C Application Programming Interface (API) that provides the capability to interact with a web server, retrieve and render web pages, download files, and manage plug-ins. WebKit® also includes content parsers (e.g., HTML, CSS parser 765 ), renderer 770 , a JavaScript® bridge 775 (e.g., for synchronizing between a web browser and Java applets), a JavaScript® engine (interpreter) 780 and a DOM 760 . The WebKit® can use services provided by Core Services 750 , which provide basic low level services. The Core Services can request services directly from the Core OS 755 (e.g., Darwin/Unix).
[0085] The software stack 700 provides the software components to create widgets, web applications, debug and test them, and the various features and processes described above. Other software stacks and architectures are possible, including architectures having more or fewer layers, different layers or no layers. Specifically, for one example, the services provided by WebKit may be provided directly by the Operating system, or incorporated into the content creation, debug and test application in other embodiments, or be otherwise provided by a disparate set of libraries. Many other variations of the depicted architecture are possible.
FIG. 8 is an Example System for Implementing the Features and Processes Described Herein.
[0086] FIG. 8 is a screen shot of example system 800 for implementing the features and processes described in reference to FIGS. 1-7 . The system 800 may host the software stack 700 , described in reference to FIG. 7 . The system 800 includes a processor 810 , a memory 820 , a storage device 830 , and an input/output device 840 . Each of the components 810 , 820 , 830 , and 840 are interconnected using a system bus 850 . The processor 810 is capable of processing instructions for execution within the system 800 . In some implementations, the processor 810 is a single-threaded processor. In other implementations, the processor 810 is a multi-threaded processor or multi-core processor. The processor 810 is capable of processing instructions stored in the memory 820 or on the storage device 830 to display graphical information for a user interface on the input/output device 840 .
[0087] The memory 820 stores information within the system 800 . In some implementations, the memory 820 is a computer-readable medium. In other implementations, the memory 820 is a volatile memory unit. In yet other implementations, the memory 820 is a non-volatile memory unit.
[0088] The storage device 830 is capable of providing mass storage for the system 800 . In some implementations, the storage device 830 is a computer-readable medium. In various different implementations, the storage device 830 may be a floppy disk device, a hard disk device, an optical disk device, or a tape device.
[0089] The input/output device 840 provides input/output operations for the system 800 . In some implementations, the input/output device 840 includes a keyboard and/or pointing device. In other implementations, the input/output device 840 includes a display unit for displaying graphical user interfaces.
[0090] In some embodiments the system 800 may be an Apple computer, such as a Mac Pro, MacBook Pro, or other Apple computer running Mac OS. In other embodiments the system may be a Unix system, a Windows system, or other system as is known.
[0000] FIGS. 25A and 25B is a User Interface for Mobile Device that can Implement the Invention.
FIG. 30 is a Hardware Architecture of the Mobile Device of FIGS. 25A & 25B for Implementing the Invention.
[0091] In some implementations, the mobile device 2500 can implement multiple device functionalities, such as a telephony device, as indicated by a Phone object 2510 ; an e-mail device, as indicated by the Mail object 2512 ; a map devices, as indicated by the Maps object 2514 ; a Wi-Fi base station device (not shown); and a network video transmission and display device, as indicated by the Web Video object 2516 . In some implementations, particular display objects 2504 , e.g., the Phone object 2510 , the Mail object 2512 , the Maps object 2514 , and the Web Video object 2516 , can be displayed in a menu bar 2518 . In some implementations, device functionalities can be accessed from a top-level graphical user interface, such as the graphical user interface illustrated in FIG. 25A . Touching one of the objects 2510 , 2512 , 2514 , or 2516 can, for example, invoke a corresponding functionality.
[0092] In some implementations, the mobile device 2500 can implement a network distribution functionality. For example, the functionality can enable the user to take the mobile device 2500 and provide access to its associated network while traveling. In particular, the mobile device 2500 can extend Internet access (e.g., Wi-Fi) to other wireless devices in the vicinity. For example, mobile device 2500 can be configured as a base station for one or more devices. As such, mobile device 2500 can grant or deny network access to other wireless devices.
[0093] In some implementations, upon invocation of a device functionality, the graphical user interface of the mobile device 2500 changes, or is augmented or replaced with another user interface or user interface elements, to facilitate user access to particular functions associated with the corresponding device functionality. For example, in response to a user touching the Phone object 2510 , the graphical user interface of the touch-sensitive display 2502 may present display objects related to various phone functions; likewise, touching of the Mail object 2512 may cause the graphical user interface to present display objects related to various e-mail functions; touching the Maps object 2514 may cause the graphical user interface to present display objects related to various maps functions; and touching the Web Video object 2516 may cause the graphical user interface to present display objects related to various web video functions.
[0094] In some implementations, the top-level graphical user interface environment or state of FIG. 25A can be restored by pressing a button 2520 located near the bottom of the mobile device 2500 . In some implementations, each corresponding device functionality may have corresponding “home” display objects displayed on the touch-sensitive display 2502 , and the graphical user interface environment of FIG. 25A can be restored by pressing the “home” display object.
[0095] In some implementations, the top-level graphical user interface can include additional display objects 2506 , such as a short messaging service (SMS) object 2530 , a Calendar object 2532 , a Photos object 2534 , a Camera object 2536 , a Calculator object 2538 , a Stocks object 2540 , a Address Book object 2542 , a Media object 2544 , a Web object 2546 , a Video object 2548 , a Settings object 2550 , and a Notes object (not shown). Touching the SMS display object 2530 can, for example, invoke an SMS messaging environment and supporting functionality; likewise, each selection of a display object 2532 , 2534 , 2536 , 2538 , 2540 , 2542 , 2544 , 2546 , 2548 , and 2550 can invoke a corresponding object environment and functionality.
[0096] Additional and/or different display objects can also be displayed in the graphical user interface of FIG. 25A . For example, if the device 2500 is functioning as a base station for other devices, one or more “connection” objects may appear in the graphical user interface to indicate the connection. In some implementations, the display objects 2506 can be configured by a user, e.g., a user may specify which display objects 2506 are displayed, and/or may download additional applications or other software that provides other functionalities and corresponding display objects.
[0097] In some implementations, the mobile device 2500 can include one or more input/output (I/O) devices and/or sensor devices. For example, a speaker 2560 and a microphone 2562 can be included to facilitate voice-enabled functionalities, such as phone and voice mail functions. In some implementations, an up/down button 2584 for volume control of the speaker 2560 and the microphone 2562 can be included. The mobile device 2500 can also include an on/off button 2582 for a ring indicator of incoming phone calls. In some implementations, a loud speaker 2564 can be included to facilitate hands-free voice functionalities, such as speaker phone functions. An audio jack 2566 can also be included for use of headphones and/or a microphone.
[0098] In some implementations, a proximity sensor 2568 can be included to facilitate the detection of the user positioning the mobile device 2500 proximate to the user's ear and, in response, to disengage the touch-sensitive display 2502 to prevent accidental function invocations. In some implementations, the touch-sensitive display 2502 can be turned off to conserve additional power when the mobile device 2500 is proximate to the user's ear.
[0099] Other sensors can also be used. For example, in some implementations, an ambient light sensor 2570 can be utilized to facilitate adjusting the brightness of the touch-sensitive display 2502 . In some implementations, an accelerometer 2572 can be utilized to detect movement of the mobile device 2500 , as indicated by the directional arrow 2574 . Accordingly, display objects and/or media can be presented according to a detected orientation, e.g., portrait or landscape. In some implementations, the mobile device 2500 may include circuitry and sensors for supporting a location determining capability, such as that provided by the global positioning system (GPS) or other positioning systems (e.g., systems using Wi-Fi access points, television signals, cellular grids, Uniform Resource Locators (URLs)). In some implementations, a positioning system (e.g., a GPS receiver) can be integrated into the mobile device 2500 or provided as a separate device that can be coupled to the mobile device 2500 through an interface (e.g., port device 2590 ) to provide access to location-based services.
[0100] In some implementations, a port device 2590 , e.g., a Universal Serial Bus (USB) port, or a docking port, or some other wired port connection, can be included. The port device 2590 can, for example, be utilized to establish a wired connection to other computing devices, such as other communication devices 2500 , network access devices, a personal computer, a printer, a display screen, or other processing devices capable of receiving and/or transmitting data. In some implementations, the port device 2590 allows the mobile device 2500 to synchronize with a host device using one or more protocols, such as, for example, the TCP/IP, HTTP, UDP and any other known protocol.
[0101] The mobile device 2500 can also include a camera lens and sensor 2580 . In some implementations, the camera lens and sensor 2580 can be located on the back surface of the mobile device 2500 . The camera can capture still images and/or video.
[0102] The mobile device 2500 can also include one or more wireless communication subsystems, such as an 802.11b/g communication device 2586 , and/or a Bluetooth™ communication device 2588 . Other communication protocols can also be supported, including other 802.x communication protocols (e.g., WiMax, Wi-Fi, 3G), code division multiple access (CDMA), global system for mobile communications (GSM), Enhanced Data GSM Environment (EDGE), etc.
[0103] FIG. 25B illustrates another example of configurable top-level graphical user interface of device 2500 . The device 2500 can be configured to display a different set of display objects.
[0104] In some implementations, each of one or more system objects of device 2500 has a set of system object attributes associated with it; and one of the attributes determines whether a display object for the system object will be rendered in the top-level graphical user interface. This attribute can be set by the system automatically, or by a user through certain programs or system functionalities as described below. FIG. 25B shows an example of how the Notes object 2552 (not shown in FIG. 25A ) is added to and the Web Video object 2516 is removed from the top graphical user interface of device 2500 (e.g. such as when the attributes of the Notes system object and the Web Video system object are modified).
[0105] FIG. 30 is a block diagram 3000 of an example implementation of a mobile device (e.g., mobile device 2500 ). The mobile device can include a memory interface 3002 , one or more data processors, image processors and/or central processing units 3004 , and a peripherals interface 3006 . The memory interface 3002 , the one or more processors 3004 and/or the peripherals interface 3006 can be separate components or can be integrated in one or more integrated circuits. The various components in the mobile device can be coupled by one or more communication buses or signal lines.
[0106] Sensors, devices, and subsystems can be coupled to the peripherals interface 3006 to facilitate multiple functionalities. For example, a motion sensor 3010 , a light sensor 3012 , and a proximity sensor 3014 can be coupled to the peripherals interface 3006 to facilitate the orientation, lighting, and proximity functions described with respect to FIG. 25A . Other sensors 3016 can also be connected to the peripherals interface 3006 , such as a positioning system (e.g., GPS receiver), a temperature sensor, a biometric sensor, or other sensing device, to facilitate related functionalities.
[0107] A camera subsystem 3020 and an optical sensor 3022 , e.g., a charged coupled device (CCD) or a complementary metal-oxide semiconductor (CMOS) optical sensor, can be utilized to facilitate camera functions, such as recording photographs and video clips.
[0108] Communication functions can be facilitated through one or more wireless communication subsystems 3024 , which can include radio frequency receivers and transmitters and/or optical (e.g., infrared) receivers and transmitters. The specific design and implementation of the communication subsystem 3024 can depend on the communication network(s) over which the mobile device is intended to operate. For example, a mobile device can include communication subsystems 3024 designed to operate over a GSM network, a GPRS network, an EDGE network, a Wi-Fi or WiMax network, and a Bluetooth™ network. In particular, the wireless communication subsystems 3024 may include hosting protocols such that the mobile device may be configured as a base station for other wireless devices.
[0109] An audio subsystem 3026 can be coupled to a speaker 3028 and a microphone 3030 to facilitate voice-enabled functions, such as voice recognition, voice replication, digital recording, and telephony functions.
[0110] The I/O subsystem 3040 can include a touch screen controller 3042 and/or other input controller(s) 3044 . The touch-screen controller 3042 can be coupled to a touch screen 3046 . The touch screen 3046 and touch screen controller 3042 can, for example, detect contact and movement or break thereof using any of a plurality of touch sensitivity technologies, including but not limited to capacitive, resistive, infrared, and surface acoustic wave technologies, as well as other proximity sensor arrays or other elements for determining one or more points of contact with the touch screen 3046 .
[0111] The other input controller(s) 3044 can be coupled to other input/control devices 3048 , such as one or more buttons, rocker switches, thumb-wheel, infrared port, USB port, and/or a pointer device such as a stylus. The one or more buttons (not shown) can include an up/down button for volume control of the speaker 3028 and/or the microphone 3030 .
[0112] In one implementation, a pressing of the button for a first duration may disengage a lock of the touch screen 3046 ; and a pressing of the button for a second duration that is longer than the first duration may turn power to the mobile device on or off. The user may be able to customize a functionality of one or more of the buttons. The touch screen 3046 can, for example, also be used to implement virtual or soft buttons and/or a keyboard.
[0113] In some implementations, the mobile device can present recorded audio and/or video files, such as MP3, AAC, and MPEG files. In some implementations, the mobile device can include the functionality of an MP3 player, such as an iPod™. The mobile device may, therefore, include a 32-pin connector that is compatible with the iPod™. Other input/output and control devices can also be used.
[0114] The memory interface 3002 can be coupled to memory 3050 . The memory 3050 can include high-speed random access memory and/or non-volatile memory, such as one or more magnetic disk storage devices, one or more optical storage devices, and/or flash memory (e.g., NAND, NOR). The memory 3050 can store an operating system 3052 , such as Darwin, RTXC, LINUX, UNIX, OS X, WINDOWS, or an embedded operating system such as VxWorks. The operating system 3052 may include instructions for handling basic system services and for performing hardware dependent tasks. In some implementations, the operating system 3052 can be a kernel (e.g., UNIX kernel).
[0115] The memory 3050 may also store communication instructions 3054 to facilitate communicating with one or more additional devices, one or more computers and/or one or more servers. The memory 3050 may include graphical user interface instructions 3056 to facilitate graphic user interface processing; sensor processing instructions 3058 to facilitate sensor-related processing and functions; phone instructions 3060 to facilitate phone-related processes and functions; electronic messaging instructions 3062 to facilitate electronic-messaging related processes and functions; web browsing instructions 3064 to facilitate web browsing-related processes and functions; media processing instructions 3066 to facilitate media processing-related processes and functions; GPS/Navigation instructions 3068 to facilitate GPS and navigation-related processes and instructions; camera instructions 3070 to facilitate camera-related processes and functions; and/or other software instructions 3072 to facilitate other processes and functions, e.g., access control management functions as described in reference to FIGS. 5 and 6 . The memory 3050 may also store other software instructions (not shown), such as web video instructions to facilitate web video-related processes and functions; and/or web shopping instructions to facilitate web shopping-related processes and functions. In some implementations, the media processing instructions 3066 are divided into audio processing instructions and video processing instructions to facilitate audio processing-related processes and functions and video processing-related processes and functions, respectively. An activation record and International Mobile Equipment Identity (IMEI) 3074 or similar hardware identifier can also be stored in memory 3050 .
[0116] Each of the above identified instructions and applications can correspond to a set of instructions for performing one or more functions described above. These instructions need not be implemented as separate software programs, procedures, or modules. The memory 3050 can include additional instructions or fewer instructions. Furthermore, various functions of the mobile device may be implemented in hardware and/or in software, including in one or more signal processing and/or application specific integrated circuits.
Closing
[0117] The disclosed and other embodiments and the functional operations described in this specification can be implemented in digital electronic circuitry, or in computer software, firmware, or hardware, including the structures disclosed in this specification and their structural equivalents, or in combinations of one or more of them. The disclosed and other embodiments can be implemented as one or more computer program products, i.e., one or more modules of computer program instructions encoded on a computer-readable medium for execution by, or to control the operation of, data processing apparatus. The computer-readable medium can be a machine-readable storage device, a machine-readable storage substrate, a memory device, a composition of matter effecting a machine-readable propagated signal, or a combination of one or more them. The term “data processing apparatus” encompasses all apparatus, devices, and machines for processing data, including by way of example a programmable processor, a computer, or multiple processors or computers. The apparatus can include, in addition to hardware, code that creates an execution environment for the computer program in question, e.g., code that constitutes processor firmware, a protocol stack, a database management system, an operating system, or a combination of one or more of them. A propagated signal is an artificially generated signal (e.g., a machine-generated electrical, optical, or electromagnetic signal), that is generated to encode information for transmission to suitable receiver apparatus.
[0118] A computer program (also known as a program, software, software application, script, 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 in a file system. A program can be stored in a portion of a file that holds other programs or data (e.g., one or more scripts stored in a markup language document), 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).
[0119] 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).
[0120] 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 performing 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. However, a computer need not have such devices. Computer-readable media suitable for storing computer program instructions and data include all forms of non-volatile memory, media and memory devices, including by way of example semiconductor memory devices, e.g., EPROM, EEPROM, and flash memory devices; magnetic disks, e.g., 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.
[0121] To provide for interaction with a user, the disclosed embodiments can be implemented on a computer having a display device, e.g., a CRT (cathode ray tube), LCD (liquid crystal display) monitor, touch sensitive device or display, for displaying information to the user and a keyboard and a pointing device, e.g., a mouse or a trackball, by which the user can provide input to the computer. Other kinds of devices can be used to provide for interaction with a user as well; for example, feedback provided to the user can be any form of sensory feedback, e.g., visual feedback, auditory feedback, or tactile feedback; and input from the user can be received in any form, including acoustic, speech, or tactile input.
[0122] While this specification contains many specifics, these should not be construed as limitations on the scope of what is being claimed or of what may be claimed, but rather as descriptions of features specific to particular embodiments. Certain features that are described in this specification in the context of separate embodiments can also be implemented in combination in a single embodiment. Conversely, various features that are described in the context of a single embodiment can also be implemented in multiple embodiments separately or in any suitable subcombination. Moreover, although features may be described above as acting in certain combinations and even initially claimed as such, one or more features from a claimed combination can in some cases be excised from the combination, and the claimed combination may be directed to a subcombination or variation of a subcombination.
[0123] Similarly, while operations are depicted in the drawings in a particular order, this should not be understand as requiring that such operations be performed in the particular order shown or in sequential order, or that all illustrated operations be performed, to achieve desirable results. In certain circumstances, multitasking and parallel processing may be advantageous. Moreover, the separation of various system components in the embodiments described above should not be understood as requiring such separation in all embodiments, and it should be understood that the described program components and systems can generally be integrated together in a single software product or packaged into multiple software products.
[0124] The systems and techniques described here 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 a Web browser through which a user can interact with an implementation of the systems and techniques described here), 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.
[0125] 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.
[0126] Although a few implementations have been described in detail above, other modifications are possible. For example, the flow diagrams depicted in the figures do not require the particular order shown, or sequential order, to achieve desirable results. In addition, other steps may be provided, or steps may be eliminated, from the described flow diagrams, and other components may be added to, or removed from, the described systems. Accordingly, various modifications may be made to the disclosed implementations and still be within the scope of the following claims. | Among other disclosed subject matter, a method includes providing a user interface allowing the insertion of elements into a document flow comprising static and dynamic elements, the user interface presenting a graphical depiction of the document that is dynamically altered by the insertion of the element, wherein the dynamically altered appearance of the document correctly reflects the position and type of the inserted element and rearranges all existing static and flow elements of the document around the inserted element. | 63,274 |
This invention relates to phlorophenone derivatives, processes for preparing such compounds, uses and pharmaceutical compositions of phlorophenone compounds. More particularly, this invention relates to various phlorophenone and related chroman and dihydrobenzofuran compounds, processes for preparing such compounds; antibacterial and antimycotic uses, and pharmaceutical compositions of such-like compounds.
BACKGROUND OF THE INVENTION
W. Riedl in Chemische Berichte, 85, 692 (1952) described the synthesis of humulon and lupulone compounds which had been known to exist in nature and which had further been known to possess certain antibiotic properties. In this publication he reported the synthesis of humulon by diprenylation of the disodium salt of phlorisovalerophenone yielding as a byproduct (9%--see compound XV on page 701) 3-phenyl phlorisovalerophenone. In this publication, W. Riedl also reported that, during the synthesis of 4-desoxy humulon, a byproduct was obtained which was speculated to comprise a chroman or benzodipyran. However, the structure hereof was not further examined nor reported, although this byproduct exhibited certain antibacterial activity.
F. Bohlman and various co-workers in a number of publications have reported the extraction of various compounds (mainly in the form of mixtures) from certain Helicrysum plant species, which compounds were postulated to have the 3-alkenyl phlorophenone structure. Certain related chromans were also extracted or prepared from compounds extracted from the plant material. However, as far as the inventors of the present invention are aware, no antimicrobial properties of these compounds have been reported.
V. K. Ahluwalia and various co-workers in Synthesis, 526 and 527, (1981) reported the synthesis of chromans and dichromans, both classes of compounds being derived from the corresponding phlorophenone compound. Although the aforementioned types of compounds are known to have certain physiological activities, for example including antioxidant, tranquillizing, and antidepressant properties and properties relating to fertility, it appears as if no antimicrobial properties of these compounds have been reported (see reference number 2 in the first-mentioned paper by Ahluwalia et al).
Other workers are known to have prepared phlorophenones, chromans, and dihydrobenzofurans, for example, A. Robertson and T. S. Subramanian, J. Chem. Soc., 286 (1937) and 1545 (1937); R. A. Finnegan et al, Tetrahedron Letters, 13, 11 (1959); E. D. Burling et al, Tetrahedron, 21, 2653 (1965); P. W. Austin et al, Tetrahedron, 24, 3247 (1968); R. H/a/ nsel et al, Phytochem, 19, 639 (1980). Likewise, however, as far as the inventors of the present invention are aware, no antimicrobial activity or properties of these compounds have been reported.
It has long been known that phenols and chlorinated phenols exhibit bactericidal action. Phenol itself, the simplest member of the series was already introduced as an antiseptic during the nineteenth century. It has been shown that the more highly substituted phenol derivatives are more selective in their action than the simpler phenols, and some of the more highly substituted phenol derivatives also exhibit antifungal activity. The more selective phenols are used mostly for skin disinfections, whilst the less refined members are used as general disinfectants, for instance in the disinfection of floors, drains, and stables for example. Phenols are also used as preservatives in pharmaceutical preparations.
OBJECTS OF THE INVENTION
This invention has as an object novel phlorophenone compounds and related chromans and dihydrobenzofurans; novel processes for preparing phlorophenone compounds and related chromans and dihydrobenzofurans; novel antibacterial and/or antimycotic uses of such-like compounds; and pharmaceutical compositions of these types of compounds.
SUMMARY OF THE INVENTION
According to one aspect of the present invention there are provided novel compounds of general formula I ##STR2## wherein R is a branched or unbranched alkyl, cycloalkyl, or aralkyl group, which group may optionally contain or be substituted by a halogen or oxygen function, the oxygen function preferably being in the form of a hydroxy or ether moiety;
R 1 , R 2 , and R 3 , which may be the same or different, is hydrogen, an alkyl, acyl, or benzoyl group, which group may optionally contain or be substituted by a halogen or oxygen function;
R 4 is hydrogen, an alkyl, alkenyl (preferably such as an allyl or prenyl) or aralkyl group, which group may optionally contain or be substituted by an alkyl, aryl, halogen or oxygen function;
R 5 is hydrogen, an alkyl, aralkyl, alkenyl or aryl group, which group may optionally contain or be substituted by an alkyl, aryl, halogen, or oxygen function;
except that R 4 and R 5 are not both hydrogen; and except for the compounds when R 5 is hydrogen and R is methyl, i-propyl, branched butyl, methoxy methyl, 2-phenylethyl, or 2-phenylethylene;
pharmaceutically acceptable salts thereof, and metabolites and metabolic precursors of the aforegoing.
It is to be understood that the novel phlorophenone compounds, and related chromans and dihydrobenzofurans according to the invention are included within the scope of general formula I. However, for purposes of further discussion, these three types of compounds will be discussed hereunder with reference to further general formulae in order to define these novel compounds more clearly. Therefore also according to the invention there are provided novel phlorophenone compounds of general formula II ##STR3## wherein R, R 1 , R 2 , R 3 , R 4 , and R 5 are as defined for general formula I, and wherein R 1 , R 2 , and/or R 3 is/are not directly bonded to any group defined by R 4 and/or R 5 . In other words, compounds of general formula II are to be understood to exclude compounds having a cyclic moiety associated with substituents R 1 , R 2 , and/or R 3 .
In the case that in general formula II the substituent group for R 4 is directly bonded to either R 2 or R 3 respectively, there are obtained
(i) chromans of general formula III as defined hereunder: ##STR4## wherein R, R 1 , and/or R 2 in the case of general formula IIIa, and R 3 in the case of general formula IIIb, and R 5 are as hereinbefore defined for general formula II;
and wherein the O-containing ring is optionally unsaturated and/or optionally substituted by one or more alkyl, aralkyl, or aryl groups(s), which group(s) optionally contain(s) or is/are substituted by an alkyl, halogen or oxygen function; and
(ii) dihydrobenzofurans of general formula IV ##STR5## wherein R, R 1 , R 2 in the case of general formula IVa and R 3 in the case of general formula IVb, and R 5 are as hereinbefore defined for general formula II;
and wherein the O-containing ring is optionally unsaturated and/or optionally substituted by one or more alkyl, aralkyl, or aryl group(s), which group(s) optionally contain(s) or is/are substituted by an alkyl, halogen or oxygen function.
Generally preferred compounds of general formula II include compounds wherein R 1 , R 2 , and R 3 are hydrogen, R 4 is an allyl, prenyl, or benzyl group, and R 5 is hydrogen; or compounds wherein R 1 , R 2 , R 3 , and R 4 are hydrogen, and R 5 is an acyl group.
Generally preferred compounds of general formula III are the compounds having structure IIIa wherein R 1 , R 2 , and R 5 are hydrogen, and the α carbon atom in the O-containing ring is mono or dialkylated, more specifically mono or dimethylated.
Preferred compounds of general formula IV include compounds wherein R 1 , R 2 , or R 3 , and R 5 are hydrogen.
Particularly preferred compounds of the above general formulae are listed in Table 1 hereunder.
TABLE 1 SUBSTITUENTS IN O-CONTAINING GENERAL RING COMP. FORMULA R R.sub.1 R.sub.2 R.sub.3 R.sub.4 R.sub.5 POSITION(S) SUBSTITUENT(S) NUMBER II CH.sub.2 CH.sub.2 CH.sub.3 H H H H ##STR6##1 II CH.sub.2 CH.sub.3 H H H CH.sub.2 CH:C(CH.sub.3).sub.2 H 2 II CH.sub.2 CH.sub.2 CH.sub.3 H H H CH.sub.2 CH:C(CH.sub.3).sub.2 H 3 II CH.sub.2 CH.sub.2 CH.sub.2 CH.sub.3 H H H CH.sub.2 CH:C(CH.sub.3).sub.2 H 4 II CH.sub.2 CH.sub.2 CH.sub.2 CH.sub.2 CH.sub.3 H H H CH.sub.2 CH:C(CH.sub.3).sub.2 H 5 II CH.sub.2 C.sub.6 H.sub.5 H H H CH.sub.2 CH:C(CH.sub.3).sub.2 H 6 II CH.sub.2 CH.sub.2 CH(CH.sub.3).sub.2 H H H CH.sub.2 CH:C(CH.sub.3).sub.2 H 7 II ##STR7## H H H CH.sub.2 CH:C(CH.sub.3).sub.2 H 8 II ##STR8## H H H CH.sub.2 CH:C(CH.sub.3).sub.2 H 9 II CH.sub.2 (CH.sub.2).sub.6 CH.sub.3 H H H CH.sub.2 CH:C(CH.sub.3).sub.2 H 10 II C H.sub.2 (CH.sub.2).sub.5 CH.sub.3 H H H CH.sub.2 CH:C(CH.sub.3).sub.2 H 11 II CH.sub.2 (CH.sub.2).sub.4 CH.sub.3 H H H CH.sub.2 CH:C(CH.sub.3).sub.2 H 12 II CH.sub.2 C.sub.6 H.sub.4 Cl(p) H H H CH.sub.2 CH:C(CH.sub.3).sub.2 H 14 II CH.sub.2 CH.sub.3 H H H CH.sub.2 CH:CH.sub.2 H 15 II CH.sub.2 CH.sub.2 CH.sub.3 H H H CH.sub.2 CH:CH.sub.2 H 16 II CH.sub.2 CH.sub.2 CH.sub.2 CH.sub.3 H H H CH.sub.2 CH:CH.sub.2 H 17 II CH.sub.2 (CH.sub.2).sub.3 CH.sub.3 H H H CH.sub.2 CH:CH.sub.2 H 18 II CH.sub.2 CH.sub.2 CH(CH.sub.3).sub.2 H H H CH.sub.2 CH:CH.sub.2 H 19 II ##STR9## H H H CH.sub.2 CH:CH.sub.2 H 20 II CH.sub.2 CH.sub.2 CH.sub.3 H H H CH.sub.2 CH:CH.sub.2 ##STR10## 21 II CH.sub.2 CH.sub.2 OCH.sub.2 CH.sub.3 H H H CH.sub.2 CH:CH.sub.2 H 22 II CH.sub.2 C.sub.6 H.sub.4 Cl(p) H H H CH.sub.2 CH:CH.sub.2 H 23 II CH.sub.2 CH.sub.2 CH.sub.3 H H H CH.sub.2 C.sub.6 H.sub.5 H 24 II CH.sub.2 CH.sub.2 CH(CH.sub.3).sub.2 H H H CH.sub.2 C.sub.6 H.sub.5 H 25 II ##STR11## H H H CH.sub.2 C.sub.6 H.sub.5 H 26 II CH.sub.2 (CH.sub.2).sub.6 CH.sub.3 H H H CH.sub.2 C.sub.6 H.sub.5 H 27 II CH.sub.2 CH.sub.2 CH(CH.sub.3).sub.2 ##STR12## ##STR13## H CH.sub.2 CH:C(CH.sub.3).sub.2 H 28 II CH.sub.2 CH.sub.2 CH(CH.sub.3).sub.2 CH.sub.3 CH.sub.3 H CH.sub.2 CH:C(CH.sub.3).sub.2 H 29 IIIa CH.sub.2 CH.sub.2 CH.sub.3 H H H 2,2 CH.sub.3, CH.sub.3 30 IIIa CH.sub.2 CH.sub.2 CH(CH.sub.3).sub.2 H H H 2,2 CH.sub.3, CH.sub.3 31 IIIa CH.sub.2 (CH.sub.2).sub.6 CH.sub.3 H H H 2,2 CH.sub.3, CH.sub.3 32 IIIb CH.sub.2 CH.sub.2 CH(CH.sub.3).sub.2 H H H 2,2 CH.sub.3, CH.sub.3 33 IIIb CH.sub.2 (CH.sub.2).sub.6 CH.sub.3 H H H 2,2 CH.sub.3, CH.sub.3 34 IVa or IVb CH.sub.2 CH.sub.2 CH.sub.3 H R2 or R3 = H H 2 CH.sub.3 35 IIIa CH.sub.2 CH.sub.2 CH.sub.3 H H ##STR14## 2,2 CH.sub.3, CH.sub.3 36 IVa CH.sub.2 CH.sub.2 CH.sub.3 H H ##STR15## 2 CH.sub.3 37
Most preferred compounds of the above general formulae are listed hereunder. The number appearing after each compound is the compound reference number referred to in the last column in Table 1 as Compound (comp.) number. These compound numbers are also used in the examples hereunder to assist in clearly defining the various compounds according to this invention.
2,4-Dibutyrylphloroglucinol. (1)
2-Caproyl-4-(3-methylbuten-2-yl)phloroglucinol. (5)
2-Isocaproyl-4-(3-methylbuten-2-yl)phloroglucinol. (7)
2-Hexahydrobenzoyl-4-(3-methylbuten-2-yl)phloroglucinol. (8)
2-(2-Cyclopentyl-1-oxo)-4-(3-methylbuten-2-yl)phloroglucinol. (9)
2-Isocaproyl-4-(propen-2-yl)phloroglucinol. (19)
2-Isocaproyl-4-benzylphloroglucinol. (25)
2-Nonanoyl-4-benzylphloroglucinol. (27)
5,7-Dihydroxy-2,2-dimethyl-8-isocaproylchroman. (31)
5,7-Dihydroxy-2,2-dimethyl-8-nonanoyl chroman. (32)
7-Butyryl-4,6-dihydroxy-2-methyl-2,3-dihydrobenzofuran
5-Butyryl-4,6-dihydroxy-2-methyl-2,3-dihydrobenzofuran. (35)
According to another aspect of the invention there are provided novel processes for preparing compounds of general formula I as hereinbefore defined including the excepted compounds, one process including the step of treating a parent phlorophenone compound with an appropriate organic halide, preferably an organic chloride compound, in the presence of a catalyst and a base. A preferred catalyst is cuprous chloride and a preferred base is for example sodium carbonate. This reaction is preferably carried out in a two phase system by dissolving or suspending the phlorophenone and cuprous chloride in ether or any suitable hydrophobic solvent, adding saturated sodium carbonate, and finally adding the organic chloride to the well stirred two phase system. Alternatively the process includes treatment of the sodium salt of the parent phlorophenone in an aprotic medium, such as benzene, with an appropriate halide, preferably the bromide compound.
Compounds of general formula II wherein R 5 is hydrogen can be prepared as outlined above; whilst compounds of general formula II wherein R 5 is an acyl group can be prepared
(i) by acylation of a phlorophenone compound, for example with an appropriate acid chloride in the presence of aluminium chloride; or alternatively,
(ii) for preparing compounds wherein R 5 is butyryl (see for example compound 1), an appropriate phlorophenone compound can be reacted with methanesulphonic acid and acrylic acid in the presence of phosphorous pentoxide.
The invention also provides a process for preparing compounds of the general formula III, one such preferred process being treatment of a phlorophenone derivative, wherein R 4 is prenyl with an appropriate acid, for example with trifluoro acetic acid in benzene, yielding the corresponding chroman derivatives IIIa and/or IIIb.
Reaction of 3-prenyl phloroglucinol (which can be prepared by treatment of phloroglucinol with prenyl chloride in the presence of a catalyst, such as cuprous chloride, and a base such as sodium carbonate, in a two phase system according to the general procedure as described above for the preparation of the prenyl compounds of general formula II) with an acid chloride in the presence of aluminium chloride in a suitable solvent such as carbon disulphide and nitrobenzene, leads to the formation of a mixture of products from which the corresponding chroman compound wherein R 5 is an acyl group can be isolated, for example by means of chromatography, or any other known method.
Reaction of a 3-allyl phloroglucinol, which can be prepared according to the method outlined immediately above from phloroglucinol and allyl chloride, with acid chloride in the presence of aluminium chloride in a suitable solvent such as carbon disulphide and nitrobenzene, leads to formation of compounds of general formula IV, i.e. dihydrobenzofuran in which R 5 is hydrogen or an acyl group.
It will be readily apparent to a person skilled in the art that the ether derivatives of compounds of the general formula I are prepared according to standard procedures applied for the etherification of a phenol, for example by reaction with dimethyl sulphate under basic conditions. Likewise, acetylation of phenolic groups of compounds of general formula I is accomplished according to standard procedures described for phenols, for example by treatment with an appropriate acid chloride in dry benzene, or by treatment with an appropriate anhydride in a basic medium.
Treatment of chromans and dihydrobenzofurans, being compounds of general formulae III and IV respectively, with 2,3-dichloro-5,6-dicyanobenzoquinone (DDQ) in a dry aprotic solvent, such as benzene, leads to the formation of the corresponding chromenes and benzofurans, a conversion that usually proceeds at a high yield.
The invention naturally extends to compounds whenever prepared according to any of the novel processes of the invention.
Compounds of general formula I and the related chromans and dihydrobenzofurans, including the excepted compounds, have generally shown useful antimicrobial activity, more particularly antibacterial and/or antimycotic properties. Accordingly, the invention extends to use of such compounds for these purposes, for example for treating humans or animals for bacterial and/or mycotic infections, or preserving food, beverages, natural products, and as a general disinfectant.
According to a further aspect of the invention there are provided pharmaceutical compositions comprising as an active ingredient, a pharmaceutically acceptable amount of at least one pharmacologically acceptable compound of general formula I including the excepted compounds, either alone or in admixture with a suitable diluent or adjuvant.
Preliminary investigations into the formation of bacterial/fungal resistance to certain of these compounds indicate no significant formation of resistance by the bacteria/fungi tested. These investigations indicate that such resistance is at least lower than against nitrofurantoin which was used as a reference compound.
DETAILED DESCRIPTION OF THE INVENTION
The invention will now be described in greater detail hereunder by way of the following nonlimiting examples.
EXAMPLE 1
The entire plant material of Helichrysum caespititium was air dried, crushed and extracted consecutively with benzene, ethyl acetate and methanol. These extractions were carried out at room temperature for a period of 48 hours. The extracts were separately stripped to dryness under reduced pressure at temperatures not exceeding 50° C. 2-Isocaproyl-4-(3-methylbuten-2-yl)phloroglucinol was isolated from each of the three extraction residues by means of chromatography preferably on silica gel (open column chromatography, preparative HPLC chromatography or preparative TLC) using preferably mixtures of benzene and ethyl acetate or petroleum ether and ethyl acetate for eluation. The 2-isocaproyl-4-(3-methylbuten-2-yl)phloroglucinol (7) was obtained as straw coloured crystals, m.p. 132°-133° C., from benzene.
IR spectrum (KBr-disc): 3420 (br, st), 2970 (m), 2930 (m), 2880 (w), 1630 (sh), 1610 (st), 1595 (st), 1560 (m), 1440 (st), 1385 (w), 1365 (w), 1280 (m), 1225 (st), 1215 (sh), 1145 (m), 1120 (w), 1075 (m) and 820 (m) cm -1 .
1 H NMR spectrum (CDCl 3 +CD 3 OD): δ 13.33 (s; 1H); 5.90 (s; 1H); 5.25 (br,t; J≃7 Hz; 1H); 3.4-2,9 (c; four prominant signals at δ 3.33; 3.22; 3.08 and 2.97; 4H); 1.83-1.43 (c; with sharp signals at δ 1.78 and 1.79; 9H) and 0.93 (d; J≃5 Hz; 6H).
13 C NMR spectrum (DMSO-d 6 ): δ 205.6; 163.4; 162.1; 159.8; 129.3; 123.5; 105.9; 103.6; 94.2; 41.1; 33.7; 27.4; 25.4; 22.3; 20.9 and 17.6.
EXAMPLE 2
Phlorisocaprophenone (4.48 g) was dissolved in ether (30 ml). To this solution was added cuprous chloride (100 mg), a saturated aqueous solution (30 ml) of sodium carbonate and prenyl chloride (2.1 g). The mixture was stirred or shaken vigorously for 12 hours. The ether phase was separated and the water phase was extracted twice with ether (25 ml). The ether solutions were combined, washed with water, dried over sodium sulphate and stripped to dryness under reduced pressure at room temperature. 2-Isocaproyl-4-(3-methylbuten-2-yl)phloroglucinol (7) was isolated from the residue by means of chromatography on silica gel (open column chromatography or preparative HPLC) using preferably mixtures of benzene and ethyl acetate or petroleum ether and ethyl acetate for eluation. Recrystallization from benzene afforded straw coloured crystals, identical to the sample prepared in Example 1.
EXAMPLE 3
To a solution of phlorisocaprophenone (5 g) in dry ether (50 ml) was first added dry benzene (100 ml) and then a solution of sodium (0.52 g) in absolute ethanol (30 ml). The mixture was concentrated to about 80 ml, whereupon the sodium salt of phlorisocaprophenone separated as a fine yellowish precipitate. To this well stirred suspension was added a solution of prenyl bromide (3.3 g) in benzene (10 ml) over a period of 15 minutes. The mixture was refluxed for a period of 3 hours and filtered to remove sodium bromide. The filtrate was evaporated to dryness and 2-isocaproyl-4-(3-methylbuten-2-yl)phloroglucinol (7) was isolated from the residue by chromatography according to the procedure described in Example 2. The 2-isocaproyl-4-(3-methylbuten-2-yl)phloroglucinol prepared according to this method was identical to the compound obtained in Examples 1 and 2.
EXAMPLES 4 TO 14
The compounds described in Examples 4 to 14 vary only in the phenone moiety and were prepared by starting with the appropriate phlorophenone, purified and recrystallized according to both the procedures described in Example 2 and Example 3. The quantity of phlorophenone substrate used in each of the preparations was adjusted according to its molecular mass.
EXAMPLE 4
2-Butyryl-4-(3-methylbuten-2-yl)phloroglucinol (3) from phlorobutyrophenone
IR spectrum (KBr-disc): 3430 (st), 3360 (br, st), 2980 (w), 2950 (w), 2930 (w), 2890 (w), 1640 (sh), 1625 (st), 1610 (sh), 1580 (m), 1460 (st), 1400 (m), 1380 (m), 1325 (m), 1300 (w), 1230 (st), 1160 (m), 1120 (w), 1090 (st), 1060 (w) and 835 (m) cm -1 .
1 H NMR spectrum (CDCl 3 +CD 3 OD): δ 5.86 (s; 1H); 5.18 (br,t; J≃7 Hz; 1H); 3.40-2.90 (c; with prominent signals at δ 3.28; 3.15; 3.05 and 2.90; 4H); 1.90-1.50 (c; with sharp signals at δ 1.75 and 1.65; 8H) and 0.97 (t; J≃7 Hz; 3H).
13 C NMR spectrum (DMSO-d 6 ): δ 163.4; 162.1; 159.8; 129.4; 123.5; 105.9; 103.7; 94.2; 45.1; 25.4; 21.0; 17.9; 17.6 and 13.8 and one signal below 200.
EXAMPLE 5
2-Nonanoyl-4-(3-methylbuten-2-yl)phloroglucinol (10) from phlorononaphenone
IR spectrum (KBr-disc): 3420 (br, st), 2930 (m), 2870 (m), 1625 (st), 1610 (st), 1580 (m), 1510 (w), 1475 (w), 1445 (st), 1395 (w), 1375 (w), 1280 (m), 1240 (st), 1210 (m), 1160 (m), 1085 (st) and 840 (m) cm -1 .
13 C NMR spectrum (DMSO-d 6 ): δ 205.3; 163.4; 162.1; 159.8; 129.4; 123.5; 105.9; 103.6; 94.1; 43.1; 31.3; 29.0 (2×C); 28.6; 25.4; 24.6; 22.1; 21.0; 17.6 and 13.9.
EXAMPLE 6
2Phenylacetyl-4-(3-methylbuten-2-yl)phloroglucinol (6) from phlorophenylacetophenone
IR spectrum (KBr-disc): 3420 (st), 3340 (br,m), 2980 (w), 2920 (w), 1635 (st), 1625 (st), 1595 (m), 1560 (m), 1435 (br, st), 1395 (w), 1350 (m), 1240 (st), 1210 (m), 1180 (w), 1150 (m), 1085 (st), 830 (m), 735 (m) and 710 (w) cm -1 .
1 H NMR spectrum (CDCl 3 +CD 3 OD): δ 7.23 (s; 5H); 5.88 (s; 1H); 5.25 (br,t; J≃7 Hz; 1H); 4.45 (s; 2H); 3.31 (d; J≃7 Hz; 2H); 1.82 (s; 3H) and 1.73 (s; 3H).
13 C NMR spectrum (CDCl 3 +CD 3 OD): δ 203.3; 163.2; 162.1; 160.3; 136.1; 132.8; 129.9 (2×C); 128.3 (2×C); 126.5; 122.7; 106.8; 104.8; 94.5; 49.9; 25.7; 21.5 and 17.8.
EXAMPLE 7
2-Hexahydrobenzoyl-4-(3-methylbuten-2yl)phloroglucinol (8) from phlorohexahydrobenzophenone
IR spectrum (KBr-disc): 3490 (br, m), 2920 (m), 2860 (w), 1625 (st), 1600 (sh), 1540 (w), 1510 (w), 1445 (st), 1375 (m), 1335 (w), 1315 (w), 1265 (st), 1255 (sh), 1220 (st), 1180 (m), 1150 (m), 1130 (m), 1080 (m), 1070 (sh), 1050 (sh), 1000 (w) and 825 (w) cm -1 .
1 H NMR spectrum (DMSO-d 6 ): δ 14.02 (s; 1H); 5.90 (s; 1H); 5.05 (br, t; J≃7 Hz; 1H); 3.28 (c; 1H); 3.03 (br, d; J≃7 Hz; 2H) and 1.95-1.05 (c with sharp signals at 1.66 and 1.58; 16H).
13 C NMR spectrum (DMSO-d 6 ): δ 208.5; 163.8; 162.0; 159.5; 129.3; 123.5; 106.0; 102.9; 94.3; 48.5; 29.2 (2×C); 25.8 (3×C); 25.4; 21.0 and 17.6.
EXAMPLE 8
2-Propionyl-4-(3-methylbuten-2-yl)phloroglucinol (2) from phloropropiophenone
IR spectrum (KBr-disc): 3400 (br, st), 2990 (w), 2940 (w), 1620 (br, st), 1585 (m), 1525 (w), 1510 (w), 1465 (sh), 1450 (st), 1435 (sh), 1400 (w), 1380 (m), 1370 (m), 1255 (st), 1240 (st), 1160 (m), 1100 (sh), 1090 (m), 1055 (w), 1000 (w), 900 (br, w) and 840 (m) cm -1 .
13 C NMR spectrum (DMSO-d 6 ): δ 205.7; 163.2; 162.1; 159.9; 129.4; 123.5; 105.8; 103.5; 94.1; 36.4; 25.4; 21.0; 17.6 and 8.9.
EXAMPLE 9
2-Valeryl-4-(3-methylbuten-2-yl)phloroglucinol (4) from phlorovalerophenone
IR spectrum (KBr-disc): 3430 (st), 3330 (br, m), 2960 (w), 2930 (br, w), 2880 (w), 1640 (sh), 1630 (st), 1605 (m), 1565 (m), 1530 (w), 1510 (w), 1465 (sh), 1450 (st), 1435 (sh), 1395 (m), 1385 (sh), 1360 (w), 1290 (m), 1240 (st), 1225 (m), 1185 (w), 1160 (m), 1120 (w), 1090 (st), 1060 (w), 1020 (w), 905 (w) and 835 (m) cm -1 .
13 C NMR spectrum (DMSO-d 6 ): δ 205.3; 163.4; 162.1; 159.8; 129.4; 124.5; 105.9; 103.6; 94.2; 42.8; 26.8; 25.4; 22.1; 21.0; 17.6 and 13.8.
EXAMPLE 10
2-Caproyl-4-(3-methylbuten-2-yl)phloroglucinol (5) from phlorocaprophenone
IR spectrum (KBr-disc): 3410 (br, st), 2970 (w), 2930 (br, m), 2880 (w), 1635 (sh), 1625 (st), 1610 (m), 1580 (m), 1525 (w), 1510 (w), 1450 (st), 1400 (w), 1380 (w), 1355 (m), 1300 (w), 1275 (m), 1250 (sh), 1235 (w), 1215 l (st), 1195 (w), 1160 (m), 1125 (br, w), 1085 (st) and 835 (m) cm -1 .
13 C NMR spectrum (DMSO-d 6 ): δ 205.3; 163.4; 162.1; 159.8; 129.4; 123.5; 105.9; 103.7; 94.2; 43.1; 31.2; 25.4; 24.3; 22.0; 21.0; 17.6 and 13.8.
EXAMPLE 11
2-Octanoyl-4-(3-methylbuten-2-yl)phloroglucinol (11) from phloroctanophenone
IR spectrum (KBr disc): 3420 (br, st), 2960 (w), 2920 (m), 2850 (w), 1650 (st), 1630 (st), 1610 (m), 1590 (m), 1555 (w), 1530 (w), 1520 (w), 1470 (sh), 1450 (st), 1400 (m), 1380 (br, m), 1290 (m), 1255 (st), 1245 (sh), 1210 (m), 1195 (w), 1155 (m), 1130 (w), 1080 (st), 905 (br, w) and 830 (m) cm -1 .
13 C NMR spectrum (DMSO-d 6 ): δ 205.3; 163.4; 162.1; 159.8; 129.3; 123.5; 105.9; 103.7; 94.2; 43.1; 31.2; 28.9; 28.6; 25.4; 24.6; 22.1; 21.0; 17.6 and 13.8.
EXAMPLE 12
2(2-Cyclopentyl-1-oxo)-4-(3-methylbuten-2yl)phloroglucinol (9) from 2-(2-cyclopentyl-1oxo)phloroglucinol
IR spectrum (KBr-disc): 3420 (br, st), 2960 (m), 2920 (br, w), 2860 (w), 1645 (sh), 1635 (st), 1615 (st), 1585 (w), 1570 (w), 1520 (br, w), 1465 (sh), 1460 (st), 1450 (sh), 1380 (br, m), 1310 (br, w), 1290 (br, w), 1245 (st), 1180 (w), 1150 (m), 1110 (w), 1080 (st) and 830 (m) cm -1 .
Mass spectrum: m/e 290 (M + ), 235, 221, 207, 191, 165 (100%), 153, 139, 97 and 69.
EXAMPLE 13
2-Heptanoyl-4-(3-methylbuten-2yl)phloroglucinol (12) from phloroheptanophenone
IR spectrum (KBr-disc): 3420 (br, st), 2960 (w), 2940 (sh), 2920 (m), 2860 (sh), 2850 (w), 1660 (sh), 1645 (m), 1635 (st), 1615 (m), 1590 (m), 1530 (w), 1520 (w), 1455 (st), 1400 (m), 1380 (m), 1355 (w), 1310 (sh), 1300 (m), 1265 (m), 1250 (m), 1230 (w), 1210 (st), 1195 (w), 1155 (m), 1130 (w), 1085 (st), 1070 (sh), 905 (br, w) and 830 (m) cm -1 .
13 C NMR spectrum (DMSO-d 6 ): δ 205.3; 163.4; 162.1; 159.8; 129.3; 123.5; 105.9; 103.7; 94.2; 43.1; 31.2; 28.6; 25.4; 24.6; 22.0; 21.0; 17.6 and 13.8.
EXAMPLE 14
2-(4-Chlorophenyl)acetyl-4-(3-methylbuten-2-yl)phloroglucinol (14) from phloro-p-chlorophenylacetophenone
IR spectrum (KBr-disc): 3420 (st), 3320 (br, m), 2970 (w), 2910 (w), 1650 (sh), 1630 (m), 1620 (st), 1600 (m), 1555 (m), 1520 (w), 1505 (w), 1490 (w), 1455 (sh), 1440 (st), 1430 (m), 1395 (m), 1375 (w), 1340 (m), 1310 (w), 1280 (w), 1250 (sh), 1230 (st), 1200 (m), 1180 (w), 1145 (m), 1095 (w), 1080 (st), 1050 (w), 1025 (w), 875 (m), 830 (w), 815 (m) and 780 (w) cm -1 .
13 C NMR spectrum (DMSO-d 6 ): δ 201.8; 163.4; 162.6; 159.9; 135.1; 131.5 (2×C); 131.0; 129.5; 127.9 (2×C); 123.3; 106.0; 103.5; 94.2; 48.2; 25.4; 20.9 and 17.5.
EXAMPLES 15 TO 22
The compounds described in Examples 15 to 22 were prepared and purified according to the procedure described in Example 2 by reacting the appropriate phlorophenone with slightly more than one molar equivalent allyl chloride instead of prenyl chloride.
EXAMPLE 15
2-Isocaproyl-4-(propen-2-yl)phloroglucinol (19) from phlorisocaprophenone
IR spectrum (KBr-disc): 3440 (st), 3140 (br, m), 2950 (m), 2920 (sh), 2870 (w), 1630 (m), 1600 (st), 1565 (m), 1495 (w), 1445 (st), 1425 (m), 1365 (w), 1315 (m), 1295 (st), 1275 (st), 1250 (m), 1225 (st), 1195 (m), 1150 (w), 1125 (st), 1100 (w), 1070 (st), 915 (m), 860 (w) and 805 (m) cm -1 .
1 H NMR spectrum (CDCl 3 +CD 3 OD): δ 13.35 (s; 1H); 6.30-5.60 (c; with sharp signal at δ 5.80; 2H); 5.20-4.80 (c; 2H); 3.45-2.90 (c; with prominent signals at δ 3.33; 3.23; 3.17; 3.05 and 2.92; 4H); 1.80-1.30 (c; with prominent signals at δ 1.65; 1.55 and 1.45; 3H) and 0.91 (d; J≃5 Hz; 6H).
13 C NMR spectrum (DMSO-d 6 ): δ 205.6; 163.6; 162.3; 160.1; 136.8; 113.8; 104.1; 103.6; 94.2; 41.2; 33.7; 27.5; 26.1 and 22.3 (2×C).
EXAMPLE 16
2-Butyryl-4-(propen-2-yl)phloroglucinol (16) from phlorobutyrophenone
IR spectrum (KBr-disc): 3460 (br, st), 3360 (br, st), 2980 (w), 2960 (w), 2900 (w), 1625 (st), 1610 (sh), 1570 (m), 1530 (w), 1515 (sh), 1450 (st), 1390 (m), 1375 (sh), 1320 (w), 1300 (m), 1230 (st), 1160 (m), 1120 (w), 1090 (m), 1010 (w), 930 (w) and 835 (m) cm -1 .
1 H NMR spectrum (CDCl 3 +CD 3 OD): δ 6.25-5.73 (c with singlet at 5.90; 2H); 5.30-4.90 (c; 2H); 3.50-2.95 (c with triplet at 3.1; J≃7.5 Hz; 4H); 2.03-1.43 (c; 2H); 0.98 (t; J≃7 Hz; 3H).
13 C NMR spectrum (DMSO-d 6 ): δ 205.2; 163.5; 162.3; 160.2; 136.8; 113.8; 104.1; 103.7; 94.1; 45.1; 26.1; 17.9 and 13.9.
EXAMPLE 17
2-Hexahydrobenzoyl-4-(propen-2-yl)phloroglucinol (20) from phlorohexahydrobenzophenone
IR spectrum (KBr-disc): 3360 (br, st), 2940 (m), 2860 (w), 1620 (st), 1600 (sh), 1575 (m), 1510 (w), 1450 (st) 1385 (m), 1335 (m), 1320 (w), 1295 (w), 1260 (st), 1225 (st), 1185 (w), 1155 (m), 1140 (m), 1080 (m), 1070 (w), 1050 (w), 1010 (w), 930 (w), 905 (w) and 830 (m) cm -1 .
1 H NMR spectrum (CDCl 3 +CD 3 OD): δ 6.18-5.65 (c with singlet at 5.83; 2H); 5.27-4.83 (c; 2H); 3.47-3.20 (c with strong signals at 3.38 and 3.30; 3H); 2.10-1.10 (c; 10H).
13 C NMR spectrum (DMSO-d 6 ): δ 208.6; 163.9; 162.2; 159.8; 136.8; 113.8; 104.3; 102.9; 94.3; 48.6; 29.3 (2×C); 26.1 and 25.8 (3×C).
EXAMPLE 18
2-Propionyl-4-(propen-2-yl)phloroglucinol (15) from phloropropiophenone
IR spectrum (KBr-disc): 3420 (st), 3370 (br, st), 3080 (w), 2990 (w), 2950 (w), 2930 (w), 1645 (sh), 1630 (st), 1620 (m), 1600 (m), 1580 (w), 1565 (w), 1555 (w), 1520 (w), 1505 (w), 1455 (st), 1410 (w), 1380 (w), 1365 (m), 1295 (w), 1245 (st), 1150 (m), 1130 (w), 1090 (sh), 1080 (m), 1035 (w), 1000 (w), 990 (w), 920 (m) and 830 (m) cm -1 .
13 C NMR spectrum (DMSO-d 6 ): δ 205.8; 163.4; 162.2; 160.2; 136.8; 113.8; 104.1; 103.5; 94.1; 36.4; 26.1 and 8.8.
EXAMPLE 19
2-Valeryl-4-(propen-2-yl)phloroglucinol (17) from phlorovalerophenone
IR spectrum (KBr-disc): 3450 (st), 3400 (br, sh), 3160 (br, w), 2970 (m), 2940 (w), 2880 (w), 1655 (sh), 1645 (sh), 1640 (st), 1630 (st), 1620 (st), 1610 (st), 1570 (m), 1510 (w), 1500 (w), 1465 (sh), 1455 (st), 1435 (sh), 1390 (w), 1360 (w), 1330 (m), 1305 (m), 1290 (m), 1280 (m), 1235 (st), 1215 (sh), 1200 (sh), 1160 (m), 1135 (m), 1080 (st), 1060 (sh), 930 (m), 875 (br, w) and 825 (m) cm -1 .
13 C NMR spectrum (DMSO-d 6 ): δ 205.4; 163.5; 162.3; 160.2; 136.8; 113.8; 104.1; 103.6; 94.1; 42.8; 26.8; 26.1; 22.1 and 13.8.
EXAMPLE 20
2-Caproyl-4-(propen-2-yl)phloroglucinol (18) from phlorocaprophenone
IR spectrum (KBr-disc): 3430 (st), 3320 (br, m), 2960 (m), 2930 (w), 2870 (w), 1635 (st), 1625 (st), 1600 (m), 1580 (m), 1560 (m), 1525 (w), 1510 (w), 1445 (st), 1400 (w), 1380 (w), 1360 (w), 1330 (w), 1300 (br, w), 1275 (m), 1265 (sh), 1250 (w), 1230 (st), 1215 (sh), 1155 (m), 1120 (w), 1090 (m), 1010 (br,w), 925 (w) and 830 (m) cm -1 .
13 C NMR spectrum (DMSO-d 6 ): δ 205.4; 163.5; 162.3; 160.2; 136.8; 113.7; 104.1; 103.6; 94.2; 43.1; 31.2; 26.1; 24.3; 21.3 and 13.8.
EXAMPLE 21
2-(4-chlorophenyl)acetyl-4-(propen-2-yl)phloroglucinol (23) from phloro-(4-chlorophenyl)acetophenone
IR spectrum (KBr-disc): 3420 (st), 3330 (br, m), 1655 (sh), 1640 (st), 1630 (st), 1610 (st), 1565 (m), 1530 (w), 1515 (w), 1500 (w), 1465 (sh), 1450 (m), 1405 (m), 1355 (m), 1290 (br, w), 1260 (sh), 1245 (st), 1210 (m), 1160 (m), 1130 (w), 1110 (w), 1090 (m), 1035 (w), 1010 (br, w), 935 (w), 885 (w), 835 (sh), 825 (w) and 800 (w) cm -1 .
13 C NMR spectrum (DMSO-d 6 ): δ 201.8; 163.6; 162.8; 160.2; 136.6; 135.1; 131.5 (2×C); 131.0; 127.9 (2×C); 113.8; 104.2; 103.5; 94.2; 48.3 and 26.0.
EXAMPLE 22
2-(3-Ethoxy)propionyl-4-(buten-2-yl)phloroglucinol (22) from phlor-(3-ethoxy)propiophenone
IR spectrum (KBr-disc): 3370 (br, st), 3200 (br, w), 2990 (w), 2940 (w), 2900 (w), 1665 (sh), 1650 (st), 1640 (st), 1620 (st), 1600 (sh), 1540 (w), 1460 (st), 1455 (sh), 1400 (w), 1380 (w), 1350 (w), 1310 (br, w), 1250 (st), 1160 (m), 1130 (m), 1110 (m), 1080 (m), 1030 (m), 1010 (w), 940 (w), 925 (br, w), 900 (w) and 835 (w) cm -1 .
Mass spectrum; m/e 266, 227, 222, 207 (100%), 193, 191, 165 and 164.
EXAMPLES 23 TO 26
The compounds described in Examples 23 to 26 were prepared and purified according to the procedure described in Example 2 by reacting the appropriate phlorophenone with slightly more than one molar equivalent benzyl chloride instead of prenyl chloride.
EXAMPLE 23
2-Isocaproyl-4-benzylphloroglucinol (25) from phlorisocaprophenone
IR spectrum (KBr-disc): 3450 (st), 3270 (br, st), 3030 (w), 2980 (m), 2960 (w), 2880 (w), 1620 (st), 1570 (m), 1520 (w), 1500 (w), 1445 (st), 1400 (w), 1375 (w), 1340 (w), 1290 (w), 1270 (w), 1230 (st), 1155 (m), 1130 (m), 1090 (m), 1040 (w), 940 (w), 915 (w), 830 (m) and 715 (m) cm -1 .
1 H NMR spectrum (CDCl 3 +CD 3 OD): δ 7.25-6.95 (c with sharp signal at 7.12; 5H); 5.74 (s; 1H); 3.85 (s: 2H); 3.02 (t; J≃7.5 Hz; 2H); 1.75-1.35 (c; 3H) and 0.89 (d; J=5Hz; 6H).
13 C NMR spectrum (DMSO-d 6 ): δ 205.7; 163.7; 162.4; 160.2; 141.8; 128.2 (2×C); 127.8 (2×C); 125.2; 105.7; 103.6; 94.2; 41.2; 33.7; 27.5 (2×C) and 22.3 (2×C).
EXAMPLE 24
2-Nonanoyl-4-benzylphloroglucinol (27) from phlorononaphenone
IR spectrum (KBr-disc): 3420 (br, st), 2930 (m), 2860 (w), 1615 (st), 1600 (sh), 1570 (m) 1515 (w), 1500 (w), 1490 (w), 1460 (w), 1430 (st), 1385 (w), 1310 (w), 1270 (m), 1240 (m), 1200 (m), 1150 (m), 1125 (w), 1075 (m), 1045 (w), 825 (w), 735 (m), 700 (w) and 650 (w) cm -1 .
1 H NMR spectrum (CDCl 3 +CD 3 OD): δ 7.33-6.98 (c; 5H); 5.79 (s; 1H); 3.87 (s; 2H); 3.05 (t; J≃7.5 Hz; 2H); 1.80-1.10 (c with strong signal at 1.28; 12H) and 1.03-0.73 (c with strong signal at 0.87; 3H).
13 C NMR spectrum (DMSO-d 6 ): δ 205.4; 163.6; 162.4; 160.3; 141.8; 128.2 (2×C); 127.8 (2×C); 125.2; 105.7; 103.6; 94.2; 43.1; 31.2; 28.9 (2×C); 28.6; 27.5; 24.5; 22.0 and 13.9.
EXAMPLE 25
2-Butyryl-4-benzylphloroglucinol (24) from phlorobutyrophenone
IR spectrum (KBr-disc): 3420 (br, st), 3400 (br, st), 2970 (w), 2940 (w), 2890 (w), 1610 (st), 1575 (m), 1520 (w), 1510 (w), 1450 (st), 1390 (m), 1370 (m), 1315 (m), 1245 (sh), 1220 (st), 1150 (m), 1115 (m), 1085 (m), 830 (m), 740 (m), 710 (m) and 695 (m) cm -1 .
1 H NMR spectrum (CDCl 3 +CD 3 OD): δ 7.38-7.05 (c; 5H); 5.83 (s; 1H), 3.92 (s; 2H); 3.05 (t; J≃7.5 Hz; 2H); 1.88-1.38 (c; 2H) and 0.95 (t; J≃7 Hz; 3H).
13 C NMR spectrum (DMSO-d 6 ): δ 205.2; 163.6; 162.4; 160.3; 141.8; 128.2 (2×C); 127.8 (2×C); 125.2; 105.7; 103.7; 94.2; 45.1; 27.5; 17.8 and 13.8.
EXAMPLE 26
2-Hexahydrobenzoyl-4-benzylphloroglucinol (26) from phlorohexahydrobenzophenone
IR spectrum (KBr-disc): 3350 (br, m), 2940 (m), 2870 (w), 1640 (st), 1620 (sh), 1590 (m), 1530 (w), 1505 (w), 1460 (m), 1450 (sh), 1390 (w), 1350 (w), 1280 (m), 1245 (m), 1165 (w), 1150 (w), 1100 (m), 1085 (sh), 850 (w), 750 (w), 720 (w) and 700 (w) cm -1 .
1 H NMR spectrum (CDCl 3 +CD 3 OD): δ 7.36-7.00 (c, 5H); 5.76 (s; 1H); 3.90 (s; 2H); about 3.80-3.33 (c; 1H) and 2.13-1.06 (c; 10H).
13 C NMR spectrum (DMSO-d 6 ): δ 208.6; 164.1; 162.3; 159.9; 141.7; 128.2 (2×C); 127.8 (2×C); 125.1; 105.9; 102.9; 94.3; 48.5; 29.2 (2×C); 27.5 and 25.7 (3×C).
EXAMPLE 27
To a mixture of anhydrous phloroglucinol (12.6 g) and aluminium chloride (48 g) in carbon disulfide (60 ml) was added nitrobenzene (45 ml) slowly over a period of 30 minutes. The latter mixture was then heated to reflux, whereupon cyclohexane carbonyl chloride (14.5 ml) in nitrobenzene (5 ml) was added over a period of 30 minutes. The reaction mixture was then refluxed for 3 hours, cooled and poured into ice water (500 ml). The resulting mixture was then subjected to steam distillation until all the nitrobenzene was removed. The residual solution was then cooled and the precipitated light yellow phlorohexahydro=benzophenone was collected and washed with water. Recrystallization from benzene afforded off-white crystals of phlorohexahydrobenzophenone, m.p. 110°-113° C.
EXAMPLE 28
p-Bromobenzoyl chloride (1.0 g) was added to a suspension of 2-isocaproyl-4-(3-methylbuten-2-yl)phloroglucinol (7) in dry benzene (25 ml) and the mixture was heated under reflux for 2 hours and evaporated to dryness. The residue was chromatographed on silica gel, as described earlier (Example 2), whereupon 2-isocaproyl-4-(3-methylbuten-2-yl)phloroglucinol-1.5(O)-bis(4-bromobenzoate) (28) was obtained. This was recrystallized from benzene/ethanol.
IR spectrum: 2970 (m), 2940 (w), 2880 (w), 1745 (st), 1630 (m), 1590 (st), 1485 (w), 1410 (sh), 1400 (m), 1260 (st), 1170 (m), 1095 (br, st), 1070 (st), 1010 (m), 905 (w), 880 (w) and 840 (m) cm -1 .
1 H NMR spectrum (CDCl 3 ): δ 13.28 (s; 1H); 8.00 (dd; J≃9 and 2 Hz; 4H); 7.63 (dd; J≃9 and 2 Hz; 4H); 6.60 (s; 1H); 5.13 (br; t; J≃7 Hz; 1H); 3.35 (d; J≃7 Hz; 2H); 2.87 (t; J≃7 Hz; 2H); 1.80-1.00 (c; with sharp signal at 1.60; 9H) and 0.72 (d; J≃6 Hz; 6H).
X-ray crystallographic data obtained for 28, with reference to the accompanying sketch: ##STR16##
TABLE 2______________________________________ THERMALFRACTIONAL COORDINATES PARAMETERSATOM X/A Y/B Z/C U______________________________________Br1 .0817 .3629 .0296 .0624B101 .2272 .2442 .2991 .0534B1C1 .1294 .3449 .0999 .0650B1C2 .1206 .2853 .1402 .0525B1C3 .1554 .2681 .1932 .0511B1C4 .1988 .3105 .2051 .0368B1C5 .2100 .3764 .1639 .0459B1C6 .1736 .3928 .1095 .0456B1C7 .2339 .2878 .2612 .0544C1 .3161 .3247 .3199 .0438C2 .3131 .3845 .3663 .0319C3 .3541 .3848 .4129 .0480C4 .3936 .3315 .4173 .0348C5 .3945 .2753 .3692 .0417C6 .3546 .2691 .3188 .0311C7 .3548 .2062 .2675 .0420C8 .3590 .3706 .2346 .0529C9 .3905 .3984 .2182 .0761C10 .4291 .2779 .2323 .1158C10A .3840 .5805 .1866 .1103C11 .4368 .3250 .4692 .0346C12 .4367 .3385 .5230 .0515C13 .4846 .2785 .5707 .0664C14 .4779 .2759 .6236 .1019C15 .4511 .1047 .6244 .1555C16 .5213 .2207 .6723 .1672O1 .2773 .3290 .2682 .0450O2 .3506 .4713 .4580 .0423O3 .4338 .2273 .3687 .0559O4 .4729 .2940 .4677 .0612B2C1 .3023 .7767 .5795 .0549B2C2 .2828 .6046 .5711 .0678B2C3 .2920 .4692 .5407 .0547B2C4 .3184 .5232 .5151 .0420B2C5 .3370 .7039 .5221 .0752B2C6 .3290 .8308 .5565 .0654B2C7 .3266 .3949 .4792 .0430B201 .3119 .2391 .4705 .0634Br2 .2907 .9488 .6223 .0738______________________________________
EXAMPLE 29
A stirred mixture of 2-isocaproyl-4-(3-methylbuten-2yl)phloroglucinol (7 (1 g) and anhydrous potassium carbonate (1 g) in dry acetone (50 ml) was heated to reflux and dimethyl sulphate (2 ml) was added dropwise. After completion of the addition the mixture was heated under reflux for a further period of 4 hours, cooled to room temperature and filtered. The filtrate was evaporated to dryness under vacuum. The residue was stirred overnight with aqueous sodium hydroxide (5%, 50 ml) and extracted with ether. The ether extract was washed with water, dried over sodium sulphate and evaporated to dryness. The residue was chromatographed on silica gel, as described earlier (Example 2), whereupon 2-isocaproyl-4-(3-methylbuten-2-yl)phloroglucinol-1,5-(O)-dimethylether (29, which melted at 86°-88° C. after recrystallization from benzene/petroleum ether, was obtained.
IR spectrum: 3010 (w), 2970 (m), 2940 (br, m), 2880 (m), 2860 (sh), 1615 (st), 1590 (st), 1465 (br, m), 1430 (m), 1410 (m), 1380 (m), 1325 (w), 1275 (m), 1220 (st), 1210 (st), 1200 (sh), 1170 (m), 1140 (m), 1120 (st), 875 (m), 795 (w), 785 (m) and 770 (w) cm -1 .
1 H NMR spectrum (CDCl 3 ): δ 13.73 (s; 1H); ;b 5.90 (s; 1H); 5.15 (br t; J≃7 Hz; 1H); 3.83 (s; 6H); 3.33-2.77 (c; 4H); 2.00-1.20 (c; two sharp signals at 1.75 and 1.63; 9H) and 0.92 (d; J≃5 Hz; 6H).
EXAMPLE 30
2-Isocaproyl-4-(3-methylbuten-2-yl)phloroglucinol (7 (2 g) was suspended in benzene (25 ml). Trifluoro acetic acid (1.5 ml) was added and the mixture was stirred for 6 hours at room temperature. The resulting solution was stripped to dryness under vacuum. The residue was chromatographed, preferably on silica gel (open column chromatography, preparative HPLC or preparative TLC) using preferably mixtures of benzene and ethyl acetate or petroleum ether and ethyl acetate for eluation. Two chromanes, namely 5,7-dihydroxy-2,2-dimethyl-8-isocaproyl chroman (31 and 5,7 -dihydroxy-2,2-dimethyl-6-isocaproyl chroman (33, were obtained in a ratio of about 3 to 2. These chromanes were both recrystallized from petroleum ether to give light straw coloured crystals.
Chroman (31 with longest column retention time (benzene:ethyl acetate; 9:1):
IR spectrum (KBr-disc): 3300 (br, m), 2960 (sh), 2940 (m), 2920 (m), 2860 (w), 1610 (st), 1595 (st), 1500 (m), 1415 (st), 1370 (w), 1350 (m), 1340 (m), 1270 (m), 1250 (m), 1230 (m), 1155 (st), 1115 (sh), 1105 (st), 1080 (m), 1030 (w), 1015 (w), 945 (w), 930 (w), 885 (w) and 830 (m) cm -1 .
1 H NMR spectrum (CDCl 3 ): δ 13.90 (s; 1H); 5.93 (s; 1H); 3.03 (t; J≃7.5 Hz; 2H); 2.57 (t; J≃7 Hz; 2H); 2.0-1.5 (c, with prominant signals at δ 1.87; 1.77 and 1.67; 5H); 1.37 (s; 6H) and 0.93 (d; J≃5 Hz; 6H).
Chroman (33 with shortest column retention time (benzene:ethyl acetate; 9:1):
IR spectrum (KBr-disc): 3400 (sh), 3340 (m), 2970 (m), 2950 (m), 2890 (w), 1625 (st), 1610 (st), 1515 (w), 1475 (w), 1465 (w), 1455 (w), 1435 (m), 1400 (w), 1385 (m), 1330 (m), 1315 (m), 1290 (m), 1270 (m), 1210 (w), 1170 (m), 1125 (st), 1100 (m), 940 (w), 910 (w), 895 (m), 875 (w), 835 (w), 820 (m) and 720 (w) cm -1 .
1 H NMR spectrum (CDCl 3 ): δ 13.48 (s; 1H); 5.77 (s; 1H); 3.07 (t; J≃7.5 Hz; 2H); 2.58 (t, J≃7 Hz; 2H); 2.12-1.43 (c; with prominant signals at δ 1.87; 1.77 and 1.66; 5H); 1.30 (s; 6H) and 0.91 (d; J≃5 Hz; 6H).
EXAMPLE 31
Following the procedure outlined in Example 30, the reaction of 3-prenyl phlorononaphenone (10 with trifluoro acetic acid gave rise to 2 chromanes, namely 5,7-dihydroxy-2,2-dimethyl-8-nonanoyl chroman (32 and 5,7 -dihydroxy-2,2-dimethyl-6-nonanoyl chroman (34, in a ratio of about 3 to 2.
Chroman (32 with longest column retention time (benzene: ethyl acetate; 9:1):
IR spectrum (KBr-disc): 3200 (br, m), 2940 (m), 2910 (st), 2840 (m), 1600 (st), 1595 (sh), 1545 (w), 1485 (w), 1400 (w), 1360 (w), 1345 (w), 1325 (m), 1270 (m), 1245 (st), 1225 (m), 1210 (sh), 1155 (m), 1145 (m), 1115 (m), 1105 (st), 1075 (m), 880 (w) and 845 (w).
13 C NMR spectrum (CDCl 3 +CD 3 OD): δ 206.8; 164.9; 160.9; 157.4; 106.0; 100.0; 95.5; 76.1; 44.6; 31.9; 31.6; 29.7; 29.6; 29.3; 26.8 (2×C); 25.4; 22.7; 16.4 and 14.1.
Chroman (34 with shortest column retention time (benzene:ethyl acetate; 9:1):
IR spectrum (KBr-disc): 3300 (br, m), 2990 (m), 2930 (st), 2870 (m), 1630 (st), 1595 (st), 1505 (w), 1470 (w), 1460 (w), 1435 (m), 1395 (m), 1340 (w), 1280 (m), 1240 (m), 1165 (st), 1130 (m), 1095 (m), 1085 (m), 1060 (w), 980 (w), 935 (w), 900 (m), 845 (m), 760 (w), 745 (w) and 730 (m) cm -1 .
13 C NMR spectrum (CDCl 3 +CD 3 OD): δ 206.9; 163.9; 160.6; 159.0; 104.5; 101.2; 95.5; 75.9; 44.0; 32.3; 32.0; 29.7; 29.6; 29.3; 26.7 (2×C); 25.3; 22.7; 16.2 and 14.1.
EXAMPLE 32
Following the procedure outlined in Example 30, the reaction of 2-butyryl-4-(3-methylbuten-2-yl)phloroglucinol (3 with trifluoro acetic acid gave rise to two chromanes, of which the chromane with the longest column retention time (silica gel, benzene:ethyl acetate; 9:1), 5,7-dihydroxy-2,2-dimethyl-8-butyryl chroman (30, was isolated.
IR spectrum (KBr-disc): 3300 (br, m), 2970 (m), 2940 (m), 2880 (w), 1620 (st), 1600 (st), 1580 (sh), 1520 (m), 1500 (w), 1460 (w), 1425 (m), 1390 (sh), 1380 (m), 1340 (w), 1320 (w), 1295 (w), 1270 (w), 1255 (m), 1230 (br, m), 1170 (m), 1155 (m), 1130 (m), 1120 (m), 1090 (m), 1040 (w), 1020 (w), 960 (w), 945 (w), 910 (w), 895 (w) and 830 (m) cm -1 .
13 C NMR spectrum (DMSO-d 6 ): δ 205.0; 164.2; 162.4; 156.6; 104.5; 99.8; 94.6; 75.7; 45.7; 31.0; 26.3 (2×C); 18.3; 16.2 and 13.8.
EXAMPLE 33
Phloroglucinol (12.6 g) was reacted with allyl chloride (7.6 g) according to the procedure outlined in Example 2. The crude reaction product, containing 2-allyl phloroglucinol, and aluminium chloride (48 g) were dissolved in carbon disulfide (60 ml). To this solution, well-stirred, was added nitrobenzene (45 ml) over a period of 30 minutes. A solution of butyryl chloride (12.7 g) in nitrobenzene (5 ml) was then added over a period of 20 minutes to the latter mixture. The reaction mixture was refluxed for 4 hours, then cooled to room temperature and finally poured into ice-cold diluted hydrochloric acid (prepared from 20 ml concentrated hydrochloric acid and 500 ml water). The latter mixture was extracted three times with ether. The ether extracts were combined and dried over sodium sulphate and then stripped to dryness under vacuum to yield a light yellow oil. The oil was chromatographed over silica gel (petroleum ether:ethyl acetate: 4:1).
Two dihydrobenzofuran compounds were isolated:
The compound with shortest column retention time, 4,6-dihydroxy-5,7-dibutyryl-2-methyl-2,3-dihydrobenzofuran (37:
IR spectrum (KBr-disc): 2980 (sh), 2960 (m), 2930 (w), 2870 (w), 1650 (st), 1640 (st), 1600 (m), 1490 (w), 1470 (w), 1460 (w), 1440 (m), 1405 (w), 1390 (w), 1355 (w), 1330 (w), 1310 (w), 1290 (w), 1270 (w), 1240 (br, w), 1215 (m), 1170 (m), 1120 (w), 1100 (w), 1065 (w), 1040 (w), 950 (br, w), 930 (br, m), 825 (w), 805 (w), 790 (w) and 770 (w) cm -1 .
13 C NMR spectrum (DMSO-d 6 ): δ 206.3; 204.8; 170.6; 166.5; 166.1; 104.5; 104.1; 100.0; 83.5; 45.7; 44.3; 32.1; 21.8; 17.8; 17.5 and 13.8 (2×C).
The compund (35 with longest column retention time, either 7-butyryl-4,6-dihydroxy-2-methyl-2,3-dihydrobenzofuran or 5-butyryl-4,6-dihydroxy-2-methyl-2,3-dihydrobenzofuran:
IR spectrum (KBr-disc): 3200 (br, m), 2960 (m), 2930 (w), 2870 (w), 1645 (st), 1615 (w), 1580 (m), 1570 (m), 1550 (w), 1530 (w), 1520 (w), 1505 (w), 1490 (w), 1470 (sh), 1460 (m), 1450 (sh), 1440 (w), 1420 (w), 1395 (w), 1360 (br, w), 1335 (br, w), 1290 (st), 1270 (w), 1250 (m), 1225 (m), 1175 (st), 1120 (m), 1085 (m), 1060 (m), 1015 (w) and 835 (m) cm -1 .
13 C NMR spectrum (DMSO-d 6 ): δ 203.6; 164.5; 162.5; 160.6; 103.9; 100.7; 95.4; 81.7; 43.8; 32.8; 21.6; 17.7 and 13.7.
EXAMPLE 34
2,4-Dibutyrylphloroglucinol (1
METHOD 1
A solution of phorbutyrophenone (4.9 g) in anhydrous (vacuum-distilled) methanesulphonic acid (10 ml) was added concomitantly (under a nitrogen atmosphere) with 1.8 g acrylic acid to a stirring solution of phosphorous pentoxide (2 g) in 40 ml methanesulphonic acid at 70° C. The reaction mixture was stirred for a further 30 minutes at 70° C., cooled to room temperature and poured into an ice/water mixture. This solution was extracted with ether (3×150 ml). The combined extracts were washed with water, sodium bicarbonate solution and dried over sodium sulphate. Evaporation of the ether afforded an oily product which was chromatographed (silica gel, petroleum ether:ethyl acetate, 4:1) to yield 2,4-dibutyrylphloroglucinol (1 as the first product to eluate. The solution was stripped to dryness and the product recrystallized from benzene to yield 10 as colourless needles.
METHOD 2
To a solution of phlorbutyrophenone (4.9 g) and aluminium chloride (15 g) in carbon disulphide (20 ml), nitrobenzene (15 ml) was added over a period of 30 minutes under heavy stirring. The reaction mixture was heated to 46° C. whereafter a mixture of butyrylchloride (8 ml) and nitrobenzene (5 ml) was added dropwise over a period of 30 minutes. The reaction mixture was boiled for a further 2 hours and poured into ice cold water (500 ml) containing 20 ml concentrated HCl. Nitrobenzene was removed by means of steam distillation and the mixture was allowed to stand overnight. The crystals were filtered, washed with petroleum ether and chromatographed (silica gel, petroleum ether:ethyl acetate, 4:1) to yield pure 2,4-dibutyrylphloroglucinol (1 upon evaporation of the solvent.
IR spectrum (KBr-disc): 3180 (br, m), 2980 (m), 2940 (w), 2890 (w), 1635 (sh), 1625 (st), 1600 (sh), 1560 (m), 1450 (br, w), 1425 (m), 1400 (sh), 1385 (m), 1335 (br, w), 1275 (m), 1210 (st), 1135 (w), 1120 (w), 1050 (w), 1015 (w), 990 (br, w), 910 (w), 860 (br, w) and 835 (m) cm -1 .
13 C NMR spectrum (DMSO-d 6 ): δ 205.9 (2×C); 170.9; 168.2 (2×C); 103.5 (2×C); 94.8; 45.3 (2×C); 17.5 (2×C) and 13.7 (2×C).
EXAMPLE 35
2-Butyryl-4-(propen-2-yl)phloroglucinol (16 was treated by the same procedure as described for the preparation of 2,4-dibutyrylphloroglucinol in Example 34 (Method 2) to yield 2,4-dibutyryl-6-(propen-2-yl)phloroglucinol (21 after chromatography on silica gel (petroleum ether, ethyl acetate, 4:1).
IR spectrum (KBr-disc): 2980 (sh), 2960 (st), 2940 (m), 2870 (m), 2600 (br, w), 1650 (st), 1635 (st), 1600 (st), 1570 (sh), 1555 (w), 1490 (w), 1470 (m), 1460 (m), 1440 (st), 1405 (m), 1390 (m), 1355 (m), 1330 (w), 1310 (w), 1285 (w), 1270 (w), 1240 (w), 1215 (st), 1170 (st), 1130 (w), 1120 (m), 1100 (w), 1070 (w), 1040 (w), 955 (w), 925 (br, st), 825 (w), 805 (w), 790 (w), 770 (w) and 700 (w) cm -1 .
Mass spectrum: m/e 306 (M + ), 291, 263 (100%), 245, 193 and 43.
EXAMPLE 36
5,7-Dihydroxy-6,8-dibutyryl-2,2-dimethylchroman (36
Phloroglucinol was treated with prenylchloride using the same procedure as described in Example 2 to yield prenylphloroglucinol. Prenylphloroglucinol was treated with butyrylchloride, according to the same procedure as described for the preparation of 2,4-dibutyrylphoroglucinol in Example 34 (Method 2) to yield 5,7-dihydroxy-6,8-dibutyryl-2,2-dimethylchroman (36 after chromatography with silica gel (petroleum ether, ethyl acetate, 4:1).
IR spectrum (KBr-disc): 2960 (m), 2930 (m), 2870 (m), 1625 (br, st), 1570 (w), 1555 (w), 1470 (w), 1460 (w), 1450 (w), 1430 (w), 1385 (br, w), 1300 (br, w), 1275 (w), 1200 (m), 1170 (m), 1130 (m), 1070 (br, w), 960 (w), 950 (w), 930 (w), 900 (w) and 800 (br, w) cm -1 .
Mass spectrum: m/e 334 (M + ), 289 (100%), 279, 201, 121, 69 and 43.
Antibacterial/antifungal properties and results
For testing against the bacteria, concentrations of each of the compounds were prepared in Brain Heart Infusion broth (Oxoid CM225) in two-fold steps from 1000 μg/ml to 1 μg/ml. Solutions containing 1000 μg/ml were prepared by dissolving 20 mg of each compound in 5 ml of acetone and this was then made up to 20 ml with Brain Heart Infusion Broth. Serial two-fold dilutions were then prepared in the broth down to 1 μg/ml.
For testing against the fungi, concentrations of each of the compounds were prepared in Sabouraud liquid medium in two-fold steps from 100 μg/ml to 0.1 μg/ml. 500 μg/ml solutions were prepared by dissolving 10 mg in 5 ml of acetone, made up to 20 ml with Sabouraud liquid medium. 4 ml of the 500 μg/ml concentration was then made up to 20 ml with Sabouraud liquid medium to give a concentration of 100 μg/ml. Serial two-fold dilutions were prepared from this in the same medium down to 0.1 μg/ml.
For testing against the bacteria each of the prepared test concentrations and acetone controls prepared in Brain Heart Infusion were dispensed in 2 ml amounts for each organism. A growth control of 2 ml of Brain Heart Infusion was included in each series.
For the fungi the same procedure was followed using the concentrations made up in Sabouraud liquid medium. The Nystatin concentrations were also dispensed in 2 ml amounts for each organism. Growth controls of Sabouraud liquid medium were included in each series.
To each of the prepared sets of concentrations of each compound were added 0.1 ml aliquots of the organism suspensions prepared as described previously. All the bottles were incubated at 37° C. for 48 hours in the case of the bacteria and from 5 to 15 days for the fungi (until growth controls had grown in each case).
After incubation the broths were examined for evidence of growth. The lowest concentration of the test compound which prevented growth was recorded as the Minimum Inhibitory Concentration (MIC).
Sub-cultures were made from all the broths showing no growth and from the growth controls. The sub-cultures were made onto Brain Heart Infusion Agar (Oxoid CM375) for the bacteria and onto Sabouraud Dextrose Agar (Oxoid CM41) for the fungi. The plates were incubated at 37° C. for 48 hours for bacteria and 5 to 14 days for fungi.
After incubation the plates were examined for growth. The lowest concentration showing no evidence of growth was recorded as the Minimal Microbiocidal Concentration (MMC).
The antibacterial/antifungal activities of a number of representative compounds are illustrated by the examples given in the accompanying table.
ACUTE TOXICITY DATA
Male and female CD-1 mice were fasted for 18 hours prior to the experiment, but water was available ad libitum except during the observation period. The test compounds were prepared in 1% tragacanth and were administered orally to groups of two male and two female mice.
All compounds were tested at dose levels of 1000, 464, 215 and 100 mg/kg. Immediately after dosing, the mice were replaced in their "home" cage and were observed daily for 7 days post dose and any mortalities recorded.
The acute toxicities, as determined by the above procedure, of a number of representative compounds are given in the accompanying table.
TABLE 3__________________________________________________________________________LD.sub.50 VALUES AND ANTIMICROBIC ACTIVITIES (MIC VALUES IN μg/ml) Tr.COMPOUND S. St. C. MENTAGRO- Tr. Sp. Mic.NUMBER AUREUS PYOGENES ALBICANS PHYTES RUBRUM SCHENKII CANIS LD.sub.50__________________________________________________________________________ 1 2 1 13 6 6 6 3 >1000 2 125 8 50 25 13 25 13 >1000 4 64 16 25 13 13 25 13 >1000 5 8 4 13 6 3 13 1,6 >1000 6 250 8 >100 100 25 50 50 >1000 7 16 8 25 6 6 25 6 1000 8 32 8 13 6 6 13 6 >1000 9 32 8 6,2 6,2 3,1 6,2 1,6 <10011 64 2 100 100 50 >100 50 59714 16 8 100 100 >100 100 50 100015 250 125 100 25 50 50 50 >100017 64 16 25 13 13 25 6 >100018 16 8 13 6 13 13 6 >100019 16 4 25 13 6 13 6 >100020 32 8 25 13 25 25 13 >100023 32 8 13 13 13 25 6 >100024 16 8 25 13 6 25 13 100025 16 8 13 3 6 25 6 100027 2 1 100 5 >100 50 50 >100030 32 32 25 13 13 25 6 >100031 16 8 100 6 25 6 13 >100032 64 <1 100 >100 >100 100 100 >100033 125 64 100 >100 25 >100 100 >100034 500 4 100 >100 100 >100 >100 >100035 125 32 25 25 25 50 12,5 >100036 250 64 100 100 100 100 100 >100037 125 32 >100 >100 100 >100 >100 >215__________________________________________________________________________
As can be seen from the aforegoing, these compounds generally exhibit useful in vitro antibacterial and antimycotic activity, and in particular very low oral acute toxicity. Antibacterial activity of these compounds is directed particularly against Gram-positive bacteria for example Staphylococcus aureus. Consequently the physiologically acceptable compounds of the invention may enjoy useful applications in the medical and veterinary fields.
These compounds have also shown useful antimycotic activity, in respect of which they may likewise be employed both in the medical and in the veterinary fields, for example for treating local and systemic mycotic infections for example mycotic infections in or on the skin or under nails, in the lungs, upper airways, eyes, hair, for vaginal infections, or any other local or systemic mycotic infection. Likewise these compounds may have useful veterinary applications, for example for treating mastitis.
A further interesting attribute of these compounds is that there are indications that these compounds generally exhibit both antibacterial and antimycotic activity. A consequence of this dual activity is that in treatment of a bacterial or mycotic infection, these compounds are in principle capable of maintaining a balance between bacteria and fungi mycosis.
In addition to the abovementioned pharmaceutical indications, these compounds because of their activity can also be used as a preservative for food and beverages, for example for humans and animals such as livestock, in addition to a preservative for natural products.
Furthermore, such compounds can be used as a general disinfectant, for example in hospitals, storerooms, dairies, or for spraying or washing any area requiring to be disinfected. In this regard, these compounds can also be used in soaps, detergents, and the like.
In respect of pharmaceutical compositions, it may be mentioned that one or more of the above suitable compounds may be incorporated in a pharmaceutical composition for administration to a human or animal patient. The method of preparing such composition includes the steps of ensuring that the compound(s) are free of undesirable impurities--this may require repeated re-crystallisation, or washing; comminuting the compound(s) to a required particle size; and incorporating and providing the compounds in a desired form for administration to a patient, for example in solid (powder, tablet or capsule form), or liquid form (injectable or liquid medicine) for internal or external application, for example in a suspension or cream for topical application, or in a (dissolvable) jelly form.
Although the invention in its various aspects has been described above in certain preferred embodiments, it will be readily apparent to any person skilled in the art that various modifications and/or variations of the invention are possible. Such modifications and/or variations of the invention are to be considered as forming part of the invention and as falling within the scope of the appended claims which are also to be considered as part of the disclosure of this invention. | Novel compounds of general formula I ##STR1## wherein R is a branched or unbranched alkyl, cycloalkyl, or aralkyl group, which group optionally contains or is substituted by a halogen or oxygen function, the oxygen function optionally being in the form of an alcohol or ether moiety;
R 1 , R 2 , and R 3 , which may be the same or different, is hydrogen, an alkyl, acyl, or benzoyl group, which group optionally contains or is substituted by a halogen or oxygen function;
R 4 is hydrogen, an alkyl, alkenyl preferably being an allyl or prenyl group, or aralkyl group which group optionally contains or is substituted by an alkyl, aryl, halogen or oxygen function;
R 5 is hydrogen, an alkyl, aralkyl, acyl, or aryl group, which group optionally contains or is substituted by an alkyl, aryl, halogen, or oxygen function;
except that R 4 and R 5 are not both hydrogen;
and except for the compounds when R 5 is hydrogen and R is methyl, i-propyl, branched butyl, methoxy methyl, 2-phenylethyl, or 2-phenylethylene;
chromans and dihydrobenzofurans derived from these compounds;
pharmaceutically acceptable salts, and metabolites and metabolic precursors of these compounds;
processes for preparing the aforementioned types of compounds;
use of the aforementioned types of compounds as antibacterial and/or antimycotic agents;
and pharmaceutical compositions of such compounds. | 60,467 |
FIELD OF THE INVENTION
[0001] This invention relates generally to fabrication processes for microelectromechanical systems (MEMS) devices and more specifically to the manufacture of interferometric modulators.
BACKGROUND OF THE INVENTION
[0002] An interferometric modulator is a class of MEMS (micro-electromechanical systems) devices which have been described and documented in a variety of patents including U.S. Pat. Nos. 5,835,255, 5,986,796, 6,040,937, 6,055,090, and U.S. Pending patent application Ser. Nos. 09/966,843, 09/974,544, 10/082,397, 10/084,893, and 10/878,282, herein incorporated by reference. One of the key attributes of these devices is the fact that they are fabricated monolithically using semiconductor-like fabrication processes. Specifically, these devices are manufactured in a sequence of steps which combine film deposition, photolithography, and etching using a variety of techniques. More detail on these processes is described in patent application Ser. No. #10/074,562 filed on Feb. 12, 2002, and herein incorporated by reference.
BRIEF DESCRIPTION OF THE DRAWINGS
[0003] [0003]FIG. 1 shows a block diagram of an integrated MEMS processing facility;
[0004] [0004]FIG. 2 shows a block diagram of a non-integrated MEMS processing facility;
[0005] [0005]FIG. 3 shows a block diagram of a MEMS device which can be fabricated using a precursor stack of the present invention; and
[0006] [0006]FIGS. 4A to 4 F show block diagrams of precursor stacks of the present invention, according to different embodiments.
DETAILED DESCRIPTION OF THE INVENTION
[0007] In the following detailed description of embodiments of the invention, numerous specific details are set forth such as examples of specific materials, machines, and methods in order to provide a thorough understanding of the present invention. It will be apparent, however, to one skilled in the art that these specific details need not be employed to practice the present invention. In other instances, well known materials, machines, or methods have not been described in detail in order to avoid unnecessarily obscuring the present invention.
[0008] A common characteristic of processes for manufacturing MEMS devices is that they begin with the deposition of a stack of thin films which are crucial to the operation and subsequent fabrication of the device. These precursor films are useful in the fabrication of a broad variety of MEMs devices including interferometric modulators, and their deposition can occur as a part of a larger process to manufacture the MEMS device. In one embodiment of the present invention the films are deposited separately in a stand alone facility to form a precursor stack, which is then sent to multiple facilities which complete the processing. The primary benefit is that the stand alone facility can be optimized to produce these films or precursor stacks at very high throughputs that allow for economies of scale not possible in an integrated factory, i.e., one that does both the deposition and post-deposition processing. Furthermore, since the technology development of the precursor stack occurs at the stand alone facility, entities which desire to perform the subsequent processing steps are faced with a lower technological barrier to entry.
[0009] Patent application Ser. No. 10/074,562 herein incorporated by reference describes a prototypical fabrication sequence for building interferometric modulators. In general, interferometric modulator fabrication sequences and categories of sequences are notable for their simplicity and cost effectiveness. This is due in large part to the fact that all of the films are deposited using physical vapor deposition (PVD) techniques with sputtering being the preferred and least expensive of the approaches. Part of the simplicity derives from the fact that all interferometric modulator structures, and indeed many other planar MEMS structures are bound by the fact that they require a lower electrode, an insulating structure to prevent shorting, a sacrificial material, and an actuatable or movable structure. An insulating structure differs from a film in that it is not continuous in its form but by mechanical means is able to prevent electrical contact through its body. This fact presents an opportunity in that a subset of these films, a precursor stack comprising one or more of the lower electrode, insulating structure, the sacrificial layer, and optionally an actuatable structure may be manufactured separately and in advance of the actuatable structure or structures.
[0010] [0010]FIG. 1 of the drawings provides a block diagram of an integrated MEMS fabrication facility 102 . A precursor film deposition tool 100 , comprises a single or series of deposition tools which are configured to deposit these films using one or more deposition techniques, e.g., sputtering. The films are deposited on a suitable carrier substrate, which could be glass or plastic, for example, depending on the application, and subsequently transported to micro-machining loop 104 . Here, and as described in the aforementioned patent applications, a sequence of repeated steps, such as etching, patterning, and deposition, are performed and serve to define the actuatable structure of the MEMS device.
[0011] [0011]FIG. 2 of the drawings shows a non-integrated MEMS processing facility. Referring to FIG. 2, a pre-cursor facility 200 contains only a precursor film deposition tool 100 which is equivalent to that described in FIG. 1, hence the use of the same reference numeral. The facility 200 is capable of providing variations on both precursor film type and substrate size. After the deposition, the substrates are containerized and shipped as appropriate to one or more processing facilities indicated by reference numeral 202 . These facilities then perform the machining steps as required for the particular MEMS product that they are designed to produce.
[0012] [0012]FIG. 3 shows a schematic drawing of a simple MEMS device which can be fabricated using a precursor stack of the present invention. In this case an actuatable membrane 304 , is supported on posts 306 . Films 302 comprise materials which at a minimum provide a lower electrode and an insulating structure, though other functions, as will be discussed, may be incorporated. The entire assembly resides on a substrate 300 .
[0013] [0013]FIGS. 4A to 4 F of the drawings show block diagrams of precursor stacks in accordance with different embodiments of the invention. In FIGS. 4A to 4 F, the same reference numerals have been used to identify the same or similar features/components.
[0014] [0014]FIG. 4B shows a block diagram of a generalized precursor stack 400 A that includes conductor stack or structure 404 , an insulator layer 406 , and a sacrificial material layer 408 . All the films reside on a substrate 402 . The conductor stack 404 may comprise a single metal, a conductive oxide or polymer, a fluoride, a silicide or combinations of these materials. The exact composition of the conductive stack is determined by the requisite electrode properties of the MEMS device to be manufactured. The insulator 408 , can be any one or a combination of a variety of insulating materials which include but are not limited to oxides, polymers, fluorides, ceramics, and nitrides. The sacrificial material 408 , may include, for example, a single layer of materials such as silicon, molybdenum, or tungsten which are all etchable by XeF2, which is a process etch gas that has been described in prior patents. Other materials are possible subject to the compatibility of the etching medium to the materials and structures which must remain. Thicknesses vary according to the requisite behavior of the final device.
[0015] [0015]FIG. 4B shows a block diagram of a precursor stack 400 B designed for use in the fabrication of an interferometric modulator device. The stack 400 B includes a conductor stack 404 , the composition of which has been described above. Suitable metals for the conductor stack 404 in the present case include glossy metals such as Chromium, Tungsten, Molybdenum, or alloys thereof. The conductor stack 404 may have a thickness of up to 150 angstroms. Transparent conductors suitable for use in the conductor stack 404 include indium tin oxide (ITO), zinc oxide (ZnO), and titanium nitride (TiN). Typical thicknesses for the transparent conductors range from 100 to 800 angstroms. The conductor stack 404 resides on a transparent compensating oxide layer 410 , in one embodiment. The oxide layer 410 may be of a metallic oxide, such as zirconia (ZrO2) or hafnia (HfO2), which have a finite extinction coefficient within the visible range. The compensating oxide layer 410 is an optional film for all the designs discussed in this patent application. Typical thicknesses for the oxide layer 410 range from 100 to 800 angstroms. It should be noted that the positions of the conductor stack 404 and the compensating oxide layer 410 are interchangeable with only subtle changes in the optical behavior. This design, however, can be considered an embedded optical film design since the metal, which plays the primary optical function, resides on the side of insulator layer 406 , opposite that of the sacrificial layer 408 . The insulator layer 406 , may comprise a silicon dioxide film with a thickness ranging from 280 to 840 angstroms for good black states, although other thicknesses are useful for different interference modulator operational modes. Other oxides or combinations of oxides are possible as well. The sacrificial layer 408 may include a single layer of materials such as silicon, molybdenum, tungsten, for example, which are all etchable by XeF2, a process etch gas which has been described in prior patents. For the stack 400 B, the thickness of the layer 408 may vary from 1000, to 7000 angstroms.
[0016] [0016]FIG. 4C shows a block diagram of a precursor stack 400 C, in accordance with another embodiment. In this case, the conductor stack 404 does not perform any optical functions. Instead, a separate optical film 412 performs the optical function. The optical film 412 is separated from the conductor stack 404 by an insulator film or structure 414 . This design allows for high quality white states to be achieved when the actuatable membrane is driven. In this case the optical film 412 does not serve as a conductor. It is the transparent conductor stack 404 which functions as a conductor. An ancilliary insulator film or structure which is not shown in FIG. 4C but which is similar to the insulator layer 406 of FIG. 4B, may reside between the sacrificial layer 408 and the optical film 412 , in some embodiments. The thickness of the insulator film or structure may be less than 100 angstroms for this design.
[0017] [0017]FIG. 4D shows an embodiment 400 D of a precursor stack, known as a buried optical film design. In this case, an optical film 412 , resides over an optical compensation film 410 , which resides below an insulator film/structure 406 . A transparent conductor film or film stack 404 , follows and is capped by an additional oxide layer 416 , and a sacrificial film layer 408 . One advantage of the stack 400 D is that it allows for the effective optical distance between the optical film 412 and the mechanical film to be large while allowing the driving voltages to remain small. This is because the driving voltages are significantly determined by the distance between the conductor and the actuatable membrane.
[0018] [0018]FIG. 4E shows a precursor stack 400 E which includes a multi-layer etch stop stack 418 incorporated instead of a single layer sacrificial film. This 418 stack provides a convenient means for predefining the heights for multiple actuatable structures to be defined during subsequent micro-machining processes. In one embodiment, the stack 418 comprises at least two materials which can be etched using the same release etch, but can utilize alternative and different etch chemistries so that one material may act as an etch stop for the other. One example would be a combination of molybdenum and silicon that are both etchable in XeF2. However, a phosphoric based wet etchant may be used to etch molybdenum without attacking silicon, and a tetra-methyl-ammonium hydroxide (TMMA) which may be used to etch silicon without etching molybdenum. Many other combinations exist and can be identified and exploited by those skilled in the art. Further, it should be noted that the etch stop stack may be applied to any of the previously defined precursor stacks in place of the single sacrificial layer.
[0019] [0019]FIG. 4F of the drawings shows an embodiment 400 F of a precursor stack The precursor stack 400 F includes a mechanical structural material 420 . Using proper micro-machining techniques and sequences, a functioning MEM device may be fabricated using the precursor stack 400 F using only patterning and etching. Thus, during post-processing of the precursor stack 400 F no deposition is required. This means that a post-processing facility such as the facility 202 (see FIG. 2) does not require capital investment in deposition tools. The material 420 may comprise any number of materials, including but not limited to metals, polymers, oxides, and combinations thereof, whose stress can be controlled. | This invention provides a precursor film stack for use in the production of MEMS devices. The precursor film stack comprises a carrier substrate, a first layer formed on the carrier substrate, a second layer of an insulator material formed on the first layer, and a third layer of a sacrificial material formed on the second layer. | 13,766 |
CROSS REFERENCE TO RELATED APPLICATIONS
The present application is a continuation of U.S. patent application Ser. No. 11/177,232 filed Jul. 8, 2005, which claims the benefit of U.S. Provisional Patent Application No. 60/586,491 filed Jul. 8, 2004, the full disclosures of which are incorporated by reference herein.
FIELD
The present invention(s) relate to a container. The present invention(s) more specifically relate to a container for retaining matter and for dispensing the matter.
BACKGROUND
It is known to provide for containers that may be used for retaining and dispensing matter. Such known containers do not realize certain advantageous features (and/or combination of features).
BRIEF DESCRIPTION OF THE DRAWINGS
FIGS. 1A-1D illustrate different views of a container according one exemplary embodiment.
FIGS. 2A-2D illustrate different views of a container according another exemplary embodiment.
FIGS. 3A-3D illustrate different views of a container according another exemplary embodiment.
FIGS. 4A-4D illustrate different views of a container according another exemplary embodiment.
FIGS. 5A-5D illustrate different views of a container according another exemplary embodiment.
FIGS. 6A-6D illustrate different views of a container according another exemplary embodiment.
FIGS. 7A-7D illustrate different views of a container according another exemplary embodiment.
FIGS. 8A-8C illustrate different views of a container according another exemplary embodiment.
FIG. 9 illustrates the closure of the container illustrated in FIGS. 8A-8C .
FIGS. 10A-10C illustrate different views of the receptacle of the container illustrated in FIGS. 8A-8C .
FIG. 11 is a cross-sectional view of a portion of the closure of FIG. 8B taken along line 11 - 11 .
FIGS. 12A-12C illustrate partial cross-sectional views of the engagement structures on a closure and a receptacle according to an exemplary embodiment.
FIG. 13 illustrates a partial cross-sectional view of the engagement structures on a closure and a receptacle according to another exemplary embodiment.
FIGS. 14A-14C illustrate different views of a closure for a container according another exemplary embodiment.
FIGS. 15A-15C illustrate different views of a closure for a container according to another exemplary embodiment.
FIGS. 16A-16C illustrate different views of a closure for a container according to another exemplary embodiment.
DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS
According to various exemplary embodiments shown in the FIGURES, a container 10 may be provided for receiving, holding, storing, transporting, and dispensing various matters or substances, in particular, granular or particulate matter (e.g., pet food, cat litter, etc.). Container 10 may also be provided for use with other types of matter such as liquids, chemicals, or any other viscous materials or fluids. According to various exemplary and alternative embodiments shown in the FIGURES, container 10 may comprise a closure 20 (e.g., cap, cover, etc.) and a receptacle 30 (e.g., bottle, pail, bucket, etc.).
Receptacle 30 may be provided for receiving, holding, storing, transporting, etc. a wide variety of different materials and substances. According to various exemplary embodiments, receptacle 10 generally includes a bottom 40 , sidewalls 50 , and a collar 52 .
As shown in FIGS. 1A-7D , 8 C, and 10 A- 10 C, bottom 40 of receptacle 30 is a generally flat, rectangular, panel. According to various exemplary embodiments, bottom 40 may include one or more indentations or recesses 42 that facilitate the handling of receptacle 30 by a user. For example, indentations or recesses 42 may be configured and located such that a user may insert his or her fingers into recesses 42 as he or she picks up receptacle 30 or tips it one way or the other, such as to pour out the contents of receptacle 30 . The location of indentations or recesses 42 within bottom 40 of receptacle 30 may depend on certain characteristics of closure 10 , such as the orientation or location of a handle (discussed below) and/or the orientation and location of an opening (discussed below) in closure 10 configured to allow a user to selectively remove the contents of receptacle 30 . According to one exemplary embodiment, at least one indentation or recess 42 is located such that a user may place one hand on a handle of closure 10 and grasp indentation 42 with the other hand to pour or dispense the contents of container 10 out of the opening in closure 10 .
According to other exemplary embodiments, such as those shown in FIGS. 4A-7D and 8 C, bottom 40 may include a lip or rim 44 around the periphery of bottom 40 that a user may grasp when handling receptacle 30 or pouring the contents of receptacle 30 .
As shown in FIGS. 1A-8A , 8 C, and 10 A- 10 C, sidewalls 50 are substantially flat and rigid panels or members that extend generally perpendicularly from the periphery of bottom 40 to form a substantially rectangular shaped tube that is closed on one end by bottom 40 . The intersection between the different sidewalls 50 (e.g., the “corners” of the receptacle) may be a sharp corner, or may be radiused to provide a more gradual transition between sidewalls 50 .
As best shown in FIGS. 10A-10C , a collar or reinforcement member 52 may be provided around the upper edge of sidewalls 50 to provide support for sidewalls 50 and to provide structure to which closure 20 may be coupled. According to various exemplary embodiments, collar 52 generally extends around the periphery of the upper end of sidewalls 50 (i.e. the end of sidewalls 50 opposite bottom 40 ) and may be solid or may be substantially hollow and include intermittently spaced reinforcing ribs 54 that extend between sidewalls 50 and the inside surface of collar 52 . Collar 52 may extend outwardly from sidewalls 50 such that its outer periphery generally follows the outer periphery of closure 20 .
According to one exemplary embodiment shown in FIGS. 12A-13 , sidewalls 50 (or collar 52 ) may include one or more projections (e.g., fingers, barbs, locking members, etc.) or recesses 56 proximate the open end of receptacle 30 that are configured to engage corresponding projections or recesses 58 that are provided on closure 20 (see discussion below). The engagement of the projections and/or recesses 56 on receptacle 30 and the projections and/or recesses 58 on closure 20 serves to maintain the coupled condition of receptacle 30 and closure 20 , particularly when closure 20 (and a corresponding handle, described below) are called upon to support the weight of container 10 and its contents.
A closure 20 may be provided for generally protecting, sealing, enclosing, and/or selectively closing an open end of receptacle 30 to retain or selectively retain the contents of receptacle 30 within receptacle 30 . The closure generally includes sidewalls 60 , a top portion 70 , a handle 80 , and a flap 90 .
As shown in FIGS. 1A-9 , sidewalls 60 of closure 20 generally form the outer periphery of closure 20 and are configured to couple to sidewalls 50 (or collar 52 ) of receptacle 30 (e.g., generally in the region of collar 52 ).
As shown in FIGS. 12A-13 , sidewalls 60 may include one or more projections (e.g., fingers, barbs, locking members, etc.) or recesses 58 that engage or lock with projections or recesses 56 provided on sidewalls 50 (or collar 52 ) of receptacle 30 to retain closure 20 in place on receptacle 30 . An example of such projections or barbs 56 and 58 are provided in U.S. patent application Ser. No. 10/764,819, filed Jan. 26, 2004, which is hereby incorporated by reference in its entirety.
As shown in FIGS. 1A-9 , top portion 70 couples to one end of sidewalls 60 of closure 20 to form a generally rectangular, cup-shaped member that has its opening facing receptacle 30 . When closure 20 is coupled to receptacle 30 , sidewalls 60 of closure 20 and sidewalls 50 of receptacle 30 may overlap so that the corresponding projections or recesses 56 and 58 (discussed above) located on sidewalls 60 of closure 20 and on sidewalls 50 of receptacle 30 engage one another to retain closure 20 on receptacle 30 . Top portion 70 is generally flat and may be configured to receive bottom 40 of a like receptacle 30 that may be stacked on top of closure 20 . To facilitate this stacking, top portion 70 may include one of a recess 72 and a raised region 74 that cooperates with the other one of recess 72 and raised region 74 provided on bottom 40 of receptacle 30 .
As shown in FIGS. 1A-8B , closure 20 may include a handle 80 that a user may grasp to pick up container 10 , pour the contents of container 10 , or otherwise maneuver container 10 . According to one exemplary embodiment illustrated in FIGS. 1A-1D , handle 80 may be stationary and cooperate with a recess 82 in top portion 70 to allow a user's hand to fit underneath handle 80 . Handle 80 may be formed separately from closure 20 and then coupled to closure 20 , or handle 80 may be integrally formed as a single unitary body with closure 20 .
According to another exemplary embodiment illustrated in FIGS. 2A-2D , handle 80 may translate between an extended position in which handle 80 is spaced apart from top portion 70 of closure 20 , and a retracted position in which handle 80 may be located proximate top portion 70 of closure 20 . To accommodate the translational movement of handle 80 , closure 20 and/or receptacle 30 (in particular, sidewalls 50 of receptacle 30 and sidewalls 60 of closure 20 ) may include channels 84 that are configured to guide the translational movement of handle 80 . In order to allow a user to move handle 80 from the retracted position to the extended position, recess 82 may be provided in top portion 70 around and underneath handle 80 to allow a user to place his fingers under handle 80 .
According to other exemplary embodiments illustrated in FIGS. 3A-8C , handle 80 may be a bail-type handle that pivots between a non-use position in which handle 80 is located proximate top portion 70 of closure 20 (and aligned generally parallel with the plane of top portion 70 ), and a use position in which handle 80 is rotated upward (and aligned generally perpendicular with the plane of top portion 70 ). Top portion 70 of closure 20 may include a recess 86 that is configured to receive handle 80 when handle 80 is in the non-use position. Recess 86 allows handle 80 to rest in a position that does not interfere (such as by extending above the general plane of top portion 70 or beyond the general periphery of closure 20 ) with bottom 40 of a receptacle 30 that may be stacked on top of closure 20 . As shown schematically in FIG. 11 , to couple handle 80 to top portion 70 or sidewalls 60 of closure 20 , handle 80 may include one or more projections 88 that extend from handle 80 and that are received within corresponding recesses 89 provided in top portion 70 or sidewalls 60 of closure 20 . Alternatively, handle 80 may include recesses that are configured to receive projections extending from top portion 70 or sidewalls 60 of closure 20 . According to an exemplary embodiment, projections 88 and recesses 89 are substantially aligned so as to share a common axis around which handle 80 may pivot. Projections 88 and recesses 89 may be sized such that projections 88 frictionally engage recesses 89 . Depending on the amount of friction between projections 88 and recesses 89 , the friction may be sufficient to retain handle 80 in any position until a force sufficient to overcome the friction is applied by a user.
According to various exemplary embodiments shown in FIGS. 3A-4D and 6 A- 6 D, the shape of handle 80 may follow the general shape of closure 20 and/or receptacle 30 . According to various other exemplary embodiments shown in FIGS. 1A-2D , 5 A- 5 D, and 7 A- 8 C, the shape and profile of handle 80 may remain within the general shape of closure 20 and/or receptacle 30 .
As shown in FIGS. 1A-9 and 14 A- 16 C, closure 20 may include a flap 90 that moves between a closed position, in which no opening is provided in closure 20 for dispensing material within receptacle 30 , and an open position, in which an opening 92 is provided that allows a user to dispense material from receptacle 30 through opening 92 . Flap 90 is coupled to the body of closure 20 (e.g., sidewalls 60 and/or top portion 70 ) by a living hinge 94 that allows flap 90 to move between the open and closed positions. According to various exemplary embodiments shown in FIGS. 1A-8B and 15 A- 15 C, flap 90 and living hinge 94 may be configured so that flap 90 pivots upwardly and inwardly toward the center of closure 20 . According to other various exemplary embodiments shown in FIGS. 14A-14C and 16 A- 16 C, flap 90 and living hinge 94 may be configured so that flap 90 pivots upwardly and outwardly away from the center of closure 20 .
According to various exemplary embodiments shown in FIGS. 1A-5D , 7 A- 8 B, 9 , and 15 A- 15 C, flap 90 may be located in a corner of closure 20 . This has the effect of utilizing the general V-shape of the corner of closure 20 and receptacle 30 to obtain a result similar to that which would be obtained by a similarly shaped spout coupled to closure 20 . The placement of flap 90 and dispensing opening 92 in the corner facilitates the dispensing of the contents of receptacle 30 in a relatively efficient and controlled manner. According to another exemplary embodiment shown in FIGS. 14A-14C , flap 90 may take the form of a flip-out spout and include side portions that help to facilitate the dispensing of the contents of receptacle 30 in a relatively efficient and controlled manner.
As shown in FIGS. 1A-9 , flap 90 may be integrally formed with the other portions of closure 20 . When formed, flap 90 is retained in the closed position by a “tear strip,” or a strip of material 96 that is designed to be removed by the user prior to his or her use of closure 20 and/or flap 90 . When closure 20 is formed, tear strip 96 is coupled to a portion of flap 90 (and may also be coupled to another portion of closure 20 , such as sidewalls 60 ) by a relatively thin web of material. To remove tear strip 96 , the user simply pulls on tear strip 96 , which tears the web of material that couples tear strip 96 to flap 90 (and/or to any other portion of closure 20 ). To assist the user in removing tear strip 96 , tear strip 96 is usually formed with a tab or free end 97 that a user can grasp to remove tear strip 96 from closure 20 .
According to various exemplary embodiments, tear strip 20 may form a primary portion of the sidewalls 60 in the area of closure 20 immediately adjacent flap 90 such that removing tear strip 96 removes any portion of sidewalls 60 immediately adjacent flap 90 (see FIGS. 1A-3D and 8 A- 8 C), or tear strip 96 may form a portion of the sidewalls 60 immediately adjacent flap 90 such that removing tear strip 96 removes only a portion of sidewalls 96 immediately adjacent flap 90 (see FIGS. 4A-7D ). In the former case, tear strip 96 serves to releasably couple flap 90 to receptacle 30 , whereas in the latter case, tear strip 96 serves to releasably couple flap 90 to sidewalls 60 of closure 20 .
Once tear strip 96 has been removed, the user may freely open and close flap 90 . In the closed position, a portion of flap 90 couples with or engages a portion of either sidewall(s) 60 of closure 20 or sidewall(s) 50 of receptacle 30 to releasably retain or lock flap 90 in the closed position. Accordingly to one exemplary embodiment, flap 90 and sidewall(s) 60 or receptacle 30 are coupled together through the use of a projection (not shown) extending from one member that engages a recess or detent (not shown) in the other member. According to another exemplary embodiment, flap 90 may be releasably retained in the closed position by frictionally engaging a portion of receptacle 30 and/or sidewall(s) 60 of closure 20 .
According to another exemplary embodiment shown in FIGS. 14A-14C , flap 90 may be initially retained in the closed position by a label, sticker, or cover 98 that is designed to be removed or torn by the user prior to his or her use of closure 20 and/or flap 90 .
According to one exemplary embodiment, each of the closure and receptacle is integrally-formed through a molding operation. According to various exemplary embodiments, the assemblies and components of the container, including the closure and the receptacle, may be constructed from one or more separate components assembled together and may be constructed from a variety of suitable materials, including various polymers and elastomers (e.g., plastics, rubbers, etc.). Each element of the container may be made from the same material, or the different portions of the container, such as the handle, for example, may made from a different material than the other elements of the container. According to alternative embodiments, other well known processes may be used to construct the container.
It is important to note that the construction and arrangement of the elements of the container as shown in the preferred and other exemplary embodiments is illustrative only. Although only a few embodiments of the present inventions have been described in detail in this disclosure, those skilled in the art who review this disclosure will readily appreciate that many modifications are possible (e.g., variations in sizes, dimensions, angles, structures, shapes and proportions of the various elements, values of parameters, mounting arrangements, use of materials, colors, orientations, etc.) without materially departing from the novel teachings and advantages of the subject matter recited. For example, elements shown as integrally formed may be constructed of multiple parts or elements show as multiple parts may be integrally formed, the operation of the interfaces may be reversed or otherwise varied, the length or width of the structures and/or members or other elements of the container may be varied, and the nature or number of the projections or recesses may be varied in size, shape and configuration. It should be noted that the elements and/or assemblies of the container may be constructed from any of a wide variety of materials that provide sufficient strength, durability, or flexibility, in any of a wide variety of colors, textures and combinations. It should also be noted that the container may be used in association with a variety of materials in a wide variety of different environments and situations. Accordingly, all such modifications are intended to be included within the scope of the present inventions. Other substitutions, modifications, changes and omissions may be made in the design, operating conditions and arrangement of the preferred and other exemplary embodiments without departing from the spirit of the present inventions. | A container having a receptacle and a cover is disclosed. The receptacle includes a generally rectangular base portion, a continuous sidewall portion, and a collar. The sidewall portion includes a lower end and an upper end. The lower end of the sidewall portion is coupled to the base portion and the upper end defines an opening. The collar extends around the sidewall portion proximate the upper end. The cover is coupled to the receptacle and includes a top portion, a skirt, a flap, and a tear strip. The skirt extends downwardly from the periphery of the top portion. The flap is hingeably coupled to the top portion proximate a corner of the closure and is moveable between an open position in which access is provided to the opening in the receptacle and a closed position in which the opening in the receptacle is closed. The flap includes a closing apparatus to releasably retain the flap in the closed position. The tear strip is removable and is coupled to the flap and the skirt. The tear strip substantially prevents the flap from being moved into the open position until the tear strip is removed. | 19,833 |
RELATED APPLICATION DATA
This application is a continuation of U.S. patent application Ser. No. 11/621,459, filed Jan. 9, 2007 (now U.S. Pat. No. 7,403,633) which is a continuation of U.S. patent application Ser. No. 10/359,550, filed Feb. 5, 2003 (now U.S. Pat. No. 7,162,052), which is a continuation-in-part of U.S. patent application Ser. No. 10/286,357, filed Oct. 31, 2002 (now U.S. Pat. No. 7,065,228). The 10/359,550 application is also a continuation of U.S. patent application Ser. No. 10/165,751, filed Jun. 6, 2002 (now U.S. Pat. No. 6,754,377), which is a continuation of U.S. patent application Ser. No. 09/074,034, filed May 6, 1998 (now U.S. Pat. No. 6,449,377). The Ser. No. 09/074,034 application claims the benefit of U.S. Provisional Patent Application No. 60/082,228, filed Apr. 16, 1998. Each of these U.S. Patent documents is herein incorporated by reference.
FIELD OF THE INVENTION
The present invention relates to methods and systems for steganographically arranging data on specular surfaces (e.g., mirror-like surfaces) and associated methods/systems for decoding steganographically-arranged data from such surfaces.
BACKGROUND AND SUMMARY OF THE INVENTION
Counterfeiting and forgeries continue to proliferate. A hot area of counterfeiting is consumer products, such as cellular phones, logos and cameras. Often cellular phones include interchangeable faceplates. (Or a camera includes a logo plate, which is easily replicated by thieves.). A common counterfeiting scenario involves counterfeiting the faceplate, and then passing off the counterfeit faceplate as genuine.
One solution is to provide steganographic auxiliary data in or on consumer products to help prevent or detect counterfeiting. The data can be decoded to determine whether the object is authentic. The auxiliary data may also provide a link to a network resource, such as a web site or data repository. The absence of expected auxiliary data may also provide a clue regarding counterfeiting.
One form of steganography includes digital watermarking. Digital watermarking systems typically have two primary components: an encoder that embeds the watermark in a host media signal, and a decoder (or reader) that detects and reads the embedded watermark from a signal suspected of containing a watermark. The encoder can embed a watermark by altering the host media signal. The decoding component analyzes a suspect signal to detect whether a watermark is present. In applications where the watermark encodes information, the decoder extracts this information from the detected watermark. Data can be communicated to a decoder, e.g., from an optical sensor.
One challenge to the developers of watermark embedding and reading systems is to ensure that the watermark is detectable even if the watermarked media content is transformed in some fashion. The watermark may be corrupted intentionally, so as to bypass its copy protection or anti-counterfeiting functions, or unintentionally through various transformations (e.g., scaling, rotation, translation, etc.) that result from routine manipulation of the content. In the case of watermarked images, such manipulation of the image may distort the watermark pattern embedded in the image.
A watermark can have multiple components, each having different attributes. To name a few, these attributes include function, signal intensity, transform domain of watermark definition (e.g., temporal, spatial, frequency, etc.), location or orientation in host signal, redundancy, level of security (e.g., encrypted or scrambled), etc. The components of the watermark may perform the same or different functions. For example, one component may carry a message, while another component may serve to identify the location or orientation of the watermark. Moreover, different messages may be encoded in different temporal or spatial portions of the host signal, such as different locations in an image or different time frames of audio or video. In some cases, the components are provided through separate watermarks.
There are a variety of alternative embodiments of an embedder and detector. One embodiment of an embedder performs error correction coding of a binary message, and then combines the binary message with a carrier signal to create a component of a watermark signal. It then combines the watermark signal with a host signal. To facilitate detection, it may also add a detection component to form a composite watermark signal having a message and detection component. The message component includes known or signature bits to facilitate detection, and thus, serves a dual function of identifying the mark and conveying a message. The detection component is designed to identify the orientation of the watermark in the combined signal, but may carry an information signal as well. For example, the signal values at selected locations in the detection component can be altered to encode a message.
One embodiment of a detector estimates an initial orientation of a watermark signal in a host signal, and refines the initial orientation to compute a refined orientation. As part of the process of refining the orientation, this detector may compute at least one orientation parameter that increases correlation between the watermark signal and the host signal when the watermark or host signal is adjusted with the refined orientation.
Another detector embodiment computes orientation parameter candidates of a watermark signal in different portions of a signal suspected of including a digital watermark, and compares the similarity of orientation parameter candidates from the different portions. Based on this comparison, it determines which candidates are more likely to correspond to a valid watermark signal.
Yet another detector embodiment estimates orientation of the watermark in a signal suspected of having a watermark. The detector then uses the orientation to extract a measure of the watermark in the suspected signal. It uses the measure of the watermark to assess merits of the estimated orientation. In one implementation, the measure of the watermark is the extent to which message bits read from the target signal match with expected bits. Another measure is the extent to which values of the target signal are consistent with the watermark signal. The measure of the watermark signal provides information about the merits of a given orientation that can be used to find a better estimate of the orientation. Of course other watermark embedder and detectors can be suitably interchanged with some embedding/detecting aspects of the present invention.
Some techniques for embedding and detecting watermarks in media signals are detailed in the assignee's co-pending U.S. patent application Ser. No. 09/503,881, U.S. Pat. No. 6,122,403 and PCT patent application PCT/U.S. Pat. No. 02/20832 (published as WO 03/005291), which are each herein incorporated by reference. The artisan is assumed to be familiar with the foregoing prior art.
In the following disclosure it should be understood that references to watermarking and steganographic hiding encompass not only the assignee's technology, but can likewise be practiced with other technologies as well.
Recent developments of highly reflective films and surfaces have required consideration of how best to steganographically mark these types of surfaces. One such surface is a so-called specular surface. A specular surface often reflects light away from the light's source. This can create signal detection problems since relevant optical scan data may be reflected away from a co-located optical sensor.
Accordingly, one aspect of the present invention provides a method of steganographically marking a specular surface. The method includes steps to provide a steganographic signal including at least plural-bit data, and to arrange ink in a pattern on the specular surface to represent the steganographic signal. The ink, once arranged on the specular surface, provides a surface including at least a diffuse reflection property.
Another aspect of the present invention provides a method of marking a specular surface. The method includes the steps of: providing an image including generally uniform pixel values; embedding a digital watermark signal in the image, which effects a change to at least some of the generally uniform pixel values; thresholding the digitally watermarked image; and printing the thresholded, digitally watermarked image on the specular surface with an ink or dye that, once printed, provides an ink or dye surface comprising at least a diffuse reflection property.
Yet another aspect of the present invention is a three-dimensional molded article. The article includes a decorative film or substrate and an adjacent molded polymeric base. The decorative film or substrate includes a specular surface. An improvement to the article is a steganographic signal applied to the decorative film or substrate through arranging an ink pattern on the specular surface. A coloration of the ink is selected to conceal the ink pattern on the specular surface.
Still another aspect of the present invention is a method of steganographically marking a mirror-like surface. The mirror-like surface includes a first coloration and a first finish. The method includes the steps of providing a steganographic signal including at least plural-bit data, and arranging ink in a pattern on the mirror-like surface to represent the steganographic signal. The ink forms a surface which provides Lambertian reflection. At least one of an ink coloration and ink finish is selected to hide the ink with respect to at least one of the first coloration and the first finish.
Yet another aspect of the present invention is a laminate comprising a multi-layered structure including a film having a specular surface. The film is sandwiched between a polymeric substrate and an over-laminate. An improvement to the laminate is ink adjacently arranged to the specular surface so as to convey a steganographic signal. The ink provides an ink surface with a diffuse reflection property.
The foregoing and other features and advantages of the present invention will be even more readily apparent from the following detailed description, which proceeds with reference to the accompanying drawings. Of course, the drawings are not necessarily presented to scale, but rather focus on inventive aspects of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 illustrates changes to the width of a line to effect watermark encoding. FIG. 1 corresponds to FIG. 5 in parent U.S. Pat. No. 6,449,377.
FIG. 2 illustrates a reflectance example for a specular surface.
FIG. 3 illustrates the specular surface of FIG. 2 including a steganographic signal conveyed through arrangement of ink or dye.
FIG. 4 a illustrates a reflectance example for a preferred ink or dye that conveys a steganographic signal.
FIG. 4 b illustrates a reflectance example including an optical sensor remotely located with respect to a light source.
FIG. 5 a illustrates a flow diagram for a signal hiding method according to one aspect of the present invention.
FIG. 5 b illustrates a flow diagram for the FIG. 5 a method including a thresholding step.
FIG. 6 illustrates a cross-sectional view of a multi-layered disc according to one embodiment of the present invention.
DETAILED DESCRIPTION
In parent U.S. Pat. No. 6,449,377 we teach:
In a first embodiment of the invention, shown in FIG. [ 1 ], the width of the line is controllably varied so as to change the luminosity of the regions through which it passes. To increase the luminosity (or reflectance), the line is made narrower (i.e. less ink in the region). To decrease the luminosity, the line is made wider (i.e. more ink).
Whether the luminance in a given region should be increased or decreased depends on the particular watermarking algorithm used. Any algorithm can be used, by changing the luminosity of regions 12 as the algorithm would otherwise change the luminance or colors of pixels in a pixelated image.
In an exemplary algorithm, the binary data is represented as a sequence of −1s and 1s, instead of 0s and 1s. (The binary data can comprise a single datum, but more typically comprises several. In an illustrative embodiment, the data comprises 100 bits.)
Each element of the binary data sequence is then multiplied by a corresponding element of a pseudo-random number sequence, comprised of −1s and 1s, to yield an intermediate data signal. Each element of this intermediate data signal is mapped to a corresponding sub-part of the image, such as a region 12 . The image in (and optionally around) this region is analyzed to determine its relative capability to conceal embedded data, and a corresponding scale factor is produced. Exemplary scale factors may range from 0 to 3. The scale factor for the region is then multiplied by the element of the intermediate data signal mapped to the region in order to yield a “tweak” value for the region. In the illustrated case, the resulting tweaks can range from −3 to 3. The luminosity of the region is then adjusted in accordance with the tweak value. A tweak value of −3 may correspond to a −5% change in luminosity; −2 may correspond to −2% change; −1 may correspond to −1% change; 0 may correspond to no change; 1 may correspond to +1% change; 2 may correspond to +2% change, and 3 may correspond to +5% change. (This example follows the basic techniques described in the Real Time Encoder embodiment disclosed in patent U.S. Pat. No. 5,710,834.)
In FIG. [ 1 ], the watermarking algorithm determined that the luminance of region A should be reduced by a certain percentage, while the luminance of regions C and D should be increased by certain percentages.
In region A, the luminance is reduced by increasing the line width. In region D, the luminance is increased by reducing the line width; similarly in region C (but to a lesser extent).
No line passes through region B, so there is no opportunity to change the region's luminance. This is not fatal to the method, however, since the watermarking algorithm redundantly encodes each bit of data in sub-parts spaced throughout the line art image.
The changes to line widths in regions A and D of FIG. [ 1 ] are exaggerated for purposes of illustration. While the illustrated variance is possible, most implementations will modulate the line width 3-50% (increase or decrease).
. . .
In still a further embodiment, the luminance in each region is changed while leaving the line unchanged. This can be effected by sprinkling tiny dots of ink in the otherwise-vacant parts of the region. In high quality printing, of the type used with banknotes, droplets on the order of 3 μm in diameter can be deposited. (Still larger droplets are still beyond the perception threshold for most viewers.) Speckling a region with such droplets (either in a regular array, or random, or according to a desired profile such as Gaussian), can readily effect a 1% or so change in luminosity. (Usually dark droplets are added to a region, effecting a decrease in luminosity. Increases in luminosity can be effected by speckling with a light colored ink, or by forming light voids in line art otherwise present in a region.)
In a variant of the speckling technique, very thin mesh lines can be inserted in the artwork—again to slightly change the luminance of one or more regions.
We have found that we can apply analogous and/or improved techniques to steganographically encode specular reflective surfaces. With reference to FIG. 2 , a specular surface generally reflects light away from (and not generally back to) the light's source. In one implementation, a specular surface reflects light in a directional manner such that the angle of reflection is equal to the angle of incidence. While the specular surface of FIG. 2 is illustrated as being adjacently arranged with a substrate, the present invention is not so limited.
Specular surfaces can be devoid of text or images, and often include a metallic-like surface luster (or finish). Examples of specular reflective materials include some of 3M's Radiant Light Films™ (e.g., 3M's Radiant Mirror and Visible Mirror products). The Radiant Light Films™ can be combined with a Lexan® sheet (from GE Corporation) and an over-laminate (e.g., a polycarbonate, polyvinyl fluoride, polyester, etc.). Dorrie Corporation in the United States provides a variety of suitable laminates. Of course, a specular surface can include coloration and textures (e.g., tints, patterns, sparkles, etc.). Some of these specular surfaces even change color hue at different viewing angles and thinning ratios across the specular surface (e.g., 3M's Color Mirror Film).
Steganographically encoding specular surfaces has heretofore presented unique challenges. A first challenge is that with such a reflective surface, information is difficult to hide without being aesthetically displeasing. A second challenge is signal detection. Some steganographic readers include or cooperate with a light source (e.g., LED or illumination source) to facilitate better detection. These steganographic readers often position or co-locate an optical sensor at or near the light source. Yet, with a specular surface, light reflects away from the light source (and optical sensor), yielding little or no optical data for capture by the optical sensor. An optical sensor would need to be placed along the angle of reflection to capture relevant optical data. This configuration is awkward and practically impossible for a steganographic reader. Accordingly, it is very difficult to capture and read a signal on a specular surface.
With reference to FIG. 3 , we overcome these challenges by sprinkling (or providing, over-printing, etc.) ink and/or dye on the specular surface. The ink or dye is provided on the specular surface so as to convey a steganographic signal.
The ink or dye is preferably selected or applied to blend in, hide or otherwise avoid contrast with the specular surface. For example, if the specular surface includes a chrome, gold or silver coloration, the ink or dye preferably includes at least a complimentary chrome, gold or silver coloration. Or if the specular surface includes a pattern or background, the ink or dye can be selected to match or otherwise blend in with the pattern or background. In other cases the ink or dye is generally opaque or transparent. Yet the transparent ink still preferably includes favorable reflective properties. Still further, the ink can be selected to include a somewhat glossy finish so as to even further improve the ink's hiding characteristics. In other implementations the ink includes a dull or even matt-like finish. A dull or matt-like finish may provide preferred reflection properties (e.g., approximating Lambertian reflection) as discussed below.
The ink or dye preferably comprises a diffuse reflection surface or property. A diffuse reflection surface is one that generally diffuses a light ray in multiple directions, including, e.g., back toward the source of the light ray (see FIG. 4 a ). This characteristic allows for steganographic signal capture by an optical sensor positioned at or near a light source. For example, the optical sensor captures optical scan data that includes a representation of the steganographic signal. The captured scan data is communicated to a decoder to decipher the steganographic signal. (In some implementations the ink approximates Lambertian reflection, which implies that the ink reflects light in multiple directions, and hence can be perceived (or optically captured) from the multiple directions. With Lambertian reflection, the brightness of a reflected ray depends on an angle between a direction of the light source and the surface normal.). We note, with reference to FIG. 4 b , that the optical sensor need not be positioned at the light source, but instead can be positioned to receive another (or additional) reflected light ray(s). One FIG. 4 b implementation packages the optical sensor and light source in a signal apparatus (e.g., a hand-held steganographic signal detector).
The steganographic signal preferably conveys a message or payload. In some implementations the message or payload includes a unique identifier for identifying the object or surface. Or the message or payload may provide authentication clues. In other implementations the message or payload provides auxiliary information, e.g., pertaining to an associated object or manufacturing details, distribution history, etc. In still other implementations the message or payload includes a link or index to a data repository. The data repository includes the identifier, authentication clues, and/or auxiliary information. (See assignee's U.S. patent application Ser. No. 09/571,422, herein incorporated by reference, for some related linking techniques. The disclosed techniques are suitably interchangeable with the linking aspect of the present invention.).
The steganographic signal may be optionally fragile, e.g., the signal is destroyed (or irreproducible) or predictably degrades upon signal processing such as scanning and printing.
The steganographic signal may include an orientation component which is useful in helping to resolve image distortion such as rotation, scaling, and translation, etc., and/or to help detect the message or payload. The orientation component may be a separate signal, or may be combined (or concatenated) with the message or payload.
The steganographic signal may also be redundantly provided across a specular surface so as to redundantly convey the orientation, message or payload (or plural-bit data). Or the signal may be object or location specific. For example, if the specular surface includes a graphic or background pattern/texture/tint, the signal can be limited to over the graphic or background pattern/texture/tint.
In one implementation, the ink pattern is arranged according to a so-called digital watermark signal. The signal can be a “pure” or “raw” signal. A pure or raw digital watermark signal is generally one that conveys information without influence or consideration of a host image or text. In some implementations the pattern appears as (or includes) a background texture or tint. In other implementations the pattern appears as if a random (or pseudo-random) pattern.
In one digital watermarking implementation, and with reference to FIG. 5 a , we start with a gray or monotone image (e.g., a flat gray image including substantially uniform pixel values or subtly varying grayscale texture, tint or pattern). We can use standard image editing software such as Adobe's Photoshop or Jasc Software's PaintShop Pro, etc., etc. to provide the gray image. The gray image serves as a “host” image and is passed to a digital watermark-embedding module (step 50 ). The digital watermarking module can encode the gray image, e.g., based on a transform domain watermark embedding technique or spatial domain watermark embedding technique, etc. The resulting embedded, gray image is then printed or otherwise applied to the specular surface (step 54 ). (In some implementations, a specular surface is provided as a thin film, which can be readily feed through an offset printing press or laser/ink jet printer.).
In another implementation, we “threshold” the embedded gray image prior to printing or applying to the specular surface (step 52 in FIG. 5 b ). Generally, thresholding reduces the watermark signal and/or watermarked image. In one implementation, a watermark signal is embedded as a plurality of peaks and valleys (or plus and minus signal tweaks). The tweaks can be encoded in a gray image by changing or effecting pixel values, e.g., changing gray-scale levels for pixels. (We note that transform domain embedding also effects pixels values.). Thresholding this embedded gray image may then include selecting a grayscale level (e.g., level 128 in an 8-bit (or 256 level) grayscale image) and discarding all pixels with a grayscale level below (or above) level 128. Of course, there are many other thresholding techniques that can be employed, such as filtering the embedded gray image, creating a binary image (e.g., toggling image pixels to be on or off based on pixel values of the embedded gray image), discarding pixels based on coefficient values (or blocks of coefficient values), etc., etc. The thresholded, embedded gray image is then applied or printed to the specular surface ( 56 ).
In some implementations two or more digital watermarks are provided in the steganographic signal. The two or more watermarks can cooperate for authentication. For example, each of the two watermarks may include overlapping payload information that can be compared to determine authenticity. Or a first digital watermark may be fragile, while a second digital watermark is robust. Still further, a first digital watermark may include an orientation component, while the second digital watermark includes a message or payload. Or a first digital watermark may include a key to decrypt or otherwise assist in decoding a second digital watermark.
If using a sheet of specular material (e.g., 3M's Radiant Light Films), ink can be printed (e.g., screen-printed, dye-diffusion thermal transfer (D2T2), and ink or laser jet printing, etc.) directly onto the sheet. A tie coat can be laid down on the film, prior to printing, to help the ink better adhere to the film's surface.
The printed sheet can then be applied to an object such as a consumer device, electronics device, label, sticker, identification documents (e.g., driver's licenses, passports, identification cards, badges, access cards, etc.) certificate, automobile (e.g., as a paint substitute or as an overlay, etc.), credit cards, personal digital assistants (PDAs), molded logos (e.g., for attachment to articles such as shoes and clothing, equipment or consumer products), handheld and console video games, pagers, dashboards, stereo faceplates or covers, plastic articles, etc. The printed sheet can also be used as or in conjunction with a holographic structure or optical variable device. In some cases we even use the specular surface as a hologram-like structure or component.
In one embodiment, the printed sheet is provided to a molding process, e.g., as contemplated in our parent U.S. patent application Ser. No. 10/286,357. In some implementations of this embodiment, the printed sheet is combined with (e.g., adhered to) a carrier sheet such as a Lexan® polycarbonate sheet (Lexan® is provided by GE Plastics in the United States). A layered printed specular sheet/Lexan® sheet structure is also hereafter referred to as a “printed sheet.” The printed sheet is provided to an injection mold, perhaps after pre-forming or pre-molded the printed sheet. The printed sheet is preferably positioned in the mold so as to have the bottom surface of the printed sheet adjacent to a second material, e.g., injected polycarbonate or polymeric resin (or other suitable injection materials). A three-dimensional object results including a printed specular sheet/Lexan®/injection material structure. (We note that the various layer materials will sometimes fuse or migrate into other layers during an injection molding process.) We can also provide an over-laminate (e.g., polycarbonate, polyester, polyurethane, etc.) over the printed specular surface. The printed steganographic signal can be reversed if applied to a bottom layer of the printed sheet when the signal will be viewed from a top-surface of the printed sheet. Reversing the printing will typically allow for an easier read when the signal is scanned from a top layer of the printed sheet.
In another molding implementation, we provide the printed specular sheet to be sandwiched in between a sheet of Lexan® and injection molding material. The Lexan® is preferably somewhat transparent to allow viewing of the printed specular surface through the Lexan®.
In a related embodiment, we provide a substrate (e.g., a Lexan® sheet) and a specular surface (e.g., a Radiant Light Film®) adjacently arranged on or adhered to the substrate (collectively referred to as a “structure”). The specular surface is printed to include a steganographic signal as discussed herein. The structure can optionally include a laminate layer. The structure is then used as a laminate or covering. The laminate or covering is applied (e.g., with an adhesive or via a molding process) to various objects (cell phones, automotive parts, labels, identification documents, plastic parts, computer equipment, etc.).
Another embodiment involves the application of our techniques to compact discs (e.g., CDs, CD-Rs and CD-RWs) and digital video discs (e.g., DVDs, DVD-Rs and DVD-RWs). An example is given with respect to CD-Rs, but our techniques apply to other CDs and DVDs as well. With reference to FIG. 6 , a CD-R generally includes a multi-layered structure including a plastic (e.g., polycarbonate) substrate ( 61 ), a translucent data layer of recordable material such as an organic dye ( 62 ) and a specular reflective layer ( 63 ). Some CD-Rs also have an additional protective or printable coating ( 64 ) adjacent to the specular reflective layer ( 63 ).
When making CD-R media, instead of pits and lands, a spiral is pressed or formed into the substrate, e.g., by injection molding from a stamper, as a guide to a recording laser. The recording laser selectively melts the translucent data layer of CD-R discs during the recording process. The positions where the data layer is melted becomes opaque or refractive, scattering a reading laser beam so it is not reflected back (or is reflected as a different intensity) into a reader's sensors. The reader interprets a difference between reflected and non-reflected light as a binary signal.
We can apply our steganographic signal on a top or bottom side of the specular reflective layer 63 (or other adjacently arranged layers) as discussed above. We preferably threshold the steganographic signal (or embedded grayscale image) prior to application to the specular reflective layer 63 . A high threshold will help prevent reading errors due to the printed ink.
In one implementation of this embodiment, the steganographic signal includes a decoding key. The decoding key is used to decode (or decrypt) the data (e.g., audio, video, data) on the disc. In another implementation, the steganographic signal includes an identifier which is used to determine whether the disc is authentic. Illegal copies will not include the steganographic watermark on the specular surface—evidencing an unauthorized copy.
Concluding Remarks
To provide a comprehensive disclosure without unduly lengthening this specification, each of the above-identified patent documents is herein incorporated by reference.
Having described and illustrated the principles of the invention with reference to illustrative embodiments, it should be recognized that the invention is not so limited. The present invention finds application beyond such illustrative embodiments.
For example, the technology and solutions disclosed herein have made use of elements and techniques known from the cited documents. Other elements and techniques can similarly be combined to yield further implementations within the scope of the present invention. Thus, for example, single-bit watermarking can be substituted for multi-bit watermarking, technology described as using steganographic watermarks or encoding can alternatively be practiced using visible marks (glyphs, etc.) or other encoding, local scaling of watermark energy can be provided to enhance watermark signal-to-noise ratio without increasing human perceptibility, various filtering operations can be employed to serve the functions explained in the prior art, watermarks can include subliminal graticules to aid in image re-registration, encoding may proceed at the granularity of a single pixel (or DCT coefficient), or may similarly treat adjoining groups of pixels (or DCT coefficients), the encoding can be optimized to withstand expected forms of content corruption. Etc., etc., etc. Thus, the exemplary embodiments are only selected samples of the solutions available by combining the teachings referenced above. The other solutions necessarily are not exhaustively described herein, but are fairly within the understanding of an artisan given the foregoing disclosure and familiarity with the cited art.
It should be realized that the reflectance characteristics shown in FIGS. 2 , 4 a and 4 b are for illustrative purposes only. Of course, a specular surface and applied ink can include additional or different reflectance characteristics. Also, a specular surface is often provided as a thin film or sheet, which can be attached or adhered to a carrier sheet or directly to an object surface. Hence, the FIGS. 2-4 representations of a dome-like surface is only but one of the many possible forms that a specular surface can take.
In an alternative embodiment, a specular surface includes a generally transparent over-laminate (e.g., polycarbonate, polyurethane, and/or polyester, etc.). The over-laminate provides protection to a steganographic signal printed or applied to the specular surface.
Also, instead of applying a steganographic signal on the specular surface, we could provide a steganographic signal in or on a surface of an over-laminate, yet this requires an additional layer.
In still another alternative embodiment, we print a thresholded digital watermark signal or other steganographic signal on an over-laminate or specular surface using invisible (e.g., ultraviolet or infrared) inks.
In yet another embodiment, a thin film of specular material receives the printed steganographic signal on a bottom or underside surface. The film is sufficiently transparent so that the printed ink is viewable through the top surface of the film.
We note that some specular surface may be semi-specular. That is, they reflect some light specularly and some light diffusely. Our inventive techniques work well with such specular surfaces.
While specific dimension of sprinkled ink droplets are provided by way of example in our parent application, the present invention is not so limited. Indeed, ink or dye can be arranged or printed onto a specular surface using conventional printers and printing techniques. And droplet size can be larger or smaller than given in the example.
The implementation of some of the functionality described above (including watermark or steganographic encoding and decoding) can be implemented by suitable software, stored in memory for execution on an associated processor or processing circuitry. In other implementations, the functionality can be achieved by dedicated hardware, or by a combination of hardware and software. Reprogrammable logic, including FPGAs, can advantageously be employed in certain implementations.
In view of the wide variety of embodiments to which the principles and features discussed above can be applied, it should be apparent that the detailed embodiments are illustrative only and should not be taken as limiting the scope of the invention. Rather, we claim as our invention all such modifications as may come within the scope and spirit of the following claims and equivalents thereof. | The present invention relates generally to steganographic encoding. Once claim recites a method including: obtaining plural-bit auxiliary data; creating an original carrier signal representing the plural-bit auxiliary data; reducing information content of the original carrier signal so that the carrier still conveys the plural-bit auxiliary data, yielding a reduced carrier signal; and hiding the reduced carrier signal in host data. Another claim recites a mechanical part including: a metallic surface including a pattern, the pattern conveying plural-bit auxiliary data in a steganographic manner, and the pattern provides at least diffuse reflection. Of course, other claims and combinations are also provided. | 36,017 |
RELATED APPLICATIONS INFORMATION
[0001] This application claims the benefit of priority as a Continuation under 35 U.S.C. §120 of U.S. patent application Ser. No. 11/473,759, filed Jun. 22, 2006 and entitled “Method For the Eradication of Pathogens Including S. Aureus and Antibiotic Resistant Microbes from the Upper Respiratory Tract of Mammals and for Inhibiting the Activation of Immune Cells,” which is incorporated herein by reference in its entirety as if set forth in full.
BACKGROUND INFORMATION
[0002] 1. Field
[0003] The application of molecular iodine for the eradication of pathogens including S. aureus and antibiotic resistant microbes from the upper respiratory tract of mammals and for inhibiting the activation of immune cells. Molecular iodine is also employed in the inhibition of superantigens in the treatment of atopic dermatitis, eczema, psoriasis, impetigo or sinusitis.
[0004] 2. Background of Invention
[0005] Nasal carriage of Staphylococcus aureus is a well-defined risk factor for subsequent infection in nearly all categories of hospitalized patients that have been studied. S. aureus carriage has been studied extensively in surgical patients (general, orthopedic, and thoracic surgery), in patients on hemodialysis, in patients on continuous ambulatory peritoneal dialysis (CAPD), HIV-infected patients, and in patients in intensive care units.
[0006] The morbidity and mortality and economic impact of surgical-site infections (SSIs) are enormous. SSIs, the most common nosocomial infections among surgical patients, are thought to complicate approximately 500,000 of the estimated 27 million operations performed annually in the United States. S. aureus is the most frequently identified pathogen in SSIs. The estimated annual hospital charges associated with these infections is more than $1.6 billion. SSIs prolong hospital stays by more than 5 days per episode. More importantly, SSI patients are more than twice as likely to die in the postoperative period.
[0007] The pathogenicity of S. aureus is normally associated with the ability of a particular strain to produce coagulase enzymes but these organisms contain antigens and produce toxins with superantigenic properties and have been implicated in at least two disease states. S. aureus enterotoxins activate T-cells by binding to the variable beta-chain of the T-cell receptor major histocompatibility class II complex (MHC) outside of the antigen specific groove. Clinical studies demonstrate that bacterial superantigens induce Ig-E synthesis which may have a major impact on upper and lower airway disease such as nasal polyposis and asthma.
[0008] Elimination of S. aureus nasal carriage seems to be the most straightforward strategy to prevent the real and potential negative affects of S. aureus in the nasal cavity as well as other areas of the upper respiratory tract which for purposes of the present invention is defined to include the nose, paranasal sinuses, pharynx, trachea, bronchi and the mouth. The introduction of mupirocin ointment in the late 1980s was intended to meet this need. Mupirocin nasal ointment is an effective treatment for eliminating S. aureus . The treatment of carriers with mupirocin in the nasal cavity results in a significant reduction of the nosocomial S. aureus infection rate for hemodialysis and CAPD patients. A review mupirocin studies concluded that treatment of S. aureus carriers with mupirocin in the nasal cavity significantly reduces (50%) of the rate of nosocomial S. aureus infection. Many randomized and non-randomized mupirocin trials indicate that mupirocin nasal treatment of patients prior to surgery reduces Staphylococcus aureus postoperative infection.
[0009] Mupirocin resistant strains were described soon after its introduction. Moreover, the increased use of mupirocin, especially for chronic infections, has led to an increased incidence of resistance. In a recent survey from Spain, levels of mupirocin resistance in clinical isolates was reported to have increased for 7.7% in 1998 to 17% in 2000, and some hospitals have reported incidences as high as 63%. The continuing spread of methicillin resistant S. aureus (MRSA) and the increase in mupirocin-resistant strains prevents the prophylactic use of this product and highlights the need for alternative agents. Before mupirocin can be administered to a patient suspected of being a S. aureus carrier they must be tested for the presence of S. aureus in their nasal nares. This requires a medical professional to swab the nasal cavity for subsequent evaluation for the presence of S. aureus by a microbiology laboratory; a process that takes at least 24 hours and often 48 hour.
[0010] Most investigators studying mupirocin for elimination of S. aureus carriage in hospitalized patients have commented that prophylactic use or generalized pre-surgical application will lead to increased rates of mupirocin resistant S. aureus . In some cases investigators have looked for alternative treatments to eradicate S. aureus from nasal nares. One well-known antimicrobial agent, polyvinylpyrolodone-iodine (PVP-I), has been investigated by several groups for eradicating S. aureus and MRSA in the nasal cavity.
[0011] In these studies PVP-I was diluted to reduce potential toxicity and the results were promising. These investigators point out that PVP-iodine provides useful properties for local anti-infective treatment in general and for surface decontamination in particular. The microbial action spectrum is broad even after short exposure times and no known microbial resistance to iodine occurs. In contrast to antibiotics PVP-I not only destroys bacteria, but also effectively inhibits the release of pathogenic factors, such as exotoxins, endotoxins and tissue-destroying enzymes.
[0012] The label claim on iodine-based germicides is based on “total iodine” which is measured by thiosulfate titration. Unfortunately, three species of iodine are titrated by thiosulfate: triiodide, HOI (hypoiodious acid) and I 2 . The overwhelming majority of the iodine titrated in these germicides exists as triiodide. The high concentrations of iodide, buffering agents (pH<4) and povidone in these germicides are included to improve the stability of the I 2 molecule.
[0013] The formulators of these compositions did not give consideration to use in the nasal cavity. The prior art applications using iodine in the nasal cavity make no attempt to optimize the efficacy to toxicity properties of these agents as they are intended for use on the skin. When these agents are applied to the skin the only species of iodine that are of concern with respect to systemic toxicity is the I 2 species since it is the only species of iodine that can penetrate the skin. When PVP-I is applied to the skin of mammals less than 0.01% of the iodine contained in these compositions is absorbed systemically. Consequently, the amount of iodine that is absorbed systemically is so low that it is not possible to detect the increase in systemic iodine (if any) above the background level. Consequently, the ratio of I 2 to other iodine species in complex iodine formulations applied to the epidermis is not a meaningful safety consideration. However, when iodine-based compositions are applied to mucous membranes the risk to the thyroid is distinct. For instance, when PVP-I is administered to the nasal cavity 100% of the iodine administered is absorbed systemically.
[0014] Kramer in Dermatology Vol. 204 (Suppl.) 1; 86-91, 2002 examined the irritation potential of iodophors in the nasal cavity and cartilage tissue. The hen's egg-chorioallantoic membrane (HET-CAM) test and explant test was used to evaluate the tolerability of and PVP-I. As shown in the Table below 10% PVP-I inhibits growth.
[0000]
TABLE
Growth rates in explant test with prepared peritoneal tissue.
Exposure
Growth rate %
Agent
Concentration
min
(control = 100%)
PVP-I
10%
1
63
10%
30
40
[0015] Masano in Postgrad Med J 1993, 69 Suppl 3, S122-5 treated patients and healthcare workers with PVP-I cream. Daily application of 10% PVP-I for 2 months did not induce goiter but the TSH levels in four of seven family members was elevated. These results indicate that iodine, like almost all other chemical and biological ingredients in nasal formulations, is absorbed in the nasal cavity. Kramer and Gluck in Krankenhaus - und Praxishygiene (Hospital and Practice Hygiene); Kramer, A., Heeg, P. et al., Eds.; München, Fischer BEI Elsevier: 2001; pp 252-268 recognized safety concerns related to the use of agents with high levels of iodine and diluted PVP-I to a concentration of 1.25% before application in the nasal cavity. A total of 88 volunteers (77 males and 11 females) were treated twice a day for three days and the principal side effects reported were dryness, itchiness and sneezing. No thyroid dysfunction was observed. The prior art does not describe an approach that provides a composition with a high therapeutic index (ratio of efficacy to side effects).
[0016] U.S. Pat. No. 6,171,611 describes a nasal moisturizing saline (0.65%) solution made of water, iodine or an iodine salt that is buffered at physiological pH, namely pH 7.4 but does not identify the basic formulation parameters that would enable one to devise a biocidal composition of matter. The iodine described in U.S. Pat. No. 6,171,611 is either “iodine” or an “iodine salt” selected from the group consisting of ammonium iodate, ammonium iodide, calcium iodate, calcium iodide, iodine monochloride, iodine trichloride, magnesium iodate, magnesium iodide, potassium iodate, potassium iodide, sodium iodate, sodium iodide, zinc iodate and zinc iodide. It is well known to one skilled in the art that these iodide salts are not, biocidal; in fact, at a pH of 7.4 the iodide salts in this group are not biocidal either individually or when combined. Moreover, a pH of 7.4 is not compatible with the I 2 species since I 2 is not stable at a pH of 7.4 and at a pH of 7.4 the I 2 species hydrolyzes very rapidly to form other species of iodine including iodide, HOI, iodate and triiodide. U.S. Pat. No. 5,962,029 describes the hydrolysis of I 2 at a pH of 7 and above. At a pH of 7.0 about 21% of the I 2 is hydrolyzed in one hour; at a pH of 8.0 the loss increases to 78% in one hour. This is not a new observation since the rate of hydrolysis of I 2 was first published over 50 years ago by Wyss in Arch Biochem 1945, 6, 261-268.
[0017] König et al. in Dermatology 1997, 195 Suppl 2, 42-48 studied the effect of PVP-I on polymorphonuclear leukocytes (PMN) cells. PMN cells play a role in the immune response by engulfing a foreign pathogen and processing it prior to presenting the processed antigen to the immune system. PMN cells engulf a pathogen using a process known as phygocytosis. Following phagocytosis, the pathogen is moved into a phagolysozome where degredative enzymes actively lyse the pathogen. When pathogens are lysed they release proteins like TNF-α which can stimulate an immune response Immune responses like these are well known in several medical conditions including atopic dermatitis, eczema, psoriasis, impetigo and sinusitis. König et al. combined a S. aureus strain of unknown enterotoxin status with various concentrations of PVP-I, added PMN cells and then incubated the mixture for 6 hours. The data indicate that PMN cells released increasing amounts of TNF-α as PVP-I is diluted demonstrating PVP-I inactivation of the cytokine TNF-α after its release from PMN cells. The PVP-I reaction observed by König was a PMN-specific response (recognition-phagocytosis-processing).
[0018] Hill and Casewell J Hosp Infect 2000, 45, 198-205 demonstrated that the nasal secretions from 11 different samples reduced the biocidal activity of PVP-I. They calculated that 1.0 milliliter of nasal secretions inactivated the equivalent of approximately 22.5 mg of PVP-I. This is not a surprising result since it is known that the nose has a well defined mucociliary apparatus. Airway mucus consists of two layers, a low vicoelasticity periciliary layer that envelops the cilia, and a more viscous layer that rides on top of the periciliary layer. The primary glycoproteins that comprise nasal mucous are mucins. Mucins contain a very high concentration of cysteine which can react with I 2 and thereby neutralize its activity. Consequently, it is necessary to insure a minimum I 2 concentration that can overcome whatever residual mucin resides in the nasal cavity.
[0019] Given the presence of a bioburden in the nasal cavity, one of the key formulation parameters is the minimum concentration of biocidal iodine (i.e., I 2 ) required for efficacy. In theory, the concentration of I 2 is a function of the amount of material that is contacted to the interior of the nasal cavity. In practice, it is only feasible to use about 0.25 grams of material per nostril if the formulation is provided in the form of a gel, cream or ointment and no more than two times that amount (i.e., 0.5 grams per nostril) if the formulation is delivered as a liquid in the form of nose drops or a spray. U.S. Pat. No. 6,171,611 claims a lower concentration range of 0.001% iodine by weight which is equivalent to 10 ppm I 2 (assuming that all of the iodine species were present in the biocidal form). It has been found in accordance with the present invention that a concentration of 10 ppm I 2 is not adequate to eliminate S. aureus when the formulation is provided as a gel. Even when the composition is sprayed into the nasal cavity, thereby allowing a larger number of I 2 molecules to contact the mucous membranes of the nasal cavity, a 10 ppm composition is not adequate to overcome the bioburden associated with endogenous mucin.
DEFINITIONS
[0020] The term “molecular iodine” as used herein refers to the I 2 species which is often referred to as diatomic iodine or elemental iodine in the literature. The term molecular iodine refers to I 2 that can react with pathogens in that the I 2 is not complexed with other molecules.
[0021] The term “iodide anion” as used herein, refers to the species that is represented by the chemical symbol I. Suitable counter-ions for the iodide anion include sodium, potassium, calcium and the like.
[0022] The term “triiodide” as used herein, refers to the species which is represented by the chemical symbol I 3 . It is recognized by one skilled in the art that triiodide can dissociate into one iodide anion and one molecule of free molecular iodine.
[0023] The term “total iodine” as used herein, refers to the iodine contained in all of the following iodine species: free molecular iodine, iodide, organically complexed forms of iodine, triiodide, iodate, iodite, hypoiodious acid (HOI) etc.
[0024] The term “therapeutic index” has traditionally been defined as the ratio of the desired effect to the undesired effect. It should be noted that a single drug can have many therapeutic indices, one for each of its undesirable effects relative to a desired drug action. I 2 is the sole biologically active form of iodine in the anticipated compositions; toxicity is associated with all forms of iodine. Therefore, the term “therapeutic index” as used herein, refers to lowest concentration of total iodine that achieves the desired clinical effect.
[0025] The term “unpleasant odor” from I 2 refers to the vapor pressure of I 2 generated at 20° C. from 0.15 mL of a composition that will, within 67 seconds, turn a moistened 1 inch strip of potassium iodide starch paper (Whatman International, Ltd, Cat No. 2602-500A) blue when said starch paper is vertically aligned with and adhered to the top inside of a sealed 50 mL self-standing graduated plastic tube (Corning Cat No. 430897).
[0026] The term “rate of iodine generation” as used herein, refers to the rate at which molecular iodine is formed. The compositions in the present application all need to be activated by mixing and then applied to the surface of interest. Application of the compositions in this application should occur from 20 seconds to 60 minutes after mixing; therefore, the rate of I 2 generation is a meaningful consideration.
[0027] The term “ratio of molecular iodine” as used herein, refers to the ratio of molecular iodine (I 2 ) to all other iodine species including complexed iodine.
[0028] The term “superantigen” refers to a class of immune stimulants that are unique because they do not require cellular processing and presentation to elicit a response. The S. aureus enterotoxin B is a potent enterotoxin. Superantigens indiscriminately activate T-cells of the immune system causing localized as well as system-wide inflammatory responses including synthesis and release of cytotoxins. Superantigens are secreted as exotoxins by bacteria. Superantigens bind externally to the Vβ domain of the T-cell receptors (TCR) and to the complementary chain of major histocompatibility complex type II molecules (MHC II) causing antigen-independent T-cell activation.
[0029] The term “iodination” refers to the chemical addition of an iodine atom to an organic molecule. Iodine is known to iodinate the amino group, sulphydral groups, aromatic carbon atoms containing hydroxyl groups and unsaturated bonds.
SUMMARY OF THE INVENTION
[0030] In accordance with the present invention the minimum concentration necessary to provide an effective biocidal activity in the upper respiratory tract is 25 ppm I 2 . This minimum value is based upon quantitative microbiological measurements with swabs taken from the nasal cavity. Accordingly, when iodide and iodate are used as the reductant and oxidant species a minimum concentration of 20 ppm of iodide and 6.9 ppm iodate is required respectively when the ratio of generated I 2 is at least 40%.
[0031] A major consideration when formulating I 2 for use in the nasal cavity is the vapor pressure of the I 2 molecule. Iodine vapor is considered to be more irritating on a molar basis than either chlorine or bromine vapor. Iodine vapor causes nose and throat irritation, coughing, wheezing, laryngitis. The Canadian Center for Occupational Health and Safety indicate that repeated exposure to iodine vapor or exposure to high concentrations of iodine vapor may cause airway spasm, chest tightness, breathing difficulty, severe inflammation and fluid accumulation in the voice box, upper airways and lungs. Humans can work undisturbed at 0.1 ppm of atmospheric I 2 ; with difficulty at 0.15-0.2 ppm and are unable to work at concentrations of 0.3 ppm. However, the odor threshold for I 2 has been reported at 0.9 ppm so irritation may occur before the odor is detected. Clearly, if an odor is detected than the level of I 2 is not optimal. Given the well established safety concerns for I 2 in the vapor phase it is necessary to maintain a level that will not cause harm.
[0032] At 25° C. and 1.0 atmosphere of pressure the equilibrium constant for sublimation of I 2 is 4×10-4. This equilibrium accounts for the I 2 vapor pressure of 0 3 mm at 25° C. and 1.0 mm at 38.7° C. Using standard atmospheric pressure, a maximum concentration of atmospheric I 2 of about 1300 ppm could build up at body temperature. Therefore, administration of I 2 in the nasal cavity can lead to an unpleasant odor. If a strong odor is detected with a particular formulation then the nasal mucosa is being exposed to a concentration of I 2 that has been established as unsafe. The upper limit of I 2 in water is 330 ppm so it is theoretically possible to obtain a concentration of 300 ppm I 2 in a totally aqueous formulation which would fall within the scope of this application. It has been found that a 300 ppm I 2 solution emits an odor that is easily detectable by humans and is not optimal for repeated administration in the nasal cavity.
[0033] The characterization of an odor from I 2 is related directly to the vapor pressure of I 2 in a particular formulation. Some agents suitable for incorporation in the formulations contemplated in this application e.g., cyclodextrins, have the ability to reduce the vapor pressure of I 2 even while the I 2 species remains chemical active, i.e. detectable by potentiometric analysis. The actual potential to generate a detectable odor from I 2 in a particular formulation must be measured and cannot be predicted for most formulation matrices other than water.
[0034] Efficacy, as determined by the elimination of S. aureus , must be balanced against I 2 odor and nasal irritation when establishing the upper level of I 2 suitable for use in a nasal formulation. A 300 ppm concentration of I 2 at 37° C. produces a strong odor which is not optimal. It is clear that the optimum use concentration of I 2 is the minimum necessary to eliminate S. aureus from the nasal cavity. It was found that an appropriately formed gel formulation containing 250 ppm of I 2 were acceptable with respect to odor. For the purposes of this application the preferred concentration of I 2 is one that yields a vapor pressure that is equal to or less than that observed in a 250 ppm solution of I 2 in 0.1 N hydrochloric acid.
[0035] The residence time for an agent applied to the nasal cavity is affected by a variety of factors. One of these is the location of deposition since deposition in the anterior portion of the nose provides a longer nasal residence time. A second consideration is the viscosity of the composition as a higher viscosity provides a longer residence time. This application anticipates formulations with a viscosity that ranges from a value that is substantially similar to water (i.e., 1.0 cp) to values with a viscosity of 40,000 cp. The speed of kill from I 2 is extremely rapid (seconds) and the residence time is not anticipated to be a significant a factor the inherent bioburden in the nasal cavity or the issue of insuring that I 2 is uniformly disturbed within the nasal cavity so it can contact pathogens.
[0036] The pH of the nasal mucosa is preferentially maintained in a range of 4.5 to 6.5 since this allows the endogenous lysozyme to inactivate bacteria. In addition, normal ciliary movement is maintained within this pH range. I 2 can be formulated to remain stable during the anticipated residence time of the drug in the nasal cavity in this pH range. The preferred pH range of the formulations described in this application lies between 3.0 and 6.0. The volume of a gel medicament per nostril anticipated in this application is between 25 to 500 μL with 100-250 μL it being the most common dose volumes. If the formulation has a viscosity that is 10 cp or less then a volume as large as 3 mL may be administered. Therefore, an adequate formulation buffer capacity is required to maintain the desired pH in situ. The use of preservatives to prevent microbial growth is anticipated in this application provided that such preservatives are effective between pH 2.0 and 6.0. Humectants are anticipated in this application and can be added easily in gel-based nasal products; common examples include glycerin, sorbitol and mannitol.
[0037] Iodine is a relatively bulky atom with a molecular weight of 129. The interaction between T-cell receptor (TCR) and Staphylococcus aureus enterotoxin (SE) superantigen is blocked by the covalent binding of I 2 with amino acids within the binding domain. The net effect of these reactions is to prevent the binding reaction between S. aureus superantigens and T-cell receptors. This means that I 2 can prevent the binding of SE to T-cell receptors in the absence of S. aureus since S. aureus secretes SE into the medium surroundings the bacteria. Examples of these locations include the nasal vestibule, sinuses, skin and wounds. In addition, I 2 -binding to these amino acids may block the ability of kinases to add phosphate groups to tyrosine, serine, histidine and threonine which would, in turn, block cell signaling processes. The ability of I 2 to interfere with both T-cell binding via sup erantigen and protein phosphorylation prior to cell signaling provides a previously unidentified means to mitigate the severe immune responses caused by S. aureus.
[0038] The present invention describes a method to inhibit a lymphocyte/T-cell response that does not have a phagocytic processing step and therefore inhibit a lymphocyte/T-cell response to enterotoxin. In fact the method of the present invention teaches how to block the superantigen binding to the T-cell receptor. This invention also describes a method that will eradicate S. aureus from the upper respiratory tract but not irritate the nasal tissue or cause systemic toxicity.
DESCRIPTION
[0039] The formation of I 2 in an aqueous composition is preferably generated in accordance with this invention from a reaction by an oxidant and a reductant in a manner such that at least 40% of the total iodine present in the aqueous composition is I 2 at a minimum concentration of I 2 above about 25 ppm. The concentration of I 2 contemplated in this application ranges from 25 ppm up to 250 ppm with at least 40%, but preferably at least 50%, of the total iodine being in the form of I 2 . The preferred concentration of I 2 — is from 25 ppm to 150 ppm. The most preferred concentration of molecular iodine is from 50 ppm to 75 ppm.
[0040] The concentration of total iodine contemplated in this application ranges from 25 ppm up to 500 ppm. The preferred concentration of total iodine is from 25 ppm to 300 ppm. The most preferred concentration of total I 2 is about 50 to 150 ppm.
[0041] The ratio of I 2 contemplated in this application ranges from 40 to 100%. The preferred ratio of molecular iodine is from 70 to 100%. The most preferred ratio of molecular iodine is 100%.
[0042] The rate of iodine generation is defined herein, as the time required for the generation of I 2 to reach a maximum value. The rate of iodine generation contemplated in this application ranges from seconds for diffusion controlled reactions such as that between iodide and iodate in an aqueous environment to a high of 15 minutes. The most preferred rate of I 2 generation contemplated in this application is 2-5 seconds. It is possible to practice this application by diluting stable compositions of iodine and then immediately applying the product of said dilution. This approach is also contemplated under the current application and would be considered to have an instantaneous rate of I 2 generation.
[0043] Numerous methods known in the art can be utilized to generate I 2 as contemplated in this application. For in situ generation of I 2 from iodide the most common oxidants are active chlorine compounds and hydrogen peroxide. The preferred oxidant to generate I 2 from iodide is iodate. Iodate can be introduced as a salt from the following group: calcium iodate, sodium iodate, potassium iodate, magnesium iodate, zinc iodate, ammonium iodate, and the like. Molecular iodine can also be generated by dilution of formulations that contain complexed iodine or by dissolution of elemental iodine as is done in several devices utilized for water disinfection.
[0044] Suitable dry sources of iodide anion include sodium iodide, calcium iodide, ammonium iodide, magnesium iodide, zinc iodide and potassium iodide as well as other salts of iodide. Any compound that yields iodide anion upon dissolution in an aqueous environment is suitable for this application. The simple salts of iodide are preferred and have the advantage of being less costly. Additionally, they have a long shelf life in solid and liquid form.
[0045] The types of compositions contemplated under this application include liquids, gels, creams, ointments and emulsions with the proviso that oil-based creams and emulsions are not contemplated in this application. The type of composition is not a determinative aspect of this application rather the absolute and relative concentration of I 2 and complexed I 2 are the two most critical aspects of this invention. Examples of the different types of compositions are provided, by way of example, in the Examples section of this application. It is clear from these experiments that many different types of compositions are compatible with the teachings of this application.
[0046] The thickeners useful in the context of the invention are preferably taken from the group consisting of alkyl celluloses, the alkoxy celluloses, xanthan gum, guar gum, polyorgano sulfonic acid and mixtures thereof. The thickeners are chosen based on compatibility with the other formulation ingredients and desired viscosity. Generally speaking the thickener should be present at a level of from about 0.01-10% by weight, and more preferable from about 0.1-1% by weight.
[0047] Cyclodextrins are crystalline, water soluble, cyclic, non-reducing, oligosaccharides comprised of glucopyranose units. I 2 is substantially less hydrophilic than water, and therefore has the potential to be included in the cyclodextrin cavity in the presence of water. Such complexation of I 2 with a cyclodextrins reduces its capacity to evaporate. There are three classes of cyclodextrins (i.e., α, β and γ) comprised of 6, 7 and 8 glucopyranose units respectively. Cyclodextrins are potentially useful for the formulations contemplated in this application since they can bind I 2 and thereby reduce the effective vapor pressure of I 2 in a formulation.
[0048] Suitable buffers for the compositions contemplated in this application include water and hydroalcoholic mixtures buffered with glycine, phthalic acid, citric acid, phosphates, dimethylglutaric acid, acetate, succinic acid, phthalic acid, malic acid, boric acid, and the like. The commonly available salts of these agents, e.g. sodium citrate, potassium phosphate, calcium maleate, are equally suitable for use in this compositions contemplated in this application.
[0049] Generally, any dispersible conditioning agent, humectants and emollients, known to those of skilled in the art may be used in the present invention. Preferred emollients to be used in the invention are taken from the group consisting of glycerin, propylene glycol, sorbitol, lanolin, lanolin derivatives, polyethylene glycol, aloe vera, glucamate polyethoxylated glucose dioleates containing at least 100 ethoxy units in the polyethylene glycol moiety, available, polyethoxylated methyl glucose containing at least 10 ethoxy units, allantoin, alginates, monoester salts of sulfosuccinates, alphahydroxy fatty acids, esters of fatty acids, ceramides, and mixtures thereof. Broadly, the conditioning agents are used at a level of from about 0.5-20% by weight. The most preferred conditioning agents are sorbitol, mineral oil, glycerin and/or mannitol, and are usually employed at a level of from about 1-20% by weight, and more preferably from about 2-10% by weight.
[0050] Chelating agents or sequestrants can be useful stabilizing agents in the invention particularly when a complexed form of iodine is present. Commonly available chelating agents can be used in the invention including both inorganic and organic chelating agents. Organic chelating agents include alkyl diamine polyacetic acid, chelating agents such as EDTA (ethylenediamine tetracetic acid tetrasodium salt), acrylic acid and polyacrylic acid type stabilizing agents, phosphonic acid and phosphonate type chelating agents and others. Preferable organic sequestants include phosphonic acids and phosphonate salts including 1-hydroxy ethylidene-1,1-diphosphonic acid, amino [tri(methylene phosphonic acid)], ethylene diamine [tetra(methylene-phosphonic acid)], 2-phosphonobutane-1,2,4-tricarboxylic acid as well as alkali metal salts, ammonium salts, or alkyl or alkanol amine salts including mono-, di- or triethanol amino salts. Inorganic chelating agents include commonly available polyphosphate materials such as sodium pyrophosphate, sodium or potassium tripolyphosphate along with cyclic or higher polyphosphate species. Preferably, such a sequestering agent is used at a concentration ranging from about 0.05 wt % to about 0.5 wt % of the composition.
[0051] Commonly available organic acids that can be used in the invention include benzoic acid, mandelic acid, sorbic acid, citric acid, lower alkanoic acids and their food-grade salts, such as the sodium potassium or ammonium salts thereof. These organic acids, their salts, or mixtures thereof are present in the composition in an amount between about 0.010 to 0.5 percent by weight, preferably from 0.050 to 0.20 percent by weight. The presently preferred organic acids are mandelic acid, benzoic acid, citric acid and sorbic acid, with benzoic acid suitably present as sodium benzoate and sorbic acid suitably present as the free acid. Each of these acids, or their salts, and others, alone or in combinations, can be incorporated into the compositions contemplated in this invention.
[0052] The present invention demonstrates that a dose dependent application of molecular iodine reacts with Staphylococcus aureus enterotoxin superantigen and renders it incapable of binding to T-cell lymphocytes as measured by the failure of T-cells to synthesize and release various cytokines The ability of iodine to interfere with T-cell binding of superantigen in a dose-dependent fashion is a novel observation of the present invention.
[0053] The teachings and examples in this application do not make any attempt to specifically enumerate the entire prior art in the area of topical iodine preparations. Excipients that are known to be compatible with iodine may also be of use with compositions and conditions described in this application. Such excipients include surfactants, thickeners, humectants, emollients, skin conditioning agents, stabilizing agents, opacifiers, wetting agents, essential oils, chelating agents, buffers, preservatives, organic acids and fragrances.
EXAMPLES
Example 1
[0054] Nasal secretions were gathered from 10 volunteers (7 males and 3 female) after exercise in cold air (between 20 and 35° F.); four of the volunteers had colds. Dripping or blown secretions were collected in plastic graduated beakers (Fisher, Scientific) and the tops were covered with Parafilm M. The initial samples were frozen until all samples were collected. Samples were mixed with water (2 part sample to 1 part water (v/v)) and vortexed in a pulsatile manner until all samples were substantially homogeneous and uniform aliquots were able to be removed with a pipette.
[0055] Iodine crystals (ACS Reagent Grade, Sigma-Aldrich) were placed in a 1 liter volumetric flask and then 0.01N HCl was added to the flask QS to 1 liter; a rubber stopper was placed in the top of the flask to prevent evaporation. The rubber stopper had a small glass tube inserted through it; the top of this tube was sealed with parafilm. The I 2 crystals were stirred at room temperature for 3 hours with a magnetic stir bar and magnetic stir plate. After two hours the glass tube was pushed down such that the bottom of the tube was located at a point about 3 inches above the bottom of the flask. Samples of the saturated I 2 solution were withdrawn through this glass tube by using 50 mL glass syringe with an 18 gauge hypodermic needle that had a thin plastic tube (PVC ID 0.046″) attached to its end. The stopper was therefore maintained on the flask at all times. Samples of the stock I 2 solution were withdrawn and the concentration of I 2 was determined to be 330 ppm using the potentiometric method of Gottardi.
[0056] A 0.25 mL aliquots of the vortexed nasal secretions were placed in a 1 dram vial (15×45 mm) vial and a cap was placed on the top. Aliquots of a pH 5.0 citric acid buffer (100 mM) was placed in 7 dram vials (29×65 mm) and sealed by placing a thin plastic cap onto the vials. One mL of the stock I 2 solution was injected into the vials containing 1, 3, 6, 10 or 15 mL of the 100 mM citric acid buffer; this yielded solutions containing 165, 83, 47, 30 and 21 ppm I 2 . A sample (0.25 mL) was withdrawn from each I 2 solutions and injected through the plastic cap into the samples of vortexed nasal secretions; the combined samples were mixed by vortex. A control sample received 0.25 mL of citric acid buffer without any I 2 . All samples were allowed to incubate at room temperature for 10 minutes.
[0057] After ten minutes 1.0 mL of 0.5% sodium thiosulfate was added to each sample including the control. Trypticase Soya Agar (TSA) plates were inoculated by spreading 0.5 mL of each sample across the surface of the TSA plates. Plates were incubated for 24 hr at 37 degrees Centigrade. The plates were examined for the presence of bacterial colonies after 24 hours of incubation. The nasal cavity is conducive to bacterial replication since the mucopolysaccharides provide a source of nutrients; consequently, all bacteria need to be eliminated for an agent to be effective. Consequently, plates were scored as either positive (the presence of colonies) or negative (the absence of colonies). The results are shown in Table 1 and indicate that nasal secretions affect the ability of I 2 to inactivate pathogens. This result is not surprising since the mucopolysaccharides that comprise nasal secretions contain a relatively high percentage of sulphydral groups.
[0000]
TABLE 1
Effect of Nasal Secretion of I 2 Inactivation of Endogenous Nasal Bacteria
ppm I 2
Sample #
0
21
30
47
83
165
1
positive
positive
negative
negative
negative
negative
2
positive
negative
negative
negative
negative
negative
3
positive
negative
negative
negative
negative
negative
4
positive
positive
negative
negative
negative
negative
5
positive
negative
negative
negative
negative
negative
6
positive
negative
negative
negative
negative
negative
7
positive
negative
positive
negative
negative
negative
8
positive
negative
negative
negative
negative
negative
9
positive
positive
negative
negative
negative
negative
10
positive
positive
negative
negative
negative
negative
Example 2
[0058] The minimum concentration of I 2 necessary to eliminate S. aureus from the nasal cavity was evaluated in human volunteers. Thirty-five adult volunteers were used to evaluate the ability of different concentrations of I 2 to eliminate S. aureus from the nasal cavity. Specimens were taken from the anterior nares of adults by swabing the anterior 1.5 cm of each nasal vestibule with a BBL CultureSwab. The swab was rotated 4 times around the inner walls of each nasal opening and then placed into Stewart's medium and transported to the lab for evaluation. TSA II plates were inoculated with the swabs. The plates were inoculated at 37° C. in a non-CO 2 incubator. Following incubation, the TSA II plates were examined for colonies suggestive of S. aureus. S. aureus were identified using standard methods including the Gram stain and coagulase testing. The volunteers were screened for nasal carriage of S. aureus on five separate occasions, 1 week apart. Only persistent carriers (i.e., at least 80% cultures positive) were used for the test.
[0059] The test article consisted of a two component get-liquid system. The gel and liquid were mixed prior to application in the nasal cavity with a swab. The gel was prepared using USP citric acid (10% w/v), NF glycerin (10% w/v), NF carboxymethylcellulose (0.75% w/v), NF and boric acid (0.3% w/v); the pH of the gel was adjusted to 3.0 with sodium hydroxide. An aqueous mixture of USP sodium iodide (0.354% w/v) and FCC potassium iodate (0.303%) in sodium carbonate (0.2% w/v) was prepared. The I 2 treatment was prepared prior to use by mixing 9 parts of the gel with 1 part of the aqueous solution; this yielded a mixture with 300 ppm I 2 as determined by the potentiometric method of Gottardi and by thiosulfate titration.
[0060] Seven different concentrations of I 2 were used. The different I 2 treatments were prepared by mixing different amounts of the carboxymethylcellulose (CMC) gel with the aqueous mixture of iodide/iodate. Table 2 identifies the concentrations of I 2 and the relative volumes of gel-iodide/iodate solution used.
[0000]
TABLE 2
I 2 Concentration for Nasal Application
CMC Gel (mL)
9.95
9.9
9.8
9.65
9.5
9.15
9
Iodide/Iodate
0.05
0.1
0.2
0.35
0.5
0.85
1
Mixture (mL)
ppm I 2
15
30
60
105
150
255
300
[0061] Chronically colonized volunteers were treated with test article for five (4) consecutive days. On each day of treatment the volunteers the activated gel was applied before the start of the work day and then 6 hours later. The CMC gel was mixed with the iodide/iodate mixture and then applied to each of the nostrils of each volunteer with sterile cotton tipped swabs. The CMC gel was activated and then applied within 5 minutes. To apply the gel the swabs were dipped into the activated gel and then rotated inside each nostril; this was done two times for each application with each nostril. Before treatment a BBL CultureSwab was taken to confirm the presence of S. aureus ; a second BBL CultureSwabs was taken 24 hours after treatment had ended’. Volunteers were also evaluated 1 and 2 weeks after the last treatment.
[0000]
Number of Plates Positive for S. aureus
ppm I 2
15
30
60
105
150
255
300
Pre treatment
5/5
5/5
5/5
5/5
5/5
5/5
5/5
After Treatment
4/5
0/5
0/5
0/5
0/5
0/5
0/5
1 week
5/5
2/5
1/5
0/5
1/5
0/5
0/5
2 weeks
5/5
3/5
4/5
2/5
3/5
1/5
2/5
Example 3
[0062] A gel of cross-linked acrylic acid was used to evaluate the yield of I 2 versus several formulation variables. Cross-linked acrylic acid polymers have rheological properties that may render them useful for use in the nasal cavity. In addition, cross-linked acrylic acid polymers are odor free and have a high number of carboxylic acids groups on the polymer, which helps to maintain a stable acidic pH. Three different gels (B182, NoE-026, NoE-004) were prepared to explore the yield of I 2 versus different concentrations of the excipients in the formulation.
[0000]
Materials
B182
NoE-026
NoE-004
Carbopol 980 (g)
5.0
(1%)
4
(0.8%)
6.0
(1%)
Glycerin (g)
51
(10%)
50
(10%)
60
(10%)
EDTA (g)
0.5
(0.1%)
0.5
(0.1%)
0.6
(0.1%)
Boric acid (g)
0
0.5
(0.1%)
0.6
(0.1%)
10 NNaOH (ml)
5.5
(0.11%)
7
(1.4%)
12
(2%)
Water (ml)
440
(88%)
437
(87%)
505
(87%)
[0063] A beaker was charged with about 400 ml of water; the polyacrylic acid polymer of interest, e.g. Carbopol 980 NF, was then added and stirred on a Lightnin LabMaster mixer at 800-1000 rpm for 1-2 hour until the Carbopol was hydrated and then the glycerin was added. A solution containing EDTA, boric acid, and 10 N NaOH in 80 ml of water was then added to the mixture. The mixture was then stirred for 1 hour at 600 ppm and stored at room temperature and then QS to 1 liter. A stock solution of sodium iodide and sodium iodate was prepared for admixture with the gel in order to generate defined amounts of I 2 . Sodium iodide (0.60 grams) and sodium iodate (2.0 grams) was dissolved in 120 ml of water that contained 1.4 ml of 10 N NaOH. The final pH of the gels was between 4.5 and 6.0.
[0064] One ml of gel was mixed with 1.0 ml of the stock iodide/iodate mixture. The reactions were stopped at 0.5, 1.0, 2.0, and 4.0 minutes. The gels were then extracted with 10 ml of chloroform and 50 ml of a 1.0 N phosphate buffer pH 4.8 that contains 300 grams of sodium sulfate per liter. The absorbance at 520 nm was measured in a Schimadzu UV-1602 spectrophotometer. Gel NoE-026 was tested prepared freshly and compared to NoE-026 gel stored at 40° C. for 4 months. The yield of I 2 was above 50% in all instances; storage of the gels did not appear to impact the yield of I 2 . The rate of the reaction between iodide and iodate is known to be diffusion controlled and it is not surprising that the yield of 12 was not a function of time.
[0000]
Time (min)
0.5
1
2
4
Yield (%)
B182
63.7
66.9
66.0
69.4
NOE-004
64.3
65.0
58.6
59.3
NoE-026 (room temp.)
65.5
73.5
67.1
63.9
NoE-026 (4 months at 40° C. )
65.0
65.5
64.0
60.5
Example 4
[0065] The perceived I 2 odor of the formulations contemplated in this application bear directly on utility. The actual potential to generate a detectable odor from I 2 in a particular formulation must be measured and cannot be predicted for most formulation matrices other than water. This experiment provides a quantitative means of characterizing the perceived odor from the complex compositions contemplated in this application based upon the I 2 odor perceived by humans in an aqueous medium.
[0066] Several different concentrations of pure I 2 in 0.1N HCl were prepared by dissolution of I 2 crystals (Sigma-Aldrich Cat No. 266426-250G) in a glass volumetric flask with stopper in place. A 1 inch strip of potassium iodide starch paper (Whatman International, Ltd, Cat No. 2602-500A) was completely moistened with distilled water and vertically aligned flush to the surface of the inside of a 50 mL self-standing graduated plastic tube (Corning Cat No. 430897). Once the start paper was adhered to the inner side of the wall 150 μl of the I 2 solutions were transferred into the bottom of the plastic tube; the bottom section of these tubes are conical in shape and hold this volume of fluid in a relatively well defined area. Once the samples were transferred into the graduated plastic tube the top was immediately screwed on and a stopwatch was started. The time required for the starch paper to turn blue was recorded in seconds.
[0000]
Starch Paper Coloration from I 2 Vapor
I 2 Conc.
12.25
22.5
55
110
165
220
250
275
330
(ppm)
Average
>120
>120
114
80.2
75.6
70.3
67.8
62.1
60.9
Time
(sec)
[0067] Five volunteers (3 male; 2 female) were used to evaluate the odor from the aqueous solutions of I 2 . An odor free room not adjacent to a laboratory, cafeteria or bathroom was used for the evaluation. The individuals selected to evaluate the iodine odor did not have colds or allergies. Tests were conducted in the morning and volunteers were instructed to shower on the morning of the test and not to use lotions or after shave on that morning. The volunteers were instructed to identify any sample that provided an unpleasant odor. None of the volunteers detected any odor at I 2 concentrations of 22.5 ppm or less. All of the volunteers were able to detect the presence of a aroma above 55 ppm but this odor was not deemed to be objectionable (4 out of 5 volunteers) until the concentration of I 2 was 275 ppm and above.
Example 5
[0068] This experiment demonstrates that a dose dependent application of I 2 reacts with superantigens, such as Staphylococcus aureus enterotoxin B (SEB), rendering them incapable of binding to T-cell lymphocytes. Stimulation of T-cells by superantigen binding is required for cytokine synthesis. The inventors were investigating methods of disinfecting cultured mammalian cells to kill bacteria or fungi/yeast without killing the mammalian cells. The mammalian cells chosen were human peripheral blood leukocytes (PBL) collected fresh using BD vacutainer CPT cell preparation tubes with sodium citrate. Previously described procedures were used to yield highly enriched lymphocytes, which include both B- and T-cells. Staphylococcus aureus was obtained from a local hospital on an agar slant. The S. aureus isolate was from a patient suffering from food poisoning. The S. aureus isolate expressed SEB.
[0069] Lymphocytes (10 6 /mL counted by hemocytometer) were suspended in Hanks' balanced salt solution with HEPES (3 mM) and 2% (v/v) fetal bovine serum and varying amounts of S aureus were added ranging from 103-105 cfu/rnL and assays were incubated at 37° C. for one hour. After one hour 500 microliters of I 2 was added to various cultures in various concentrations (0.1-100 ppm free molecular iodine, final concentration). After an additional 10 minutes 200 microliters of a 2N solution of sodium thiosulfate was added; 100 microliter aliquots were removed from each reaction vessel and streaked for isolation of S. aureus on nutrient agar plates; reaction tubes were then returned to the incubator (37° C.). The results were somewhat predictable. Lymphocyte- S. aureus (10 3 -10 5 ) cultures treated with 0.1-10 ppm of the iodine had viable S. aureus that grew on the agar.
[0070] Reaction vessels with 10-100 ppm I 2 had no viable S. aureus . However, the surprising discovery occurred three days later. Each reaction vessel was examined using the microscope/hemocytometer to observe and count the number of lymphocytes. Reaction vessels with 10 5 S. aureus and 10-ppm iodine had 100-fold more lymphocytes (˜10 8 /mL) than similar cultures treated with 100 ppm I 2 . These results were confusing. We knew that the S. aureus strain used in these experiments expressed SEB, a known superantigen. We predicted that something triggered the lymphocyte proliferation at 10 ppm I 2 but not at 100 ppm I 2 and assumed that it was S. aureus SEB. The key assumption was that I 2 blocked lymphocyte proliferation at higher I 2 concentrations because somehow the I 2 blocked a reaction between S. aureus and lymphocytes. These results prompted us to perform experiments that might explain the proliferation result.
[0071] We decided that the most direct way to test our hypothesis was to mix S. aureus SEB with I 2 ; neutralize the mixture with sodium thiosulfate and then treat fresh lymphocytes with the neutralized solution. We could then measure cytokine synthesis following interaction with T-cells. We chose to measure interleukin 6 (IL-6) and interferon gamma (IFN-γ) as markers of T-cell stimulation based on published studies. All reagents including S. aureus SEB (US Biological, Swampscott, Mass.; cat# S7965-35A), purified mouse anti-enterotoxin B monoclonal IgG antibody, purified mouse monoclonal IgG to interferon IFN-γ and the cytokine IL-6 were purchased from commercial sources. The control experiments were conducted using fresh PBL and 1 pg/mL SEB. Two site capture ELISA immunoassays in 96 well microtiter plates were purchased as commercial kits IFN-γ (eBioscience, San Diego, Calif.; cat#88-7314-76) and IL-6 (eBioscience, San Diego, Calif.; cat#88-7066). The enzyme used was horseradish peroxidase (HRP) and the linkers were biotin-streptavidin, substrate was tetramethylbenzidine (TMB); color development was terminated with sulfuric acid and color was read at 570 nm with a Schimadzu UV-1602 spectrophotometer. The optical density of each unknown was determined and compared to the concentrations of IL-6 and IFN-γ obtained using standards supplied with each commercial kit.
[0072] Standard curves were prepared for both IL-6 (6-200 pg/mL) and IFN-γ (0.1-3.0 ng/mL). I 2 was prepared fresh at a stock concentration of 330 ppm/mL and aliquots were added to various reaction tubes to achieve the desired final iodine concentration.
[0073] SEB (10 microliters) was mixed undiluted with I 2 (10 microliters) and buffer (1M citrate buffer pH 5.0) at room temperature for 30 minutes. After 1 hour, 5 μL of 2N sodium thiosulfate was added to all samples and gently agitated to insure complete neutralization of the I 2 . PBL cells, the iodinated SEB were gently mixed in reaction tubes and placed at 37° C. After 1 hour, cells were pelleted and 5 μL was removed from the supernatant of each tube and analyzed for the presence of cytokines IL-6 and IF-γ in the cell-free fraction. Samples of the supernatant were also collected at 12, 24, 36 and 48 hours and analyzed for IL-6 and IFN-γ. The sample wells of the ELISA immunoassays 96 well microtiter plates were washed two times after binding of label to insure removal of all of the sodium azide used to preserve SEB. The results of these assays (shown below) demonstrate that at a concentration of >25 ppm I 2 inhibits the ability of superantigens to activate T-cells synthesis of cytokines.
[0074] Concentration of IL-6 (pg/ml) Versus Time
[0000]
Hours
I 2 (ppm)
0
12
24
36
48
0
<6
14
65
104
125
0.1
<6
16
71
111
134
2
<6
19
68
89
121
10.3
<6
18
74
96
129
14
<6
20
69
99
131
27.5
<6
21
72
100
136
55
<6
<6
<6
<6
<6
110
<6
<6
<6
<6
<6
[0075] Concentration of IF-γ (ng/mL) Versus Time
[0000]
Hours
I 2 (ppm)
0
12
24
36
48
0
<0.1
0.3
0.91
1.7
2.3
0.1
<0.1
0.35
0.96
1.65
2.4
2
<0.1
0.34
0.9
1.59
2.25
10.3
<0.1
0.32
0.89
1.68
2.44
14
<0.1
0.29
0.96
1.66
2.35
27.5
<0.1
0.31
0.90
1.69
2.53
55
<0.1
<0.1
<0.1
<0.1
<0.1
110
<0.1
<0.1
<0.1
<0.1
<0.1 | A method for killing or substantially eradicating a pathogen in the upper respiratory tract of a mammal is disclosed. The method comprises generating molecular iodine (I 2 ) in situ using an oxidant-reductant reaction with a minimum concentration of at least about 25 ppm of I 2 and I 2 comprises at least 40% of the total iodine atoms. A method for inhibiting superantigens using molecular iodine is also disclosed. | 68,678 |
BACKGROUND OF THE INVENTION
This invention relates to plastic article shaping or the like and specifically to a tire building drum or mandrel and apparatus associated therewith.
In the building of a radial tire, a plurality of layers or plies of stock are positioned upon a rotatable drum or mandrel until such time as the material on the drum is forced to assume a torroidal shape. The cap belts and base stock are then placed upon the tire body after which they are subjected to a stitching operation. The then finished uncured green tire is ready for removal from the building drum or mandrel and the delivery of same to a storage or handling area or to a conveyor for subsequent manufacturing steps, such as vulcanizing. Uncured tires, especially truck tires and off-the-road machinery tires, by virtue of their weight and physical characteristics, are not only delicate but also cumbersome to the point that manually handling said tires becomes a laborious task.
The strength and ability of a green tire to withstand physical abuse is minimal to the extent that said tire is not capable of supporting its own weight when placed upon a planar surface. Thus, any surface that is adapted to receive green uncured tire bodies must be of either a flexible nature or have a dished or contoured surface that can readily conform to that of the tire or tires being moved. Furthermore, the physical properties of green rubber are those of a sticky, easily distorted plastic substance which will flow, become distorted, adhere to foreign substances and permit foreign bodies to become embedded therein.
In the tire building and processing field, the usual practice is to have the machine operator effect the removal of the tire and the delivery of same to a handling or storage area or to place same upon a conveyor to permit subsequent manufacturing steps or operations. Such a procedure does not entail any undue hardship or burden upon the operator as long as small size tires for passenger cars are being manufactured. In the manufacture of large truck tires, especially the all steel radial variety, as well as large off-the-road machinery tires, it has been customary to resort to the use of slings and cranes. The use of a sling, in combination with a hoist or crane, is time consuming and the utilization of same as a supporting means still requires great physical exertion on the part of the operator in effecting the manipulation and removal of such a tire from the building drum and if dropped, the tire becomes badly distorted due to its ductility and if moved in contact with the floor, said tire's surface will become contaminated with foreign matter.
SUMMARY OF THE INVENTION
The present invention is directed to a supporting device that is disposed adjacent a tire building drum for receiving from said drum a green uncured tire. The supporting device constitutes a dolly or caddy that is positioned near the head stock of the tire building machine and beneath the building drum or mandrel so as to be capable of receiving and supporting the green tire as it is either being removed from the drum or being positioned upon the drum.
The tire caddy or dolly of the present invention prevents the green uncured tire from becoming distorted through the use of a supporting surface of adequate area for contacting the tire. This arrangement reduces fatigue of the operator of the tire building machine, greatly reduces loading and unloading time for said machine, and greatly reduces the danger of injury inasmuch as the operator is not required to lift and manhandle a heavy green uncured tire. Thus, an object of the present invention is to provide a support having sufficient area to receive a green uncured tire from a tire building machine and/or support a green uncured tire while it is being positioned upon a tire building machine and to transport same to a position where it may be easily transferred to a subsequent handling means.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is a side elevational view of a tire supporting device of the present invention in the vertically extended position;
FIG. 2 is a side elevational view showing the tire supporting device of FIG. 1 in a horizontally extended position;
FIG. 3 is a top plan view of the tire supporting device of the present invention;
FIG. 4 is a vertical sectional view of the tire supporting device, the view being taken on line 4--4 of FIG. 3;
FIG. 5 is sectional view of the tire supporting device, the view being taken on line 5--5 of FIG. 1;
FIG. 6 is a cross sectional view of the tire supporting device, the view being taken on line 6--6 of FIG. 3;
FIG. 7 is an end view of the tire supporting device with certain portions removed and other portions shown in sections in the interest of clarity, the view being taken on line 7--7 of FIG. 4; and
FIG. 8 is a detailed vertical sectional view of a portion of the drive mechanism, the view being on the line 8--8 of FIG. 4.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to the drawings, there is shown in FIGS. 2 and 4, a tire supporting device of the present invention that is adapted to be positioned adjacent the building drum or mandrel end of a tire building machine, not shown. The supporting device includes a base member 10 having formed integrally therewith vertical upright elements 12 that are of channel configuration to define trackways 14. The supporting device includes a pair of vertically disposed side plate members 16 which are maintained in spaced parallel relation with one another by means of a transverse bracing member 18. The side plate members 16 are each provided with upper and lower rollers 20 which are positioned in the trackways 14 for movement therein under the action of a fluidic elevating device 22 of the rolling lobe pneumatic type which engages the lower surface of the transverse bracing member 18. The vertical upright elements 12 have segments 23 thereof projecting beyond trackways 14 and said segments 23 are provided with a plurality of spaced apertures 24 which are designed to receive a stop pin 26. The side plate members 16 each have mounted thereon a horizontally disposed boss or lug 28 that is drilled and tapped to receive a threaded pin 30 which, in turn, has a jam nut 32 provided thereon beneath the head 34. The boss or lug 28 and the threaded pin 30 are mounted on the side plate members 16 so as to be in vertical alignment with the segments 23 and the stop pin 26, so that upon the elevation of the side plate members 16 under the action of the elevating mechanism 22, the head 34 of the pin 30 will engage the stop pin 26 to limit the upward travel of the side plate members. The side plate members 16 terminate forwardly of the elevating mechanism 22 in a pair of reduced segments 36 which are provided with transversely extending bottom or bracing member 37, FIG. 4.
The segments 36 each have mounted therein a pair of spaced pins 38, FIGS. 2 and 3, which carry on their inner ends a roller 40. The rollers 40 support an elongated slotted plate 42 with the rollers being positioned within an elongated slot 44 in the center of the plate 42 so that said plate will be capable of being advanced and retracted with respect to the side plate members 16 shown in FIGS. 1 and 2. The plates 42, FIG. 2, in turn are each adapted to carry and support an inner plate 46 that is provided with a plurality of upper and lower rollers 48 that engage the upper and lower edges of said slotted plate 42. Thus, the inner plate is capable of being advanced and retracted with respect to the slotted plate 42 and the side plate members 16. The forward end of the slotted plate 42 is formed with stops 49 which are engaged by the forward rollers 48 on the inner plate member 46. Thus, movement of the inner plate 46 in a direction away from the segments 36 will cause the rollers 48 to engage the stops 49 and result in the movement of the slotted plate 42 under the action of said inner plate 46.
The forward end of the inner plates 46 are connected to one another by a transverse bracing member 50 with the rear ends of said inner plates 46 being connected by a plate 52 that is formed with a recessed or cut out portion which encircles the elevating mechanism 22. The forward bracing member 50 in conjunction with the plate 52 tends to maintain the inner plate members 46 in relatively rigid spaced parallel relation to one another. In addition, the inner plate members 46 have mounted thereon a contoured or dish shaped supporting plate-like element 54 which is adapted to receive and support a green uncured tire when same is being removed from or being positioned upon a tire building drum or mandrel of the tire building machine. The contoured shaped plate member 54 is provided at each side portion thereof with a depending flange 56, FIG. 4, which flanges are formed with a pair of spaced vertically extending slots 58 that, in turn, are adapted to receive pins 60 which are carried by the inner surface to the inner plates 46. The pins 60 are threaded to receive suitable nuts 62 so that said contoured shaped plate 54 may be vertically adjusted with respect to the inner plate members 46. This arrangement defines the lower limit of travel of the contoured shaped member 54 with respect to the inner plate members 46.
The inner plates 46 each have mounted on the inner surface thereof, an elongated rack bar or member 64 which is engaged by gears 66 that are mounted on a transversely extending shaft 68. The shaft 68 also has mounted thereon for rotation therewith a pinion gear 70. The bracing member 37 of the reduced segments 36 of the side plate members 16 is provided with a supporting plate 72, FIG. 4, and there is mounted thereon a pair of spaced pillow blocks 74 and 76 which constitute supports for the shaft 68. A second shaft 78 is disposed in spaced parallel relation to shaft 68 and has one end thereof supported by a pillow block 80. The second shaft 78 has mounted on the other end thereof a gear 82 which is engaged by a rack 84 that is interposed between said gear and a roller 86 mounted on the lower portion of the pillow block 80. The rack bar 84 is connected to a piston 88 which is disposed within a cylinder 90 mounted on the bracing member 37.
In the use of the supporting device of the present invention, the base member 10 is positioned adjacent a tire processing machine and the contoured shaped supporting element 54 is then vertically adjusted with respect to the inner plates 46 by means of the nuts 62 on the pins 60. Thus, the supporting element is adjusted depending upon the type of work that is to be performed, such as building a tire on a mandrel or finishing the building of a green uncured tire or the reconditioning of a used tire wherein same is to be retreaded or the like. In this manner, the supporting element 54 is adjusted to define its lower limit of travel. It is to be understood that the device of the present invention is readily usable in positioning completed or partially completed tires on the process machine in the same general manner that said items may be removed from said machine.
Upon the completion of the building of a tire and in order to effect its removal from the tire processing machine, the elevating mechanism 22 is actuated by fluidic means or the like so as to raise the transverse bracing member 18 in conjunction with the side plate members 16. In their elevated position, the plate members 16 through the head 34 of the adjusting pin 30 engages the stop pin 26 that has been positioned in one of the apertures 24 in the vertical upright elements 12, to limit the upward movement of the tire supporting element 54. This upward movement of the contoured supporting element 54 should bring said element into engagement with the lowermost portion of the tire on said machine so as to facilitate the removal of the tire therefrom.
The contoured supporting element 54 being in engagement with the green uncured tire and supporting same, the tire can then be effectively removed from the mandrel or holding means of the tire processing machine after which the cylinder 90 can be energized by suitable fluid means for moving the piston 88 outwardly from said cylinder and in turn, moving the rack bar 84 and the gears 82-70 and 66. The rotation of the gear 66 will cause the rack bar or member 64 to advance the inner plates 46 and to extend same with respect to the reduced segments 36 of the side elements 16 to the position as shown in FIG. 2. The extension of the inner plates 46 will cause the slotted plate 42 to be advanced by the rollers 48 engaging the stops 49. During this movement, the green uncured tire is supported by the contoured shaped plate element 54 and effectively moves said tire clear of the tire processing machine to a position wherein said tire can then be effectively transferred from said contoured supporting plate to a suitable storage area or to a conveyor for further processing.
Upon the removal of the green uncured tire from the contoured supporting element 54, the source of air to the cylinder 90 is reversed, so as to effect a retraction of the piston within said cylinder, which movement causes a retraction of the rack bar 84 and the inner plate members 46 and slotted plate 42 to a position within the reduced segments 36 of the side plate members 16 wherein the contoured supporting plate 54 then assumes the retractive position as shown in FIG. 1. The supporting plate 54 in conjunction with the side plate members 16 can then be lowered to the position as shown in FIG. 4 by permitting the source of fluid directed to the elevating mechanism 22 to return to a suitable sump or the like so that the rollers 20 will then move downwardly in the trackways 14 until the side plate members 16 engage the base 10.
Although, the foregoing description is necessarily of a detailed character, in order that the invention may be completely set forth, it is to be understood that the specific terminology is not intended to be restrictive or confining, and that various rearrangements of parts and modifications of detail may be resorted to without departing from the scope or spirit of the invention as herein claimed. | A supporting and handling device located adjacent a tire processing machine for positioning and/or removing a tire, either in its cured or uncured state, to or from the holding device of said machine. The device is provided with an adjustable contoured surface that may be raised and lowered for handling said tire while same is being positioned upon or removed from the building drum or mandrel and while being moved to a position for further handling. | 14,382 |
TECHNICAL FIELD
The invention relates to semiconductor modules.
BACKGROUND
For making electrical contact with and connecting up a semiconductor module, electrical connections are required which have to be led through the housing to the outer side of the housing. Through the corresponding bushings on the housing, water vapor and/or other substances can penetrate into the interior of the semiconductor module, which can lead to impairment of the elements situated in the module, for example as a result of corrosion. Although semiconductor modules are potted with silicone gels for various reasons, said gels do not constitute a particularly good barrier for water vapor or other harmful substances, and so the problem outlined is scarcely improved.
In further module designs, that region of the housing interior which is situated above the silicone gel is filled with a hard potting composed of epoxy resin that bears on the silicone gel. Although such modules are less permeable to gases and water vapor than modules which contain a silicone gel but no hard potting, the hard potting encloses the silicone gel together with the housing. Silicone gels have a high coefficient of cubical thermal expansion, which, in the event of the semiconductor module being subjected to high loads resulting from temperature cycles, can give rise to an excess pressure or a reduced pressure which can cause damage in the interior of a module. In the case of excess pressure in the gel, it is possible for gel to escape between baseplate and housing. In the case of reduced pressure, cracks can form in the gel. Apart from that, in the corresponding commercially available modules, the purpose of the additional hard potting is to mechanically stabilize components in the interior of the semiconductor module.
SUMMARY
The object of the invention is to provide a semiconductor module which is well protected against corrosion and/or other damage which can be caused by moisture and/or other harmful substances surrounding the semiconductor module. A further object is to provide a method for producing such a semiconductor module.
According to an embodiment of a semiconductor module, the semiconductor module comprises a housing having two outer wall sections arranged at opposite sides of the housing, a cover extending from one of the outer wall sections to the other of the outer wall sections, and a first shaft wall arranged between the outer wall sections and spaced apart therefrom, said first shaft wall delimiting a first shaft. Furthermore, the semiconductor module comprises a circuit carrier having a top side, and also a semiconductor chip arranged in the housing and on the top side of the circuit carrier. An electrically conductive first connection element runs through the first shaft and extends out of the housing. A first potting compound is situated between the circuit carrier and the cover and partly between the first connection element and the first shaft wall, said first potting compound sealing the first shaft in interaction with the first connection element. The first shaft wall has, at its side facing the circuit carrier, a lower end dipping into the first potting compound. Optionally, the first potting compound can in this case extend continuously from the circuit carrier as far as above all semiconductor chips cohesively connected to the circuit carrier. In so far as said semiconductor chips are connected by bonding wires at their sides facing away from the circuit carrier, the first potting compound, likewise optionally, can also extend continuously beyond all of said bonding wires.
Furthermore, a second potting compound is situated between the first potting compound and the cover and partly between the first connection element and the first shaft wall, said second potting compound likewise sealing the first shaft in interaction with the first connection element. Moreover, one or a plurality of volume regions which directly adjoin the first potting compound in each case and are filled with gas are present in the housing. The gas situated in the volume region or in the volume regions compensates for a change—caused e.g. by a change in temperature—in the volume of the first potting compound, such that the elements situated in the module are not subjected to any disturbing loads.
The second potting compound acts as a diffusion barrier in particular against the penetration of water vapor into the interior of the module housing. For this purpose, the second potting compound can optionally have a diffusion coefficient for water vapor which is less than 5*10 −9 m 2 /s (=5E-9 m 2 /s), relative to a temperature of 40° C.
The penetration of water vapor into the interior of the module housing is substantially determined by the lengths and the cross sections of the second potting compound in the regions in which it closes the shafts, and by the water vapor diffusion coefficient of the second potting compound. Overall, a desired minimum impermeability of the semiconductor module against the penetration of water vapor into the interior of the module housing can be set by means of a combination of the parameters mentioned. The statements above analogously also apply to the penetration of harmful substances other than water vapor into the interior of the module housing.
In order to produce such a semiconductor module, an integral or multipartite housing is provided, having two outer wall sections, a cover and a first shaft wall. The outer wall sections are situated at opposite sides of the housing. A circuit carrier having a top side, a semiconductor chip and an electrically conductive first connection element are likewise provided. The semiconductor chip, the circuit carrier, the housing and the first connection element are arranged relative to one another in such a way that the cover extends from one of the outer wall sections to the other of the outer wall sections, that the first shaft wall is arranged between the outer wall sections and delimits a first shaft, that the semiconductor chip is arranged in the housing and is arranged on the top side of the circuit carrier, and that the first connection element runs through the first shaft and extends out of the housing.
A first potting compound is filled into the interior of the housing and subsequently crosslinked, such that the crosslinked first potting compound is arranged between the circuit carrier and the cover and partly between the first connection element and the first shaft wall and seals the first shaft in interaction with the first connection element, wherein the first shaft wall has a lower end dipping into the first potting compound.
After the crosslinking of the first potting compound, a second potting compound is filled into the interior of the housing in such a way that the second potting compound is arranged between the first potting compound and the cover and partly between the first connection element and the first shaft wall and seals the first shaft in interaction with the first connection element, and that one or a plurality of gas-filled volume regions directly adjoining the first potting compound in each case remain in the housing.
Those skilled in the art will recognize additional features and advantages upon reading the following detailed description, and upon viewing the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
Various possible configurations of the invention are explained below with reference to the accompanying figures. The components shown in the figures are not necessarily illustrated to scale with respect to one another, rather importance has been attached to illustrating the principles of the invention. Furthermore, in the figures identical reference signs designate identical elements or elements corresponding to one another.
FIGS. 1A to 10 show different steps during the production of a semiconductor module having a solid baseplate.
FIGS. 2A to 2C show different steps during the production of a further semiconductor module having a solid baseplate.
FIG. 3 shows a semiconductor module which differs from the semiconductor module in accordance with FIG. 10 by virtue of the absence of a baseplate.
FIG. 4 shows a semiconductor module wherein shafts each having an electrical connection element arranged therein are connected to one another by a connecting channel.
FIG. 5 shows a semiconductor module which differs from the semiconductor module in accordance with FIG. 3 in that the second potting compound does not extend as far as that side of the housing cover which faces the circuit carrier.
FIG. 6 shows a semiconductor module which differs from the semiconductor module in accordance with FIG. 4 in that the second potting compound does not extend as far as that side of the housing cover which faces the circuit carrier.
FIG. 7 shows an integral housing of a semiconductor module.
FIGS. 8A to 8C show different steps during the production of a semiconductor module having a multipartite housing.
FIG. 9 shows a comparative module which is constructed in accordance with a semiconductor module of the present invention, but in which a sensor for detecting the relative air humidity is inserted into a cavity produced in the first potting compound.
FIG. 10 shows a diagram which reveals, for two different semiconductor modules constructed according to the present invention, wherein the semiconductor chip was replaced in each case by an air-filled cavity, the profile of the relative air humidity present in the cavity when the comparative module is introduced into a moist atmosphere.
FIG. 11 shows a horizontal section through the arrangement in accordance with FIG. 6 in a sectional plane E-E running through the shafts and the volume regions.
DETAILED DESCRIPTION
FIG. 1A shows a cross section through a partly finished semiconductor module 100 . The semiconductor module 100 comprises a housing 6 , one or a plurality of substrates 2 , one or a plurality of semiconductor chips 8 , and one or a plurality of electrically conductive connection elements 91 , 92 .
The housing 6 has two outer wall sections 61 arranged at opposite sides of the housing 6 , a cover 62 extending from one of the outer wall sections 61 to the other of the outer wall sections 61 , and one or a plurality of shaft walls 63 arranged between the outer wall sections 61 and spaced apart therefrom. Furthermore, one or a plurality of shafts 65 are present, each of which is delimited by at least one shaft wall 63 . The electrically conductive connection elements 91 , 92 , which extend out of the housing 6 , run in each case through one of the shafts 65 . In this and all other semiconductor modules 100 of the invention, one, a plurality or all of the connection elements 91 , 92 of the semiconductor module 100 can be spaced apart from the shaft wall 63 situated closest to the relevant connection element 91 , 92 .
Independently of this, a shaft wall 63 can optionally enclose one or a plurality of the connection elements 91 , 92 in a ring-shaped manner. Likewise, there is also the possibility of a shaft 65 being delimited by an outer wall section 61 and a shaft wall 63 in such a way that said outer wall section 61 and said shaft wall 63 together enclose one of the connection elements 91 , 92 in a ring-shaped manner.
The substrate 2 comprises an electrically insulating circuit carrier 20 having a top side 201 facing the housing 6 . The semiconductor chip 8 is arranged in the housing 6 and on the top side 201 of the circuit carrier 20 . In other configurations, an electrically conductive circuit carrier 20 , for example composed of metal, can also be used. A structured upper metallization layer 21 is applied to the top side 201 of the circuit carrier 20 , and a lower metallization layer 22 , which can be unstructured or structured, is applied to the underside 202 of the circuit carrier, said underside being opposite the top side 201 . The substrate 2 can be, for example, a DCB substrate (DCB=direct copper bonded), a DAB substrate (DAB=direct aluminum brazed) or an AMB substrate (AMB=active metal brazed).
The semiconductor chip or semiconductor chips 8 is/are mounted on the top-side metallization layer 21 and mechanically and optionally also electrically conductively connected by means of a connecting layer 81 , for example a solder, an electrically conductive adhesive or a pressure-sintered silver-containing connecting layer. The semiconductor chips 8 can be, for example, arbitrary combinations of controllable semiconductor chips such as transistors, MOSFETs, IGBTs, thyristors, JFETs (inter alia also HEMTs [HEMT=High Electron Mobility Transistor]), and/or non-controllable semiconductor chips such as power diodes. The semiconductor chips 8 can be embodied as power semiconductor chips having high nominal currents, for example more than 10 A or more than 50 A, and/or having high rated reverse voltages of, for example, 400 V or more. In addition, the basic area of each of the semiconductor chips 8 can be greater than 2.4 mm×2.4 mm, or greater than 5 mm×5 mm.
Bonding wires 5 are provided for connecting up the semiconductor chips 8 , said bonding wires being bonded to sections of the top-side metallization layer 21 . Instead of bonding wires 5 , metallic clips can likewise be used, which are connected for example to the top sides of the semiconductor chips and/or to the top-side metallization layer 21 by means of a solder, an electrically conductive adhesive or a layer comprising a sintered, electrically conductive powder.
In order to externally connect the power semiconductor module, for example to a voltage supply, a load, a control device or the like, electrical connection elements 91 , 92 are provided, which can be electrically conductively and/or mechanically connected to sections of the top-side metallization layer 21 . Only some of the connection elements 91 , 92 of the semiconductor module 100 are illustrated by way of example. In principle, the number and the design of the connection elements 91 , 92 can be chosen as desired and can be adapted to the electrical circuit to be realized in the semiconductor module 100 . Some of the connection elements 91 , 92 can serve e.g. to connect the semiconductor module 100 to a supply voltage, for example an intermediate circuit voltage or an AC voltage to be rectified. A load, e.g. an inductive load, such as a motor, for example, can be connected to other connection elements 91 , 92 in order to drive it by means of the semiconductor module 100 . Still other connection elements 91 , 92 can serve as control inputs or as control outputs, or as output connections for outputting signals representing information regarding the status of the power semiconductor module 100 .
In order to electrically conductively connect the connection elements 91 , 92 to the upper metallization layer 21 , they can be soldered, welded, sintered or electrically conductively adhesively bonded on to the upper metallization layer 21 or can be connected thereto by wire bonding. The connection elements 91 , 92 can be embodied e.g. as straight or bent metallic pins, as stamped and bent metallic sheets, as small tubes, as electrically conductive contact springs, etc. In the case of pins, the latter can also be inserted into sleeves which are soldered, welded or electrically conductively adhesively bonded on to the upper metallization layer 21 . Independently of the configuration of the other connection elements 91 , 92 of a semiconductor module 100 , a connection element 91 , 92 such as e.g. the connection element 92 shown can also have a plurality of connection legs at which it is electrically conductively connected to the upper metallization layer 21 .
At their free ends spaced apart from the substrate 2 , the connection elements 91 , 92 can be configured arbitrarily depending on the desired electrical connection technique, e.g. as shown as screw-on openings, but also as soldering contacts, as spring contacts, as press-fit contacts, as clamping contacts, etc.
Independently of their configuration, one or a plurality of connection elements 91 , 92 can, as shown, be arranged between two outer wall sections 61 situated at opposite sides of the housing 6 and can be spaced apart therefrom.
Optionally, the substrate 2 can be arranged on a solid baseplate 1 and at its lower metallization layer 22 can be mechanically connected thereto using a connecting layer 42 . The connecting layer 42 can be e.g. a solder layer, a pressure-sintered, silver-containing connecting layer or an adhesive layer. The baseplate 1 itself can be embodied as a metallic plate, for example composed of copper, aluminum or an alloy comprising at least one of said metals, or composed of a metal-matrix composite material (MMC). Optionally, it can also have a coating for example in order to improve the solderability or the adhesion of a sintered connecting layer. Independently of its configuration, the baseplate 1 can have a thickness of at least 1 mm, at least 2 mm or at least 3 mm. The lower metallization layer 22 can have for example a thickness of less than or equal to 1 mm or of less than or equal to 0.63 mm.
A unit comprising a substrate 2 previously populated—in the manner explained—with one or a plurality of semiconductor chips 8 and one or a plurality of connection elements 91 , 92 , which substrate 2 can optionally be connected to a baseplate 1 , can then be connected to a housing 6 . For this purpose, the housing 6 can be embodied integrally and have a shaft 65 for each of the connection elements 91 , 92 , said shaft 65 being embodied such that, when the housing 6 is placed on to the unit, the connection elements 91 , 92 can be pushed into the associated shafts 65 , such that their free ends are accessible on the outer side of the housing 6 for the purpose of making electrical contact with the connection elements 91 , 92 .
The housing 6 placed onto the unit can be connected to the unit with the aid of a connecting means 9 , for example an adhesive.
After the emplacement of the housing 6 , optionally also after the connection of the unit to the housing 6 , a first potting compound 51 , for example a silicone gel, can be filled into said housing. For this purpose, the first potting compound 51 can be filled into the interior of the housing 6 via a filling shaft 64 , which is formed by one of the shafts 65 , such that said potting compound is distributed on the substrate 2 . In this case, the amount of the first potting compound 51 is dimensioned such that the ends 631 of the shaft walls 63 facing the carrier 20 dip into the first potting compound 51 and also remain dipped therein after the first potting compound 51 has subsequently been cross-linked in order to reduce or eliminate the flowability thereof. In this case, the crosslinking can be effected by an increase in temperature, by long storage under normal ambient conditions or by irradiation with ultraviolet light. The result is shown in FIG. 1B . In this and all other configurations of the invention, the crosslinking can be effected such that only a low degree of crosslinking is present, with the result that the first potting compound 51 is only incipiently gelled in order to close the shafts 65 to an extent such that a second potting compound 52 , if the latter is subsequently filled into the shafts 65 as explained further below, can pass only as far as the closure locations produced by the first potting compound 51 and thus remains in a position above the first potting compound 51 .
By virtue of the fact that the ends 631 of the shaft walls 63 facing the carrier 20 are dipped into the first potting compound 51 even after the crosslinking thereof, the first potting compound 51 seals the relevant shaft 65 in interaction with the connection element 91 , 92 situated in said shaft 65 if a second potting compound is subsequently filled therein, as described below. The filling shaft 64 is also correspondingly sealed by the first potting compound 51 in the region of its ends 631 . In principle, the dipping depth t63 after the crosslinking of the first potting compound 51 in the case of the ends 631 —facing the carrier 20 —of the shaft walls 63 of one, a plurality or each of the shafts 65 (including the filling shaft 64 ) of the semiconductor module 100 can be greater than or equal to 0.5 mm.
Independently of this, in the case of one, a plurality or each of the shaft walls 63 of the semiconductor module 100 , the distance d2 between the top side 201 and the end 631 of the relevant shaft wall 631 facing the carrier 20 can be a maximum of 4 mm or a maximum of 2 mm.
After the crosslinking of the first potting compound 51 , the shafts 65 and the optional filling shaft 64 are closed by the first potting compound 51 in each case at their ends 631 facing the carrier 20 , such that a second potting compound 52 , for example an epoxy resin or some other potting having a sufficiently high diffusion resistance or a sufficiently low diffusion coefficient for water vapor, can then be filled into the interior of the housing 6 , and forms a barrier against the penetration of water vapor and/or other harmful substances into the interior of the housing 6 . In this and all other configurations of the invention, for this purpose the second potting compound 52 can have a diffusion coefficient for water vapor which is less than 5*10 −9 m 2 /s (5E10-9 m 2 /s) at a temperature of 40° C.
In particular configurations, the second potting compound of the invention can have a diffusion coefficient for water vapor of less than 5*10 −9 m 2 /s (5E-9 m 2 /s), of less than 1*10 −12 m 2 /s (1E-12 m 2 /s), or of less than 1*10 −11 m 2 /s (1E-11 m 2 /s), in each case at 40° C. In the example shown, the second potting compound 52 has to be filled in each case individually into the individual shafts 65 and the filling shaft 64 , since these are now closed and so the second potting compound 52 , unlike the first potting compound 51 previously, cannot be distributed laterally over the interior of the housing. The second potting compound 52 , which is filled into the shafts 65 and then cured, seals the relevant shaft 65 in interaction with the connection element 91 , 92 situated in said shaft 65 . The filling shaft 64 is also sealed by the second potting compound 52 . The result is illustrated in FIG. 1C .
In all semiconductor modules 100 of the invention, the first potting compound 51 can optionally have, after crosslinking, a penetration which is greater than the penetration of the second potting compound 52 after the crosslinking thereof. Independently of this, the penetration of the finished cross-linked second potting compound 52 can be greater than the penetration of the housing 6 . The penetration is determined according to DIN ISO 2137 in each case. The first potting compound can have e.g. a penetration of at least 20, for example in the range of 30 to 90. Independently of this, the second potting compound can optionally have, likewise in all semiconductor modules 100 of the invention, e.g. a penetration of at most 20, for example in the range of 10 to 20.
Independently of this, in the exemplary embodiments of the invention explained with reference to the previous figures and also in all other exemplary embodiments of the invention, the finished cross-linked second potting compound 52 can have a penetration which ranges from the penetration of a gel to the penetration or hardness of an epoxy resin or polyester resin. By way of example, epoxy resins polyester resins, silicone resins or silicone gels are suitable as suitable second potting compounds 52 .
As is shown in FIG. 1C , the filling level of the cured second potting compound 52 , relative to the top side 201 of the circuit carrier 20 , can extend as far as above the level of the underside 622 of the housing cover 62 facing the circuit carrier 20 .
At all events, one or a plurality of volume regions 60 filled with gas, e.g. air, remain, each of which directly adjoins the first potting compound 51 , such that a change in the volume of the first potting compound 51 caused by loading as a result of temperature cycles is largely compensated for because the gas situated in the volume region or volume regions 60 can be compressed or expanded as necessary, without the elements of the semiconductor module 100 that are situated in the housing 6 being subjected to significant pressure loads in the process. In this case, a “volume region” should be understood to mean the maximum volume of a continuous gas-filled spatial region which directly adjoins the first potting compound 51 and in which the particles of the gas can move freely.
As is likewise evident from FIG. 10 , it is possible to choose the filling level of the cross-linked first potting compound 51 relative to the level of the top side 201 such that each, a plurality or all of the volume regions 60 directly adjoining the first potting compound 51 in the interior of the semiconductor module 100 have an identical or different height t60 in a vertical direction v perpendicular to the top side 201 , each of said heights being e.g. greater than or equal to 1 mm or greater than or equal to 5 mm. This ensures that for a thermally governed expansion of the first potting compound 51 enough volume is available into which the first potting compound 51 can expand.
Furthermore, FIG. 10 shows that shafts 65 —measured in a direction v perpendicular to the top side 201 of the circuit carrier 20 —have a filling level t65. In this case, the filling levels t65 of the different shafts 65 of the semiconductor module 100 can be identical or different. By way of example, in one, a plurality or all of the shafts 65 of the semiconductor module 100 , the respective filling level t65 can be at least 1 mm. This optional criterion can also be realized in all other semiconductor modules 100 of the present invention.
In order to achieve a particularly efficient effect of the volume region 60 or of the volume regions 60 , it is advantageous if, in one, a plurality or all of the shafts 65 of the semiconductor module 100 , the external dimensions b65 of the relevant shaft 65 measured parallel to the top side 201 are less than or equal to 5 mm.
FIG. 2A shows a cross section through a partly finished semiconductor module 100 , which differs from the partly finished semiconductor module 100 in accordance with FIG. 1A merely in that various shafts 65 and the filling shaft 64 are connected to one another by connecting channels 66 running horizontally. The connecting channels 66 can optionally be arranged such that all of the shafts 65 and the filling shaft 64 form a channel system via which the second potting compound 52 is distributed along the individual shafts 65 and the filling shaft 64 and seals them when it is filled into the interior of the housing 6 via the filling shaft 64 .
FIG. 2B shows the arrangement after the filling and crosslinking of the first potting compound, and FIG. 2C after the filling and curing of the second potting compound 52 .
FIG. 3 shows a cross section through a semiconductor module 100 which differs from the semiconductor module 100 shown in FIG. 10 merely in that it has no baseplate 1 and no connecting layer 42 , such as were described above, rather that the lower metallization layer 22 is exposed at the underside of the semiconductor module 100 , and that the course of the housing 6 in the connecting region with respect to the substrate 2 and also the course of the connecting means 9 have been adapted.
FIG. 4 shows a cross section through a semiconductor module 100 which differs from the semiconductor module 100 shown in FIG. 2C merely in that it has no baseplate 1 and no connecting layer 42 , such as were described above, rather that the lower metallization layer 22 is exposed at the underside of the semiconductor module 100 , and that the course of the housing 6 in the connecting region with respect to the substrate 2 and also the course of the connecting means 9 have been adapted.
FIG. 5 shows a further example of a semiconductor module 100 . The latter differs from the semiconductor module 100 in accordance with FIG. 3 merely in that the filling level of the cured second potting compound 52 , relative to the top side 201 of the circuit carrier 20 , is smaller than the distance between the top side 201 of the circuit carrier 20 and the underside 622 of the housing cover 62 facing the circuit carrier 20 .
FIG. 6 correspondingly shows a semiconductor module 100 which differs from the semiconductor module 100 shown in FIG. 4 merely in that the filling level of the cured second potting compound 52 , relative to the top side 201 of the circuit carrier 20 , is smaller than the distance between the top side 201 of the circuit carrier 20 and the underside 622 of the housing cover 62 facing the circuit carrier 20 .
FIG. 7 shows a housing 6 of a semiconductor module 100 , here on the basis of the example of the housing 6 of the semiconductor module 100 elucidated in FIG. 10 . Generally, a housing 6 of a semiconductor module 100 can be formed integrally, i.e. from a single part, and consist of any uniform material, for example a thermoplastic or a thermosetting plastic. Such a housing 6 can be produced by injection molding, for example. If permitted by the undercuts of the housing 6 to be produced, a housing 6 can be produced in one piece by injection molding. Alternatively, there is also the possibility of two or more housing parts being produced separately by injection molding and then being fixedly connected to one another, thus giving rise to an integral housing 6 . The connection can be effected cohesively, e.g. with the aid of an adhesive, by laser, ultrasonic or thermal welding, or by screwing or any other connecting techniques.
In principle, the housing 6 can be embodied integrally as explained already in the uninstalled state, i.e. in a state in which it has not yet been mounted on the above-explained unit with the previously populated substrate 2 (with or without baseplate 1 ).
As an alternative thereto, however, a housing 6 can also be assembled from two or more parts, which will be explained by way of example with reference to FIGS. 8A , 8 B and 8 C. FIG. 8A shows at the bottom a unit comprising a previously populated substrate 2 and a baseplate 1 connected to the substrate 2 , as was described above with reference to FIGS. 1A to 10 . FIG. 8A also shows a housing 6 having a circumferential housing frame, which forms the side walls 61 , and a cover 62 , which is independent of the housing frame and on which shaft walls 63 are embodied for realizing the shafts 65 including the filling shaft 64 . Moreover, the connecting channels 66 are integrated into the cover 62 .
In principle, a housing 6 and/or a second potting compound 52 can have a glass transition temperature which is greater than 50° C., greater than 120° C., greater than 140° C., or even greater than 150° C., which can be achieved with available plastics or potting compounds.
In all semiconductor modules 100 within the meaning of the present invention there is likewise the possibility of using a material having a glass transition temperature in the range of 55° C. to 95° C., for example of approximately 90° C., for the housing 6 and/or the second potting compound 52 . Such a configuration has the effect that the glass transition temperature is exceeded during the operation of the semiconductor module 100 , such that the water vapor permeability of the housing 6 and/or of the second potting compound 52 rises and the moisture is driven out from the interior of the housing 6 and delivered to the outer environment of the housing 6 . Temperatures of 40° C. and relative air humidities of 90% rH are generally not exceeded at customary ambient conditions.
The housing frame and the cover 62 —taken by themselves in each case—can be embodied integrally, i.e. from a single part, and consist of a uniform material, for example a thermoplastic or a thermosetting plastic. In this case, the housing frame and the cover 62 can be formed from the same material or from different materials. The housing frame and housing cover 62 can be produced e.g. by injection molding. The housing 6 can be embodied integrally as explained already in the uninstalled state, i.e. in a state in which it has not yet been mounted on the above-explained unit with the previously populated substrate 2 (with or without baseplate 1 ).
The further mounting can then be effected such that the housing frame is placed on to the unit with the previously populated substrate 2 and is connected thereto, for example with the aid of the connecting means 9 or in some other way, the result of which is shown in FIG. 8B .
Afterward, as is illustrated in FIG. 8C , the housing cover 62 is placed onto this composite assembly and is then connected to the housing frame. The connection can be effected cohesively, e.g. with the aid of an adhesive, by laser, ultrasonic or thermal welding, or by screwing or any other connecting techniques. As is shown in FIG. 8A , the connection between housing frame and cover 62 can be embodied as a tongue-and-groove connection. This firstly facilitates the mounting of the cover 62 on the housing frame and secondly increases the length of the gap 7 between cover 62 and housing frame and in association therewith reduces the risk of harmful substances penetrating through the gap 7 and possibly through an adhesive situated therein into the interior of the housing 6 . In the example shown in FIGS. 8A to 8C , the groove is embodied on the housing frame and the tongue on the housing cover 62 . Conversely, however, the tongue can also be embodied on the housing frame and the groove on the housing cover 62 . Apart from the fact that the housing 6 is not embodied integrally, the arrangement shown in FIG. 8C is identical to the arrangement in accordance with FIG. 10 . In the same ways, housings 6 of arbitrary other semiconductor modules 100 can also be embodied and produced in two parts or in a multipartite fashion.
The connection between the housing frame and the cover 62 can be produced, in principle, before or after the filling of the first potting compound 51 and/or the second potting compound 52 , alternatively also by means of the filling of the second potting compound 52 . In the last-mentioned case, the second potting compound 52 also acts as an adhesive that connects the housing frame and the cover 62 .
In order to complete a semiconductor module 100 as illustrated in FIG. 8C , a first potting compound 51 is also filled into the housing 6 of said semiconductor module, followed by a second potting compound 52 in accordance with the method explained above.
In all semiconductor modules of the invention, the second potting compound 52 in interaction with the shafts 65 constitutes an effective barrier against the penetration of moisture and possibly other harmful substances into the interior of the housing 6 . This barrier effect is all the higher, the smaller the gaps between the shafts 65 and the connection elements 91 , 92 respectively running through the latter, the smaller the cross-sectional area of the filling opening 64 and the larger the layer thickness of the second potting compound 52 .
In order to test the explained sealing effect for a specific semiconductor module 100 , use can be made of a comparative or “dummy” module 101 , as shown by way of example in FIG. 9 . Such a comparative module 101 can be constructed in the same way as the underlying semiconductor module 100 with the sole difference that a sensor element is incorporated into a cavity 35 produced in the first potting compound 51 (see e.g. FIG. 10 ), which sensor element can be read via connection lines 31 , 32 and serves for determining the relative air humidity present in said cavity. Optionally, a temperature sensor element and/or a pressure sensor element can also be arranged in the cavity 35 . One, a plurality or all of said sensor elements can be integrated in a common sensor 30 as shown. However, the sensor elements can also be integrated into separate sensors situated in the cavity, or two sensor elements, e.g. for determining the temperature and the relative air humidity, can be integrated in a common sensor 30 , while the pressure sensor element is integrated in a further sensor, which is likewise arranged in the cavity 35 . It is also possible, as necessary, to use more than two electrical connection lines for connecting up the sensor 30 and—if present—one or a plurality of additional sensors.
Such a comparative module 101 can be produced, for example, by a procedure in which, in the case of a semiconductor module 100 wherein the interior of the housing 6 has been potted with the first and with the second potting compound 51 , 52 , the first potting compound 51 is removed again. This can be done, for example, by drilling through the housing 6 of a completed semiconductor module 100 until the first potting compound 51 is reached, and, through the drilled hole produced, removing a sufficient amount of the first potting compound 51 such that a cavity 35 arises into which one or a plurality of sensors 30 can be inserted. In this case, the insertion of the sensor or sensors 30 into the cavity 35 is effected such that an air-filled measurement volume 33 remains behind the sensor or sensors 30 , the relative air humidity of which measurement volume is detected. In this case, the connections 31 , 32 are led through the drilled hole toward the outside and the drilled hole is then tightly closed, which can be effected e.g. by means of an adhesive such as e.g. an epoxy resin adhesive.
Alternatively or supplementary, such a sensor 30 could also be inserted into the or into one of the volume regions 60 in a corresponding manner. In this case, the relevant volume region 60 would form the cavity 35 . The partial removal of the first potting compound 51 through the drilled hole would be obviated in this case.
There is likewise the possibility of embedding one or a plurality of sensors 30 into the first potting compound 51 during the filling thereof. In order to ensure that a cavity 35 remains with an air volume which extends as far as the sensor element situated in the sensor 30 , the sensor 30 can be covered by an air-permeable, for example grid-like protective cap which retains the first potting compound 51 when the latter is filled into the housing 6 .
Furthermore, one or a plurality of such sensors 30 can also be arranged in a volume region 60 prior to the filling of the potting compounds 51 and 52 and then, as already explained, firstly the first potting compound 51 and subsequently the second potting compound 52 can be filled into the housing 6 .
In principle, still other variants which can be used to produce such a comparative module 101 are also conceivable. What is of importance in any case is that an air-filled measurement volume 33 which is situated in the housing 6 and which extends as far as the sensor element situated in the sensor 30 directly adjoins the first potting compound 51 .
With the aid of such a comparative module 101 it is now possible to examine the sealing effect by measuring the relative air humidity in the cavity 35 if the comparative module 101 is situated in a defined environment at constant temperature T EXT , constant relative air humidity rH EXT and constant pressure P EXT and the temporal development of the relative air humidity in the measurement volume 33 is measured. It is assumed here that the interior of the module, before the beginning of the measurement, has a humidity that is significantly lower than the relative humidity in the defined environment, and an air pressure that is identical or substantially identical to the pressure in the defined environment. The assumption of a significantly lower relative humidity can be attained by drying the semiconductor module 100 at high temperature. Since the relative air humidity is greatly dependent on the temperature, the comparative module, in preparation for measuring the temporal development of the relative air humidity, can firstly be brought to a specific temperature, for example 20° C., and then at a point in time t0 can be introduced into a defined environment which is at the same temperature and the relative air humidity of which is higher than the relative air humidity rH 35 (t=t0) which is present at the point in time t0 in the cavity 35 (likewise at the specific temperature). Since the value of the relative air humidity present in the cavity 35 is dependent on the variables of pressure and temperature prevailing in the cavity 35 , the temporal development of said variables can likewise be measured, with the result that it is possible to convert the relative air humidity measured in a time-dependent manner to standard values of pressure and temperature (for example 1013.25 hPa and 20° C.) and thereby to obtain comparable results.
Starting from the point in time t0, the humidity contained in the environment penetrates into the housing 6 and in the process also reaches the gas (e.g. air) situated in the cavity 35 , such that the relative humidity rH 35 (t) thereof increases with time t. As a measure of the sealing effect, in the present case use is made of the duration D after which the initial relative air humidity rH 35 (t=t0) present in the cavity 35 at the point in time t0—relative to a pressure of 1013.25 hPa and 20° C.—rises by 0.6 times the difference between the relative ambient air humidity rH35(t=t0+D) and the relative initial humidity rH 35 (t=t0)—likewise relative to a pressure of 1013.25 hPa and 20° C. Said duration D can be, for example, at least 24 hours, at least 48 hours, at least 168 hours or at least 400 hours.
In this respect, FIG. 10 shows, for two semiconductor modules sealed with different degrees of success, the respective temporal development of the relative air humidity rH 35 (t) present in the cavity 35 starting from the point in time t0, i.e. starting from the introduction of the relevant comparative module 101 into the environment having defined relative humidity rH EXT , defined temperature T EXT and defined pressure p EXT . Curve 1 corresponds to the profile of the more poorly sealed comparative module 101 , and curve 2 corresponds to the profile of the better sealed comparative module 101 . In the examples shown, the initial relative air humidity rH 35 (t=t0) in the cavity 35 at a temperature of 20° C. is 20%, while the defined relative humidity rH EXT in the environment of the respective comparative module 101 at 20° C. is 90%.
The sealing effect is then determined by determining in each case the duration for which the relative humidity rH 35 (t) in the cavity 35 has risen by 0.6 times the difference (90%-20%=70%), that is to say by 0.6*70%=42%, in relation to the initial relative humidity rH 35 (t=t0) amounting to 20%, i.e. until the relative air humidity rH 35 (t) has risen to a value of 20%+42%=62%. In the case of the more poorly sealed comparative module 101 (curve K1), this value of 62% is reached at a point in time t1, that is to say after a duration D1=t1−t0, and in the case of the better sealed comparative module 101 (curve K2) said value is reached at a point in time t2, that is to say after a duration D2=t2−t0. In the examples shown, D1=28 hours and D2=310 hours.
FIG. 11 shows a horizontal section through the arrangement in accordance with FIG. 2C in a sectional plane E-E running through the shafts 65 and the (in this example sole) volume region 60 . However, the same sectional view would also arise in the case of a corresponding section through the semiconductor modules 100 from FIGS. 10 and 3 to 6 .
As can be discerned in this view, all shafts 65 of the semiconductor module 100 that are delimited by the shaft walls 63 either are sealed, as in the case of the filling shaft 64 , only by the second potting compound 52 or are sealed, as in the case of the other shafts 65 , by the second potting compound 52 in conjunction with the connection element 91 , 92 running in the relevant shaft 65 , such that the atmosphere situated outside the housing 6 cannot pass directly through the shafts 64 , 65 to the first potting compound 51 .
It can likewise be discerned that the semiconductor module 100 contains just a single volume region 60 , the orthographic projection of which on to the top side 201 of the circuit carrier 20 has an area A60. In other semiconductor modules 100 , two or more volume regions 60 independent of one another in pairs can also be present. In this case, “independent” means that no free gas exchange is possible between two independent volume regions 60 . In the case of two or more volume regions 60 that are independent in this sense, their orthographic projection onto the top side 201 of the circuit carrier 20 can form a continuous area A60, or else two or more independent areas, the total area of which is again A60. Independently of whether a semiconductor module 100 has only exactly a single or else two or more volume regions 60 of this type, A60 indicates the total projection area of all volume regions 60 directly adjoining the first potting compound 51 .
FIG. 11 furthermore illustrates with a broken line, because it is concealed, the lateral boundary line of the top side 201 of the circuit carrier 20 , the area size of which is designated by A20. The semiconductor module 100 can be configured, then, such that the ratio of A60 to A20 is greater than or equal to 0.7, that is to say that A60 is at least 70% of A20.
The shafts 65 provided in the present invention make it possible to use only very little second potting compound 52 in conjunction with a high sealing effect against the penetration of moisture and other harmful substances into the housing 6 . By way of example, the second potting compound 52 can have a total mass which, relative to the area A20 of the top side 201 , is less than or equal to 1 gram per square centimeter.
Independently of this, the cured second potting compound 52 and the material of the housing 6 can be chosen such that the solubility of water in the second potting compound 52 and in the housing is in each case a maximum of 0.5% by weight or a maximum of 0.2% by weight relating to the common weight of second potting compound 52 and housing 6 .
Various exemplary embodiments for possible configurations of semiconductor modules 100 have been explained above. One or more features mentioned in this context in one exemplary embodiment can be combined in any desired manner with one or more features from one or more other exemplary embodiments, provided that these features are not mutually exclusive.
Various exemplary embodiments of a semiconductor module 100 have been explained above. In these and all other exemplary embodiments of the invention, such potting compounds which are present as gel, for example as silicone gel, after crosslinking can optionally be used here as first potting compound 51 . In principle, however, it is possible to use potting compounds 51 which have after crosslinking a penetration according to DIN ISO 2137 of less than 40 and thus a lower penetration than a typical cross-linked gel (penetration according to DIN ISO 2137 in the range of 40-70).
Spatially relative terms such as “under,” “below,” “lower,” “over,” “upper” and the like, are used for ease of description to explain the positioning of one element relative to a second element. These terms are intended to encompass different orientations of the device in addition to different orientations than those depicted in the figures. Further, terms such as “first,” “second,” and the like, are also used to describe various elements, regions, sections, etc. and are also not intended to be limiting. Like terms refer to like elements throughout the description.
As used herein, the terms “having,” “containing,” “including,” “comprising” and the like are open-ended terms that indicate the presence of stated elements or features, but do not preclude additional elements or features. The articles “a,” “an” and “the” are intended to include the plural as well as the singular, unless the context clearly indicates otherwise.
It is to be understood that the features of the various embodiments described herein may be combined with each other, unless specifically noted otherwise.
Although specific embodiments have been illustrated and described herein, it will be appreciated by those of ordinary skill in the art that a variety of alternate and/or equivalent implementations may be substituted for the specific 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 specific embodiments discussed herein. Therefore, it is intended that this invention be limited only by the claims and the equivalents thereof. | A semiconductor module is provided which is well protected against corrosion and/or other damage which can be caused by moisture and/or other harmful substances surrounding the semiconductor module. A method for producing such a semiconductor module is also provided. | 50,604 |
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority under 35 U.S.C. § 119, to EP 02015047.0 filed Jul. 5, 2002, the disclosure of which is incorporated herein by reference in its entirety.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The invention relates to a protein from plasma membranes of adipocytes which has specific binding affinity to phosphoinositolglycans.
[0004] 2. Description of the Background
[0005] The role of phospholipids and phospholipases in trans-membrane signaling is firmly established. Equally well-established is the concept of anchoring proteins into cell membranes through a covalently linked glycosylphosphatidylinositol (GPI), and the precise chemical structure of the GPI anchor has been worked out for several GPI-anchored proteins, such as acetylcholinesterase (AchE) from human erythrocytes, rat Thy-1, and several coat proteins of parasites like the variant surface glycoprotein (VSG) from Trypanosoma brucei. Lipid anchoring occurs through phosphatidylinositol (PI), which consists of a diacyl- or an alkylacyl glycerol type phospholipid. Since the latter occurs, among others, in mammalian anchors, and differs from the bulk PI present in membranes, it could provide a novel molecular species involved in the generation of second messengers derived from GPIs. Signaling by GPIs is of special interest as these lipid-anchored molecules do not span the membrane, but in most cases are embedded in the outer half of the lipid bilayer. The signal-mediated release from the cell membrane of GPIs has been demonstrated for a variety of endocrine and paracrine molecules, ranging from hormones to growth factors. The involvement of GPIs in transmembrane signaling and their intracellular effects seems by now established, but little is known about the signaling pathway leading to the observed metabolic effects.
[0006] The notion that GPI-anchored molecules possess signaling properties results from early experiments in which it was shown that the binding of insulin to its receptor activates the hydrolysis of GPIs. A low-molecular-weight substance was identified that mimics certain actions of insulin on metabolic enzymes. This substance has an inositol glycan structure and is produced by the insulin-sensitive hydrolysis of a GPI in the plasma membrane. Although the GPI precursor for the inositol glycan enzyme modulator was originally thought to be structurally analogous to the GPI membrane protein anchor, there are distinct differences in the carbohydrate moiety between the signal transducing GPI and the GPI anchor of membrane proteins. The GPI-membrane protein anchor invariably consists of the trimannose core followed by an ethanolamine phosphate, which provides the link to the C-terminal amino acid of the attached protein.
[0007] Regulated GPI hydrolysis is not only restricted to insulin but has been observed with a number of other hormones.
[0008] In practically all cases, the stimulation of cells by hormones or growth factors leads to a transient release of GPI-anchored proteins from the cell surface. Most of the receptors for these agonists are either tyrosine kinase receptors or receptors coupled to tyrosine kinases.
[0009] Many of the proteins involved in insulin action have been identified at the molecular level. The insulin receptor is a transmembrane tyrosine kinase, which when activated by insulin binding, undergoes rapid autophosphorylation and phosphorylates a number of intracellular substrates, among them one or more 50-60 kDa proteins, including the Shc, a 15 kDa fatty acid binding protein and several so-called insulin receptor substrate proteins, IRS-1/2/3/4. After tyrosine phosphorylation, the IRS polypeptides act as docking proteins for several Src homology 2 domain-containing adaptor molecules and enzymes, including phosphatidylinositol 3-kinase (PI 3-K), Grb2, SHP2, Nck, and Fyn. The interaction between the IRS proteins and PI 3-K occurs through the p85 regulatory subunit of the enzyme and results in an increase in catalytic activity of the p110 subunit. PI 3-K is essential for many insulin-sensitive metabolic processes, including stimulation of glucose transport and glycogen synthesis. In all cases in which there is stimulation of tyrosine phosphorylation of IRS proteins, there is concomitant docking of these proteins to the p85 subunit of PI 3-K and, with the exception of the cross-talk between the insulin and angiotensin signaling systems, this docking was associated with stimulation of PI 3-K activity.
[0010] In addition to the identification of the signal-transduction pathways leading directly from the insulin receptor to down-stream targets, several cross-talks have been delineated between signaling transmission by insulin and other hormones/growth factors or diverse exogenous stimuli, which either mimic (to a certain degree) or modulate in a positive or negative fashion metabolic and/or mitogenic insulin action in various cellular systems. Since none of these ligands activates the insulin receptor kinase directly, their signaling pathways may converge with that of insulin at a more distal signaling step. This property is shared by phosphoinositolglycan-peptide (PIG-P) molecules of different type as for example for PIG-P prepared from the glycosylphosphatidylinositol anchor of yeast Gce1p which mimic metabolic insulin action to a significant degree without concomitant induction of insulin receptor kinase activity.
[0011] Positive cross-talk of phosphoinositolglycans (PIG) and PIG-peptides (PIG-P) to the insulin signal transduction cascade in insulin-responsive target cells involves redistribution of glycosylphosphatidylinositol (GPI)-anchored plasma membrane proteins (GPI protein) and dually acylated non-receptor tyrosine kinases from detergent-resistant glycolipid-enriched plasma membrane raft domains of high cholesterol content (hcDIGs) to rafts of lower cholesterol content (IcDIGs).
[0012] In isolated rat adipocytes the primary target of PIG-P is localized in hcDIGs. Radiolabeled PIG-P, Tyr-Cys-Asn-NH—(CH 2 ) 2 —O—PO(OH)O-6Manα1-2)2Manα1-6Manα1-4GluN1-6Ino-1,2-(cyclic)-phosphate (YCN-PIG) as well as radiolabeled and lipolytically cleaved GPI protein (IcGce1p) from Saccharomyces cerevisiae, from which YCN-PIG has been derived, bind to hcDIGs in saturable fashion but not to IcDIGs, microsomes or total plasma membranes. Binding of both YCN-PIG and IcGce1 is specific, as it is completely abolished either by excess of chemically synthesized unlabeled YCN-PIG or by pretreatment of the adipocytes with trypsin and subsequent NaCl or N-ethylmaleimide (NEM) indicating that YCN-PIG is recognized by a cell surface receptor. Binding of PIG-P is considerably increased in hcDIGs from adipocytes pretreated with GPI-specific phospholipases C compatible with lipolytic removal of endogenous ligands, such as GPI proteins/lipids. Binding affinity is highest for YCN-PIG, followed by the combination of the separate constituents, Tyr-Cys-Asn-NH—(CH 2 ) 2 —OH(YCN) plus HO—PO(H)O-6Manα1 (Manα1-2)-2-Manα1-6Manα1-4GluN1-6Ino-1,2-(cyclic)-phosphate (PIG37), and the peptide variant, YMN-PIG. PIG37 and YCN alone exhibit intermediate and low affinity. Incubation of adipocytes with YCN-PIG diminishes subsequent labeling by [ 14 C]NEM of the 115 kDa polypeptide released from the cell surface by sequential trypsin/NaCl-treatment. These data show that in rat adipocytes insulin-mimetic PIG(-P) are recognized by a trypsin/NaCl/NEM-sensitive 115 kDa protein of hcDIGs which acts as receptor for GPI proteins.
[0013] Several types of DIGs seem to exist in the same cell. Caveolae represent special DIGs in terminally differentiated cells which form flask-shaped invaginations driven by the abundant expression of the marker and structural protein, caveolin 1-3.
[0014] Caveolae which account for 20% of the plasma membrane surface area in adipocytes participate in receptor-mediated potocytosis, endocytosis, transcytosis and signal transduction. In isolated rat adipocytes IcDIGs of low cholesterol/caveolin content exhibiting high buoyant density (according to sucrose density gradient centrifugation) can be discriminated from typical hcDIGs with high cholesterol/caveolin content characterized by low buoyant density. The major fraction of GPI proteins, such as Gce1 and Nuc, as well as of dually acylated proteins, such as the NRTK Non Receptor Tyrosine Kinase, pp59 Lyn , are located at hcDIGs. In response to insulin-mimetic stimuli such as synthetic PIG or the sulfonylurea, glimepiride, both GPI proteins and NRTKs are translocated from hcDIGs to IcDIGs. This redistribution is not caused by loss of their lipid modification.
[0015] The polar core glycan head group without (PIG) or with (PIG-P) adjacent amino acids from the carboxyl-terminus of the GPI protein polypeptide moiety provides the molecular basis of the distribution of GPI proteins between hcDIGs and IcDIGs in the basal state and their redistribution in response to insulin-mimetic stimuli.
[0016] GPI proteins are cell surface antigens, ectoenzymes, receptors or cell adhesion molecules expressed in eucaryotes from yeast to man and anchored to the outer leaflet of the plasma membrane by a covalently attached glycosylphosphatidylinositol (GPI) lipid moiety. Despite the lack of a transmembrane domain, they have been implicated in signal transduction across the plasma membrane.
[0017] The finding that GPI proteins associate with specialized lipid raft domains, so-called detergent-insoluble glycolipid-enriched rafts, DIGs, rather than with distinct transmembrane binding/linker proteins demonstrates the possibility of lipid-lipid interactions as the major coupling mechanism for signal transduction mediated by GPI proteins.
[0018] The basic structural element of DIGs is a lateral assembly of (glyco)sphingolipids and cholesterol which adopts a liquid-ordered (I o ) organization distinct from that of adjacent liquid-disordered (I d ) regions in the membrane lipid bilayer. The plasma membranes of mammalian cells contain cholesterol (30-50 mol %) and a mixture of lipids with preference for the Id domains (e.g. phosphatidylcholines with unsaturated tails) and lipids bearing saturated acyl chains with preference for I o domains (e.g. [glyco]sphingolipids and GPI lipids). Cholesterol is thought to contribute to the tight packing of lipids in I o domains by filling interstitial spaces between lipid molecules, and the formation of I o domains is seen only within certain ranges of cholesterol concentration.
[0019] Insulin is a very important hormone, which exerts a significant effect on the metabolism of the body. In the general terms it promotes anabolic processes and inhibits catabolic processes. Specifically it increases the rate of synthesis of glycogen, fatty acids and protein, and inhibits the breakdown of protein and glycogen. A vital action of the hormone is to stimulate cells from a liver, muscle and fat to remove glucose, some other sugars and amino acids from the blood.
[0020] Bovine insulin consists of two polypeptide chains, polypeptide A containing 21 AA and polypeptide B containing 30 AA, which are joined by two —S—S— (disulfide bridges). This same structural pattern occurs in insulin of many mammals including humans.
[0021] The structure is compact cylinder-like with only the carboxyl end of the B chain sticking out from the rest of the protein. There are many hydrophobic residues, which interact to form a central hydrophobic core, and interdispersed are some polar residues on either side that further stabilize the protein. Three disulfide bridges clamp the structure together, two inter-chain and one intra-chain.
[0022] A common feature in the biosynthesis of many proteins, but in particular for proteins exported from cells, is that the protein is produced in a precursor form then modified to produce the final form during storage and before release. Insulin is synthesized by a group of cells in the pancreas called Islets of Langerhans, stored in granules then released into the blood when required.
[0023] When insulin is first synthesized it consists of a 100 AA single polypeptide chain consisting of a signal sequence of 16 AA, a B chain, a C chain called connecting chain of 33 AA, and a A chain. This structure is called pre-proinsulin (PPI). It is thought that the signal region is responsible for directing the PPI from the site of synthesis to the ER (endoplasmic reticulum) in the cell, which collect and package the insulin to form storage granules. When located in the ER, the signal peptide is removed by a protease enzyme.
[0024] Diabetes mellitus is a chronic disease that requires long-term medical attention both to limit the development of its devastating complications and to manage them when they do occur. Diabetes is associated with acute and chronic complications as hypoglycemia, diabetic ketoacidosis and hyperosmolar non-ketotic syndrome.
[0025] Type 1 diabetes generally occurs in young, lean patients and is characterized by the marked inability of the pancreas to secrete insulin because of autoimmune destruction of the beta cells. The distinguishing characteristics of a patient with type 1 diabetes is that if insulin is withdrawn, ketosis and eventually ketoacidosis develop. These patients are, therefore, dependent on exogenous insulin to sustain their lives.
[0026] Type 2 diabetes typically occurs in individuals older than 40 years who have a family history of diabetes. Type 2 diabetes is characterized by peripheral insulin resistance with an insulin-secretory defect that varies in severity. These defects lead to increased hepatic gluconeogenesis, which produces fasting hyperglycemia. Most patients (90%) who develop type 2 diabetes are obese, and obesity itself is associated with insulin resistance, which worsens the diabetic state.
[0027] A variety of other types of diabetes, previously called “secondary diabetes”, are caused by other illnesses or medications. Depending on the primary process involved (i.e., destruction of pancreatic beta cells or development of peripheral insulin resistance), these types of diabetes behave similarly to type 1 or type 2 diabetes. The most common are diseases of the pancreas that destroy the pancreatic beta cells (e.g., hemochromatosis, pancreatitis, cystic fibrosis, pancreatic cancer), hormonal syndromes that interfere with insulin secretion (e.g., pheochromocytoma) or cause peripheral insulin resistance (e.g., acromegaly, Cushing syndrome, pheochromocytoma), and drug-induced diabetes (e.g., phenytoin, glucocorticoids, estrogens).
[0028] Diabetes mellitus is characterized by inappropriate regulation of serum glucose levels. In Type 1 diabetes an autoimmune attack on the endocrine pancreas results in progressive and irreversible destruction of the insulin secreting beta cells. Loss of insulin action on insulin-sensitive target cell glucose uptake and metabolism results. Type 2 diabetes has several etiologies, most often reflected in cellular resistance to insulin action, also with attendant alterations in the regulation of serum glucose levels. Insulin acts through a disulfide-bonded heterotetrameric cell surface receptor comprised of an extracellular alpha subunit coupled via disulfide bonds to a transmembrane and intracellular beta subunit. In Type 1 diabetes, absence of the ligand with normal cellular receptor structure and function is most often the cause of the subsequent metabolic defects. Hormone replacement therapy in the form of daily insulin injections supplies the ligand for receptor action, though not necessarily in a normal physiologic fashion. In Type 2 diabetes, resistance to the action of insulin often underlies the disease with some of the resistance due to defects in receptor action.
[0029] It is known in case of insulin resistance that a higher amount of insulin is required to set on the insulin signaling cascade by the insulin receptor. The present invention is related to a cell membrane protein of adipocytes which is able to stimulate glucose uptake by circumventing the insulin receptor triggered signaling pathway. This provides for a powerful solution of the problem not to have in hands a screening tool to identify compounds which could act as alternatives for insulin.
SUMMARY OF THE INVENTION
[0030] Therefore the present invention refers to a protein from the plasma membrane of an adipocyte which is possibly stabilized by simultaneous presence of plasma membranes and/or lipid vesicles and/or raft domains with high cholesterol and/or lipid vesicles and which has specific binding affinity to phosphoinositolglycan or a phosphoinositolglycan-peptide characterized by
a) ability to trigger tyr phosphorylation of insulin receptor substrate 1 or 2 in an adipocyte after specific binding of a phosphoinositolglycan or a phosphoinositolglycan-peptide to this protein and b) ability to stimulate glucose uptake in an adipocyte after specific binding of a phosphoinositolglycan or a phosphoinositolglycan-peptide to this protein.
[0033] The amount of the protein with respect to other proteins and/or the stabilizing components and/or other compounds (e.g. salts, ion, puffer) is in a range between 0.01 to 10%, or about 0.01 to 10%, with respect to the wet weight.
[0034] The amount of the protein is preferably in a range of 0.1 to 5%, or about 0.1 to 5% with respect to the wet weight and most preferably in a range of 0.1 to 1%, or about 0.1 to 1% with respect to the wet weight.
[0035] Under native conditions the amount of the said protein in plasma membranes is in the range of less than 10 −6 % with respect to the wet weight.
[0036] In preferred modifications of the invention the phosphoinositolglycan or phosphoinositolglycan-peptide consists at least of one compound of the following: YCN-PIG, YMN-PIG, PIG37, YCN or IcGce1.
[0037] The binding of the phosphoinositolglycan or phosphoinositolglycan-peptide to the protein takes place preferably with a binding constant (K D ) of 0.001 to 10 μM, or about 0.001 to 10 μM.
[0038] The binding constant is a thermodynamic order for quantitative description of the equilibrium between the dissociated and non-dissociated forms of the complexes between the protein and the phosphoinositolglycan or phosphoinositolglycan-peptide.
[0039] The binding constant is formed by the quotient of the velocity constants of forward and backward reaction. High values of the binding constant (e.g. larger than 10 mM) define a weak and unspecific binding whereas low values (e.g. not more than 100 μM) define a strong and specific binding.
[0040] The binding constants can be determined by different methods as for example by equilibrium dialysis, spectroscopy or graphical approaches (Scatchard-Plot).
[0041] The adipocyte plasma membrane referring to is preferably from a rat, mouse or human.
[0042] The molecular weight of the protein is between 100 to 120 kDa, preferably between 110 to 120 and most preferably of 115 kDa. It must be mentioned that determination of molecular weight of proteins by any method in particular by SDS-PAGE occurs with an uncertainty of ±5 to 10%.
[0043] The invention further relates to a complex which is formed by the protein of the invention as aforementioned and by at least one compound of the following group: YCN-PIG, YMN-PIG, PIG37, YCN or IcGce1.
[0044] Prerequisite of complex formation is specific binding of the ligand to the protein. The complex may be stabilized by forming of an ionic or covalent bondage between ligand and protein.
[0045] The invention refers also to the production of a protein of the invention wherein
a) adipocytes will be provided from a rat, mouse or human tissue, b) the plasma membranes of the adipocytes from a) will be isolated, c) raft domains with high cholesterol (hcDIGs) are prepared from plasma membranes of b) d) the hcDIGs from c) are treated with a trypsin/NaCl solution, e) the incubation mixture from d) is centrifuged and the proteins of the supernatant are separated by means of SDS-PAGE Sodium-Dodecylsulfate-Polyacrylamidegel-electrophoresis, f) the protein fraction with size of 100 to 120 kDa, or about 100 to about 120 kDa is eluted from the gel and possibly solubilized by a solution or suspension containing a detergent or biological membranes.
[0052] Furthermore the invention refers to a method for identifying a compound which specifically binds to a protein of the invention wherein
a) a fraction of a cell is provided, which contains a protein of the invention, b) a compound is provided, c) the fraction of the cell from a) is brought in contact with the compound of b), d) binding of the compound to the fraction of a cell from a) is determined, e) specificity of binding is deduced by comparison of results from d) with results from an experiment in which the same compound as from b) is brought in contact with a fraction of a cell which has the same species and/or tissue specificity as the cell from a) but does not contain a protein of the invention thereby indicating a higher specificity of binding in case a higher amount of the compound from b) is binding to the fraction of the cell which contains the protein of the invention than to the fraction of the cell which does not contain the protein of the invention.
[0058] The fraction of the cell is taken preferably from an adipocyte, a skeletal muscle cell, a heart muscle cell or a liver cell. Each of these cells can be derived preferably from a mouse, rat or a human. The fraction of the cell consists preferably of cell membranes of a cell or more preferably of raft domains of high cholesterol content (hcDIGs). The compound which is used for performing the method for identifying a compound which specifically binds to a protein of the invention can be labeled with a radioactive nuclide (e.g. 14 C, 3 H, 32 P, 121 J and others) or a fluorescence marker.
[0059] The invention refers further to a method for identifying a compound which specifically binds to a protein of the invention wherein
a) a glucose transporting cell is provided which contains a protein of the invention, b) a compound is provided, c) the cell from a) is brought in contact with the compound of b) d) binding of the compound to the glucose transporting cell is determined, e) the specificity if binding is deduced by comparison of results from d) with results from an experiment in which the same compound as from b) is brought in contact with a glucose transporting cell which has the same species and/or tissue specificity as the cell from a) but does not contain a protein of the invention thereby indicating a higher specificity of binding in case a higher amount of the compound from b) is binding to the glucose transporting cell which contains a protein of the invention than to the glucose transporting cell which does not contain the protein of the invention.
[0065] A glucose transporting cell which does not contain a protein of the invention can be produced from a glucose transporting cell which contains a protein of the invention by treating this cell which contains the protein of the invention with a trypsin/NaCl solution and/or a glycosidase.
[0066] The glucose transporting cell is preferably an adipocyte, a skeletal muscle cell, a heart muscle cell or a liver cell. These cells are preferably taken from a tissue or cell culture of human, mouse or human origin.
[0067] The compound used is preferably labeled with a radioactive nuclide or a fluorescence marker.
[0068] Furthermore the invention refers to a method for identifying a compound which is an agonist or antagonist for a protein of the invention wherein
a) a glucose transporting cell is provided, wherein the protein of the invention is present, b) a natural ligand of the protein of the invention is provided, c) a chemical compound is provided, d) the glucose transporting cell of a) is brought into contact with the ligand from b) and the chemical compound from c), e) the glucose uptake of the glucose transporting cell from d) is determined, f) the glucose uptake of the glucose transporting cell from d) is determined wherein stimulation of glucose uptake means agonistic activity and inhibition of glucose uptake means antagonistic activity of the compound from c).
[0075] The ligand of the aforementioned method for identifying an agonist or antagonist of the protein of the invention is preferably YCN-PIG, YMN-PIG, PIG37, YCN or IcGce1.
[0076] The glucose transporting cell of the method for identifying an agonist or antagonist of the protein of the invention is preferably an adipocyte, a skeletal muscle cell, a heart cell or a liver cell and is preferably of human, mouse or rat species origin.
[0077] The invention refers also to a medicament containing a compound which has been identified by a method of identifying a compound which binds to a protein of the invention or which is a agonist or antagonist of the protein of the invention as well as auxiliary compounds for formulation of a medicament. The medicament contains in preferable embodiments at least of one compound of the following group: YCN-PIG, YMN-PIG. PIG37, YCN or IcGce1.
[0078] The medicament could also contain a part or derivative of at least one compound of the following group: YCN-PIG, YMN-PIG, PIG37, YCN or IcGce1.
[0079] Furthermore the invention refers to use of a compound which has been identified to bind to the protein of the invention or to be an agonist or antagonist of the protein of the invention for production of a medicament for treatment of insulin resistance or diabetes.
[0080] Such compound could preferably be YCN-PIG, YMN-PIG, PIG37, YCN, IcGce1 or a part or derivative of one of these compounds.
BRIEF DESCRIPTION OF THE DRAWINGS
[0081] FIG. 1 : General scheme of synthesis of PIG, part 1 .
[0082] FIG. 2 : General scheme of synthesis of PIG, part 2 .
[0083] FIG. 3 : General scheme of synthesis of PIG, part 3 .
[0084] FIG. 4 : Synthesis of YCN-PIG, part 1 .
[0085] FIG. 5 : Synthesis of YCN-PIG, part 2 .
[0086] FIG. 6 : Synthesis of YCN-PIG, part 3 .
[0087] FIG. 7 : Synthesis of YCN.
[0088] FIG. 8 : Chemical formula of YCN-PIG.
[0089] FIG. 9 : Chemical formula of YMN-PIG.
[0090] FIG. 10 : Chemical formula of PIG37.
[0091] FIG. 11 : Chemical formula of YCN.
[0092] FIG. 12 : Specific binding of PIG(-P) to hcDIGs.
[0093] FIG. 13 : Specific binding of PIG-P to hcDIGs.
[0094] FIG. 14 : Characterization of the binding site for PIG-P at hcDIGs.
[0095] FIG. 15 : Characterization of the binding site for PIG-P at hcDIGs.
[0096] FIG. 16 : Specific binding of IcGce1p to hcDIGs.
[0097] FIG. 17 : Specific binding of IcGce1p to hcDIGs.
[0098] FIG. 18 : Effect of PL and insulin treatment of adipocytes on binding of YCN-PIG and IcGce1p to hcDIGs.
[0099] FIG. 19 : Effect of PL and insulin treatment of adipocytes on binding of YCN-PIG and IcGce1p to hcDIGs.
[0100] FIG. 20 : Effect of PIG(-P), PI-specific PLC and insulin on NEM-labeling of CIR.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0101] In a preferred embodiment, the invention provides a method of identifying a protein from a plasma membrane of an adipocyte comprising providing adipocytes from a mammal, isolating plasma membranes from said adipocytes, isolating domains with high cholesterol (hcDIGs) from the plasma membranes, isolating a protein fraction with size of about 115 kDa from said domains. The step of isolating a protein fraction with size of about 115 kDa further comprises solubilizing the fraction in a solution or suspension comprising a detergent or biological membranes. The solution or suspension further comprises one or more compounds selected from YCN-PIG, YMN-PIG, PIG37, YCN or IcGce1. The protein has specific binding affinity to phosphoinositolglycan or a phosphoinositolglycan-peptide. The phosphoinositolglycan or phosphoinositolglycan-peptide binds to the protein with a binding constant of between 0.001 to 10 μM.8. The adipocyte is preferably from rat, mouse or human origin. The molecular weight of the protein is about 100-150 kDa, preferably about 115 kDa.
[0102] In another preferred embodiment, the invention provides a method for identifying a compound which specifically binds to a protein with specific binding affinity to phosphoinositoylglycans comprising contacting a fraction of a cell with a compound, and determining if said compound binds with said protein. The method preferably further comprises the step of determining specificity of binding. This may be done by comparing binding of the compound to the fraction with results from an experiment of bringing said compound in contact with another fraction of a cell which has the same species and/or tissue specificity as the first fraction but does not comprise said protein; wherein a higher amount of the compound binding to the fraction of the cell which contains said protein indicates specificity of said compound for said protein. The fraction preferably comprises domains of high cholesterol content (hcDIGs). Preferably, the compound is labeled with a radioactive nuclide or a fluorescence marker.
[0103] In another preferred embodiment, the invention also provides a method for identifying a compound which specifically binds to a protein with specific binding affinity to phosphoinositoylglycans, wherein said cell is from a glucose transporting cell, comprising contacting a fraction of the cell with a compound and determining if said compound binds with said protein. The method also further comprises the step of determining specificity of binding, wherein said step comprises comparing a binding of the compound to the fraction with results from an experiment comprising bringing said compound in contact with a fraction of a cell which has the same species and/or tissue specificity as the first fraction but does not comprise said protein; wherein a higher amount of the compound binding to the fraction of the cell which contains said protein indicates specificity of said compound for said protein. The compound is preferably labeled with a radioactive nuclide or a fluorescence marker.
[0104] In another preferred embodiment, the invention also provides a method for identifying a compound which is an agonist or antagonist for a protein with specific binding affinity to phosphoinositoylglycans, comprising bringing a glucose transporting cell into contact with a natural ligand of the protein and a chemical compound, and determining glucose uptake of the glucose transporting cell, wherein stimulation of glucose uptake indicates that the compound is an agonist and inhibition of glucose uptake indicates he compound is an antagonist. Preferably, the natural ligand is selected from YCN-PIG, YMN-PIG, PIG37, YCN or IcGce1. The cells are of mammalian cells, preferably human, mouse or rat species origin.
EXAMPLES
[0105] Chemical Synthesis of PIG(-P): Synthesis of YCN-PIG (for the general strategy, see FIG. 1, 2 , 3 )
[0106] For synthesis of product 2 ( FIG. 4 ; i, ii), product 1 (8.0 g, 20.6 mmol) from Bachem (Heidelberg, Germany) was dissolved in 200 ml of pyridine, and 5 g (81.8 mmol) of ethanolamine and 5 ml of N-ethylmorpholine were added. After standing (16 h, room temperature), 50 ml of acetic anhydride were added dropwise at 5° C., with stirring. The reaction mixture was stirred (2 h, room temperature) and then concentrated under high vacuum. The residue was dissolved in 150 ml of hot methanol and the solution was concentrated. The product crystallizes after the addition of 100 ml of methylene chloride/methanol (15/1) and 200 ml of n-heptane/ethyl acetate (2/1). Yield of product 2: 6.1 g (84%) of white crystals of m.p. 175° C. TLC (Thin Layer Chromatography): methylene chloride/methanol (9/1), R f =0.7. MS: (M+Li) + =358.2, calculated C 16 H 21 N 3 O 6 , M=351.36.
[0107] For synthesis of product 3 ( FIG. 4 ; iii), 2.0 g of palladium-on-charcoal (10% Pd) was added to a solution of Product 2 (12.0 g, 34.0 mmol) in 200 ml of methanol/acetic acid (1/1) and the mixture was hydrogenated (2 h, room temperature). The solution was filtered on silica gel and concentrated and the residue purified by flash chromatography (methylene chloride/methanol/concentrated ammonia 30/5/1). Yield of product 3: 7.3 g (98%) of a yellowish oil. TLC: methylene chloride/methanol/concentrated ammonia (30/5/1), R f =0.5. MS: (M+Li) + =224.2, calculated C 8 H 15 N 3 O 4 , M=217.23.
[0108] For synthesis of product 4 ( FIG. 4 ; iv), 1.5 g (4.5 mmol) of 1(o-(cyano(ethoxycarbonyl)-methyliden)amino-1,1,3,3-tetramethyluronium tetrafluoroborate (TOTU), 0.64 g (4.5 mmol) of ethyl-(hydroxyimino)-cyanoacetate (oxime) and 1.7 ml (13.5 mmol) of N-ethylmorpholine were added at 0° C., with stirring, to a solution of 0.8 g (3.7 mmol) of 3 and 2.8 g (4.5 mmol) of TrtCys(Trt)OH in dimethylformamide and the mixture was stirred (2 h, 0° C.). After the addition of 200 ml of ethyl acetate, the mixture was washed 3 times with saturated NaHCO 3 solution, dried over MgSO 4 and concentrated. The residue was triturated with n-heptan/ethyl acetate (6/1) and the product crystallizes. Yield of product 4: 2.2 g (74%) of white crystals of m.p. 185° C. TLC: methylene chloride/methanol (15/1), R f =0.4. MS: (M+Li) + =811.7, calculated C 49 H 48 N 4 O 5 S, M=805.0.
[0109] For synthesis of product 6 ( FIG. 4 ; v, vi), 4.0 g (5.0 mmol) of product 4 was dissolved in 200 ml of methylene chloride. 4 ml of water and 3 ml of trifluoroacetic acid was added. After 15 min, the mixture was washed 3 times with saturated NaHCO 3 solution, dried over MgSO 4 and concentrated, to yield 99% crude product 5. This crude product was dissolved in 50 ml of methanol, and 0.5 ml of 1 M sodium methanolate solution was added dropwise. After 15 min, 50 ml of methylene chloride were added and the mixture was filtrated on silica gel. After concentration of the solvent, the residue was purified by flash chromatography (methylene chloride/methanol (9/1)). Yield of product 6: 2.2 g (85%) of a white amorphous solid. TLC: methylene chloride/methanol (5/1), R f =0.7. MS: (M+Li) + =527.3, calculated C 28 H 32 N 4 O 4 S, M=520.6.
[0110] For synthesis of product 7 ( FIG. 4 ; vii), 2.7 g (5.2 mmol) of product 6, 4.2 g (10.4 mmol) of Ztyr(Bn)OH, 3.4 g (10.4 mmol) of TOTU, 1.5 g (10.4 mmol) of oxime and 2 ml of N-ethylmorpholine in 50 ml dimethylformamide were reacted analogously to the preparation of product 4. Yield of product 7: 4.2 g (89%) of white crystals. TLC: methylene chloride/methanol (15/1), R f =0.25. MS: (M+Li) + =914.8, calculated C 25 H 53 N 5 O 8 S, M=908.1.
[0111] For synthesis of product 8 ( FIG. 5 ; viii), 6.0 g (73 mmol) of phosphorous acid was concentrated four times with pyridine and then taken up in 180 ml of dry pyridine. 13 ml of pivaloyl chloride were added dropwise at 10° C. This reaction solution was allowed to stand (45 min, room temperature). 16.4 g (18.1 mmol) of product 7 was introduced into the reaction solution as described above. After 5 h, it was diluted with 200 ml of toluene and 150 ml of methylene chloride/methanol/33% NH 3 (30/10/3). After concentration residual pyridine was distilled out a further three times with 200 ml toluene. The residue was suspended in 200 ml of methylene chloride/methanol (20/1). The non-soluble constituents were filtered and washed twice with 50 ml of methylene chloride/methanol (20/1). The filtrate was concentrated and purified by flash chromatography. Yield of product 8: 11.6 g (66%) of white crystals. TLC: methylene chloride/methanol/33% NH 3 (30/5/1), R f =0.25. MS: (M+Li) + =978.4, calculated C 52 H 54 N 5 O 10 SP, M=972.08.
[0112] For synthesis of product 10 ( FIG. 6 ; ix, x), 4.5 g of product 8 (4.6 mmol) and 6.0 g of product 9 (2.3 mmol; synthesis performed as described previously in ref. 47) were dissolved in 80 ml dry pyridine. After 30 min at room temperature, the reaction was cooled to 0° C. and 5 ml water and 1.3 g iodine was added. The reaction mixture was stirred (30 min, 10° C.) and then diluted with 500 ml methylene chloride, 150 ml of saturated NaCl solution and 30 ml of saturated thiosulfate solution and stirred for 5 min. The organic phase was dried over MgSO 4 and concentrated. The residue was purified by flash chromatography with methylene chloride/methanol/conc. NH 3 (30/5/1 to 30/10/3). Yield of product 10: 8.0 g as amorphous solid. TLC: methylene chloride/methanol (20/1), R f =0.5. MS: (M+Li) + =3583.6, calculated C 207 H 214 N 8 O 42 SP 2 , M=3580.0.
[0113] For synthesis of product 11 ( FIG. 6 ; xi), 300 ml of ammonia were condensed at −78° C. 2.1 g (91 mmol) of sodium was dissolved therein. This solution was diluted with 150 ml of dry tetrahydrofurane and 8.0 g of product 10 (2.2 mmol) of the protected final product dissolved in 50 ml of dry tetrahydrofurane were then slowly added dropwise at a reaction temperature of −78° C. After a reaction time of 15 min (blue color must not disappear), the mixture was treated cautiously with 5 g of ammonium chloride. When the blue color had disappeared, the mixture was diluted cautiously with 50 ml of water and 150 ml of methanol. It was allowed to thaw and then concentrated to about 100 ml. This solution was diluted with 500 ml of methylene chloride/methanol/33% NH 3 (3/3/1) and added to a flash silica gel column (500 ml of silica gel). It was eluted sequentially with 1 l each of methylene chloride/methanol/33% NH 3 (3/3/2) and (3/3.5/3). The product eluted was then chromatographed using n-butanol/ethanol/water/33% NH 3 (2/2/2/1). Yield of product 11: 2.4 g (67% from product 9) as a white solid. TLC: n-butanol/ethanol/water/33% NH 3 (2/2/2/1), R f =0.5. MS: (M+NH 3 ) + =1572.6; calculated C 54 H 88 N 6 O 40 P 2 S, M=1555.31. 31 P-NMR (D 2 O)=15.3 ppm for cyclic phosphate and 0.3 for phosphordiester. The data from 1 H- and 13 C-NMR are shown in Table 1.
[0114] For synthesis of product YCN ( FIG. 7 ; xii), 11.0 g (11.3 mmol) of product 7 was deprotected analogously to the preparation of product 11. Yield of YCN: 4.5 g (90%) of white crystals. TLC: methylene chloride/methanol/concentrated ammonia (30/15/5), R f =0.25. MS: (M+Li) + =448.3, calculated C 18 H 27 N 5 O 6 S, M=441.51.
[0115] For synthesis of product YMN-PIG, YMN-PIG was synthesized with the same reaction sequence as shown in FIG. 2 . The use of BocMetOH instead of TrtCys(Trt)OH resulted in YMN-PIG in similar yields as a white solid. TLC: n-butanol/ethanol/water/33% NH 3 (2/2/2/1), R f =0,5. MS: (M+NH 3 ) + =1600.6; calculated C 56 H 92 N 6 O 40 P 2 S, M=1583.38. 31 P-NMR (D 2 O)=15.3 ppm for cyclic phosphate and 0.3 for phosphordiester.
[0000] Preparation of Radiolabeled and Lipolytically Cleaved Gce1p (IcGce1p)
[0116] Gce1p with intact GPI anchor was purified from lactate-grown yeast cells which had been metabolically labeled with myo-[ 14 C]inositol and then enzymatically converted to spheroplasts. Plasma membranes were prepared, purified by Ficoll gradient centrifugation, solubilized using 0.35% β-amidotaurocholate and subjected to TX-114 partitioning. Gce1p contained in the detergent-enriched phase was purified by gel filtration chromatography on Sephadex S-300, affinity chromatography on N 6 -(2-aminoethyl)-cAMP Sepharose and phenyl Sepharose chromatography. Elution from the columns was followed by on-line monitoring of 3 H-radioactivity. Partially purified Gce1p was precipitated (12% polyethylene glycol 6000), then resuspended in buffer G (25 mM Tris/acetate, pH 7.4, 144 mM NaCl, 0.1% β-amidotaurocholate, 0.5 mM DTT, 0.2 mM EDTA, 5% glycerol, 0.1 mM PMSF, 5 μM leupeptin, 1 mM iodoacetamide, 10 μg/ml soy bean trypsin inhibitor) at 0.2 mg protein/ml and subsequently incubated (3 h, 25° C.) in the presence of 6 U/ml PI-specific PLC ( B. cereus ). After addition of 10 volumes of an ice-cold solution of 2% Triton X-114, 10 mM Tris/HCl (pH 7.4), 144 mM NaCl and phase separation (incubation for 2 min at 37° C. and centrifugation at 12,000×g for 1 min at 25° C.), IcGce1p was recovered from the upper detergent-depleted phase. After two reextractions of the lower detergent-enriched phase by addition of an equal volume of 10 mM Tris/HCl, 144 mM NaCl, redissolvation on ice and subsequent phase separation, the combined detergent-depleted phases were precipitated (12% polyethylene glycol 6000).
[0117] Radiolabeled IcGce1p was supended in buffer lacking β-amidotaurocholate at 200-1000 dpm/μl.
[0000] Preparation of Radiolabeled YCN-PIG
[0118] Radiolabeled YCN-PIG was derived from Gce1p by sequential digestion with V8 protease ( S. aureus ) and PI-PLC ( B. cereus ). YCN-PIG was recovered from the detergent-depleted phase after TX-114 partitioning and then sequentially purified by cation exchange chromatography (Dowex 50W-X8), gel filtration on BioGel-P4, anion change chromatography on SAX HPLC column, two thin layer chromatographic runs on Si-60 HPTLC plates using different solvent systems and a final gel filtration on BioGel-P4. The elution of material during each chromatographic separation was followed by measurement of 3 H-radioactivity, UV absorption (A 220 ) and insulin-mimetic activity according to stimulation of glucose transport in isolated rat adipocytes. For demonstration of radiochemical purity, the final preparation of YCN-PIG was subjected to Dionex CarboPac PA-1 anion exchange HPLC at pH 13 calibrated in Dionex units by inclusion of a glucose oligomer standard mix. The internal standards were detected using a pulsed amperiometric detector. The 14 C-labeled fragments were followed by the Raytest Ramona on-line radioactivity monitor. For determination of the concentration, YCN-PIG were hydrolyzed (6 M HCl, 16 h, 110° C.) and the amount of inorganic phosphate (2 mol/molecule) and tyrosine (1 mol/molecule ) was determined. Dried YCN-PIG was stored at −80° C. until use and then suspended in H 2 O containing 2 mM DTT at a final concentration of 100 μM.
[0000] Preparation of Rat Adipocytes and Incubation with PIG(-P)/YCN
[0119] Adipocytes were isolated by collagenase digestion from epididymal fat pads of male Sprague Dawley rats (140-160 g, fed ad libitum) and incubated in KRH buffer (0.14 mM NaCl, 4.7 mM KCl, 2.5 mM CaCl 2 , 1.2 mM MgSO 4 , 1.2 mM KH 2 PO 4 , 20 mM Hepes/KOH, pH 7.4) containing 1% (w/v) BSA, 100 μg/ml gentamycin, 100 mM 1-methyl-2-phenylethyladenosine, 0.5 U/ml adenosine deaminase, 0.5 mM sodium pyruvate and 5 mM D-glucose in the presence of PIG(-P)/YCN (dissolved in 20 mM Hepes/KOH, pH 7.4, 2 mM DTT) at 37° C. in a shaking water bath at constant bubbling with 5% CO 2 /95% O 2 for the periods indicated.
[0000] Treatment of Rat Adipocytes with Trypsin/NaCl or NEM
[0120] For trypsin/NaCl-treatment, 2 ml of adipocyte suspension (3.5×10 6 cells/ml) in KRH containing 5 mM glucose was incubated (20 min, 30° C.) in the presence of 100 μg/ml trypsin. Soy bean trypsin inhibitor (final conc. 100 μg/ml) and 2 ml of KRH containing 1 M NaCl and 0.5% BSA were added and the incubation (10 min, 22° C.) continued. For NEM-treatment, 1 ml of adipocyte suspension (3.5×10 6 cells/ml) in KRH containing 5 mM glucose was incubated (30 min, 25° C.) with NEM (1.5 mM final conc.) and then with DTT (15 mM final conc., 5 min). After the treatments, the cells were centrifuged (1500×g, 5 min, swing-out rotor) and the infranatant removed by suction. The cell suspension left (about 0.5 ml) was supplemented with 10 ml of KRH containing 0.5% BSA and then centrifuged again (500×g, 1 min, swing-out rotor). After two additional washing steps, the final cell suspension was adjusted to 25 ml of KRH containing 0.5% BSA, 50 μM glucose and 1 mM sodium pyruvate. 0.2 ml portions were assayed for lipigenesis to monitor the loss of responsiveness toward PIG41. Control cells were subjected to the same centrifugation and washing procedures as the treated cells with H 2 O replacing trypsin/NaCl. For radiolabeling of adipocytes with [ 14 C]NEM, the cell suspension was centrifuged (500×g, 1 min) and the infranatant removed. 50-μl portions (7×10 6 cells/ml) were incubated (10 min, 30° C.) with 2.5 μCi[ 14 C]NEM in a total volume of 60 μl. After addition of 5 μl of 10 mM DTT and 55 μl of KRH containing 10 mM glucose, the trypsin/NaCl-treatment was performed as described above in a total volume of 200 μl. 50-μl portions were carefully layered over 200-μl oil layers consisting of dinonyl phthalate in 0.4-ml centrifugation tubes. After centrifugation (5,000×g, 15 sec), the tubes were cut through the oil layer. Proteins of the medium contained in the lower part of the tubes were precipitated (10% TCA, two acetone washes), suspended in Laemmli sample buffer and analyzed by SDS-PAGE.
[0000] Preparation of Plasma Membranes, Total Cell Lysates and Micosomes
[0121] Postnuclear infranatant was prepared from isolated rat adipocytes as described previously. For preparation of plasma membranes, 1 ml portions were layered on top of 5 ml cushions of 38% (w/v) sucrose, 25 mM Tris/HCl (pH 7.4), 1 mM EDTA, and centrifuged (110,000×g, 1 h). The membranes at the interface between the two layers (0.5 ml) were removed by suction, diluted with four volumes of homogenization butter, and layered on top of an 8 ml cushion of 28% Percoll, 0.25 M sucrose, 1 mM EDTA, 25 mM Tris/HCl (pH 7.0). After centrifugation (45,000×g, 30 min), the plasma membranes were withdrawn from the lower third of the gradient (0.5 ml) with a Pasteur pipette, diluted with 10 volumes of homogenization buffer and centrifuged (200,000×g, 90 min). For binding studies, the washed pellet was suspended in binding buffer at 1-2 mg protein/ml. For preparation of total cell lysates, the postnuclear infranatant was supplemented with deoxycholate and Nonidet P-40 (final conc. 0.3 and 0.2%, respectively), incubated (1 h, 4° C.) and finally centrifuged (100,000×g, 1 h, 4° C.). The supernatant was used for immunoprecipitation. For preparation of microsomes, the postnuclear supernatant was centrifuged (100,000×g, 1 h, 4° C.). The pellet was suspended in binding buffer at 1-2 mg protein/ml.
[0000] Preparation of hcDIGs/IcDIGs
[0122] Purified pelleted plasma membranes (0.5-1 mg) were suspended in 1.5 ml of ice-cold 0.5 M Na 2 CO 3 (pH 11) containing 50 mM NaF, 5 mM sodium pyrophosphate, 10 μM okadaic acid, 1 mM sodium orthovanadate, 20 μM leupeptin, 5 μM pepstatin, 1 μM aprotinin, 5 mM iodoacetate, 200 μM PMSF, 1 mM EDTA and incubated (1 h, 4° C. under repeated vortexing and suction with a pipette). The suspension was then mixed with an equal volume of 85% sucrose in 15 mM MES/KOH (pH 6.5), 75 mM NaCl and overlaid with 1.5 ml cushions each of 42.5, 35, 28, 22, 15 and 5% sucrose in the same medium, and centrifuged (230,000×g, Beckman SW41 rotor, 18 h). The light-scattering opalescent bands of flocculent material at the 15-22% (fractions 4 and 5) and 28-35% (fractions 8 and 9) sucrose interfaces as well as the material of the 42.5% cushions (fractions 12-15) were collected as hcDIGs, IcDIGs and solubilized plasma membrane proteins, respectively, using a 19-gauge needle and a syringe (0.75 ml per fraction). Density was determined by measuring the refractive index of the fractions. hc/IcDIGs were characterized by enrichment/deprivation of relevant markers as described previously. For binding studies, hc/IcDIGs were suspended in binding buffer (15 mM Mes/KOH, pH 6.5, 0.25 M sucrose, 75 mM NaCl, 2 mM MgCl 2 , 0.5 mM EDTA, 0.5 mM DTT, protease inhibitors).
[0000] Binding of Radiolabeled YCN-PIG or IcGce1p to Subcellular Fractions
[0123] 10 μl, of radiolabeled YCN-PIG or IcGce1p (60,000-80,000 dpm/nmol, final conc. 5 μM) was added to 40 μl of suspended plasma membranes, microsomes or hc/IcDIGs (40-80 μg of protein) in binding buffer in the absence or presence of unlabeled competitor (as indicated in the figure legends) in a total volume of 100 μl and incubated (30 min, 4° C.). For separation of membranes from the incubation medium, 45 μl aliquots were carefully layered over 200 μl, oil layers consisting of dibutyl phthalate and dioctyl phthalate (1/1 by vol., final density 1.012) in case of plasma membranes/microsomes or dibutyl phthalate and dinonyl phthalate (1/9 by vol., final density 9.863) in case of hc/IcDIGs in 0.4 ml precooled (4° C.) centrifugation tubes (microtubes no. 72.700, Sarstedt, Germany). After centrifugation (48,000×g, 2 min), the tubes with caps closed were cut through the oil layer and the lower and upper parts of the tubes (with caps removed) containing the pelleted plasma membranes/microsomes and the floating hc/IcDIGs, which did or did not penetrate the oil layer, respectively, transferred into 10 ml scintillation vials containing 1 ml of 10% SDS. After rigorous shaking (16 h, 25° C.), the radioactivity was counted in 9 ml of ACSII scintillation cocktail (Beckman). Under these conditions, sticking to the tube walls and partitioning into the oil layer of both radiolabeled YCN-PIG and IcGce1p accounted for 50-120 dpm (i.e. less than 0.5% of total radioactivity used per incubation) and therefore was not considered for calculation of binding data. Typical recoveries of plasma membranes and microsomes were 78-85% and 65-80%, respectively, and of hcDIGs and IcDIGs 83-92% and 70-78%, respectively, according to protein determination.
[0000] Chemical Synthesis of PIG(-P)
[0124] Hydrophilic GPI structures can be generated from natural sources by two experimental approaches: (i) PIG released by GPI-specific PLC/D from free GPI lipids as their polar core glycan head groups and therefore lacking any amino acids and (ii) PIG-P generated by combined lipolytic and proteolytic cleavages from a GPI protein yielding the polar core glycan head group together with one to several amino acids derived from the carboxy-terminus of the GPI protein left. Both GPI lipids and GPI proteins reside in the outer leaflet of the plasma membrane of eucaryotic cells with the core glycan head groups conserved from yeast to man. For assaying binding of the GPI core glycan head group, the disclosure of synthesis of a radiolabeled authentic PIG(-P) structure as described in “Müller et al., Endocrinology 138, 3459-3475, 1997”; was used; YCN-PIG prepared from the radiochemically pure GPI protein, Gce1p, of the plasma membrane from S. cerevisiae, which had been metabolically labeled with myo-[ 14 C]inositol, by sequential proteolytic and lipolytic cleavages in vitro. For assessing the structure-activity relationship for binding, chemically synthesized YCN-PIG and derivatives thereof were used. ( FIG. 1 : YCN-PIG; FIG. 2 : YMN-PIG; FIG. 3 : PIG37; FIG. 4 : YCN)
[0125] Synthesis of the tripeptide of YCN-PIG was performed by means of state of the art peptide synthesis. The hexasaccharide was synthesized using the trichloroacetimide method as described in “Frick et al., Biochemistry 37, 13421-13436; 1998”. The critical step in synthesis of PIG-P turned out to be the formation of the phosphodiester bond. Among various procedures tested the H-phosphonate method produced the most yield.
[0126] Deprotection of the final compounds was performed under sodium in liquid NH 3 enforced by the presence of cysteine (no hydration possible with palladium) and acid-labile cyclic phosphate. All compounds were characterized by mass, 1 H-NMR, 13 C-NMR and 31 P-NMR spectroscopy.
[0000] PIG(-P) Specifically Bind to hcDIGs
[0127] Total plasma membranes prepared from unstimulated adipocytes by differential centrifugation were enriched (vs. total cell lysates) for specific marker enzymes of the plasma membrane. Quabain-sensitive p-nitrophenylphosphatase (corresponding to the catalytic subunit of the Na + /K + -ATPase) was enriched 9.5-fold and Nuc 10.9-fold (according to enzymic activities), β 1 -integrin 13.9-fold and syntaxin-1 16.4-fold (according to immunoblotting) and Gce1 7.8-fold (according to photoaffinity labelling). Simultaneously, the plasma membrane preparation was deprived (vs. total cell lysates) of the sarcoplasmic reticulum marker, EGTA-sensitive Ca 2+ -adenosine triphosphatase 5.7-fold and of the endosomal markers, SCAMP (Secretary Carrier Membrane Protein) 37/39 8.5-fold and GLUT4 (Glucose Transporter 4) 16.9-fold (according to immunoblotting). Microsomes from unstimulated adipocytes were enriched vs. total cell lysate for GLUT4 by 14.4-fold, SCAMP 37/39 by 8.5-fold, transferrin receptor by 6.9-fold and IGFII receptor by 9.7-fold and deprived vs. total cell lysates of p-nitrophenyl-phosphatase by 24.6-fold, Gce1 by 12.5-fold, Nuc by 15.8-fold, β 1 -integrin by 39.5-fold and syntaxin-1 by 48.5-fold according to immunoblotting and of Ca 2+ -sensitive adenosine triphosphatase activity by 19.9-fold. This indicates that this fraction represented primarily endoplasmic reticulum and endosomal structures and was virtually devoid of plasma membranes and sarcoplasmic reticulum fragments. hsDIGs and IcDIGs were prepared from unstimulated adipocytes on basis of their insolubility in 0.5 M Na 2 CO 3 (pH 11) and low buoyant density in sucrose density gradient centrifugation. They were characterized by their deprivation (vs. total plasma membranes) of GLUT4 and the insulin receptor β-subunit. hcDIGs and IcDIGs differed from one another in significantly higher enrichment of caveolin, pp59 Lyn and Gce1 in hcDIGs compared to IcDIGs.
[0128] Isolated subcellular membrane fractions were incubated with increasing amounts of radiolabeled YCN-PIG and the incubation terminated by rapid separation from the incubation medium by centrifugation through an oil layer of appropriate density.
[0129] Membrane-associated YCN-PIG was recovered predominantly with hcDIGs in concentration-pependent and saturable fashion and to a minor degree with IcDIGs, whereas plasma membranes and microsomes were virtually devoid of radiolabel ( FIG. 5 ). Within the linear range, unspecific binding of YCN-PIG to hcDIGs accounted for less than 20% as assessed by the presence of a 500 fold excess of unlabeled synthetic YCN-PIG or other competitors ( FIG. 5 ). The following experiments were performed using a concentration of YCN-PIG, corresponding to the end of the linear range of binding.
[0130] Other methods for determination of receptor-ligand interaction, such as rapid filtration and centrifugation on basis of sedimentation rather than density, failed to detect specific binding of YCN-PIG to any adipocyte membrane subfraction (data not shown), presumably due to the medium binding affinity and/or high dissociation rate. Scatchard plot analysis for YCN-PIG revealed a K d in the range of 50 nM-500 nM and a B max of 50-200 pmol per mg protein of hcDIGs. The specificity of binding of YCN-PIG to hcDIGs was demonstrated by significantly reduced efficacy of the peptide variants, YMN-PIG and PIG37 lacking the peptidylethanolamidyl moiety, as well as the very low activity of the peptidylethanolamidyl moiety, YCN, alone in the competition assay ( FIG. 6 ).
[0131] A combination of unlabeled YCN plus PIG37 (equimolar ratio) displaced binding of radiolabeled YCN-PIG to hcDIGs only slightly less efficiently than unlabeled YCN-PIG and more potently than either the PIG or peptidylethanolamidyl moiety alone as well as YMN-PIG. This finding demonstrates simultaneous and synergistic recognition of the PIG and peptidylethanolamidyl moieties. The IC 50 for competition was just 3 to 4 fold higher for YCN plus PIG37 compared to covalently linked YCN-PIG ( FIG. 6 ). Further it was studied whether the identified binding site for PIG(-P) is of proteinaceous nature. hcDIGs were pretreated with trypsin/NaCl or NEM and then incubated with increasing concentrations of radiolabeled YCN-PIG in the absence or presence of excess of unlabeled synthetic YCN-PIG (for evaluation of unspecific binding).
[0132] Sequential treatment with trypsin and 0.5 M NaCl or treatment with NEM completely abrogated specific binding of radiolabeled YCN-PIG to hcDIGs, whereas trypsin or NaCl alone or NEM in the presence of DTT had no significant effect ( FIG. 7 ). The identical inactivation pattern was observed for the lower affinity interaction of YCN-PIG with IcDIGs. These data demonstrate the existence of a trypsin/NaCl and NEM-sensitive binding protein for PIG(-P) at DIGs of the adipocyte cell surface. The preference of YCN-PIG for binding to hcDIGs compared to IcDIGs was confirmed by their conversion in course of cholesterol depletion of the adipocytes plasma membrane using m-βCD and subsequent analysis of hc/IcDIGs for specific binding of radiolabeled YCN-PIG. In control adipocytes, the major portion of YCN-PIG was recovered along with hcDIGs compared to 20% left associated with IcDIGs ( FIG. 8 ). However, treatment of intact rat adipocytes with m-βCD (1-10 mM) revealed a concentration-dependent decline in the amount of YCN-PIG bound to hcDIGs accompanied by corresponding increase at IcDIGs. Trypsin/NaCl or NEM treatment of the adipocytes after cholesterol depletion but before preparation of the DIGs significantly impaired specific binding of YCN-PIG to both hcDIGs and IcDIGs (data not shown). These findings demonstrate the predominant location of the PIG(-P) receptor in hcDIGs of rat adipocytes the formation of which critically depends on cholesterol.
[0000] A Lipolytically Cleaved GPI Protein Specifically Binds to hcDIGs
[0133] The PIG moiety, —NH—(CH 2 ) 2 O—PO(OH)O-6Manα1(Manα1-2)-2Manα1-6Manα1-4GluN1-6Ino-1,2-(cyclic)-phosphate, of YCN-PIG, YMN-PIG and PIG37 ( FIGS. 1, 2 and 3 ) is identical to the polar core glycan head group of all eucaryotic GPI proteins. Consequently, it was studied whether the proteinaceous binding site for PIG-P interacts with IcGPI proteins, i.e. whether it recognizes the PIG(-P) moiety if attached to the complete polypeptide portion of a GPI protein. In order to obtain a radiolabeled IcGPI protein, Gce1p from metabolically labeled S. cerevisiae cells was treated with PI-specific PLC ( B. cereus ) and the hydrophilic cleavage product purified to radiochemical homogeneity. Using the same oil-centrifugation-method as for PIG(-P), it was found that IcGce1p associated with DIGs from isolated rat adipocytes in a concentration-dependent and saturable fashion with hcDIGs being 11- to 15-fold more efficient than IcDIGs. Unspecific binding in the presence of a 200 fold molar excess of unlabeled IcGce1p accounted for less than 15% of the total IcGce1p recovered with DIGs at non-saturating concentrations of IcGce1p. According to Scatchard plot analysis, the K d for IcGce1p binding to hcDIGs is in the range of 0.1-1 μM with B max of 70-200 pmol per mg protein of hcDIGs. Total plasma membranes and microsomes did not exhibit specific binding of IcGce1p. Thus, hcDIGs of the adipocyte plasma membranes apparently harbor specific binding sites for IcGce1p p from yeast. For further analysis of the identity of the binding sites for PIG(-P) and IcGPI proteins as indicated by the similar K d and B max values, the relative affinities of the synthetic PIG(-P) compounds for the IcGce1p binding site at hcDIGs were compared in competition studies ( FIG. 9 ).
[0134] The binding of radiolabeled IcGce1p to hcDIGs was displaced by excess (more than 500 fold) of labeled synthetic YCN-PIG, YMN-PIG and YCN plus PIG37 by more than 75% of total IcGce1p bound confirming the specificity of the interaction of IcGce1p with hcDIGs. Competition of IcGce1p binding with PIG37 and YCN was considerably less efficient. The relative ranking of the different PIG(-P) as reflected in their apparent IC 50 for displacing IcGce1p from hcDIGs was YCN-PIG>YCN+PIG37>YMN-PIG>PIG37>YCN and is, thus, identical to that for interference with YCN-PIG binding ( FIG. 6 ). Moreover, the apparent IC 50 values were very similar for competition of IcGce1p and YCN-PIG binding arguing that in both cases the same determinants are recognized and the residual protein moiety of the GPI protein (except of the carboxy-terminal tripeptidylethanolamidyl residue) does not contribute to binding. Next the sensitivity of the interaction of IcGce1p with hcDIGs toward trypsin/NaCl— and NEM-treatment of intact rat adipocytes was studied under conditions which almost completely disrupted binding of radiolabeled YCN-PIG ( FIG. 7 ). hcDIGs from trypsin/NaCl— as well as NEM-treated adipocytes displayed association of radiolabeled IcGce1p not exceeding unspecific binding in the presence of a 500 fold excess of unlabeled YCN-PIG (which accounts for about 30% of total Gce1p recovered with hcDIGs from untreated control cells) ( FIG. 10 ). In contrast, incubation of the adipocytes with NEM in the presence of excess of DTT ( FIG. 10 ) or with either trypsin or NaCl alone (data not shown) did not impair binding of radiolabeled IcGce1p and its competition by 3 μM YCN+PIG37, 5 μM PIG37 and 10 μM YCN compared to untreated cells. Taken together, the specific binding sites for YCN-PIG and IcGce1p display very similar characteristics with regard to localization at hcDIGs of the adipocyte plasma membrane, absolute and relative affinities (to structural derivatives), expression level and sensitivity toward both trypsin/NaCl and NEM.
[0000] Endogenous Ligands for the Receptor for PIG(-P) and IcGPI Proteins
[0135] Candidates for physiological ligands of the apparently identical binding sites for PIG(-P) and IcGPI proteins are uncleaved GPI structures, i.e. GPI lipids and/or GPI protein anchors. To test this possibility, isolated rat adipocytes were subjected to treatment with various GPI-specific PLs and subsequent salt wash (0.5 M NaCl) prior to preparation of hcDIGs in order to specifically remove putative endogenous GPI molecules which interact with the receptor and thereby mask the binding sites for YCN-PIG/IcGce1p.
[0136] Incubation of rat adipocytes with increasing concentrations of PI-specific PLC from B. cereus or GPI-specific PLD from human serum resulted in a concentration-dependent increase in the amounts of radiolabeled YCN-PIG and Gce1p which specifically bind to hcDIGs ( FIG. 11 ). The efficiency of the lipolytic digestions was demonstrated in parallel by the loss of Gce1p and Nuc from hcDIGs.
[0137] Their losses by 75 and 65%, respectively, correlated with the increase in binding of YCN-PIG or IcGce1p to hcDIGs by 200 and 260%. The specificity of the GPI cleavages was demonstrated by the complete failure of PC-specific PLC ( B. cereus ) and PLD from cabbage (which do not attack GPI structures) to significantly displace Gce1 or Nuc from hcDIGs as well as to stimulate YCN-PIG (IcGce1p) binding to hcDIGs ( FIG. 11, 12 ). Scatchard plot analysis of specific binding to hcDIGs from PI-specific PLC-prepreated adipocytes (unspecific binding was not significantly altered) revealed that the increased association of radiolabeled YCN-PIG/IcGce1p was mainly due to the 2 to 3 fold higher B max with almost unaltered K d . These findings demonstrate that about 50% of the binding sites for PIG(-P) or IcGPI proteins at hcDIGs in isolated rat adipocytes in the basal state are occupied by endogenous GPI structures cleavable by (G)PI-specific PLC/D. Remarkably, insulin at a physiological concentration mimicked the effect of GPI-specific PLC/D treatment in rat adipocytes to a certain degree causing a moderate, but significant, decline in the amounts of Gce1p and Nuc in hcDIGs. Insulin-induced loss of GPI proteins from hcDIGs led to marked increase of binding capacities for YCN-PIG or IcGce1p ( FIG. 11, 12 ).
[0138] Furthermore, it could be demonstrated that the receptor for PIG(-P) and IcGPI proteins is identical to the trypsin/NaCl and NEM-sensitive 115 kDa protein which was called CIR.
[0139] Binding of PIG-P to the receptor will affect its accessibility to subsequent covalent modification by NEM and/or cleavage and release from the adipocyte cell surface by trypsin/NaCl.
[0140] Rat adipocytes were incubated with PIG(-P) and then sequentially subjected to labeling with [ 14 C]NEM and treatment with trypsin/NaCl. Analysis of the released radiolabeled polypeptides by SDS-PAGE and phosphorimaging revealed ( FIG. 13 ) that PIG(-P) reduced crosslinking of a 115 kDa polypeptide by [ 14 C]NEM and/or its recovery from the infranatant of adipocytes after trypsin/NaCl-treatment. The reduction by YCN-PIG or PIG37 at 3 μM and YCN at 30 μM was 83, 65 and 28%, respectively, compared to control cells. This protein represented the only major NEM-labeled component which was released from plasma membranes by trypsin/NaCl but not by either treatment alone ( FIG. 13 ) and is identical with CIR. In agreement with experimental evidence for the existence of endogenous ligands (e.g. GPI proteins) and their removal from the corresponding binding site by lipolytic cleavage (see FIG. 11, 12 ), treatment of adipocytes with exogenous PI-specific PLC ( B. cereus ) or insulin slightly but reproducibly stimulated the trypsin/NaCl-dependent release of [ 14 C]NEM-labeled CIR by 30 and 20%, respectively ( FIG. 13 ). Since the relative ratio of release of CIR from the adipocyte cell surface by trypsin/NaCl— vs. trypsin- vs. NaCl-treatment (100/20/10) was roughly comparable in control, PIG(-P)-stimulated and PLC/insulin-treated cells, binding of PIG(-P) and endogenous GPI ligands to hcDIGs apparently impairs labeling of CIR by NEM rather than its tryptic cleavage. This is caused by a conformational change in CIR elicited by the interaction of ligands with the PIG(-P) receptor at hcDIGs of the adipocyte plasma membrane.
TABLE 1 1 H and 13 C chemical shifts [ppm] for YCN-PIG in D 2 O, pD = 8.1 (uncorr.) Residue Position 1 H [ppm] 13 C [ppm] Tyrosine CO — ? α 4.12 55.18 β 2.99, 3.03 37.05 γ — 125.90 δ 7.05 131.20 ε 6.77 116.57 ζ — 155.30 Cysteine CO — ? α 4.56 n.d. β 2.64, 2.71 37.35 Asparagine CO — n.d. α 4.58 n.d. β 2.89, 3.05 37.05 γ-CO — ? Ethanolamine 1 n.d. n.d. 2 n.d. n.d. Mannose 1 1 4.93 102.84 2 3.96 70.83 3 3.73 71.05 4 3.64 67.19 5 3.67 73.91 6 n.d. n.d. Mannose II 1 5.18 101.40 2 4.01 79.10 3 3.87 70.60 4 3.70 67.12 5 3.76 72.87 6 n.d. n.d. Mannose III 1 4.98 99.07 2 3.89 79.69 3 3.59 73.45 4 n.d. n.d. 5 n.d. 70.85 6 n.d. n.d. Mannose IV 1 5.08 102.62 2 3.95 70.91 3 3.68 71.08 4 3.51 67.60 5 3.73 73.21 6 n.d. 67.15 Glucosamine 1 4.86 100.12 2 3.00 57.00 3 3.75 72.89 4 3.58 77.88 5 3.46 75.99 6 3.65, 3.78 61.68 Inositol 1 4.35 78.52 2 4.62 78.09 3 3.62 70.24 4 3.56 72.60 5 3.37 72.57 6 3.96 82.39
[0141] Specific binding of PIG(-P) to hcDIGs is shown in FIG. 12 . Increasing amounts of radiolabeled YCN-PIG isolated from S. cerevisiae were incubated (1 h, 4° C.) with hcDIGs (6.5 μg protein), IcDIGs (6.5 μg), plasma membranes (47.5 μg) and microsomes (68 μg) from isolated rat adipocytes. The membrane fractions/DIGs were subjected to oil-layer-centrifugation, recovered with/from the pellet/top of the oil layer, solubilized and counted for radioactivity. Specific binding was calculated as the difference between radioactivity measured in the absence and presence of 10 μM unlabeled YCN-PIG. Each point represents the mean±SD of triplicate incubations using at least 4 different membrane preparations.
[0000] Specific Binding of PIG-P to hcDIGs is Shown in FIG. 13
[0142] Radiolabeled YCN-PIG (18,000-22,000 dpm) was incubated (1 h, 4° C.) with hcDIGs (6.5 μg protein) in the absence or presence of increasing amounts of unlabeled YCN-PIG, YCN+PIG37, YMN-PIG, PIG37 and YCN (Competition). The membrane fractions/DIGs were subjected to oil-layer-centrifugation, recovered with/from the pellet/top of the oil layer, solubilized and counted for radioactivity.
[0000] Characterization of the Binding Site for PIG-P at hcDIGs is Shown in FIG. 14 .
[0143] Increasing amounts of radiolabeled YCN-PIG isolated from S. cerevisiae were incubated (1 h, 4° C.) with hcDIGs (6.5 μg protein) from isolated rat adipocytes which had been pretreated with trypsin/NaCl, trypsin, NEM+DTT, NaCl or NEM or left untreated (Control). DIGs were subjected to oil-layer-centrifugation, recovered from top of the oil layer, solubilized and counted for radioactivity. Specific binding was calculated as the difference between radioactivity measured in the absence and presence of 10 μM unlabeled YCN-PIG. Each point represents the mean±SD of triplicate incubations using at least 3 different adipocyte pretreatments.
[0000] Characterization of the Binding Site for PIG-P at hcDIGs is Shown in FIG. 15 .
[0144] Radiolabeled YCN-PIG (12,000-18,000 dpm) was incubated (1 h, 4° C.) with the (proportional) amounts of hcDIGs and IcDIGs prepared from isolated rat adipocytes which had been pretreated (50 min, 30° C.) with increasing concentrations of m-βCD or left untreated. DIGs were subjected to oil-layer-centrifugation, recovered from top of the oil layer, solubilized and counted for radioactivity measured in the absence and presence of 10 μM unlabeled YCN-PIG. Each point represents the mean±SD of triplicate incubations using at least 3 different adipocyte pretreatments.
[0000] Specific Binding of IcGce1p to hcDIGs is Shown in FIG. 16 .
[0145] Radiolabeled Gce1p prepared from S. cerevisiae and treated with PI-specific PLC ( B. cereus ) was incubated (1 h, 4° C.) with hcDIGs (6.5 μg protein) isolated from untreated rat adipocytes in the absence or presence of unlabeled PIG-P. hcDIGs were subjected to oil-layer-centrifugation, solubilized and counted for radioactivity. Each point represents the mean±SD of quadruplicate incubations using at least 3 different hcDIG preparations and adipocyte pretreatments, respectively.
[0000] Specific Binding of IcGce1p to hcDIGs is Shown in FIG. 17 .
[0146] Radiolabeled Gce1p prepared from S. cerevisiae and treated with PI-specific PLC ( B. cereus ) was incubated (1 h, 4° C.) with hcDIGs (6.5 μg protein) isolated from adipocytes which had been pretreated with trypsin/NaCl, NEM, NEM+DTT or left untreated (Control) in the absence or presence of unlabeled YCN-PIG (final conc. 3 μM), YCN+PIG37 (3 μM), PIG37 (5 μM) and YCN (10 μM). hcDIGs were subjected to oil-layer-centrifugation, solubilized and counted for radioactivity. Each point represents the mean±SD of quadruplicate incubations using at least 3 different hcDIG preparations and adipocyte pretreatments, respectively.
[0000] Effect of PL and Insulin Treatment of Adipocytes on Binding of YCN-PIG and IcGce1p to hcDIGs is Shown in FIG. 18 .
[0147] Isolated rat adipocytes (7×10 7 cells/ml) were incubated (30 min, 30° C.) with the indicated amounts of PI-specific PLC ( B. cereus ), PC-specific PLC ( B. cereus ), GPI-specific PLD (human serum) or PLD (cabbage) or human insulin in a total volume of 2 ml under mild shaking under 5% CO 2 /95% O 2 . After addition of 2 ml of 1 M NaCl, the adipocytes were washed by flotation. hcDIGs were isolated and 6.5 μg aliquots incubated (1 h, 4° C.) with radiolabeled IcGce1p prepared from S. cerevisiae and YCN-PIG (15,000-25,000 dpm) in the absence or presence of unlabeled YCN-PIG (final conc. 10 μM), subjected to oil-layer-centrifugation, recovered from top of the oil layer, solubilized and counted for radioactivity. Specific binding was calculated as the difference between absence and presence of YCN-PIG. Each point represents the mean±SD of triplicate incubations using at least two different hcDIGs preparations.
[0000] Effect of PL and Insulin Treatment of Adipocytes on Binding of YCN-PIG and IcGce1p to hcDIGs is Shown in FIG. 19 .
[0148] Isolated rat adipocytes (7×10 7 cells/ml) were incubated (30 min, 30° C.) with the indicated amounts of PI-specific PLC ( B. cereus ), PC-specific PLC ( B. cereus ), GPI-specific PLD (human serum) or PLD (cabbage) or human insulin in a total volume of 2 ml under mild shaking under 5% CO 2 /95% O 2 . After addition of 2 ml of 1 M NaCl, the adipocytes were washed by flotation. hcDIGs were isolated and 6.5 μg aliquots incubated (1 h, 4° C.) with radiolabeled IcGce1p prepared from S. cerevisiae and YCN-PIG (15,000-25,000 dpm) in the absence or presence of unlabeled YCN-PIG (final conc. 10 μM), subjected to oil-layer-centrifugation, recovered from top of the oil layer, solubilized and counted for radioactivity.
[0000] Effect of PIG(-P), PI-Specific PLC and Insulin on NEM-Labeling of CIR is Shown in FIG. 20 .
[0149] Isolated rat adipocytes were incubated (30 min, 37° C.) in the absence (Control) or presence of PIG37, YCN-PIG, YCN, PI-PLC ( B. cereus ) or insulin at the concentrations given and then labeled with [ 14 C]NEM. After treatment with trypsin/NaCl as indicated, the adipocytes were separated from the incubation medium by centrifugation through an oil layer. Proteins were recovered from the medium (below the oil layer) and resolved by SDS-PAGE.
[0150] Phosphorimages are shown from a typical experiment repeated three times with similar results. Quantitative evaluation of four different adipocyte incubations with triplicate measurements given as arbitrary units (mean±SD) with the amount of CIR released from trypsin/NaCl-treated control cells set at 100.
[0151] All documents referred to herein are incorporated herein by reference in their entirety, including the priority document, EP 02015047.0, filed Jul. 5, 2002. | The invention refers to a protein from plasma membrane of adipocytes. The protein has specific binding affinity to phosphoinositoylglycans. It regulates glucose uptake by circumventing the insulin signaling cascade. | 76,556 |
BACKGROUND OF THE INVENTION
Field of the Invention
The present invention relates to processes for preparing mixtures of anhydrous liquid perfluoropolyethers having certain definite physical and chemical characteristics which result from both their chemical structure and from the well defined and narrow molecular weight ranges (M.W.) of the individual constituents of the mixtures, as well as from their degree of purity.
SUMMARY OF THE INVENTION
The processes according to the invention provide mixtures of perfluoropolyether oils characterized by a particular combination of characteristics, that is, a definite perfluorinated chemical structure, with a high degree of absolute purity, a narrow range of molecular weights of the individual constituents of the mixtures, extremely low volatility and minimal variation in viscosity with varying temperatures, which allow one to use the mixtures of the invention in applicational fields where a low vapor pressure associated with a homogeneous chemical structure and with definite molecular weight and a limited defined dispersion range are required and where the properties of resistance to oxidation, temperature and chemical solvents and reactants are required, properties which, for the intended uses, may be compromised by only very small percentages, i.e., by amounts of only several p.p.m. of impurities present therein.
More particularly, these properties are:
(a) A high average molecular weight varying between about 3,000 and about 20,000;
(b) a chemical structure of the perfluoropolyethers corresponding to formula (1) ##STR1## wherein --C 3 F 6 O--, --CF 2 O-- and --CF(CF 3 )O-- are oxyperfluoroalkylene units randomly distributed along the chain, wherein the --C 3 F 6 -- group derives from the opening of the double bond of hexafluoropropene, m is a whole number between 15 and 100, preferably between 15 and 50, n is a whole number between 1 and 80, preferably between 1 and 10, q is a whole number between 1 and 9, preferably between 1 and 5, the sum (m+n+q) is a whole number between 17 and 100, preferably between 17 and 65, the ratio n/m+q is between 0.06 and 1, and A and B are independently selected from the group consisting of --CF 3 , --C 2 F 5 and --C 3 F 7 , or to formula (2)
A--O--(C.sub.2 F.sub.4 O).sub.p --(CF.sub.2 O).sub.r --B (2)
wherein --C 2 F 4 O-- and --CF 2 O-- are oxyperfluoroalkylene units randomly distributed along the chain, p is a whole number between 30 and 300, perferably between 35 and 250, r is a number between 5 and 300, preferably between 6 and 250, the sum (p+r) is a number between 35 and 600, preferably between 41 and 500, the ratio r/p is a number between 0.15 and 1.5, and A and B are independently selected from the group consisting of --CF 3 and --C 2 F 5 ;
(c) an absolute lack of impurities both with regard to traces of organic products outside the scope of formulae (1) and (2) as well as with regard to traces of impurities, even of the order of magnitude of parts per million (p.p.m.) of inorganic products such as water;
(d) extremely reduced vapor pressures, both at 20° C. as well as at higher temperatures (between 100° and 300° C.) with the proviso that at 220° C. the vapor pressures are less than 1×10 -8 torr and preferably between 5×10 -9 and 1×10 -13 torr.; that at 100° C. the vapor pressure is less than 5×10 -4 torr and preferably below 5×10 -5 torr; and that at 200° C. the vapor pressure is be less than 10 -1 torr. and preferably less than 10 -2 torr. More particularly, certain of the oils obtained according to the invention, i.e., those having a structure corresponding to formula (2), at 20° C. have vapor pressures equal to or less than 2×10 -12 torr., while at 200° C. and 300° C., respectively, they have vapor pressures of 5×10 -8 torr. and 5×10 -4 torr. These very low vapor pressures are most useful in conferring on the oils extremely low losses due to volatility even at high temperatures (e.g., losses of less than 0.2% according to ASTM-D972-56 at 149° C.);
(e) a narrow (limited) range of molecular weights such that the index of polydispersity defined by the ratio Mw/Mn, where Mw is the average ponderal molecular weight and Mn is the average number molecular weight of the mixture (P. J. Flory,"Polymer Chemistry" Ed. Cornell, New York, 1953, pages 273 and 292), varies between 1 and 1.3; in the case of oils having a structure corresponding to formula (1), the range of molecular weights of the individual constituents differs from each other by 500±100 units of molecular weight;
(f) reduced variations in viscosity with varying temperatures with a continuous development through a wide temperature range and defined by an inclination value ASTM (D341-39) lower than 0.7 and with lower values down to 0.20, or by a viscosity index value ASTM (D2270-64) greater than 100 and up to a value of 450.
The applicational fields in which the selected, hyperpure oils with low volatility which are obtained according to the invention, may be conveniently used with absolute reliability are:
In the vacuum field where residual pressures are required to be less than 1×10 -7 torr. in environments in which, under prolonged operational conditions, there is required the absence of direct or indirect contamination by the vapors of motor oil in diffusion pumps, or of lubrication or seal oils in mechanical pumps;
In the field of lubrication, where rigorous operational temperature conditions are prescribed or where the lubricated parts are exposed to environments of reduced pressure or to a chemically aggressive atmosphere, and any case where long lubricating life under stationary conditions and in the absence of contamination is required; in this respect, the oils of the invention may be used either as pure liquids or as dispersing media for obtaining lubricating greases that are particularly stable under the described operational conditions.
Typical examples of such applications are:
the use of non-volatile oils with structures corresponding to formula (1) as driving fluids for oil vapor diffusion vacuum pumps; with certain types of perfluoropolyether oils corresponding to formula (1), it is possible to attain final residual pressures below 10 -8 torr, which are perfectly stable for prolonged times and without any retrodiffusion of contaminating vapor from the oil into the environment subjected to such vacuum.
This is very useful, for example, in the field of UF 6 enrichment by diffusion or centrifugation in the gaseous state, where hydrocarbon type motor oils cannot be used unless all contact between the UF 6 vapors and the oil vapors is prevented, because in such case the oils can be chemically attacked by the UF 6 . On the contrary, by using the oils of the invention it is possible to permit contact between the UF 6 rich medium and the vacuum pumping unit because the present oils are immune to attack. Moreover, the perfluorinated oils of the invention are also usable as lubricating and motor fluids for vacuum diffusion pumps in the field of electron microscopy, where their resistance to exposure to accelerated elementary particles and their capacity to produce very high vacuum on the order of 10 -7 torr. combines with their stability for periods of time that are even greater than one year. They are also useful in the aerospace field for the permanent lubrication of parts exposed to widely alternating low and high temperatures, and to bombardment by elementary particles, such as occurs in interplanetary space.
The perfluoropolyether oils which are used as starting materials for the oils according to the invention are synthesized by photooxidation of perfluoropropene [to obtain oils of formula (1)], and of tetrafluoroethylene [to obtain oils of formula (2)], and are then subjected to the chemical stabilization processes described respectively in U.S. Pat. Nos. 3,442,942; 3,896,167; 3,650,928; 3,699,145; 3,704,214; 3,715,378 and 3,665,041. More specifically, oils of general formula (1) are obtained by reacting perfluoropropylene in liquid phase with oxygen, at temperatues between -80° C. and +25° C. under U.V. radiations emitted from a source of high pressure mercury vapors. Conversely, oils having general formula (2) are obtained by reacting, at temperatures from -80° C. to +25° C., tetrafluoroethylene and oxygen in an inert solvent wherein the C 2 F 4 concentration is between 0.005 and 1 mole per leter of solution and the molecular oxygen is maintained at a partial pressure between 0.3 and 2 atm. The crude products obtained from either of the two photosynthesis reactions are then stabilized by thermal treatment and subsequently transformed into inert oils by reacting them with fluorine, as described in columns 11 and 12 of U.S. Pat. No. 3,665,041.
It is clear that the particularly sophisticated applicational fields noted above require a degree of absolute purity for the compounds of formulae (1) and (2). In fact, uranium hexafluoride, would be expected to be stable when in contact with chemically resistant products such as the perfluoropolyether oils. However, when uranium hexafluoride is placed into contact with such oils contaminated even by small traces of dissolved water (e.g., such oils may contain homogeneously molecularly dissolved up to 500 p.p.m. of H 2 O) will immediately decompose and generate solid products, such as absolute or hydrated uranyl fluoride in amounts corresponding to 16-18 times the weight of the contaminating water. Such solid products are undesirable during lubrication inasmuch as they cause seizing phenomena of the lubricating mechanisms or they decompose under heat and generate reduction products of uranium (see J. H. Simons in "Fluorine Chemistry," vol. I, Accademie Press, 1950, page 60) which are undesirable because of their contamination of the environment under consideration.
However, such oils, which are the precursors and starting materials for obtaining the fractions of the oils of the invention are not suitable for the use and specific applications mentioned above because of the inordinately large distribution range of the molecular weights of the individual constituents, even when, as a result of modifications of the operational variables of the chemical synthesis, as described in the above mentioned patents, there are obtained very high average molecular weights for the mixtures and when one would expect an absolute degree of purity with respect to the H 2 O content.
In fact, in mixtures of synthetic perfluoropolyether oils there are always present more or less consistent amounts of individual constituents with a low molecular weights and of traces of water, which contribute to an increase in the volatility and vapor pressure of the mixtures, with the result that such oils do not meet the rigorous standards needed for the above mentioned uses.
Even attempts to eliminate, by simple distillation, a more or less relatively consistent portion of the low molecular weight individual constituents and of the water contained in the precursor oils, do not lead to appreciable results because the mixtures themselves consist chemically of serial homologous compounds and form, from the point of view of the liquid/vapor equilibrium systems of continuous mixability with a continuous course of vapor tension. Consequently, simple distillation does not enable one to obtain distillation fractions or residues that are completely free from the constituents with a limited molecular weights and with a high vapor pressure or from inorganic impurities such as traces of water.
On the contrary, according to the invention, there may be obtained, from mixtures of oils widely polydispersed with regard to molecular weights, oil mixtures that are hyperpure with respect to water, and selected according to molecular weight molecular weights, with a polydispersion index very near to unity and with a suitable molecular weights range, and which are capable of showing the low vapor pressure values and the purity necessary for their use in the above mentioned applicational fields.
These results may be obtained by carrying out the purification i.e., the removal of water, according to the method of the invention and by fractionating the highly polydispersed mixtures at equilibrium or near-equilibrium conditions.
The purification of the perfluoropolyethers from the water resulting from atmospheric humidity, which water dissolves in the oils in a molecular manner in amounts of up to 500 p.p.m., cannot be carried out by conventional chemical procedures such as, e.g. dehydration by powerful chemical dehydrators such as calcium oxide or phosphoric anhydride or silica, because these procedures are not sufficiently effective. Thus, these procedures only reduce the water content by a small amount, actually, to not less than 200-400 p.p.m. after such treatment. In fact, if one takes a perfluoropolyether oil sample pre-treated with a standard dehydrator such as P 2 O 5 for 48 hours under stirring, and one examines, in an alumina-glass vial, its capacity to form solid products by contact for 10 minutes with UF 6 , it is found that considerable formation of solid products which have been identified as uranyl fluorides occurs.
It has now been found in accordance with the invention that the dehydration succeeds to completion only if the perfluoropolyether oil is reacted with particular gaseous substances capable of reacting with water, which are highly soluble in the oil and which form gaseous products composed of or combined with water. In contrast, if the perfluoropolyether oil is reacted with a solid or liquid dehydrator, such as noted above, complete dehydration does not occur inasmuch as the limited solubility between the phases hinders complete contact between the dehydrator and the traces of water that are molecularly dissolved in the oil.
Our investigations have proven that the gases commonly considered to be reactive to water, such as COF 2 or COCl 2 (phosgene fluoride or chloride) do not have the exhaustive and rapid reactive action with the water dissolved in the perfluoropolyethers, which action is necessary to meet the test of turbidity of the oil in the presence of UF 6 , resulting from the residual content of water in the oil.
Moreover, fluorine does not possess sufficient reactivity toward the water dissolved in the perfluoropolyether oils, since, after all, as proven by the fact that such starting oils themselves come from a final treatment with fluorine in the last stage of the synthesis thereof (see Italian Pat. No. 793,154) and nonetheless still contain some water molecularly dissolved therein.
It has now surprisingly been found in accordance with the invention that chlorine fluorides, in particular ClF and ClF 3 , are capable of rapidly and completely eliminating the water molecularly dissolved in the perfluoropolyether oils by forming gaseous products (HF, Cl 2 , O 2 , O 3 , OF 2 ). This discovery is all the more surprising since ClF and ClF 3 are considered to be fluorination reactants and to possess general reactivity which is altogether similar to that of fluorine, especially with regard to their reactivity towards water. It is particularly preferable to use ClF 3 which, being an easily liquefiable and compressible gas, as contrasted with chlorine monofluoride (ClF), enables one to introduce it into the perfluoropolyether oil in a greater concentration and thus to achieve a rapid and complete elimination of the water dissolved therein.
The process is carried out according to the invention by placing the perfluoropolyether oil of either formula (1) or (2) into contact with ClF 3 fed in at pressures between 1 and 5 atm., preferably at pressures from 1.2 to 3 atm., at temperatures between 0° and 50° C., preferably between 15° and 30° C., for a period of time between 30 minutes and 5 hours, preferably between 1 and 3 hours, in a closed and moisture-protected environment, and by discharging the gaseous products by evacuating them either under vacuum or in a current of inert gases at the end of the reaction period. This treatment is always followed by fractionating the individual perfluoropolyether constituents with selection of the molecular weights in order to obtain mixtures with a molecular weights suited for the specific end uses of the oils.
Fractionating under equilibrium conditions may be carried out by fractional distillation under a controlled vacuum and by means of a rectification column provided with a number of discs exceeding 10 and operating with an R/D refluxing ratio greater than 5 (wherein R is the amount of liquid sent to the head disc of the column and D is the amount of distilled product removed from the column).
This rectification may be carried out in special columns with a low load loss in the column so that it is possible to attain pressures in the boiler that are lower than 1-2 torr and up to 10 -2 torr., due to the slight hold-up of liquid in the column itself.
These conditions may be achieved by means of a distillation rectification apparatus of the Spaltrohr-Fischer HMS 300 type, which is completely automated and where, in the boilers, there may be had residual pressures of 10 -2 torr, because of the spirally shaped enblock filler inside the column and where the reflux ratio R/D may be adjusted from 5 to 100. With such columns, when using a reflux ratio of from 10 to 20, one automatically obtains an excellent fractionation.
The same results may be obtained with columns having a filler body of the rotating band type or with Todd-type columns containing a helical spiral.
With columns having filling material in bulk, particularly fillers of the Protruded type (perforated hemicylinders supplied by D. E. Livingstone, New Jersey) which are characterized by a low hold-up, so as to allow the conditioning of the distillation boiler to extremely low pressures, i.e., between 1-2 torr and 10 -2 torr.
It is extremely important that this reduced pressure be controlled in such a way that the exhaustion of the volatile components is carried out completely and efficiently. The pressure is maintained constant by an electronic manostat of the Monitor-Edwards 161 type. By acting on the pressure regulator, set to a certain pressure range, it is possible to gradually shift to lower equilibrium pressures as the more volatile components are gradually removed.
The various fractions of distillate are collected in groups corresponding to about 2%-5% of the total amount of oil initially subjected to rectification, and for each fraction the vapor pressure is determined by the effusiometric Knudsen method (Weissberger Rossiter, "Physical Methods of Chemistry", vol. I, part V, page 74 and following ) measuring the loss in weight by evaporation, at a residual pressure of 10 -5 torr between 20° and 120° C., of a sample contained in a Du Pont 990 thermo-balance cell connected to a system capable of producing the vacuum previously mentioned and realized through a mechanical pump and an oil diffusion pump connected to each other in series (Thermochimica Acta, 9, 205, 1974; E. M. Barrall, J. A. Logan).
In this manner the distilled fractions and the samples of residual product in the boiler, drawn therefrom, can be characterized.
The molecular weights of the samples of distillates and of the distillation residues were determined by means of a vapor pressure osmometer (isopiestic method) so that, by combining the molecular weights data with the vapor pressure data, one obtains a total picture of the molecular weight/vapor tension relation of the residue on the basis of a few of the molecular/vapor pressure values of the last head-fraction correspondingly separated.
This relationship between the molecular weight and the vapor tension properties of the residue and of the last fraction of the distilled head, takes into account both the care given to the fractionation, that is, to the period of time allowed for effecting said fractionation under conditions near equilibrium, as well as to the composition of the residue as far as the width of the molecular weight range is concerned.
The determinations of the molecular weight may be carried out by measuring the kinematic viscosity and by calculating the molecular weight/viscosity ratio.
The various fractions selected and characteristized by extremely low vapor pressures and by a narrow molecular weight range, are combined so as to give selected mixtures with low volatility and an average molecular weight (molecular weight) between 3,000 and 5,000, and with a range of 500±100 units of molecular weight for oil mixtures having the structure of formula (1), while the selected mixtures corresponding to formula (2) have an average M.W. value between 6,000 and 20,000, an a vapor pressure equal to or less than 5×10 -11 torr, at 20° C.
Such a large percentage of constituents of high molecular weight and of low vapor pressure may have a diluting effect on the volatile products still present in the mixture and may contribute to a lowering of the apparent vapor pressure of the mixture. However, in the applicational fields wherein the selected oils are to be used, the polydispersal characteristics of the mixture must be limited; thus, for example, in particular, in the vacuum field one cannot use an excessively polydispersed mixture as a motor fluid in dispersal pumps inasmuch as in a self-fractionating process, the vacuum would not be stable and the residual pressure would tend to drop in time, thus making control of the operational conditions difficult. Moreover, an excessive amount of high molecular weight fractions would reduce that portion of the liquid capable of boiling under the conditions of the evaporation boiler of the diffusion pump and thus would reduce the flow rate of the vapors and thus the pumping rate.
In the case where the selected oils are used as driving fluids for diffusion pumps, the average molecular weight of the vapors is another variant that influences the pumping speed in relationship to the mean molecular speed of the driving fluid, which is inversely proportional to the square root of the molecular weight (molecular weight).
The spread or width of the molecular weight range of the mixture may be limited by continuously fractionating the oil by distillation through rectification and by then collecting together those fractions with the desired molecular weight and vapor pressure characteristics. The fractionating by distillation through a rectifying column may be carried out until there are no longer attained in the boiler (wherein the residual pressure is in general, 1 torr) the limited conditions of thermal resistance of the perfluoropolyether oil (320°-350° C.). Under such conditions the maximum molecular weight of the distilled perfluoropolyether components are between about 3,000 and 4,000.
At this point the fractionating may be carried out by using a molecular distiller which, operating on thin liquid layers, allows one to attain extremely reduced pressures of up to 10 -4 torr, which makes it possible to achieve a further distillation of product with a greater molecular weight (from 5,000 to 10,000).
The molecular distillation according to the invention is always carried out after the preventive elimination of the more vo latile fractions by a rectification pushed to the point of equilibrium, and by passing the liquid successively in the form of a thin film on the evaporating surface whose temperature is increased at each passage by from 1° to 5° C.
The apparatus in which the molecular distillation can be carried out are of the falling film molecular distillator Schott type (of glass) or of the Leybold type in glass or steel, or of the centrifuged film C.V.C. type (Consolidated Vacuum Co., New York) which, by producing thin films of up to 0.04 mm thickness, through centrifugation, allows one to attain the maximum thermal exchange between the evaporating surface and the liquid, thus maintaining a minimum pressure drop through the evaporating film; consequently one may achieve the attainment of conditions approaching evaporation equilibrium.
Another fractionating technique, which allows one to separate fractions at equilibrium with greater molecular weights, e.g., from 10,000 to 50,000, involves the use of fractional precipitation of the perfluoropolyether mixtures from solutions in 1,1,2-trichlorotrifluoroethane or benzotrifluoride or in mixtures of perfluoro α-isopropyl-1-oxacyclohexane and perfluoro α-isobutyl-1-oxacyclopentane with organic hydrogenated liquids highly soluble or completely mixable with the fluorinated solvents, but unmixable with the perfluoropolyether oils to be fractionated and selected from the group consisting of ethylether, methylenechloride chloroform, carbon tetrachloride and pentane.
This fractionating technique is effected under conditions near to solubility equilibrium in the manner described below. In a spherical flask with a conical bottom, immersed in a thermostatically stabilized bath, and fitted with a stirrer or a reflux cooler, a solution of 2-10%, but preferably 4-5% of perfluoropolyether oil to be fractionated was prepared in anhydrous 1,1,2-trichlorotrifluoroethane. This solution is then heat stabilized thermostatically at 15°±0.2° C. and kept under stirring. Thereupon, dropwise, there was added the precipitating organic liquid until there appeared a slight, incipient opalescence floating over the surface. At this point the addition of precipitating liquid was stopped and then, after the incipient opalescence had diffused itself over the entire mass, the temperature of the bath was raised in such a way that at 30°±1° C. the mass again became completely homogeneous. Thereupon the bath was cooled at the rate of 3° C./hour and if the opalescence reappeared, the bath was thermostabilized at 15° C. under stirring; the stirring was then interrupted and the suspended liquid phase left to precipitate until complete demixing occurred at the bottom of the phase enriched with perfluorinated product. The liquid phase was then drawn off by careful siphoning. These operations were then repeated adding additional precipitant.
The individual enriched fractions which contain the perfluoropolyether components dissolved therein, starting from the highest molecular weight, are characterized by measuring molecular weight, determined by osmometry (V.P.O.) and by determining the vapor tension by the Knudsen method. There is obtained a distribution of the molecular weight of the individual fractions after which one may then combine a certain number of fractions in order to reconstitute a particular mixture with predetermined requisites of vapor pressure, molecular weight and low polydispersity index (Mw/M≦1.3).
This fractionating technique is particularly useful for obtaining fractions with a narrow range of high molecular weight of perfluoropolyether oils of structure (2) characterized by a vapor pressure at 20° C. of <10 -12 torr.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The following examples are given to more clearly illustrate the invention without, however, being a limitation thereof. All parts given are by weight unless otherwise indicated.
EXAMPLE 1
The starting material used in this example was a perfluoropolyether oil (commercial product Fomblin Y/25 of Montedison S.p.A.), having a structure corresponding to formula (1), and having a kinematic viscosity of 250 cs at 20° C. and an average molecular weight determined by means of a vapor pressure osmometer of 3,100. The material was a mixture consisting of homologous constituents of the series having molecular weights between 1,000 and 7,000, and characterized by an n/m+q ratio of 0.1, as determined by N.M.R. (nuclear magnetic resonance) spectroscopy. It was prepared according to the teaching of example 5 of U.S. Pat. No. 3,665,041.
The water content of a sample of this oil was determined according to the technique of K. Fischer and found to be 300 p.p.m. A 1 liter sample of the oil was introduced into a 2 liter Monel autoclave fitted with a water circulation cooling jacket. The autoclave was pressurized at 1.5 atm. with ClF 3 gas coming from a gas bottle containing liquid gas.
This reaction vessel was then placed in a shaker unit with a reciprocating motion for 30 minutes after which the gaseous products were discharged. Thereupon the autoclave was again pressurized with ClF 3 and the operation was repeated. The gases were again discharged and the gaseous reaction products formed from the ClF 3 and water were completely removed by heating the oil in the autoclave at 50° C. under vacuum, after which the oil was heated in a current of anhydrous and hyperpure nitrogen at 50° C.
At the end of this operation there was obtained a water free oil. The term "water free" as used herein means that one is not able to determine the presence of water using either the K. Fischer test or the non-opalescence test with UF 6 .
A sample of the thus obtained water free oil maintained in an atmosphere of hyperpure nitrogen, which was made anhydrous by passage through LiAlH 4 , was rectified through a Spaltrohr-Fischer HMS 300 column having a number of discs corresponding in their effectiveness to theorectically 300 discs and which was automatically regulated so as to provide a reflux ratio R/D=20 (R being the quantity of liquid recycled to the topmost disc of the column and D being the quantity of distilled liquid extracted from the column), the column being subjected to a vacuum by a mechanical pump so as to have a residual absolute pressure of 0.1±0.01 torr.
The boiler was heated and the contents were distilled. A fraction amounting to 27% of the total was distilled off at between 90° C. and 235° C. at 0.2 torr, after which a 2% fraction was distilled off between 235° and 240° C. at 0.2 torr; the latter fraction having a molecular weight of 3,050 and a vapor tension of 2×10 -8 torr at 20° C. as determined according to the Knudsen method.
The residual 71% of the product was passed through a molecular distillation glass column of the Schott type under an absolute pressure of 0.1 torr and with the evaporation surface thermostatically stabilized at 242°±0.5° C. to obtain a distillate and a residue which was subsequently passed through the evaporator at the respective temperatures of: 224° C., 246° C., 248° C., 250° C. and 252° C.
The six distilled fractions were combined, and together amounted to 35% of the starting product. The combined fractions, hereinafter referred to as "selected oil 1A" had the following characteristics:
Selected oil 1A: average molecular weight 3,300; vapor tension at 20° C. determined according to the Knudsen method was 9.2×10 -10 torr; kinematic viscosity: 255 cs at 20° C.
The final residue was passed through the evaporator maintained at 256° C., and a fraction amounting to 5% of the starting product and having a molecular weight of 3,550 and a vapor pressure of 2×10 -12 torr was obtained. Consequently the 35% fraction previously distilled and referred to as selected oil 1A was found to consist of constituents with molecular weight between 3,050 and 3,550 and had a polydispersivity index Mw/Mn=1.25.
A sample of 75 ml of selected oil 1A thus obtained and with the properties described, was loaded into the boiler of an Edwards type E02 oil vapor diffusion pump. This diffusion pump was connected in series with a mechanical Edwards ES 200 pump for producing a vacuum in the system, and was surmounted at its head end by a "dome," the function of which was to act as sealing head for the system and to house the probe of an ionization vacuum-meter of the Balzers IMG 030 type whose indicator control board was connected with a Leeds-Northrup Speedomax XL 682 A recorder.
A pre-vacuum (10 -2 torr) was created in the system by means of the mechanical pump, after which running water was introduced into the cooling coil externally surrounding the diffusion pump head, while heating of the boiler of the diffusion pump was started.
The residual pressure inside the system, recorded on the recorder tape, appeared to drop rapidly and then stabilize itself at a value of 1×10 -8 torr (final pressure, ultimate vacuum).
The variation in the final pressure, at a flow rate of 100 liters/sec. (gas:air), was around 3-4%. A 220 g sample of selected oil 1A, prepared according to the invention, was used for obtaining a special grease, thickened with a polytetrafluoroethylene telomer with a molecular weight of about 30,000, in the following way:
Into a Zeta-Werner-Pfleiderer laboratory arm mixer Model 1-S having a holding capacity of 0.5 liter and fitted with a sealing lid with vacuum tight seal and coupling through-pipe, and provided with a sleeve, there were introduced 675 g of a 7% suspension of tetrafluoroethylene telomer in 1,1,2-trichlorotrifluoroethane.
The sleeve of the mixer was then heat stabilized at 60° C. and the solvent was distilled, keeping the mass under stirring and removing the solvent through the conduit passing through the lid of the mixer. In the meantime, 220 g of selected 1A perfluoropolyether oil were added.
After the distillation of the solvent at atmospheric pressure, the mixer was put under vacuum (residual pressure 50 torr) and thermostatically heat stabilized at 60° C. The stirring was maintained while continuing the processing of the grease for 3 hours, that is, until there was no longer any loss of solvent.
The thus obtained grease showed a degree of penetration at 25° C. of 270 (mm/10) and a loss by evaporation after heating at 400° F. (204° C.) for 22 hours of 0.2% (ASTM D 972 method).
A sample of this grease subjected to a wearing test on a 4-balls Shell tester, carried out according to ASTM D 2266/64 standards (1,200 r.p.m., load 40 kg, for 2 hours), was characterized by a scratch-width equal to 0.35 mm. Repeating the measurement on a grease sample preliminarily exposed for 100 hours to an air current with a flow-rate of 9 liters/min. at a temperature of 193° C., revealed a scratch-width equal to 0.4 mm. These data constitute experimental proof of the excellent resistance to wear displayed by such a grease under severe oxidation conditions.
COMPARATIVE EXAMPLE A
The starting material of Example 1, that is, the oil with a structure corresponding to formula (1) and with an average molecular weight of 3,100, was subjected to dehydration in a glass flask in an atmosphere of nitrogen made anhydrous by stirring on calcium oxide for 48 hours, and then on P 2 O 5 , after which the oil was decanted and transferred into another flask under stirring for 48 hours, still at a temperature of 50° C. The oil was found to have a residual water content of 200 p.p.m.
The thus obtained oil was placed into a flask connected directly with a Liebig cooler. 10% of the total oil was eliminated as a head product at temperature between 70° C. and 120° C. at 0.1 torr and having an average molecular weight of 1,200. At the same pressure, but at between 120° and 290° C. a central fraction (75%) which appeared to consist of individual constituents with a molecular weight between 1,500 and 6,000 was distilled off. This fraction had a poly dispersion index greater than 3, and a kinematic viscosity of 250 cs at 20° C., a vapor pressure of 5×10 -5 torr at 20° C. according to the Knudsen method, and a loss through volatility, after 22 hours at 149° C., of 7%. After condensation of the volatile products they were found, by gas-chromatography on a column based on polyethylene glycol as the stationary phase, to contain water.
COMPARATIVE EXAMPLE B
The starting product of Example 1 (with an average molecular weight of 3,100) was subjected to dehydration, on calcium oxide for 48 hours, after which the product was transferred to a percolation column of silica gel activated by dehydration, at a percolation rate such as to have a solid/liquid contact time of 24 hours. Thereby, there was obtained an oil having, according to the K. Fischer test, a water content of about 200 p.p.m.
The oil was then transferred in an anhydrous nitrogen atmosphere into a 1 liter flask surmounted by a Vigreux column 30 cm high, directly connected with the Liebig cooler, but with a reflux regulator.
Distilling with free draws, at a pressure of 1-1.5 torr, there were drawn at 130°-250° C. 10% constituting a head fraction which had an average molecular weight of 1,900 and a kinematic viscosity of 55 cs at 20° C. The residue has a kinematic viscosity of 288 cs at 20° C. and a vapor pressure of 2×10 -7 torr showing a loss, due to volatility after 22 hours at 149° C., of 2%. The presence of water was detected in the condensed volatile product by gas-chromatography.
From the measured and above-reported molecular weight it was possible to conclude that the individual constituents of the mixture had a molecular weight between 1,900 and 7,000. The polydispersity index was found to be greater than 3.
A grease made from the perfluoropolyether oil distilled according to this comparative example and from tetrafluoroethylene telomer, in the same proportions and with the same procedures followed in Example 1, showed a loss by evaporation at 400° F. (204° C.) after 22 hours (ASTM D 972) equal to 7%.
A sample of grease subjected to a wear test on a 4-balls Shell apparatus, at 1,200 r.p.m. and under a 40 kg load for two hours (ASTM D 2266/64), was characterized by a scratch-width of 0.9 mm.
Repeating the measurements on the grease sample, preliminarily exposed for 100 hours to an air current flowing at a flow rate of 9 liters/min. at a temperature of 193° C., there was found a scratch-width of 1.5 mm.
COMPARATIVE EXAMPLE C
The residual fraction resulting from the distillation at 250° C. and at a pressure of 1 torr, as described in comparative example B, and obtained starting from the perfluoropolyether product of average molecular weight 3,100 described in Example 1 was the starting material for this Example.
That fraction, with a viscosity of 288 cs, was subjected to molecular distillation at a pressure of 10 -3 torr, while maintaining the evaporator surface at 257° C. Thereby there was obtained a 71% fraction as a distillate, said fraction having a viscosity of 260 cs, a vapor pressure of 5×10 -7 torr and a loss, due to volatility after 22 hours at 149° C., of 2.8%. The presence of water was found in the condensed volatile products by gas-chromatography. The residue of that distillation had an average molecular weight of 4,700.
EXAMPLE 2
The starting material for this example was a perfluoropolyether oil (commercial product Fomblin Y/16 of Montedison S.p.A.), having a structure corresponding to formula (1) an average molecular weight of 2,800 and a kinematic viscosity of 175 cs at 20° C., and which was formed of individual constituents having a molecular weight between 1,800 and 3,500 and wherein the ratio n/m×q=0.1, as determined by N.M.R. It was prepared according to the teaching of U.S. Pat. No. 3,665,041.
The amount of molecularly dissolved water was determined on a sample of this oil and found to be 400 p.p.m. A 1.5 liter sample of this oil was introduced into a 2 liter autoclave of Monel steel fitted with a cooling sleeve with forced water circulation.
The autoclave was pressurized at 1.5 atm. with ClF 3 gas and was then subjected to oscillating stirring for 60 minutes, after which the gas was discharged and the operation repeated twice more, in each case exhausting the reaction gases. Then the autoclave was heated to 50° C., and a bubbling anhydrous current of helium gas was sent into the liquid through a drawing pipe. Thereafter, a sample of the liquid was withdrawn with a test tube of Al 2 O 3 and no opalescence was found after contacting the sample with UF 6 .
A sample of the thus treated oil was rectified in a Spaltrohr-Fischer HMS 300 column, as described in Example 1, the column being automatically set to ensure a reflux ratio R/D=20 and subjected to a vacuum corresponding to an initial residual pressure of 0.1±0.01 torr.
Then the boiler was heated and 50% of the liquid was distilled off by rectification and separated between 130° and 200° C.
Thereafter, a further fraction having molecular weight of 2,680 and amounting to 2% was obtained, followed by a fraction distilling between 200° and 220° C. at 0.02 torr (selected oil 1B). Finally a further 2% fraction having molecular weight of 3,250 was distilled. Thus, selected oil 1B could be considered as consisting of individual constituents with molecular weight's between 2,680 and 3,250. The degree of polydispersion thereof was of the order of Mw/Mn=1.2 and its average M.W. was about 3,000.
The oil (1B) had a kinematic viscosity of 190 cs at 20° C. and a vapor pressure at 20° C., determined according to Knudsen, of 1.9×10 -9 torr and a moisture content, at the limit of sensibility of the K. Fischer method of less than 1 p.p.m.
A sample of this selected oil (1B) was used for lubricating a mechanical pump, while a sample of selected oil (1A) prepared according to Example 1 was used as a motor fluid in a diffusion pump connected in series with the mechanical pump. This vacuum producing system was connected to a cylindrical Monel chamber, thermostatically stabilized at 80° C., in which, through an inlet valve, also of Monel steel, there was introduced UF 6 gas at a partial pressure of 100 torr. Thereupon the chamber was put into communication with the pumping system and evacuated until reaching a residual pressure of 10 -7 torr. Then the Monel cylindrical chamber was cut off from the pumping system and again filled with UF 6 at a partial pressure of 100 torr, whereupon it was again evacuated to a residual pressure of 10 -7 torr.
After 2,000 hours of operating the evacuated pumping system, connected to the UF 6 chamber from which evacuation of the UF 6 was carried on, the pumping system was disassembled in order to recover the oil used as lubricant in the mechanical pump and the oil of the selected type 1B prepared as described above.
The oil did not appear to be contaminated by any uranium containing solids, and its properties were found to be: kinematic viscosity=188 cs; vapor pressure, according to the Knudsen method=3×10 -9 torr at 20° C.
EXAMPLE 3
The starting material for this example was a perfluoropolyether oil (Fomblin Y/45 of Montedison S.p.A.), having a structure corresponding to formula (1) an average molecular weight 3,900 and a kinematic viscosity of 410 cs at 20° C., and which was formed of individual constituents having a molecular weight between 3,500 and 8,000, and having an m/m+Q ratio of 0.06 as determined by N.M.R. It was obtained by a further distillation of Fomblin Y/25 described in Example 1. Analysis of the oil by the K. Fischer method revealed that this oil contained 200 p.p.m. of molecularly dissolved water and on contact with UF 6 heavy opalescence occurred.
A 5 kg sample of this oil was put into a 5 liter Monel autoclave fitted with a perforated Monel toroidal ring extending to the bottom of the autoclave. The autoclave was surrounded by a sleeve with circulating cold water. Through the perforated ring ClF 3 gas was fed in until the pressure in the autoclave was 1.2 atm. At this point the pressure was maintained constant by bleeding the reaction gases and by feeding through the drawing ring into the perfluoropolyether liquid additional ClF 3 gas, continuing in this way for 1 hour. At the end of the operation, dry helium was bubbled through the system. The oil in the autoclave was then discharged in a dry helium atmosphere and appeared to be free of water as determined by the Fischer method and then by the turbidity test with UF 6 .
A sample of the oil was subjected to rectification through a Todd column provided with a spiral as a filler and of a height corresponding to a number of discs equivalent to about 10 theoretical discs. The column was surmounted by an automatic reflux regulator adjusted to a ratio R/D=10.
Distillation was started at a residual pressure of 0.1±±0.01 torr and a 30% fraction was obtained by rectification at between 150° and 202° C. Then, at 205° C. a 2% fraction was gathered, this fraction having a molecular weight of 3,650 as determined by isopiestic osmometry (V.P.O.).
The distillation residue was then transferred into a centrifugal molecular Schott distillator, set to an absolute pressure of 10 -4 torr, and the liquid was then made to flow over the evaporating body thermostatically stabilized at 190° C. and there was obtained a 7% fraction of distillate with a molecular weight of 3,700.
The residual oil was subsequently made to flow again over the evaporating body at a residual pressure of 10 -4 torr at the temperatures of: 195°, 200°, 205°, 210°, 215°, 220°, 225°, 230°, 235°, 240°, 245°and 250° C. obtaining 12 distilled fractions which were combined to yield a mixture having an average molecular weight of 4,000 (selected oil 1C) and which corresponded to 30% of the starting product.
The residue was again passed over the evaporating body at a temperature of 255° C. thereby giving a fraction of 2% of the distillate, said fraction having a molecular weight of 4,200. The previously distilled fractions which were combined to give selected oil 1C consisted of individual constituents with a molecular weight between 3,700 and 4,200. The vapor pressure of selected oil 1C was determined according to the Knudsen method and found to be 1.5×10 -11 torr at 20° C.
A sample of the oil was introduced into an Edwards diffusion pump EO2 connected to a mechanical vacuum pump, with the cooling coil of the head being run through by running water, and being surmounted by a dome in which had been arranged the probe of an ionization vacuometer Edwards 1 G 5GM. Under operational vacuum conditions attained by the apparatus, the measuring instrument indicated a final residual pressure lower than 5×10 -9 torr.
EXAMPLE 4
The starting material for this example was a perfluoropolyether oil with a structure corresponding to formula (2) with an r/p ratio of 1:1, a kinematic viscosity of 50 cs at 20° C. an average molecular weight of 5,500 as determined by vapor tension osmometry, said oil consisting of individual constituents having a molecular weight between 2,000 and 30,000. It was prepared by irradiating for three hours, with a U.V. lamp of high pressure mercury vapors, Hanau TQ 81, at a temperature of -10° C., a solution of oxygen and tetrafluoroethylene in CF 2 Cl-CFCl 2 containing 0.3 mole of olefine per liter solution, the feed rate of tetrafluoroethylene being of 20 l/h and the volume ratio of O 2 :C 2 F 4 being 2:1. The crude was then subjected to a thermal treatment, to a fractionation and then to fluorination according to the teaching of example 6 to U.S. Pat. No. 3,665,041. The fraction subjected to fluorination had a distillation range from about 140° C. to about 300° C. The obtained oil, according to a K. Fischer analysis, was found to contain 500 p.p.m. of molecularly dissolved water.
A 5 kg sample of this oil, after being placed into a Monel steel autoclave fitted with a perforated Monel steel toroidal ring reaching to the bottom of the autoclave, was treated for two hours with ClF 3 gas, as described in Example 3. At the end of the treatment, after elimination of the gaseous products, the absence of water was ascertained by means of the UF 6 test.
A sample of the thus treated oil was subjected to rectification in an adiabatic glass column containing filling bodies of the "Protruded" type with a height corresponding to about the theoretical number of 10 discs, the column being surmounted by an automatic reflux regulator adjusted for an R/D ratio equal to 10.
Distillation of the sample was carried out at a residual pressure of 0.5±0.1 torr regulated by an electronic manostat, of the Monitor 161 Edwards type, whereby 8% of the starting product was gathered and then subdivided into 3 fractions which were distilled at between 180° and 200° C. The residue was then distilled in a laboratory Schott molecular distiller, under vacuum at 10 -4 torr, and with the evaporating surface thermostabilized at 120° C. there was obtained a distilled fraction of 2%, while the residue was again passed over the evaporating body at successive temperatures, respectively, of 150° and 180° C., thereby obtaining in all, from the two passages, a second fraction of 6%. The new residue was then once again evaporated at successive temperatures of 210° and 240° C. thereby obtaining in all, from the two passages a third distilled fraction of 5% which has a molecular weight of 5,500 as found by isopiestic osmometry. The residue at 240° C. was then distilled by evaporating it at the surface at temperatures of 260°, 280° and 300° C., obtaining in total, 15% of product with an average M.W. of 6,200 (selected oil 2D) which was characterized by a vapor pressure of 5×10 -11 torr at 20° C., 5×10 -7 torr at 100° C., a kinematic viscosity of 60 cs at 20° C., a viscosity index of 340 (ASTM D 2270/64), a "pound point" below -100° C. and by a loss by evaporation after 22 hours at 400° F. (204° C.) of 0.5% (ASTM D 972).
Using a sample of selected oil 2D, it was possible to prepare a grease thickened by means of a tetrafluoroethylene telomer using the procedures and quantities set forth in Example 1, thereby obtaining a grease endowed with a penetration degree of 280 (mm/10) and which can be used as a lubricant within the temperature range of -80° C. to +200° C.
Samples of selected oil 2D were used for the lubrication of gears and bearings in operation at temperatures ranging as low as -80° C.
EXAMPLE 5
The starting material for this example was a perfluoropolyether oil having an average molecular weight of 6,200 and a structure corresponding to that of formula (2), which was obtained as the residue from the molecular distillation at 300° C. at a residual pressure of 10 -4 torr which was obtained according to Example 4.
A 100 g sample of the oil residue from the molecular distillation at 300° C. was dissolved in 1,1,2-trichlorotrifluoroethane so as to obtain a 5% solution thereof. This solution was then placed into a 5 liter flask with a conical bottom which was thermostabilized at 15° C.±0.2° C.
To this solution 250 ml of methylene chloride were then added until incipient demixing of the phases occurred. The mixture was then heated to 35° C. until complete dissolution was achieved, after which the solution was thermostabilized at 15° C. with stirring overnight. Stirring was stopped and the mixture was left standing for 5 hours after which the heavier demixed phase was separated. From this phase, by evaporation of the solvents, there was obtained a fraction (2E) of the perfluoropolyether oil with a molecular weight of 25,000, corresponding to 5% of the starting oil of Example 4.
Proceeding in the same way, and adding to the solution, which was thermostabilized at 15° C., a further 140 ml of methylene chloride, an oil fraction with a molecular weight of 20,000, corresponding to 5% of the starting oil of Example 4 (fraction 2F) was obtained.
Proceeding further in the same way, there was obtained a further fraction (2G) with molecular weight 16,000, corresponding to 4% of the starting oil of Example 4; by the addition of further portions of 150, 200, 250 and 350 ml, respectively, of methylene chloride there were obtained four further fractions (2H, 2I, 2L, 2 M) of perfluoropolyether oil, which by mixing together, gave a product with an average molecular weight of 12,000 and a viscosity of 200 cs at 20° C. (selected oil 2 N) corresponding to 20% of the starting oil of Example 4.
A still further addition of 150 ml of methylene chloride to the remaining solution yielded another fraction (2%) of oil with a molecular weight of 10,500. Thus, it appeared that the selected oil 2 N consisted of individual constituents having a molecular weight between 16,000 and 10,500.
Selected oil (2 N) had a vapor tension at 20° C. of 8×10 -13 torr as determined according to the Knudsen method and "pour point" of -60° C.
A sample of selected oil 2 N, obtained by repeating numerous preparations according to Example 4 and the above procedures was used for preparing a thickened grease with the telomer of tetrafluoroethylene (containing 15% of thickener), which showed a degree of penetration at 25° C. equal to 280 (mm/10), a dropping point of 185° C. (ASTM D 2265) and a loss of volatiles equal to 0.95% after 24 hours at 125° C. under a vacuum of 1×10 -6 torr.
By combining fractions 2F and 2G there was obtained a mixture of perfluoropolyether oils (2P) with a structure corresponding to formula (2) and with a kinematic viscosity at 20° C. of 550 cs. This mixture 2P had a vapor pressure at 20° C. of 5×10 -13 torr, at 200° C. of 3×10 -7 torr and at 300° C. a vapor pressure of 2.2×10 -4 torr, and had a pour point below -30° C.
With this mixture (2P) it was possible to prepare a grease containing 25% of a tetrafluoroethylene telomer. This grease showed a penetration degree at 25° C. equal to 290 (mm/10) and a loss in volatile substances, after 24 hours, under a vacuum of 9×10 -7 torr at 125° C., of 0.2%.
A sample of this grease, submitted to a wear test in a 4-ball Shell apparatus, at 1,200 r.p.m. under a load of 40 kg for 2 hours (according to ASTM D 2266/64), was characterized by a scratch-width equal to 0.1 mm.
These characteristics did not appreciably change after a preliminary exposure of the grease to an air current of 9 liters/min. at 193° C. for 100 hours.
EXAMPLE 6
A sample of a perfluoropolyether with a structure corresponding to formula (2) and of the selected type 2 N, obtained as described in Example 5, having a kinematic viscosity of 200 cs at 20° C., an average molecular weight of 12,000 and a vapor pressure at 20° C. of 8.0×10 -13 torr, was utilized as a lubricant in a turbomolecular pump with a spindle of the type described in "Vacuum Manual" by L. Holland, W. Steckelmacher, J. Yarwood, editor: SPON London--1974, p. 342.
This turbomolecular pump was coupled to a mechanical pump lubricated by a perfluoropolyether oil with a structure corresponding to formula (1), of the selected type 1B described in Example 3, and having a kinematic viscosity of 190 cs at 20° C., an average molecular weight of 3,000 and a vapor pressure at 20° C. of 1.9×10 -9 torr. The reserve oil of the turbomolecular pump was contained in an oil reservoir in which there was inserted a thermocouple. The thus coupled system was made to communicate with a cylindrical Monel steel chamber thermostabilized at a temperature of 70° C. Into this Monel chamber hydrogen was introduced at atmospheric pressure, after which the feed was cut off and the system, under vacuum, was made to operate. After 24 hours of operation the pressure was measured and found to be 2±1×10 -9 torr.
Into the Monel chamber there was then introduced a mixture of hydrogen and gaseous UF 6 in a volumetric ratio of 3:1 at a partial pressure of 1.0×10 -1 torr. The vacuum system was again started, while inside the Monel steel chamber a constant pressure of 1.0×10 -1 torr of the mixture of gases was maintained. After 6 days running under the described conditions during which it turned out that the temperature of the perfluoropolyether oil type 2 N, which lubricated the bearings of the pump, remained constant at 50°±1° C., the feed of hydrogen and UF 6 gas to the Monel chamber was interrupted and a high vacuum was maintained in the chamber for 24 hours.
At the end of this period the initial pressure was taken and found to be 2±1×10 -9 torr. When the feed of hydrogen/gaseous UF 6 into the Monel chamber was resumed at a partial pressure of 1.0×10 -1 torr and operation was continued for a further 6 days, while sucking the gas out of the chamber under the above indicated conditions.
After this period of operation the flow of the gases was interrupted, the pressure was gradually reduced and, after 24 hours, the pressure was measured and found to be 2±1×10 -9 torr. No variations in the temperature of the oil in the oil reservoir could be detected. After six months of this kind of working it was ascertained that the performance of the vacuum equipment previously described was still excellent and reproduced the conditions of the first week of operation. This clearly evidences the excellent resistance of the lubricating oil that, during the course of the experiment, was in contact with the flowing gas of the pump, as well as the absence of solid slag due to possible reactions of the UF 6 when coming into contact with any water which might have been present in the oil.
Variations and modifications can, of course, be made without departing from the spirit and scope of the invention. | Perfluoropolyether oils containing traces of H 2 O molecularly dissolved therein are rendered anhydrous and hyperpure by treatment with chlorine trifluoride or monofluoride at a pressure of 1-5 atm. and a temperature of 0°-50° C. after which the treated oil is selectively fractionated. | 57,768 |
BACKGROUND OF THE INVENTION
[0001] 1. Technical Field
[0002] The present invention relates to a method, a computer-executable program and a system for promoting chain transactions.
[0003] 2. Description of Related Art
[0004] The internet is now an important medium of information dissemination, data transaction and commercial activities, and has inspired various modes of the so-called E-commerce. When one wants to buy things by spending less, he/she may perform search in online auction sites or shopping sites, or he/she can seek over the web for a group-buying offer related to merchandise he/she is interested in. Group-buying allows a group of consumers to purchase together with discounted prices, so information dissemination before and/or after purchase is critical to assemble more people to join the group and make the discount offered or maintained.
[0005] Traditionally, such information dissemination is made by the vendors through commercials and marketing activities, so more transactions done means more money and energy have been spent for advertising. Some vendors thus try to reward certain consumers who initiate group-buying activities. However, this existing approach using certain consumers as hubs is quite narrow with respect to the vast web-based market and is confined to the thinking of vendors but not consumers.
SUMMARY OF THE INVENTION
[0006] In the conventional consumer-rewarding scheme, a consumer has to perform purchase and dissemination separately and the reward given thereto is immediately related to how many transactions the consumer directly causes. The existing approach is thus not popular because no consumer likes to take additional time and energy to peddle like a salesperson just for the small rewards.
[0007] In view of this, for improving the exiting consumer-rewarding scheme, it is necessary to find ways to save the time required by performing dissemination and to reward consumers more relevantly.
[0008] Therefore, the present invention provides a method, a computer executable program and a system for promoting chain transactions, wherein a transaction and corresponding dissemination can be accomplished almost simultaneously and a coadjutant consumption environment can be created to nurture social-shopping behavior.
[0009] In some of various embodiments of the present invention, the method for prompting chain transactions comprises receiving a merchandise information about a commodity from a database, and defining a part of a profit generated in a transaction of the commodity as a reward for a consumer who makes the transaction and performs dissemination of the transaction, whereby an incentive mechanism is built for promoting more sequent transactions, wherein completion of each said transaction results in generation of a unique transaction serial number and a corresponding transaction page that jointly function as a node for determining the reward and for recognizing the dissemination, in which the transaction page is associated with at least one social network where the dissemination is performed., thereby realizing the coadjutant consumption environment.
[0010] In some of various embodiments of the present invention, the incentive mechanism allows setting parameters including different amounts of the rewards for the nodes of different tiers, a number of the tiers backward traceable to be rewarded, a proportion of the reward with respect to the profit, and a limited number of said sequent transactions allowable to be made rewarded through each said transaction serial number or each said node, in which each combination of the parameters of different settings is defined as a rewarding model.
[0011] In some of various embodiments of the present invention, the transaction page is associated with said social network by adopting an API (Application Programming Interface) of a medium of the social network so as to share information with the social network.
[0012] In some of various embodiments of the present invention, the transaction page is associated with said social network by making a webpage of the social network assessable from the transaction page through a plug-in program, an RSS reader, an Atom reader or an XML protocol application.
[0013] In some of various embodiments of the present invention, the transaction page is associated with said social network by making an instant messenger related to said social network assessable from the transaction page through a plug-in program, an RSS reader, an Atom reader or an XML protocol application.
[0014] In some of various embodiments of the present invention, the transaction page is associated with said social network by accessing information from the social network through a plurality of programs that allow the information to be loaded in a smart phone, an e-book reader or a mobile electronic device.
[0015] In some of various embodiments of the present invention, only a limited number of said sequent transactions are allowed to be made through each said transaction serial number or each said node, so that when the number is reached, the incentive mechanism uses another said transaction serial number or another said node to complete further sequent transactions.
[0016] In some of various embodiments of the present invention, the computer executable program for facilitating dissemination serves to: when a transaction button is triggered by a consumer to complete a transaction of a commodity, automatically compare a merchandise information of the commodity to recommendation comment keywords, personal comment keywords set by the consumer and past comment records, and accordingly generate options of recommended comments about the commodity for the consumer to adopt, so that the consumer is allowed to use any of the automatically generated recommended comments or revise any of the automatically generated recommended comments before use, and upon the consumer's decision of the comment(s), the merchandise information, the merchandise information, a transaction and the comment(s) are automatically posted on an associated website or sent to a preset group of audience, thereby facilitating dissemination.
[0017] In some of various embodiments of the present invention, the computer executable program further serves to facilitate chain dissemination by allowing the audience interested in the dissemination to click on a response button for generating a personalized comment about the commodity.
[0018] In some of various embodiments of the present invention, the computer executable program further serves to promote chain greeting in a social network by allowing the audience to click on a greeting button for generating a personalized greeting message.
[0019] In some of various embodiments of the present invention, the computer executable program further serves to facilitate assembly of members of a social network and in turn facilitate chain response by allowing the audience to click on a reply button related to a certain activity for generating a personalized comment about the activity.
[0020] In some of various embodiments of the present invention, the comment has a format selected from the group consisting of a user diary, a user feedback, an open-box report, a blog post, an experience sharing, a user reference and any combination thereof.
[0021] In some of various embodiments of the present invention, the past comment records is extracted from comment keyword database where the past comments of all the consumers and about all the commodities are collected and classified according to consumer groups, merchandise groups and frequencies of use.
[0022] In some of various embodiments of the present invention, the system for prompting chain transactions comprises: a server for storing the system and a database for storing data about commodities, merchandise details, rewarding models, an incentive mechanism, consumers, transactions, dissemination targets, rewarding information and rewarding records, whereby upon completion of a transaction where a transaction page is generated by the incentive mechanism, when a consumer triggers a transaction button on the transaction page, an automatic personalized-comment generating mechanism is actuated so that the system disseminates the consumer's comment(s) together with information abstracted from the transaction page to the dissemination targets.
[0023] In some of various embodiments of the present invention, the server is realized by a system incorporating SaaS (Software as a Service), PaaS (Platform as a Service) and/or other cloud-based technologies.
[0024] In some of various embodiments of the present invention the transaction page is provided as a webpage of a social network, in which each said consumer is allotted with an exclusive webpage where records of the consumer's transactions are provided.
[0025] In some of various embodiments of the present invention, the transaction page appears in a webpage of a social network as a function module by adopting an API (Application Programming Interface) of a medium of the social network.
[0026] In some of various embodiments of the present invention, the system further includes a credit rating mechanism, wherein the consumers who perform transactions as parties following each other are rewarded with points in their respective credit ratings, and cancellation of any said transaction results in taking the rewarded points off.
[0027] In some of various embodiments of the present invention, the dissemination targets include a personal mobile device that accesses digital contents issued by the system through a preloaded application.
[0028] In some of various embodiments of the present invention, the chain transactions includes transactions of physical merchandise, virtual merchandise, virtual currency, digital contents, services, commercial donation and/or non-commercial donation.
BRIEF DESCRIPTION OF THE DRAWINGS
[0029] The invention as well as a preferred mode of use, 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:
[0030] FIG. 1 is a schematic diagram of an exemplary structure for realizing the present invention;
[0031] FIG. 2 illustrates how the present invention promotes chain transactions;
[0032] FIG. 3 shows rewarding models set in the rewarding-model selecting unit for selectively use;
[0033] FIG. 4 illustrates how an intellective comment managing unit works for information forwarding and controlling; and
[0034] FIG. 5 illustrates how a user access data through different media by using the method and system of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0035] While the present invention particularly proposes a method, a computer executable program and a system for promoting chain transactions, it is to be noted that the present invention is realizable in other means, such as a process, a device, a computer, a readable medium and more. Although some preferred embodiments are shown in the accompanying drawings and will be described in detail for illustrating the present invention, they are not intended to form limitation to the present invention.
[0036] FIG. 1 is a schematic diagram of an exemplary structure for realizing the present invention. In the present embodiment, the method includes receiving merchandise information about a commodity from an E-commerce database 101 and defining a part of a profit generated in a transaction of the commodity as a reward for a consumer who makes the transaction and performs dissemination of the transaction. The mechanism such built is herein referred to as an incentive unit 102 . The incentive unit 102 works with a transaction-information forwarding unit 103 that integrates functions of performing transactions, automatically providing personalized comments and automatic dissemination, and a transaction page 104 serving to publish information, accept transactions and share the comments.
[0037] FIG. 2 illustrates how the present invention promotes chain transactions. As shown, a merchandise information managing unit 201 converts the information about the commodity into an incentive information related to the reward and provides recommended comment keywords related to the commodity for intellective comment composition. After the merchandise information is converted, a rewarding-model selecting unit 202 adopts a preset setting of rewarding parameters or defines parameters on its own, so as to generate relevant reward distribution. On the other hand, a reward managing unit 203 activates calculation and payment of the reward according to the profit generated. Then a transaction managing unit 204 takes over the transaction and assigns an exclusive transaction serial number for each transaction. The transaction managing unit 204 also generates an exclusive transaction page, namely the transaction page 104 , and an identification code for each transaction. The identification code including information about the commodity, the consumer and the transaction serial number is then delivered to a track managing unit 205 . Herein, suitable flow management techniques may be used so that after the chain transactions are made, reports can be generated a website in terms of transaction relations, sequent transactions (or following transactions), comments made, dissemination effects, message hits, and how a certain transaction is followed, so as to remind the consumer making the original transaction to take interactive actions for the website. When a chain is initiated by one consumer performing an original transaction and other consumers performing sequent transactions through the transaction page of the original transaction, tiers of transaction pages/nodes are formed. For the purpose of this invention, a transaction in a lower tier is referred to as a sequent/following transaction of a transaction in a higher tier. The consumer performing the transaction in the higher tier (at the node in the higher tier) is rewarded with a certain proportion of the profit generated in the sequent transaction. The present invention allows setting different parameters, such as the amounts (or proportions) of the rewards for the nodes of different tiers, a number of the tiers backward traceable to be rewarded, a proportion of the reward with respect to the profit, and a limited number of said sequent transactions allowable to be made rewarded through each said transaction serial number or each said node. Each combination of the parameters of different settings is defined as a rewarding model, so that several rewarding models may be preset for easy adoption. For example, as shown in FIG. 3 , rewarding models 301 , 302 and 303 are set in the rewarding-model selecting unit 202 for selectively use. In one embodiment, only a limited number of said sequent transactions are allowed to be made through each said transaction page /node, so that when the number is reached at one node, consumer intending to make further sequent transactions will be guided to another transaction page /node currently “followable”. Thereby, the present invention promotes chain transactions and encourages interaction as well as mutual trust between consumers. For preventing excessive dissemination that cause “info pollution” to the irrelevant audience, consumers may optionally join one or more social groups or communities. In this case, the inventive system may further include a credit rating mechanism, wherein the consumers who perform transactions as parties following each other are rewarded with points in their respective credit ratings, and cancellation of any said transaction results in taking the rewarded points off. The credit rating mechanism thus allows consumers to build their personal credits in the groups/communities they join and thereby attract more consumers to follow their transactions, in turn promoting sequent, chain transactions.
[0038] In addition to discounts incurred by group-buying behaviors, one ignorable component of promotion is consumers' comments on, recommendation for or reference to commodities. However, it has been difficult to have consumers actively make comments and/or dissemination for the commodities they buy because, as mentioned above, this takes additional energy and time in the existing approach. The present invention thus solves this plight by, to the largest possible extent, maintaining consumers' operational habit and simplifying the process of making comment as well as dissemination. Therefore, in one embodiment of the present invention, the computer executable program for facilitating dissemination that prompts chain transactions is realized by making the best of the automatic and intellective functions of a computer. In this embodiment, consumer can make purchase, comment and dissemination in an integrated operational process, which is referred to as “Easy Push” herein. Particularly, when a transaction button is triggered by a consumer to complete a transaction of a commodity, the computer executable program automatically generates personalized comments and automatically posts the comments on an a preset webpage or sends the comments to a carrier or device that can read the comments, thereby accomplishing easy, convenient and meaningful dissemination. FIG. 4 illustrates an intellective comment managing unit 400 for this purpose. According to this embodiment, when the transaction button is triggered, the transaction managing unit 204 synchronously activates an automatic comment generator 401 that serves to compare a merchandise information of the commodity to recommendation comment keywords, personal comment keywords set by the consumer and past comment records stores in a comment managing module 402 , so as to sort these data in terms of classification and the consumer's personal preference, thereby generating combinations of these data as options to be stored in a comment keyword database 403 . Then the automatic comment generator 401 can automatically provide a predetermined set of personalized comments according to the classification or attribution of the commodity. At this time, the consumer can easily make his/her comments by confirming any or all of the options so provided. Alternatively, the consumer may make another combination of these or other comments or may draft a new comment. At last, the comments finalized so are submitted to a dissemination managing unit 404 for the latter to forward to various media. The integrated operational process of transaction, comment and dissemination is thereby accomplished. This ensures more relevant comments and more effective dissemination. Moreover, for further improving the integrated operational process by making these data more retrievable, an intellective comment retrieving unit 405 may be connected to the comment keyword database 403 . The intellective comment retrieving unit 405 statistically analyzes the comments from individual consumers, the comments for different types of transactions and the comments about individual commodities, and summarizes the comments from all consumers, so as to generate a search guide, a consumer guide, a purchase recommendation, a user reference search, a list of best sold items, a list of hot comment keywords and so on, thereby further promoting commodities in a user-specific fashion.
[0039] Referring to FIG. 5 , the present invention may be realized through the emerging “clouding” environment instead of the physical infrastructure. In another embodiment of the present invention, all the data and program codes may be stored in the cloud by using any of cloud computing technologies, such as IaaS, PaaS, SaaS or any combination thereof. Alternatively, the transaction page 104 such generated may be incorporated as a part of a social networking service, which may function as MicroBlog, so that the social networking service is used as a platform that provides a user interface for accessing and operating the system of the present invention. In addition, for making each said transaction page as a potable medium, the transaction page may be inlaid to an existing SNS (Social Networking Services) website 504 or a portal website through a plug-in program, an RSS reader, an Atom reader or an XML protocol application. In this case, the transaction page 104 can be disseminated more widely in virtue of the extensive audience base and reputation of such website. Additionally, with the increasing subscription to SNS websites, a modern messaging program or browser, like one denoted as 501 in FIG. 5 , is made to be capable of managing a person's more accounts registered in different SNS websites. Thereby, one can conveniently access data and manage his/her accounts through the messaging program preloaded in a personal computer or a mobile device, allowing his/her easy participation in the chain transactions. Also, the population of smart handsets has brought about increasing development of mobile applications such as iOS, Android OS, Symbian OS, webOS and Windows Phone OS. Such mobile application 502 can be downloaded to a mobile terminal 503 for running the transaction page 104 . In one embodiment, the dissemination managing unit 404 may generate a transaction program 505 as an object those transaction information is followed. A user may load it in a mobile terminal 506 , and send it to a mobile terminal 508 belonging to another user whose transactions are to be followed, thereby allowing a transaction program 507 to be built in both mobile terminals 506 and 508 . When the mobile terminals 506 and 508 are on line, the transaction information can be used to update the transaction page 104 , incurring more transactions. In another embodiment of the present invention, one can use the functions of automatic comment generation and dissemination to promote chain greeting in a social networking website through a bound commercial mode that promotes virtual or physical gifts. In still another embodiment, the present invention facilitates assembly of members of a social network and in turn facilitates chain response by allowing the audience to click on a reply button related to a certain activity for generating a personalized comment about the activity. In this fashion, statistic and analytic results of the comments about a certain activity can be easily obtained. In yet another embodiment, when interested in the dissemination, a user can trigger a button of subscription or interaction to reply to the dissemination in the manner similar to providing the automatically generated comments as described above. Moreover, different buttons may be provided to trigger comment scripts for improving personalized comments or responses. Then the automatic dissemination may be again performed to share the comments or responses to the audience, thus achieving interactive, viral advertising. Such dissemination can be incorporated to the reward system to encourage chain dissemination. For different commodities, the comment may be provided in different forms, such as and not limited to a user diary, a user feedback, an open-box report, a blog post, an experience sharing, a user reference and any combination thereof, as long as it is accretive to the audience and helpful to induce sequent transactions.
[0040] The present invention has been described with reference to the preferred embodiments and it is understood that the embodiments are not intended to limit the scope of the present invention. Moreover, as the contents disclosed herein should be readily understood and can be implemented by a person skilled in the art, all equivalent changes or modifications which do not depart from the concept of the present invention should be encompassed by the appended claims. | Disclosed are a method, a computer executable program and a system for promoting chain transactions. The method, program and system serve to distribute sales margin to related consumers and to automatically generate and disseminate the consumers' personalized comments upon completion of the transactions. The integrated purchase, comment and dissemination as a whole conveniently promotes chain transactions and encourage more consumers' induced consumption, thereby significantly saving marketing costs. | 24,607 |
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application is a divisional application of U.S. patent application Ser. No. 13/551,050 filed Jul. 17, 2012, which is continuation of International Application No. PCT/US2012/023029, filed Jan. 27, 2012, which claims the benefit of priority to U.S. provisional Patent Application No. 61/437,561, filed Jan. 28, 2011, all of which applications are hereby incorporated by reference in their entireties.
TECHNICAL FIELD
[0002] This description is related to implanted neural stimulators.
BACKGROUND
[0003] Neural modulation of neural tissue in the body by electrical stimulation has become an important type of therapy for chronic disabling conditions, such as chronic pain, problems of movement initiation and control, involuntary movements, dystonia, urinary and fecal incontinence, sexual difficulties, vascular insufficiency, heart arrhythmia and more. Electrical stimulation of the spinal column and nerve bundles leaving the spinal cord was the first approved neural modulation therapy and been used commercially since the 1970s. Implanted electrodes are used to pass pulsatile electrical currents of controllable frequency, pulse width and amplitudes. Two or more electrodes are in contact with neural elements, chiefly axons, and can selectively activate varying diameters of axons, with positive therapeutic benefits. A variety of therapeutic intra-body electrical stimulation techniques are utilized to treat neuropathic conditions that utilize an implanted neural stimulator in the spinal column or surrounding areas, including the dorsal horn, dorsal root ganglia, dorsal roots, dorsal column fibers and peripheral nerve bundles leaving the dorsal column or brain, such as vagus-, occipital-, trigeminal, hypoglossal-, sacral-, and coccygeal nerves.
SUMMARY
[0004] In one aspect, an implantable neural stimulator includes one or more electrodes, a first antenna, and one or more circuits. The one or more electrodes configured to apply one or more electrical pulses to neural tissue. The first antenna is a dipole antenna and is configured to receive, from a second antenna through electrical radiative coupling, an input signal containing electrical energy, the second antenna being physically separate from the implantable neural stimulator; and transmit, to the second antenna through electrical radiative coupling, one or more feedback signals. The one or more circuits are connected to the dipole antenna and configured to create one or more electrical pulses suitable for stimulation of neural tissue using the electrical energy contained in the input signal; supply the one or more electrical pulses to the one or more electrodes such that the one or more electrodes apply the one or more electrical pulses to neural tissue; generate a stimulus feedback signal, the stimulus feedback signal indicating one or more parameters of the one or more electrical pulses applied to the neural tissue by the one or more electrodes; and send the stimulus feedback signal to the dipole antenna such that the dipole antenna transmits the stimulus feedback signal to the second antenna through electrical radiative coupling.
[0005] Implementations of this and other aspects may include the following features. The input signal may also contain information encoding stimulus parameters for the one or more electrical pulses and the one or more circuits are configured to create the electrical pulses based on the information encoding stimulus parameters. The one or more parameters may include an amplitude of the one or more electrical pulses or an impedance of the one or more electrodes. The one or more circuits may be configured such that a level of the input signal directly determines an amplitude of the one or more electrical pulses applied to the neural tissue by the one or more electrodes.
[0006] The one or more circuits may be configured to limit a characteristic of the one or more electrical pulses applied to the neural tissue by the one or more electrodes so that a charge per phase resulting from the one or more electrical pulses remains below a threshold level; generate a limit feedback signal when the charge per phase resulting from the one or more electrical pulses would have exceeded the threshold level if the one or more circuits had not limited the characteristic of the one or more electrical pulses applied to the neural tissue by the one or more electrodes so that the charge per phase resulting from the one or more electrical pulses remained below the threshold level; and send the limit feedback signal to the dipole antenna such that the dipole antenna transmits the limit feedback signal to the second antenna through electrical radiative coupling. The characteristic of the one or more pulses applied to the neural tissue by the one or more electrodes may be a current level and the threshold level may be a current threshold level.
[0007] The one or more circuits may be configured to create the one or more electrical pulses such that the one or more electrical pulses result in a substantially zero net charge. To create the one or more electrical pulses such that the one or more electrical pulses result in a substantially zero net charge, the one or more circuits may include at least one capacitor in series with the one or more electrodes.
[0008] The one or more circuits may include a waveform conditioning component to create the one or more electrical pulses suitable for stimulation of neural tissue using the electrical energy contained in the input signal; an electrode interface connected to the waveform conditioning circuit, the electrode interface being configured to receive the one or more electrical pulses from the waveform condition circuit and supply the one or more electrical pulses to the one or more electrodes; and a controller connected to the electrode interface, the controller being configured to generate the stimulus feedback signal and send the stimulus feedback signal to the dipole antenna. The waveform conditioning component may include a rectifier connected to the dipole antenna, the rectifier configured to receive the input signal from the dipole antenna and generate a rectified electrical waveform based on the input signal; a charge balance component configured to create the one or more electrical pulses based on the rectified electrical waveform such that the one or more electrical pulses result in a substantially zero net charge at the one or more electrodes; and a charge limiter configured to limit a characteristic of the one or more electrical pulses so that a charge per phase resulting from the one or more electrical pulses remains below a threshold level, wherein the limited electrical pulses are sent to the electrode interface from the charge limiter.
[0009] The one or more electrodes may include a plurality of electrodes and the one or more circuits may be configured to selectively designate each of the electrodes to act as a stimulating electrode, act as a return electrode, or be inactive.
[0010] The electrodes, the dipole antenna, and one or more circuits may be configured and geometrically arranged to be located at one of the following locations: epidural space of the spinal column, near, beneath or on the dura mater of the spinal column, in tissue in close proximity to the spinal column, in tissue located near the dorsal horn, dorsal root ganglia, dorsal roots, dorsal column fibers and/or peripheral nerve bundles leaving the dorsal column of the spine, abdominal, thoracic, and trigeminal ganglia, peripheral nerves, deep brain structures, cortical surface of the brain and sensory or motor nerves.
[0011] The implantable neural stimulator may not include an internal power source. The one or more circuits may include only passive components. The input signal may have a carrier frequency in the range from about 300 MHz to about 8 GHz
[0012] In another aspect, a system includes a controller module. The controller module includes a first antenna and one or more circuits. The first antenna is configured to send an input signal containing electrical energy to a second antenna through electrical radiative coupling. The second antenna is a dipole antenna and is located in an implantable neural stimulator that is configured to create one or more electrical pulses suitable for stimulation of neural tissue using the input signal, wherein the implantable neural stimulator is separate from the controller module. The first antenna is also configured to receive one or more signals from the dipole antenna. The one or more circuits are configured to generate the input signal and send the input signal to the dipole antenna; extract a stimulus feedback signal from one or more signals received by the first antenna, the stimulus feedback signal being sent by the implantable neural stimulator and indicating one or more parameters of the one or more electrical pulses; and adjust parameters of the input signal based on the stimulus feedback signal.
[0013] Implementations of this and other aspects may include one or more of the following features. For example, the one or more parameters of the electrical pulses may include an amplitude of the one or more electrical pulses as applied to the neural tissue and the one or more circuits are configured to adjust a power of the input signal based on the amplitude of the one or more electrical pulses. The one or more circuits may be configured to obtain a forward power signal that is reflective of an amplitude of a signal sent to the first antenna; obtain a reverse power signal that is reflective of an amplitude of a reflected portion of the signal sent to the first antenna; determine a mismatch value indicative of a magnitude of an impedance mismatch based on the forward power signal and the reverse power signal; and adjust parameters of the input signal based on the mismatch value.
[0014] The system may include the implantable neural stimulator. The implantable neural stimulator may include one or more electrodes configured to apply the one or more electrical pulses to neural tissue and one or more circuits. The one or more circuits may be configured to create the one or more electrical pulses; supply the one or more electrical pulses to the one or more electrodes such that the one or more electrodes apply the one or more electrical pulses to neural tissue; generate the stimulus feedback signal; and send the stimulus feedback signal to the dipole antenna such that the dipole antenna transmits the stimulus feedback signal to the first antenna through electrical radiative coupling.
[0015] The input signal may also contain information encoding stimulus parameters for the one or more electrical pulses and the implantable neural stimulator is configured to create the one or more electrical pulses based on the information encoding stimulus parameters. The one or more parameters of the one or more electrical pulses may include an amplitude of the one or more electrical pulses or an impedance of the one or more electrodes. The one or more circuits of the implantable neural stimulator may be configured such that a level of the input signal directly determines an amplitude of the one or more electrical pulses applied to the neural tissue by the one or more electrodes.
[0016] The one or more circuits of the implantable neural stimulator may be configured to limit a characteristic of the one or more electrical pulses applied to the neural tissue by the one or more electrodes so that a charge per phase resulting from the one or more electrical pulses remain below a threshold level; generate a limit feedback signal when the charge per phase resulting from the one or more electrical pulses would have exceeded the threshold level if the one or more circuits had not limited the characteristic of the one or more electrical pulses applied to the neural tissue by the one or more electrodes so that the charge per phase resulting from the one or more electrical pulses remained below the threshold level; and send the limit feedback signal to the dipole antenna such that the dipole antenna transmits the limit feedback signal to the second antenna through electrical radiative coupling. The characteristic of the one or more pulses applied to the neural tissue by the one or more electrodes may be a current level and the threshold level may be a current threshold level. The one or more circuits of the controller module may be configured to receive the limit feedback signal from the dipole antenna; and attenuate the input signal in response to receiving the limit feedback signal.
[0017] The one or more circuits may be configured to create the one or more electrical pulses such that the one or more electrical pulses result in a substantially zero net charge. To create the one or more electrical pulses such that the one or more electrical pulses result in a substantially zero net charge, the one or more circuits of the implantable neural stimulator may include at least one capacitor in series with the one or more electrodes.
[0018] The one or more circuits of the implantable neural stimulator may include a waveform conditioning component to create the one or more electrical pulses suitable for stimulation of neural tissue using electrical energy contained in the input signal; an electrode interface connected to the waveform conditioning circuit, the electrode interface being configured to receive the one or more electrical pulses from the waveform condition circuit and supply the one or more electrical pulses to the one or more electrodes; and a controller connected to the electrode interface, the controller being configured to generate the stimulus feedback signal and send the stimulus feedback signal to the dipole antenna. The waveform conditioning component may include a rectifier connected to the dipole antenna, the rectifier configured to receive the input signal from the dipole antenna and generate a rectified electrical waveform based on the input signal; a charge balance component configured to create the one or more electrical pulses based on the rectified electrical waveform such that the one or more electrical pulses result in a substantially zero net charge at the one or more electrodes; and a charge limiter configured to limit the a characteristic of the one or more electrical pulses so that a charge per phase resulting from the one or more electrical pulses remains below a threshold level, wherein the limited electrical pulses are sent to the electrode interface through the charge limiter.
[0019] The implantable neural stimulator may include a plurality of electrodes. The one or more circuits of the controller module may be configured to generate a control signal that designates which electrodes act as stimulating electrodes, which electrodes act as return electrodes, and which electrodes are inactive; and send the control signal to the first antenna such that the first antenna transmits the control signal to the dipole antenna through electrical radiative coupling. The one or more circuits of the implantable neural stimulator may be configured to selectively designate each of the electrodes to act as a stimulating electrode, act as a return electrode, or be inactive based on the control signal.
[0020] The implantable neural stimulator may not include an internal power source. The one or more circuits of the implantable neural stimulator may include only passive components. The input signal has a carrier frequency in the range from about 300 MHz to about 8 GHz
[0021] In another aspect, a method includes implanting a neural stimulator within a patient's body such that one or more electrodes of the neural stimulator are positioned to apply electrical pulses to neural tissue. The neural stimulator includes a first antenna configured to receive an input signal containing electrical energy. The first antenna is a dipole antenna. The neural stimulator is configured to create one or more electrical pulses suitable for stimulation of the neural tissue using the electrical energy contained in the input signal; supply the one or more electrical pulses to the one or more electrodes such that the one or more electrodes apply the one or more electrical pulses to the neural tissue; generate a stimulus feedback signal, the stimulus feedback signal indicating one or more parameters of the one or more electrical pulses applied to the neural tissue by the one or more electrodes; and transmit the stimulus feedback signal from the dipole antenna to a second antenna through electrical radiative coupling. The method also includes positioning a controller module in proximity to the patient's body, wherein the controller module is connected to the second antenna; and operating the controller module such that the controller module generates the input signal and sends the input signal to the second antenna such that second antenna transmits the input signal to the dipole antenna within the implanted neutral stimulator through electrical radiative coupling; extracts the stimulus feedback signal from one or more signals received by the second antenna; and adjusts parameters of the input signal based on the stimulus feedback signal.
[0022] Implementations of this and other aspects may include one or more of the following features. For example, the parameters may include an amplitude of the one or more electrical pulses or an impedance of the one or more electrodes. The neural stimulator may be configured to create the one or more electrical pulses such that the one or more electrical pulses result in a substantially zero net charge within the patient's body. The neural stimulator may be configured to selectively designate one or more electrodes to act as a stimulating electrode, act as a return electrode, or be inactive.
[0023] Implanting the neural stimulator may include implanting the neural stimulator at one of the following locations within the patient's body: epidural space of the spinal column, near, beneath or on the dura mater of the spinal column, in tissue in close proximity to the spinal column, in tissue located near the dorsal horn, dorsal root ganglia, dorsal roots, dorsal column fibers and/or peripheral nerve bundles leaving the dorsal column of the spine, abdominal, thoracic, and trigeminal ganglia, peripheral nerves, deep brain structures, cortical surface of the brain and sensory or motor nerves.
[0024] The implanted neural stimulator may not include an internal power source. The implanted neutral stimulator may include at least one capacitor in series with the one or more electrodes.
[0025] Implementations of the technology described herein may include one or more of the following advantages. For example, implementations may avoid the numerous failure modes associated with implanted pulse generator modules that are connected to electrodes through physical leads, such as loss of electrical continuity due to mechanical flexure, mechanical dislodgement caused by natural motion of the body, impingement of the lead electrode assembly into tissue, infection, and uncomfortable irritation.
[0026] Various implementations may be useful for neural modulation therapies involving the brain. Areas of the brain can be stimulated to help treat the symptoms of chronic pain, assist with movement disorders, clinical depression, control epilepsy and more. The cortex of the brain is a neural stimulation target where stimulating electrodes are positioned outside the dura mater. Various implementations may employ lead/electrode volume more than ten times less than electrodes currently being used for such stimulation. Such electrodes may require creation of a large hole in the skull, 1.0 sq mm or more in diameter. Some implementations can be ejected from an extremely small injector lumen, such as a typical 22-gauge needle used in laparoscopic or endoscopic placements. Thus, some implementations may employ a hole in the skull much smaller than current devices. If several stimulators are to be inserted, a catheter can be placed through the hole, steered with a removable stylet, and the stimulators can be pushed out of the catheter placed at their respective locations.
[0027] Deep brain stimulation (DBS) is used to treat the symptoms arising from chronic pain, movement disorders, obsessive-compulsive disorders, and epilepsy. Target locations for electrode placement to treat chronic pain symptoms with DBS include the sensory thalamus and periventricular gray matter. Target locations in the brain for treatment of the symptoms of movement disorders, such as Parkinson' include ventral intermediate thalamus, subthalamic nucleus, and the globus pallidus. The hypothalamus is one target location for electrode placement to treat epileptic symptoms with DBS. Placement of various implementations deep in the brain may cause minimal acute trauma or chronic reactions due to the small size of the stimulator.
[0028] Applications of the technology near the spinal cord may include advantages of ease of insertion, elimination of extension wires, and no requirement for an implantable pulse generator to administer a chronic therapy. Spinal cord stimulation is used to treat chronic neuropathic pain, especially low back pain and radiculopathy, vascular insufficiency in the feet or hands, angina, and more. Various implementations of the technology may allows placement of electrodes in the epidural space, between the dura mater and arachnoid membranes, which is standard practice in the art, or subdurally in the intrathecal space, since significant reactions and scarring would be minimal. Insertion in any of these spaces may be done by ejecting the device from a 22-gauge needle or out of a catheter steered to the proper position by a removable stylet. In some implementations, once in position, no further skin incisions or placement of extensions, receivers or implanted pulse generators are needed. Various implementations of the wireless neural modulation system may have significant advantages due to the small size and lack of extension wires for transfer of energy, allowing placement with minimal trauma and long term effective therapy in places where larger implantable devices could cause more scar tissue and tissue reactions that may affect efficacy and safety.
[0029] Various implementations may be inherently low in cost compared to existing implantable neural modulation systems, and this may lead to wider adoption of neural modulation therapy for patients in need as well as reduction in overall cost to the healthcare system.
[0030] The details of one or more implementations are set forth in the accompanying drawings and the description below. Other features, objects, and advantages will be apparent from the description and drawings, and from the claims.
DESCRIPTION OF DRAWINGS
[0031] FIG. 1 depicts a high-level diagram of an example of a wireless neural stimulation system.
[0032] FIG. 2 depicts a detailed diagram of an example of the wireless neural stimulation system.
[0033] FIG. 3 is a flowchart showing an example of the operation of the wireless neural stimulator system.
[0034] FIG. 4 depicts a flow chart showing an example of the operation of the system when the current level at the electrodes is above the threshold limit.
[0035] FIG. 5 is a diagram showing examples of signals that may be used to detect an impedance mismatch.
[0036] FIG. 6 is a diagram showing examples of signals that may be employed during operation of the wireless neural stimulator system.
[0037] FIG. 7 is a flow chart showing a process for the user to control the implantable wireless neural stimulator through an external programmer in an open loop feedback system.
[0038] FIG. 8 is another example flow chart of a process for the user to control the wireless stimulator with limitations on the lower and upper limits of current amplitude.
[0039] FIG. 9 is yet another example flow chart of a process for the user to control the wireless neural stimulator through preprogrammed parameter settings.
[0040] FIG. 10 is still another example flow chart of a process for a low battery state for the RF pulse generator module.
[0041] FIG. 11 is yet another example flow chart of a process for a Manufacturer's Representative to program the implanted wireless neural stimulator.
[0042] FIG. 12 is a circuit diagram showing an example of a wireless neural stimulator.
[0043] FIG. 13 is a circuit diagram of another example of a wireless neural stimulator.
DETAILED DESCRIPTION
[0044] In various implementations, a neural stimulation system may be used to send electrical stimulation to targeted nerve tissue by using remote radio frequency (RF) energy with neither cables nor inductive coupling to power the passive implanted stimulator. The targeted nerve tissues may be, for example, in the spinal column including the spinothalamic tracts, dorsal horn, dorsal root ganglia, dorsal roots, dorsal column fibers, and peripheral nerves bundles leaving the dorsal column or brainstem, as well as any cranial nerves, abdominal, thoracic, or trigeminal ganglia nerves, nerve bundles of the cerebral cortex, deep brain and any sensory or motor nerves.
[0045] For instance, in some implementations, the neural stimulation system may include a controller module, such as an RF pulse generator module, and a passive implanted neural stimulator that contains one or more dipole antennas, one or more circuits, and one or more electrodes in contact with or in proximity to targeted neural tissue to facilitate stimulation. The RF pulse generator module may include an antenna and may be configured to transfer energy from the module antenna to the implanted antennas. The one or more circuits of the implanted neural stimulator may be configured to generate electrical pulses suitable for neural stimulation using the transferred energy and to supply the electrical pulses to the electrodes so that the pulses are applied to the neural tissue. For instance, the one or more circuits may include wave conditioning circuitry that rectifies the received RF signal (for example, using a diode rectifier), transforms the RF energy to a low frequency signal suitable for the stimulation of neural tissue, and presents the resulting waveform to an electrode array. The one or more circuits of the implanted neural stimulator may also include circuitry for communicating information back to the RF pulse generator module to facilitate a feedback control mechanism for stimulation parameter control. For example, the implanted neural stimulator may send to the RF pulse generator module a stimulus feedback signal that is indicative of parameters of the electrical pulses, and the RF pulse generator module may employ the stimulus feedback signal to adjust parameters of the signal sent to the neural stimulator.
[0046] FIG. 1 depicts a high-level diagram of an example of a neural stimulation system. The neural stimulation system may include four major components, namely, a programmer module 102 , a RF pulse generator module 106 , a transmit (TX) antenna 110 (for example, a patch antenna, slot antenna, or a dipole antenna), and an implanted wireless neural stimulator 114 . The programmer module 102 may be a computer device, such as a smart phone, running a software application that supports a wireless connection 114 , such as Bluetooth®. The application can enable the user to view the system status and diagnostics, change various parameters, increase/decrease the desired stimulus amplitude of the electrode pulses, and adjust feedback sensitivity of the RF pulse generator module 106 , among other functions.
[0047] The RF pulse generator module 106 may include communication electronics that support the wireless connection 104 , the stimulation circuitry, and the battery to power the generator electronics. In some implementations, the RF pulse generator module 106 includes the TX antenna embedded into its packaging form factor while, in other implementations, the TX antenna is connected to the RF pulse generator module 106 through a wired connection 108 or a wireless connection (not shown). The TX antenna 110 may be coupled directly to tissue to create an electric field that powers the implanted neural stimulator module 114 . The TX antenna 110 communicates with the implanted neural stimulator module 114 through an RF interface. For instance, the TX antenna 110 radiates an RF transmission signal that is modulated and encoded by the RF pulse generator module 110 . The implanted wireless neural stimulator module 114 contains one or more antennas, such as dipole antenna(s), to receive and transmit through RF interface 112 . In particular, the coupling mechanism between antenna 110 and the one or more antennas on the implanted neural stimulation module 114 is electrical radiative coupling and not inductive coupling. In other words, the coupling is through an electric field rather than a magnetic field.
[0048] Through this electrical radiative coupling, the TX antenna 110 can provide an input signal to the implanted neural stimulation module 114 . This input signal contains energy and may contain information encoding stimulus waveforms to be applied at the electrodes of the implanted neural stimulator module 114 . In some implementations, the power level of this input signal directly determines an applied amplitude (for example, power, current, or voltage) of the one or more electrical pulses created using the electrical energy contained in the input signal. Within the implanted wireless neural stimulator 114 are components for demodulating the RF transmission signal, and electrodes to deliver the stimulation to surrounding neuronal tissue.
[0049] The RF pulse generator module 106 can be implanted subcutaneously, or it can be worn external to the body. When external to the body, the RF generator module 106 can be incorporated into a belt or harness design to allow for electric radiative coupling through the skin and underlying tissue to transfer power and/or control parameters to the implanted neural stimulator module 114 , which can be a passive stimulator. In either event, receiver circuit(s) internal to the neural stimulator module 114 can capture the energy radiated by the TX antenna 110 and convert this energy to an electrical waveform. The receiver circuit(s) may further modify the waveform to create an electrical pulse suitable for the stimulation of neural tissue, and this pulse may be delivered to the tissue via electrode pads.
[0050] In some implementations, the RF pulse generator module 106 can remotely control the stimulus parameters (that is, the parameters of the electrical pulses applied to the neural tissue) and monitor feedback from the wireless neural stimulator module 114 based on RF signals received from the implanted wireless neural stimulator module 114 . A feedback detection algorithm implemented by the RF pulse generator module 106 can monitor data sent wirelessly from the implanted wireless neural stimulator module 114 , including information about the energy that the implanted wireless neural stimulator module 114 is receiving from the RF pulse generator and information about the stimulus waveform being delivered to the electrode pads. In order to provide an effective therapy for a given medical condition, the system can be tuned to provide the optimal amount of excitation or inhibition to the nerve fibers by electrical stimulation. A closed loop feedback control method can be used in which the output signals from the implanted wireless neural stimulator module 114 are monitored and used to determine the appropriate level of neural stimulation current for maintaining effective neuronal activation, or, in some cases, the patient can manually adjust the output signals in an open loop control method.
[0051] FIG. 2 depicts a detailed diagram of an example of the neural stimulation system. As depicted, the programming module 102 may comprise user input system 202 and communication subsystem 208 . The user input system 221 may allow various parameter settings to be adjusted (in some cases, in an open loop fashion) by the user in the form of instruction sets. The communication subsystem 208 may transmit these instruction sets (and other information) via the wireless connection 104 , such as Bluetooth or Wi-Fi, to the RF pulse generator module 106 , as well as receive data from module 106 .
[0052] For instance, the programmer module 102 , which can be utilized for multiple users, such as a patient's control unit or clinician's programmer unit, can be used to send stimulation parameters to the RF pulse generator module 106 . The stimulation parameters that can be controlled may include pulse amplitude, pulse frequency, and pulse width in the ranges shown in Table 1. In this context the term pulse refers to the phase of the waveform that directly produces stimulation of the tissue; the parameters of the charge-balancing phase (described below) can similarly be controlled. The patient and/or the clinician can also optionally control overall duration and pattern of treatment.
[0000]
Stimulation Parameter Table 1
Pulse Amplitude:
0 to 20
mA
Pulse Frequency:
0 to 2000
Hz
Pulse Width:
0 to 2
ms
[0053] The implantable neural stimulator module 114 or RF pulse generator module 114 may be initially programmed to meet the specific parameter settings for each individual patient during the initial implantation procedure. Because medical conditions or the body itself can change over time, the ability to re-adjust the parameter settings may be beneficial to ensure ongoing efficacy of the neural modulation therapy.
[0054] The programmer module 102 may be functionally a smart device and associated application. The smart device hardware may include a CPU 206 and be used as a vehicle to handle touchscreen input on a graphical user interface (GUI) 204 , for processing and storing data.
[0055] The RF pulse generator module 106 may be connected via wired connection 108 to an external TX antenna 110 . Alternatively, both the antenna and the RF pulse generator are located subcutaneously (not shown).
[0056] The signals sent by RF pulse generator module 106 to the implanted stimulator 114 may include both power and parameter-setting attributes in regards to stimulus waveform, amplitude, pulse width, and frequency. The RF pulse generator module 106 can also function as a wireless receiving unit that receives feedback signals from the implanted stimulator module 114 . To that end, the RF pulse generator module 106 may contain microelectronics or other circuitry to handle the generation of the signals transmitted to the stimulator module 114 as well as handle feedback signals, such as those from the stimulator module 114 . For example, the RF pulse generator module 106 may comprise controller subsystem 214 , high-frequency oscillator 218 , RF amplifier 216 , a RF switch, and a feedback subsystem 212 .
[0057] The controller subsystem 214 may include a CPU 230 to handle data processing, a memory subsystem 228 such as a local memory, communication subsystem 234 to communicate with programmer module 102 (including receiving stimulation parameters from programmer module), pulse generator circuitry 236 , and digital/analog (D/A) converters 232 .
[0058] The controller subsystem 214 may be used by the patient and/or the clinician to control the stimulation parameter settings (for example, by controlling the parameters of the signal sent from RF pulse generator module 106 to neural stimulator module 114 ). These parameter settings can affect, for example, the power, current level, or shape of the one or more electrical pulses. The programming of the stimulation parameters can be performed using the programming module 102 , as described above, to set the repetition rate, pulse width, amplitude, and waveform that will be transmitted by RF energy to the receive (RX) antenna 238 , typically a dipole antenna (although other types may be used), in the wireless implanted neural stimulator module 214 . The clinician may have the option of locking and/or hiding certain settings within the programmer interface, thus limiting the patient's ability to view or adjust certain parameters because adjustment of certain parameters may require detailed medical knowledge of neurophysiology, neuroanatomy, protocols for neural modulation, and safety limits of electrical stimulation.
[0059] The controller subsystem 214 may store received parameter settings in the local memory subsystem 228 , until the parameter settings are modified by new input data received from the programming module 102 . The CPU 206 may use the parameters stored in the local memory to control the pulse generator circuitry 236 to generate a stimulus waveform that is modulated by a high frequency oscillator 218 in the range from 300 MHz to 8 GHz. The resulting RF signal may then be amplified by RF amplifier 226 and then sent through an RF switch 223 to the TX antenna 110 to reach through depths of tissue to the RX antenna 238 .
[0060] In some implementations, the RF signal sent by TX antenna 110 may simply be a power transmission signal used by stimulator module 114 to generate electric pulses. In other implementations, a telemetry signal may also be transmitted to the stimulator module 114 to send instructions about the various operations of the stimulator module 114 . The telemetry signal may be sent by the modulation of the carrier signal (through the skin if external, or through other body tissues if the pulse generator module 106 is implanted subcutaneously). The telemetry signal is used to modulate the carrier signal (a high frequency signal) that is coupled onto the implanted antenna(s) 238 and does not interfere with the input received on the same lead to power the implant. In one embodiment the telemetry signal and powering signal are combined into one signal, where the RF telemetry signal is used to modulate the RF powering signal, and thus the implanted stimulator is powered directly by the received telemetry signal; separate subsystems in the stimulator harness the power contained in the signal and interpret the data content of the signal.
[0061] The RF switch 223 may be a multipurpose device such as a dual directional coupler, which passes the relatively high amplitude, extremely short duration RF pulse to the TX antenna 110 with minimal insertion loss while simultaneously providing two low-level outputs to feedback subsystem 212 ; one output delivers a forward power signal to the feedback subsystem 212 , where the forward power signal is an attenuated version of the RF pulse sent to the TX antenna 110 , and the other output delivers a reverse power signal to a different port of the feedback subsystem 212 , where reverse power is an attenuated version of the reflected RF energy from the TX Antenna 110 .
[0062] During the on-cycle time (when an RF signal is being transmitted to stimulator 114 ), the RF switch 223 is set to send the forward power signal to feedback subsystem. During the off-cycle time (when an RF signal is not being transmitted to the stimulator module 114 ), the RF switch 223 can change to a receiving mode in which the reflected RF energy and/or RF signals from the stimulator module 114 are received to be analyzed in the feedback subsystem 212 .
[0063] The feedback subsystem 212 of the RF pulse generator module 106 may include reception circuitry to receive and extract telemetry or other feedback signals from the stimulator 114 and/or reflected RF energy from the signal sent by TX antenna 110 . The feedback subsystem may include an amplifier 226 , a filter 224 , a demodulator 222 , and an A/D converter 220 .
[0064] The feedback subsystem 212 receives the forward power signal and converts this high-frequency AC signal to a DC level that can be sampled and sent to the controller subsystem 214 . In this way the characteristics of the generated RF pulse can be compared to a reference signal within the controller subsystem 214 . If a disparity (error) exists in any parameter, the controller subsystem 214 can adjust the output to the RF pulse generator 106 . The nature of the adjustment can be, for example, proportional to the computed error. The controller subsystem 214 can incorporate additional inputs and limits on its adjustment scheme such as the signal amplitude of the reverse power and any predetermined maximum or minimum values for various pulse parameters.
[0065] The reverse power signal can be used to detect fault conditions in the RF-power delivery system. In an ideal condition, when TX antenna 110 has perfectly matched impedance to the tissue that it contacts, the electromagnetic waves generated from the RF pulse generator 106 pass unimpeded from the TX antenna 110 into the body tissue. However, in real-world applications a large degree of variability may exist in the body types of users, types of clothing worn, and positioning of the antenna 110 relative to the body surface. Since the impedance of the antenna 110 depends on the relative permittivity of the underlying tissue and any intervening materials, and also depends on the overall separation distance of the antenna from the skin, in any given application there can be an impedance mismatch at the interface of the TX antenna 110 with the body surface. When such a mismatch occurs, the electromagnetic waves sent from the RF pulse generator 106 are partially reflected at this interface, and this reflected energy propagates backward through the antenna feed.
[0066] The dual directional coupler RF switch 223 may prevent the reflected RF energy propagating back into the amplifier 226 , and may attenuate this reflected RF signal and send the attenuated signal as the reverse power signal to the feedback subsystem 212 . The feedback subsystem 212 can convert this high-frequency AC signal to a DC level that can be sampled and sent to the controller subsystem 214 . The controller subsystem 214 can then calculate the ratio of the amplitude of the reverse power signal to the amplitude of the forward power signal. The ratio of the amplitude of reverse power signal to the amplitude level of forward power may indicate severity of the impedance mismatch.
[0067] In order to sense impedance mismatch conditions, the controller subsystem 214 can measure the reflected-power ratio in real time, and according to preset thresholds for this measurement, the controller subsystem 214 can modify the level of RF power generated by the RF pulse generator 106 . For example, for a moderate degree of reflected power the course of action can be for the controller subsystem 214 to increase the amplitude of RF power sent to the TX antenna 110 , as would be needed to compensate for slightly non-optimum but acceptable TX antenna coupling to the body. For higher ratios of reflected power, the course of action can be to prevent operation of the RF pulse generator 106 and set a fault code to indicate that the TX antenna 110 has little or no coupling with the body. This type of reflected-power fault condition can also be generated by a poor or broken connection to the TX antenna. In either case, it may be desirable to stop RF transmission when the reflected-power ratio is above a defined threshold, because internally reflected power can lead to unwanted heating of internal components, and this fault condition means the system cannot deliver sufficient power to the implanted wireless neural stimulator and thus cannot deliver therapy to the user.
[0068] The controller 242 of the stimulator 114 may transmit informational signals, such as a telemetry signal, through the antenna 238 to communicate with the RF pulse generator module 106 during its receive cycle. For example, the telemetry signal from the stimulator 114 may be coupled to the modulated signal on the dipole antenna(s) 238 , during the on and off state of the transistor circuit to enable or disable a waveform that produces the corresponding RF bursts necessary to transmit to the external (or remotely implanted) pulse generator module 106 . The antenna(s) 238 may be connected to electrodes 254 in contact with tissue to provide a return path for the transmitted signal. An A/D (not shown) converter can be used to transfer stored data to a serialized pattern that can be transmitted on the pulse modulated signal from the internal antenna(s) 238 of the neural stimulator.
[0069] A telemetry signal from the implanted wireless neural stimulator module 114 may include stimulus parameters such as the power or the amplitude of the current that is delivered to the tissue from the electrodes. The feedback signal can be transmitted to the RF pulse generator module 116 to indicate the strength of the stimulus at the nerve bundle by means of coupling the signal to the implanted RX antenna 238 , which radiates the telemetry signal to the external (or remotely implanted) RF pulse generator module 106 . The feedback signal can include either or both an analog and digital telemetry pulse modulated carrier signal. Data such as stimulation pulse parameters and measured characteristics of stimulator performance can be stored in an internal memory device within the implanted neural stimulator 114 , and sent on the telemetry signal. The frequency of the carrier signal may be in the range of at 300 MHz to 8 GHz.
[0070] In the feedback subsystem 212 , the telemetry signal can be down modulated using demodulator 222 and digitized by being processed through an analog to digital (A/D) converter 220 . The digital telemetry signal may then be routed to a CPU 230 with embedded code, with the option to reprogram, to translate the signal into a corresponding current measurement in the tissue based on the amplitude of the received signal. The CPU 230 of the controller subsystem 214 can compare the reported stimulus parameters to those held in local memory 228 to verify the stimulator(s) 114 delivered the specified stimuli to tissue. For example, if the stimulator reports a lower current than was specified, the power level from the RF pulse generator module 106 can be increased so that the implanted neural stimulator 114 will have more available power for stimulation. The implanted neural stimulator 114 can generate telemetry data in real time, for example, at a rate of 8 kbits per second. All feedback data received from the implanted lead module 114 can be logged against time and sampled to be stored for retrieval to a remote monitoring system accessible by the health care professional for trending and statistical correlations.
[0071] The sequence of remotely programmable RF signals received by the internal antenna(s) 238 may be conditioned into waveforms that are controlled within the implantable stimulator 114 by the control subsystem 242 and routed to the appropriate electrodes 254 that are placed in proximity to the tissue to be stimulated. For instance, the RF signal transmitted from the RF pulse generator module 106 may be received by RX antenna 238 and processed by circuitry, such as waveform conditioning circuitry 240 , within the implanted wireless neural stimulator module 114 to be converted into electrical pulses applied to the electrodes 254 through electrode interface 252 . In some implementations, the implanted stimulator 114 contains between two to sixteen electrodes 254 .
[0072] The waveform conditioning circuitry 240 may include a rectifier 244 , which rectifies the signal received by the RX antenna 238 . The rectified signal may be fed to the controller 242 for receiving encoded instructions from the RF pulse generator module 106 . The rectifier signal may also be fed to a charge balance component 246 that is configured to create one or more electrical pulses based such that the one or more electrical pulses result in a substantially zero net charge at the one or more electrodes (that is, the pulses are charge balanced). The charge balanced pulses are passed through the current limiter 248 to the electrode interface 252 , which applies the pulses to the electrodes 254 as appropriate.
[0073] The current limiter 248 insures the current level of the pulses applied to the electrodes 254 is not above a threshold current level. In some implementations, an amplitude (for example, current level, voltage level, or power level) of the received RF pulse directly determines the amplitude of the stimulus. In this case, it may be particularly beneficial to include current limiter 248 to prevent excessive current or charge being delivered through the electrodes, although current limiter 248 may be used in other implementations where this is not the case. Generally, for a given electrode having several square millimeters surface area, it is the charge per phase that should be limited for safety (where the charge delivered by a stimulus phase is the integral of the current). But, in some cases, the limit can instead be placed on the current, where the maximum current multiplied by the maximum possible pulse duration is less than or equal to the maximum safe charge. More generally, the limiter 248 acts as a charge limiter that limits a characteristic (for example, current or duration) of the electrical pulses so that the charge per phase remains below a threshold level (typically, a safe-charge limit).
[0074] In the event the implanted wireless neural stimulator 114 receives a “strong” pulse of RF power sufficient to generate a stimulus that would exceed the predetermined safe-charge limit, the current limiter 248 can automatically limit or “clip” the stimulus phase to maintain the total charge of the phase within the safety limit. The current limiter 248 may be a passive current limiting component that cuts the signal to the electrodes 254 once the safe current limit (the threshold current level) is reached. Alternatively, or additionally, the current limiter 248 may communicate with the electrode interface 252 to turn off all electrodes 254 to prevent tissue damaging current levels.
[0075] A clipping event may trigger a current limiter feedback control mode. The action of clipping may cause the controller to send a threshold power data signal to the pulse generator 106 . The feedback subsystem 212 detects the threshold power signal and demodulates the signal into data that is communicated to the controller subsystem 214 . The controller subsystem 214 algorithms may act on this current-limiting condition by specifically reducing the RF power generated by the RF pulse generator, or cutting the power completely. In this way, the pulse generator 106 can reduce the RF power delivered to the body if the implanted wireless neural stimulator 114 reports it is receiving excess RF power.
[0076] The controller 250 of the stimulator 205 may communicate with the electrode interface 252 to control various aspects of the electrode setup and pulses applied to the electrodes 254 . The electrode interface 252 may act as a multiplex and control the polarity and switching of each of the electrodes 254 . For instance, in some implementations, the wireless stimulator 106 has multiple electrodes 254 in contact with tissue, and for a given stimulus the RF pulse generator module 106 can arbitrarily assign one or more electrodes to 1) act as a stimulating electrode, 2) act as a return electrode, or 3) be inactive by communication of assignment sent wirelessly with the parameter instructions, which the controller 250 uses to set electrode interface 252 as appropriate. It may be physiologically advantageous to assign, for example, one or two electrodes as stimulating electrodes and to assign all remaining electrodes as return electrodes.
[0077] Also, in some implementations, for a given stimulus pulse, the controller 250 may control the electrode interface 252 to divide the current arbitrarily (or according to instructions from pulse generator module 106 ) among the designated stimulating electrodes. This control over electrode assignment and current control can be advantageous because in practice the electrodes 254 may be spatially distributed along various neural structures, and through strategic selection of the stimulating electrode location and the proportion of current specified for each location, the aggregate current distribution in tissue can be modified to selectively activate specific neural targets. This strategy of current steering can improve the therapeutic effect for the patient.
[0078] In another implementation, the time course of stimuli may be arbitrarily manipulated. A given stimulus waveform may be initiated at a time T_start and terminated at a time T_final, and this time course may be synchronized across all stimulating and return electrodes; further, the frequency of repetition of this stimulus cycle may be synchronous for all the electrodes. However, controller 250 , on its own or in response to instructions from pulse generator 106 , can control electrode interface 252 to designate one or more subsets of electrodes to deliver stimulus waveforms with non-synchronous start and stop times, and the frequency of repetition of each stimulus cycle can be arbitrarily and independently specified.
[0079] For example, a stimulator having eight electrodes may be configured to have a subset of five electrodes, called set A, and a subset of three electrodes, called set B. Set A might be configured to use two of its electrodes as stimulating electrodes, with the remainder being return electrodes. Set B might be configured to have just one stimulating electrode. The controller 250 could then specify that set A deliver a stimulus phase with 3 mA current for a duration of 200 us followed by a 400 us charge-balancing phase. This stimulus cycle could be specified to repeat at a rate of 60 cycles per second. Then, for set B, the controller 250 could specify a stimulus phase with 1 mA current for duration of 500 us followed by a 800 us charge-balancing phase. The repetition rate for the set-B stimulus cycle can be set independently of set A, say for example it could be specified at 25 cycles per second. Or, if the controller 250 was configured to match the repetition rate for set B to that of set A, for such a case the controller 250 can specify the relative start times of the stimulus cycles to be coincident in time or to be arbitrarily offset from one another by some delay interval.
[0080] In some implementations, the controller 250 can arbitrarily shape the stimulus waveform amplitude, and may do so in response to instructions from pulse generator 106 . The stimulus phase may be delivered by a constant-current source or a constant-voltage source, and this type of control may generate characteristic waveforms that are static, e.g. a constant-current source generates a characteristic rectangular pulse in which the current waveform has a very steep rise, a constant amplitude for the duration of the stimulus, and then a very steep return to baseline. Alternatively, or additionally, the controller 250 can increase or decrease the level of current at any time during the stimulus phase and/or during the charge-balancing phase. Thus, in some implementations, the controller 250 can deliver arbitrarily shaped stimulus waveforms such as a triangular pulse, sinusoidal pulse, or Gaussian pulse for example. Similarly, the charge-balancing phase can be arbitrarily amplitude-shaped, and similarly a leading anodic pulse (prior to the stimulus phase) may also be amplitude-shaped.
[0081] As described above, the stimulator 114 may include a charge balancing component 246 . Generally, for constant current stimulation pulses, pulses should be charge balanced by having the amount of cathodic current should equal the amount of anodic current, which is typically called biphasic stimulation. Charge density is the amount of current times the duration it is applied, and is typically expressed in the units uC/cm 2 . In order to avoid the irreversible electrochemical reactions such as pH change, electrode dissolution as well as tissue destruction, no net charge should appear at the electrode-electrolyte interface, and it is generally acceptable to have a charge density less than 30 uC/cm 2 . Biphasic stimulating current pulses ensure that no net charge appears at the electrode after each stimulation cycle and the electrochemical processes are balanced to prevent net dc currents. Neural stimulator 114 may be designed to ensure that the resulting stimulus waveform has a net zero charge. Charge balanced stimuli are thought to have minimal damaging effects on tissue by reducing or eliminating electrochemical reaction products created at the electrode-tissue interface.
[0082] A stimulus pulse may have a negative-voltage or current, called the cathodic phase of the waveform. Stimulating electrodes may have both cathodic and anodic phases at different times during the stimulus cycle. An electrode that delivers a negative current with sufficient amplitude to stimulate adjacent neural tissue is called a “stimulating electrode.” During the stimulus phase the stimulating electrode acts as a current sink. One or more additional electrodes act as a current source and these electrodes are called “return electrodes.” Return electrodes are placed elsewhere in the tissue at some distance from the stimulating electrodes. When a typical negative stimulus phase is delivered to tissue at the stimulating electrode, the return electrode has a positive stimulus phase. During the subsequent charge-balancing phase, the polarities of each electrode are reversed.
[0083] In some implementations, the charge balance component 246 uses a blocking capacitor(s) placed electrically in series with the stimulating electrodes and body tissue, between the point of stimulus generation within the stimulator circuitry and the point of stimulus delivery to tissue. In this manner, a resistor-capacitor (RC) network may be formed. In a multi-electrode stimulator, one charge-balance capacitor(s) may be used for each electrode or a centralized capacitor(s) may be used within the stimulator circuitry prior to the point of electrode selection. The RC network can block direct current (DC), however it can also prevent low-frequency alternating current (AC) from passing to the tissue. The frequency below which the series RC network essentially blocks signals is commonly referred to as the cutoff frequency, and in one embodiment the design of the stimulator system may ensure the cutoff frequency is not above the fundamental frequency of the stimulus waveform. In this embodiment of the present invention, the wireless stimulator may have a charge-balance capacitor with a value chosen according to the measured series resistance of the electrodes and the tissue environment in which the stimulator is implanted. By selecting a specific capacitance value the cutoff frequency of the RC network in this embodiment is at or below the fundamental frequency of the stimulus pulse.
[0084] In other implementations, the cutoff frequency may be chosen to be at or above the fundamental frequency of the stimulus, and in this scenario the stimulus waveform created prior to the charge-balance capacitor, called the drive waveform, may be designed to be non-stationary, where the envelope of the drive waveform is varied during the duration of the drive pulse. For example, in one embodiment, the initial amplitude of the drive waveform is set at an initial amplitude Vi, and the amplitude is increased during the duration of the pulse until it reaches a final value k*Vi. By changing the amplitude of the drive waveform over time, the shape of the stimulus waveform passed through the charge-balance capacitor is also modified. The shape of the stimulus waveform may be modified in this fashion to create a physiologically advantageous stimulus.
[0085] In some implementations, the wireless neural stimulator module 114 may create a drive-waveform envelope that follows the envelope of the RF pulse received by the receiving dipole antenna(s) 238 . In this case, the RF pulse generator module 106 can directly control the envelope of the drive waveform within the wireless neural stimulator 114 , and thus no energy storage may be required inside the stimulator itself. In this implementation, the stimulator circuitry may modify the envelope of the drive waveform or may pass it directly to the charge-balance capacitor and/or electrode-selection stage.
[0086] In some implementations, the implanted neural stimulator 114 may deliver a single-phase drive waveform to the charge balance capacitor or it may deliver multiphase drive waveforms. In the case of a single-phase drive waveform, for example, a negative-going rectangular pulse, this pulse comprises the physiological stimulus phase, and the charge-balance capacitor is polarized (charged) during this phase. After the drive pulse is completed, the charge balancing function is performed solely by the passive discharge of the charge-balance capacitor, where is dissipates its charge through the tissue in an opposite polarity relative to the preceding stimulus. In one implementation, a resistor within the stimulator facilitates the discharge of the charge-balance capacitor. In some implementations, using a passive discharge phase, the capacitor may allow virtually complete discharge prior to the onset of the subsequent stimulus pulse.
[0087] In the case of multiphase drive waveforms the wireless stimulator may perform internal switching to pass negative-going or positive-going pulses (phases) to the charge-balance capacitor. These pulses may be delivered in any sequence and with varying amplitudes and waveform shapes to achieve a desired physiological effect. For example, the stimulus phase may be followed by an actively driven charge-balancing phase, and/or the stimulus phase may be preceded by an opposite phase. Preceding the stimulus with an opposite-polarity phase, for example, can have the advantage of reducing the amplitude of the stimulus phase required to excite tissue.
[0088] In some implementations, the amplitude and timing of stimulus and charge-balancing phases is controlled by the amplitude and timing of RF pulses from the RF pulse generator module 106 , and in others this control may be administered internally by circuitry onboard the wireless stimulator 114 , such as controller 250 . In the case of onboard control, the amplitude and timing may be specified or modified by data commands delivered from the pulse generator module 106 .
[0089] FIG. 3 is a flowchart showing an example of an operation of the neural stimulator system. In block 302 , the wireless neural stimulator 114 is implanted in proximity to nerve bundles and is coupled to the electric field produced by the TX antenna 110 . That is, the pulse generator module 106 and the TX antenna 110 are positioned in such a way (for example, in proximity to the patient) that the TX antenna 110 is electrically radiatively coupled with the implanted RX antenna 238 of the neural stimulator 114 . In certain implementations, both the antenna 110 and the RF pulse generator 106 are located subcutaneously. In other implementations, the antenna 110 and the RF pulse generator 106 are located external to the patient's body. In this case, the TX antenna 110 may be coupled directly to the patient's skin.
[0090] Energy from the RF pulse generator is radiated to the implanted wireless neural stimulator 114 from the antenna 110 through tissue, as shown in block 304 . The energy radiated may be controlled by the Patient/Clinician Parameter inputs in block 301 . In some instances, the parameter settings can be adjusted in an open loop fashion by the patient or clinician, who would adjust the parameter inputs in block 301 to the system.
[0091] The wireless implanted stimulator 114 uses the received energy to generate electrical pulses to be applied to the neural tissue through the electrodes 238 . For instance, the stimulator 114 may contain circuitry that rectifies the received RF energy and conditions the waveform to charge balance the energy delivered to the electrodes to stimulate the targeted nerves or tissues, as shown in block 306 . The implanted stimulator 114 communicates with the pulse generator 106 by using antenna 238 to send a telemetry signal, as shown in block 308 . The telemetry signal may contain information about parameters of the electrical pulses applied to the electrodes, such as the impedance of the electrodes, whether the safe current limit has been reached, or the amplitude of the current that is presented to the tissue from the electrodes.
[0092] In block 310 , the RF pulse generator 106 detects amplifies, filters and modulates the received telemetry signal using amplifier 226 , filter 224 , and demodulator 222 , respectively. The A/D converter 230 then digitizes the resulting analog signal, as shown in 312 . The digital telemetry signal is routed to CPU 230 , which determines whether the parameters of the signal sent to the stimulator 114 need to be adjusted based on the digital telemetry signal. For instance, in block 314 , the CPU 230 compares the information of the digital signal to a look-up table, which may indicate an appropriate change in stimulation parameters. The indicated change may be, for example, a change in the current level of the pulses applied to the electrodes. As a result, the CPU may change the output power of the signal sent to stimulator 114 so as to adjust the current applied by the electrodes 254 , as shown in block 316 .
[0093] Thus, for instance, the CPU 230 may adjust parameters of the signal sent to the stimulator 114 every cycle to match the desired current amplitude setting programmed by the patient, as shown in block 318 . The status of the stimulator system may be sampled in real time at a rate of 8 kbits per second of telemetry data. All feedback data received from the stimulator 114 can be maintained against time and sampled per minute to be stored for download or upload to a remote monitoring system accessible by the health care professional for trending and statistical correlations in block 318 . If operated in an open loop fashion, the stimulator system operation may be reduced to just the functional elements shown in blocks 302 , 304 , 306 , and 308 , and the patient uses their judgment to adjust parameter settings rather than the closed looped feedback from the implanted device.
[0094] FIG. 4 depicts a flow chart showing an example of an operation of the system when the current level at the electrodes 254 is above a threshold limit. In certain instances, the implanted wireless neural stimulator 114 may receive an input power signal with a current level above an established safe current limit, as shown in block 402 . For instance, the current limiter 248 may determine the current is above an established tissue-safe limit of amperes, as shown in block 404 . If the current limiter senses that the current is above the threshold, it may stop the high-power signal from damaging surrounding tissue in contact with the electrodes as shown in block 406 , the operations of which are as described above in association with FIG. 2 .
[0095] A capacitor may store excess power, as shown in block 408 . When the current limiter senses the current is above the threshold, the controller 250 may use the excess power available to transmit a small 2-bit data burst back to the RF pulse generator 106 , as shown in block 410 . The 2-bit data burst may be transmitted through the implanted wireless neural stimulator's antenna(s) 238 during the RF pulse generator's receive cycle, as shown in block 412 . The RF pulse generator antenna 110 may receive the 2-bit data burst during its receive cycle, as shown in block 414 , at a rate of 8 kbps, and may relay the data burst back to the RF pulse generator's feedback subsystem 212 which is monitoring all reverse power, as shown in block 416 . The CPU 230 may analyze signals from feedback subsystem 202 , as shown in block 418 and if there is no data burst present, no changes may be made to the stimulation parameters, as shown in block 420 . If the data burst is present in the analysis, the CPU 230 can cut all transmission power for one cycle, as shown in block 422 .
[0096] If the data burst continues, the RF pulse generator 106 may push a “proximity power danger” notification to the application on the programmer module 102 , as shown in block 424 . This proximity danger notification occurs because the RF pulse generator has ceased its transmission of power. This notification means an unauthorized form of energy is powering the implant above safe levels. The application may alert the user of the danger and that the user should leave the immediate area to resume neural modulation therapy, as shown in block 426 . If after one cycle the data burst has stopped, the RF pulse generator 106 may slowly ramp up the transmission power in increments, for example from 5% to 75% of previous current amplitude levels, as shown in block 428 . The user can then manually adjust current amplitude level to go higher at the user's own risk. During the ramp up, the RF pulse generator 106 may notify the application of its progress and the application may notify the user that there was an unsafe power level and the system is ramping back up, as shown in block 430 .
[0097] FIG. 5 is a diagram showing examples of signals that may be used to detect an impedance mismatch. As described above, a forward power signal and a reverse power signal may be used to detect an impedance mismatch. For instance, a RF pulse 502 generated by the RF pulse generator may pass through a device such as a dual directional coupler to the TX antenna 110 . The TX antenna 110 then radiates the RF signal into the body, where the energy is received by the implanted wireless neural stimulator 114 and converted into a tissue-stimulating pulse. The coupler passes an attenuated version of this RF signal, forward power 510 , to feedback subsystem 212 . The feedback subsystem 212 demodulates the AC signal and computes the amplitude of the forward RF power, and this data is passed to controller subsystem 214 . Similarly the dual directional coupler (or similar component) also receives RF energy reflected back from the TX antenna 110 and passes an attenuated version of this RF signal, reverse power 512 , to feedback subsystem 212 . The feedback subsystem 212 demodulates the AC signal and computes the amplitude of the reflected RF power, and this data is passed to controller subsystem 214 .
[0098] In the optimal case, when the TX antenna 110 may be perfectly impedance-matched to the body so that the RF energy passes unimpeded across the interface of the TX antenna 110 to the body, and no RF energy is reflected at the interface. Thus, in this optimal case, the reverse power 512 may have close to zero amplitude as shown by signal 504 , and the ratio of reverse power 512 to forward power 510 is zero. In this circumstance, no error condition exists, and the controller 214 sets a system message that operation is optimal.
[0099] In practice, the impedance match of the TX antenna 204 to the body may not be optimal, and some energy of the RF pulse 502 is reflected from the interface of the TX antenna 110 and the body. This can occur for example if the TX antenna 110 is held somewhat away from the skin by a piece of clothing. This non-optimal antenna coupling causes a small portion of the forward RF energy to be reflected at the interface, and this is depicted as signal 506 . In this case, the ratio of reverse power 512 to forward power 510 is small, but a small ratio implies that most of the RF energy is still radiated from the TX antenna 110 , so this condition is acceptable within the control algorithm. This determination of acceptable reflection ratio may be made within controller subsystem 214 based upon a programmed threshold, and the controller subsystem 214 may generate a low-priority alert to be sent to the user interface. In addition, the controller subsystem 214 sensing the condition of a small reflection ratio, may moderately increase the amplitude of the RF pulse 502 to compensate for the moderate loss of forward energy transfer to the implanted wireless neural stimulator 114 .
[0100] During daily operational use, the TX antenna 110 might be accidentally removed from the body entirely, in which case the TX antenna will have very poor coupling to the body (if any). In this or other circumstances, a relatively high proportion of the RF pulse energy is reflected as signal 508 from the TX antenna 110 and fed backward into the RF-powering system. Similarly, this phenomenon can occur if the connection to the TX antenna is physically broken, in which case virtually 100% of the RF energy is reflected backward from the point of the break. In such cases, the ratio of reverse power 512 to forward power 510 is very high, and the controller subsystem 214 will determine the ratio has exceeded the threshold of acceptance. In this case, the controller subsystem 214 may prevent any further RF pulses from being generated. The shutdown of the RF pulse generator module 106 may be reported to the user interface to inform the user that stimulation therapy cannot be delivered.
[0101] FIG. 6 is a diagram showing examples of signals that may be employed during operation of the neural stimulator system. According to some implementations, the amplitude of the RF pulse 602 received by the implanted wireless neural stimulator 114 can directly control the amplitude of the stimulus 630 delivered to tissue. The duration of the RF pulse 608 corresponds to the specified pulse width of the stimulus 630 . During normal operation the RF pulse generator module 106 sends an RF pulse waveform 602 via TX antenna 110 into the body, and RF pulse waveform 608 may represent the corresponding RF pulse received by implanted wireless neural stimulator 114 . In this instance the received power has an amplitude suitable for generating a safe stimulus pulse 630 . The stimulus pulse 630 is below the safety threshold 626 , and no error condition exists. In another example, the attenuation between the TX antenna 110 and the implanted wireless neural stimulator 114 has been unexpectedly reduced, for example due to the user repositioning the TX antenna 110 . This reduced attenuation can lead to increased amplitude in the RF pulse waveform 612 being received at the neural stimulator 114 . Although the RF pulse 602 is generated with the same amplitude as before, the improved RF coupling between the TX antenna 110 and the implanted wireless neural stimulator 114 can cause the received RF pulse 612 to be larger in amplitude. Implanted wireless neural stimulator 114 in this situation may generate a larger stimulus 632 in response to the increase in received RF pulse 612 . However, in this example, the received power 612 is capable of generating a stimulus 632 that exceeds the prudent safety limit for tissue. In this situation, the current limiter feedback control mode can operate to clip the waveform of the stimulus pulse 632 such that the stimulus delivered is held within the predetermined safety limit 626 . The clipping event 628 may be communicated through the feedback subsystem 212 as described above, and subsequently controller subsystem 214 can reduce the amplitude specified for the RF pulse. As a result, the subsequent RF pulse 604 is reduced in amplitude, and correspondingly the amplitude of the received RF pulse 616 is reduced to a suitable level (non-clipping level). In this fashion, the current limiter feedback control mode may operate to reduce the RF power delivered to the body if the implanted wireless neural stimulator 114 receives excess RF power.
[0102] In another example, the RF pulse waveform 606 depicts a higher amplitude RF pulse generated as a result of user input to the user interface. In this circumstance, the RF pulse 620 received by the implanted wireless neural stimulator 14 is increased in amplitude, and similarly current limiter feedback mode operates to prevent stimulus 636 from exceeding safety limit 626 . Once again, this clipping event 628 may be communicated through the feedback subsystem 212 , and subsequently controller subsystem 214 may reduce the amplitude of the RF pulse, thus overriding the user input. The reduced RF pulse 604 can produce correspondingly smaller amplitudes of the received waveforms 616 , and clipping of the stimulus current may no longer be required to keep the current within the safety limit. In this fashion, the current limiter feedback may reduce the RF power delivered to the body if the implanted wireless neural stimulator 114 reports it is receiving excess RF power.
[0103] FIG. 7 is a flow chart showing a process for the user to control the implantable wireless neural stimulator through the programmer in an open loop feedback system. In one implementation of the system, the user has a wireless neural stimulator implanted in their body, the RF pulse generator 106 sends the stimulating pulse power wirelessly to the stimulator 114 , and an application on the programmer module 102 (for example, a smart device) is communicating with the RF pulse generator 106 . In this implementation, if a user wants to observe the current status of the functioning pulse generator, as shown in block 702 , the user may open the application, as shown in block 704 . The application can use Bluetooth protocols built into the smart device to interrogate the pulse generator, as shown in block 706 . The RF pulse generator 106 may authenticate the identity of the smart device and serialized patient assigned secure iteration of the application, as shown in block 708 . The authentication process may utilize a unique key to the patient specific RF pulse generator serial number. The application can be customized with the patient specific unique key through the Manufacturer Representative who has programmed the initial patient settings for the stimulation system, as shown in block 720 . If the RF pulse generator rejects the authentication it may inform the application that the code is invalid, as shown in block 718 and needs the authentication provided by the authorized individual with security clearance from the device manufacturer, known as the “Manufacturer's Representative,” as shown in block 722 . In an implementation, only the Manufacturer's Representative can have access to the security code needed to change the application's stored RF pulse generator unique ID. If the RF pulse generator authentication system passes, the pulse generator module 106 sends back all of the data that has been logged since the last sync, as shown in block 710 . The application may then register the most current information and transmit the information to a 3rd party in a secure fashion, as shown in 712 . The application may maintain a database that logs all system diagnostic results and values, the changes in settings by the user and the feedback system, and the global runtime history, as shown in block 714 . The application may then display relevant data to the user, as shown in block 716 ; including the battery capacity, current program parameter, running time, pulse width, frequency, amplitude, and the status of the feedback system.
[0104] FIG. 8 is another example flow chart of a process for the user to control the wireless stimulator with limitations on the lower and upper limits of current amplitude. The user wants to change the amplitude of the stimulation signal, as shown in block 802 . The user may open the application, as show in block 704 and the application may go through the process described in FIG. 7 to communicate with the RF pulse generator, authenticate successfully, and display the current status to the user, as shown in block 804 . The application displays the stimulation amplitude as the most prevalent changeable interface option and displays two arrows with which the user can adjust the current amplitude. The user may make a decision based on their need for more or less stimulation in accordance with their pain levels, as shown in block 806 . If the user chooses to increase the current amplitude, the user may press the up arrow on the application screen, as shown in block 808 . The application can include safety maximum limiting algorithms, so if a request to increase current amplitude is recognized by the application as exceeding the preset safety maximum, as shown in block 810 , then the application will display an error message, as shown in block 812 and will not communicate with the RF pulse generator module 106 . If the user presses the up arrow, as shown in block 808 and the current amplitude request does not exceed the current amplitude maximum allowable value, then the application will send instructions to the RF pulse generator module 106 to increase amplitude, as shown in block 814 . The RF pulse generator module 106 may then attempt to increase the current amplitude of stimulation, as shown in block 816 . If the RF pulse generator is successful at increasing the current amplitude, the RF pulse generator module 106 may perform a short vibration to physically confirm with the user that the amplitude is increased, as shown in block 818 . The RF pulse generator module 106 can also send back confirmation of increased amplitude to the application, as shown in block 820 , and then the application may display the updated current amplitude level, as shown in block 822 .
[0105] If the user decides to decrease the current amplitude level in block 806 , the user can press the down arrow on the application, as shown in block 828 . If the current amplitude level is already at zero, the application recognizes that the current amplitude cannot be decreased any further, as shown in block 830 and displays an error message to the user without communicating any data to the RF pulse generator, as shown in block 832 . If the current amplitude level is not at zero, the application can send instructions to the RF pulse generator module 106 to decrease current amplitude level accordingly, as shown in block 834 . The RF pulse generator may then attempt to decrease current amplitude level of stimulation RF pulse generator module 106 and, if successful, the RF pulse generator module 106 may perform a short vibration to physically confirm to the user that the current amplitude level has been decreased, as shown in block 842 . The RF pulse generator module 106 can send back confirmation of the decreased current amplitude level to the application, as shown in block 838 . The application then may display the updated current amplitude level, as indicated by block 840 . If the current amplitude level decrease or increase fails, the RF pulse generator module 106 can perform a series of short vibrations to alert user, and send an error message to the application, as shown in block 824 . The application receives the error and may display the data for the user's benefit, as shown in block 826 .
[0106] FIG. 9 is yet another example flow chart of a process for the user to control the wireless neural stimulator 114 through preprogrammed parameter settings. The user wants to change the parameter program, as indicated by block 902 . When the user is implanted with a wireless neural stimulator or when the user visits the doctor, the Manufacturer's Representative may determine and provide the patient/user RF pulse generator with preset programs that have different stimulation parameters that will be used to treat the user. The user will then able to switch between the various parameter programs as needed. The user can open the application on their smart device, as indicated by block 704 , which first follows the process described in FIG. 7 , communicating with the RF pulse generator module 106 , authenticating successfully, and displaying the current status of the RF pulse generator module 106 , including the current program parameter settings, as indicated by block 812 . In this implementation, through the user interface of the application, the user can select the program that they wish to use, as shown by block 904 . The application may then access a library of pre-programmed parameters that have been approved by the Manufacturer's Representative for the user to interchange between as desired and in accordance with the management of their indication, as indicated by block 906 . A table can be displayed to the user, as shown in block 908 and each row displays a program's codename and lists its basic parameter settings, as shown in block 910 , which includes but is not limited to: pulse width, frequency, cycle timing, pulse shape, duration, feedback sensitivity, as shown in block 912 . The user may then select the row containing the desired parameter preset program to be used, as shown in block 912 . The application can send instructions to the RF pulse generator module 106 to change the parameter settings, as shown in block 916 . The RF pulse generator module 106 may attempt to change the parameter settings 154 . If the parameter settings are successfully changed, the RF pulse generator module 106 can perform a unique vibration pattern to physically confirm with the user that the parameter settings were changed, as shown in block 920 . Also, the RF pulse generator module 106 can send back confirmation to the application that the parameter change has been successful, as shown in block 922 , and the application may display the updated current program, as shown in block 924 . If the parameter program change has failed, the RF pulse generator module 106 may perform a series of short vibrations to alert the user, and send an error message to the application, as shown in block 926 , which receives the error and may display to the user, as shown in block 928 .
[0107] FIG. 10 is still another example flow chart of a process for a low battery state for the RF pulse generator module 106 . In this implementation, the RF pulse generator module's remaining battery power level is recognized as low, as shown in block 1002 . The RF pulse generator module 106 regularly interrogates the power supply battery subsystem 210 about the current power and the RF pulse generator microprocessor asks the battery if its remaining power is below threshold, as shown in block 1004 . If the battery's remaining power is above the threshold, the RF pulse generator module 106 may store the current battery status to be sent to the application during the next sync, as shown in block 1006 . If the battery's remaining power is below threshold the RF pulse generator module 106 may push a low-battery notification to the application, as shown in block 1008 . The RF pulse generator module 106 may always perform one sequence of short vibrations to alert the user of an issue and send the application a notification, as shown in block 1010 . If there continues to be no confirmation of the application receiving the notification then the RF pulse generator can continue to perform short vibration pulses to notify user, as shown in block 1010 . If the application successfully receives the notification, it may display the notification and may need user acknowledgement, as shown in block 1012 . If, for example, one minute passes without the notification message on the application being dismissed the application informs the RF pulse generator module 106 about lack of human acknowledgement, as shown in block 1014 , and the RF pulse generator module 106 may begin to perform the vibration pulses to notify the user, as shown in block 1010 . If the user dismisses the notification, the application may display a passive notification to switch the battery, as shown in block 1016 . If a predetermined amount of time passes, such as five minutes for example, without the battery being switched, the application can inform the RF pulse generator module 106 of the lack of human acknowledgement, as shown in block 1014 and the RF pulse generator module 106 may perform vibrations, as shown in block 1010 . If the RF pulse generator module battery is switched, the RF pulse generator module 106 reboots and interrogates the battery to assess power remaining, as shown in block 1618 . If the battery's power remaining is below threshold, the cycle may begin again with the RF pulse generator module 106 pushing a notification to the application, as shown in block 1008 . If the battery's power remaining is above threshold the RF pulse generator module 106 may push a successful battery-change notification to the application, as shown in block 1620 . The application may then communicate with the RF pulse generator module 106 and displays current system status, as shown in block 1022 .
[0108] FIG. 11 is yet another example flow chart of a process for a Manufacturer's Representative to program the implanted wireless neural stimulator. In this implementation, a user wants the Manufacturer's Representative to set individual parameter programs from a remote location different than where the user is, for the user to use as needed, as shown in block 1102 . The Manufacturer's Representative can gain access to the user's set parameter programs through a secure web based service. The Manufacturer's Representative can securely log into the manufacturer's web service on a device connected to the Internet, as shown in block 1104 . If the Manufacturer's Representative is registering the user for the first time in their care they enter in the patient's basic information, the RF pulse generator's unique ID and the programming application's unique ID, as shown in block 1106 . Once the Manufacturer's Representative's new or old user is already registered, the Manufacturer's Representative accesses the specific user's profile, as shown in block 1108 . The Manufacturer's Representative is able to view the current allotted list of parameter programs for the specific user, as shown in block 1110 . This list may contain previous active and retired parameter preset programs, as shown in block 1112 . The Manufacturer's Representative is able to activate/deactivate preset parameter programs by checking the box next to the appropriate row in the table displayed, as shown in block 1114 . The Manufacturer's Representative may then submit and save the allotted new preset parameter programs, as shown in block 1116 . The user's programmer application may receive the new preset parameter programs at the next sync with the manufacturer's database.
[0109] FIG. 12 is a circuit diagram showing an example of a wireless neural stimulator, such as stimulator 114 . This example contains paired electrodes, comprising cathode electrode(s) 1208 and anode electrode(s) 1210 , as shown. When energized, the charged electrodes create a volume conduction field of current density within the tissue. In this implementation, the wireless energy is received through a dipole antenna(s) 238 . At least four diodes are connected together to form a full wave bridge rectifier 1202 attached to the dipole antenna(s) 238 . Each diode, up to 100 micrometers in length, uses a junction potential to prevent the flow of negative electrical current, from cathode to anode, from passing through the device when said current does not exceed the reverse threshold. For neural stimulation via wireless power, transmitted through tissue, the natural inefficiency of the lossy material may lead to a low threshold voltage. In this implementation, a zero biased diode rectifier results in a low output impedance for the device. A resistor 1204 and a smoothing capacitor 1206 are placed across the output nodes of the bridge rectifier to discharge the electrodes to the ground of the bridge anode. The rectification bridge 1202 includes two branches of diode pairs connecting an anode-to-anode and then cathode to cathode. The electrodes 1208 and 1210 are connected to the output of the charge balancing circuit 246 .
[0110] FIG. 13 is a circuit diagram of another example of a wireless neural stimulator, such as stimulator 114 . The example shown in FIG. 13 includes multiple electrode control and may employ full closed loop control. The stimulator includes an electrode array 254 in which the polarity of the electrodes can be assigned as cathodic or anodic, and for which the electrodes can be alternatively not powered with any energy. When energized, the charged electrodes create a volume conduction field of current density within the tissue. In this implementation, the wireless energy is received by the device through the dipole antenna(s) 238 . The electrode array 254 is controlled through an on-board controller circuit 242 that sends the appropriate bit information to the electrode interface 252 in order to set the polarity of each electrode in the array, as well as power to each individual electrode. The lack of power to a specific electrode would set that electrode in a functional OFF position. In another implementation (not shown), the amount of current sent to each electrode is also controlled through the controller 242 . The controller current, polarity and power state parameter data, shown as the controller output, is be sent back to the antenna(s) 238 for telemetry transmission back to the pulse generator module 106 . The controller 242 also includes the functionality of current monitoring and sets a bit register counter so that the status of total current drawn can be sent back to the pulse generator module 106 .
[0111] At least four diodes can be connected together to form a full wave bridge rectifier 302 attached to the dipole antenna(s) 238 . Each diode, up to 100 micrometers in length, uses a junction potential to prevent the flow of negative electrical current, from cathode to anode, from passing through the device when said current does not exceed the reverse threshold. For neural stimulation via wireless power, transmitted through tissue, the natural inefficiency of the lossy material may lead to a low threshold voltage. In this implementation, a zero biased diode rectifier results in a low output impedance for the device. A resistor 1204 and a smoothing capacitor 1206 are placed across the output nodes of the bridge rectifier to discharge the electrodes to the ground of the bridge anode. The rectification bridge 1202 may include two branches of diode pairs connecting an anode-to-anode and then cathode to cathode. The electrode polarity outputs, both cathode 1208 and anode 1210 are connected to the outputs formed by the bridge connection. Charge balancing circuitry 246 and current limiting circuitry 248 are placed in series with the outputs.
[0112] A number of implementations have been described. Nevertheless, it will be understood that various modifications may be made. Accordingly, other implementations are within the scope of the following claims. | An implantable neural stimulator method for modulating excitable tissue in a patient including: implanting a neural stimulator within the body of the patient such that one or more electrodes of the neural stimulator are positioned at a target site adjacent to or near excitable tissue; generating an input signal with a controller module located outside of, and spaced away from, the patient's body; transmitting the input signal to the neural stimulator through electrical radiative coupling; converting the input signal to electrical pulses within the neural stimulator; and applying the electrical pulses to the excitable tissue sufficient to modulate said excitable tissue. | 98,555 |
CROSS REFERENCE TO RELATED APPLICATION
This application is a continuation of application Ser. No. 09/557,097 filed on Apr. 21, 2000now abandoned, which is a continuation-in-part of application Ser. No. 08/817,918 filed Jul. 10, 1997, now abandoned which is a national phase filing of PCT international application No. PCT/FI94/00479 which has an International filing date of Oct. 24, 1994 which designated the United States, the entire contents of which are hereby incorporated by reference.
BACKGROUND OF THE INVENTION
The invention concerns a polyolefin based thermoplastic elastomer which can be prepared without a separate vulcanization stage and which has polyacrylate as a dispersed phase and which has been achieved by polymerization of acrylate into the polyolefin matrix.
Thermoplastic elastomers are polymers which have the desirable processing properties of thermoplastics but have the same physical properties a vulcanized rubbers. This combination of properties generates materials having segments that are soft and elastic with low glass transition temperature (t K ) and a rigid, eventually crystalline, segment with a high glass transition temperature or a high melting point. The rigid and soft segments must be thermodynamically incompatible so that they form separate phases. Unlike conventional rubber, thermoplastic elastomers do not need a separate vulcanizing stage and can be processed using methods normally used with thermoplastics, such as extrusion, injection molding and blow molding. In addition, thermoplastic elastomers can also be reprocessed, for example when recycling material from the processing stage.
Thermoplastic elastomers can be divided into two main groups, block copolymers and thermoplastic/elastomer blends. A well-known example of block copolymers, which are thermoplastic elastomers, is the anionically polymerized block copolymer of styrene and butadiene (SBS) and the hydrogenized form of the same (SEBS). When these polymers are at room temperature, the soft and elastic phase is the continuous phase and the rigid phase, polypropylene, is dispersed. Here, the rigid polystyrene gives the material its strength, but during processing the temperature is raised over the glass transition temperature of polystyrene when it melts and the material can flow. The SBS thermoplastic elastomer, however, has poor weather resistance because of the butadiene double bonds. In SBS and SEBS polybutadiene and its hydrogenated form is the continuous phase, consequently they both have low oil resistance. Additionally, SEBS is expensive and requires a complicated preparation method.
Examples of materials that belong to the group of thermoplastic/elastomer blends are blends of polypropylene and ethylene/polypropylene rubber or ethylene/polypropylene/diene rubber. In these blends the rigid polypropylene phase is the continuous phase and the soft phase is dispersed, giving the material good oil resistance properties. These blends are made by blending the two main components and various additives in an extruder. Stabile phase separation results from curing the dispersed rubber phase (see, for example, U.S. Pat. No. 4,594,390).
The current invention describes a method to produce a thermoplastic elastomer with a polyolefin as a continuous phase and a rubber-like polyacrylate as a dispersed phase. This product is made in a reactor where crosslinking, if needed, can occur during polymerization. Thus, no separate vulcanization stage is needed. The resulting product has very good weather and oil resistance properties because the polyolefin is the continuous phase and because the elastomer is a polyacrylate. Hence, the current invention provides a method to produce a polyolefin based thermoplastic elastomer with a dispersed polyacrylate phase and without requiring a separate vulcanization stage.
SUMMARY OF THE INVENTION
The object of the current invention is to provide a new thermoplastic elastomer comprising a polyolefin/polyacrylate blend that has the polyolefin as the continuous phase and the polyacrylate as a dispersed phase.
A further object of the invention is to provide a new thermoplastic elastomer which maintains its dispersed polyacrylate structure during processing due to crosslinking of the dispersed elastic polyacrylate phase to the continuous polyolefin phase during polymerization.
Another object of the current invention is to provide a method for preparation of the new thermoplastic elastomer without employing a separate vulcanization stage.
The current invention provides for a polyolefin based thermoplastic elastomer with a dispersed polyacrylate phase that is polymerized into the polyolefin matrix. The invention further provides for a method for its preparation without a separate vulcanization stage. The acrylate used in the current invention has elastic properties and a glass transition temperature that is below room temperature. The acrylate forms a dispersed phase in the polyolefin matrix and, because polymerization occurs by the free radical technique, part of the acrylate chains are crosslinked to adjacent polyolefin chains. This provides good adhesion between the continuous polyolefin phase and the dispersed polyacrylate phase. Crosslinking can be controlled using varying ratios of diacrylate and acrylate. This crosslinking is especially important in cases where low adhesion between the polyolefin matrix and the polyacrylate is expected, for example when homopolyethylene or polypropylene is used. Here, because of the crosslinking, the soft dispersed polyacrylate is maintained in its dispersed form during processing when the polyolefin melts and becomes fluid.
The material could be produced by some of the methods given in the patent literature in which monomers are polymerized by free radical polymerization techniques into polyolefin matrix, e.g. by the Finnish patent 88170. In principal the acrylate monomer, and optionally diacrylate monomer, and the initiator are absorbed into polyolefin particles. The impregnation temperature is low enough so that no decomposition of the initiator occurs, yet high enough so that the monomer and the initiator can penetrate into the polyolefin particles. When all of the monomer and initiator have been absorbed, the temperature is elevated and the initiator decomposes and initiates the polymerization of the acrylate. The polyolefin particles swell to some extent (depending on the amount of monomer added) during the impregnation, but maintain their particle structure. The polyolefin particle structure is also maintained during polymerization.
DETAILED DESCRIPTION OF THE INVENTION
Polyolefin
Useful polyolefins include high density polyethylene, low density polyethylene and linear low density polyethylene. The polyethylene can be a homopolymer or a copolymer. The co-monomer of ethylene can be vinyl acetate, vinyl chloride, propylene or some other α-olefin, C 1 -C 7 -alkylacrylate and -methacrylate, glycidylacrylate and -methacrylate, dienes such as hexadiene-1,4, hexadiene-1,5, heptadiene-1,6, 2-methylpentadiene-1,4, octadiene-1,7, 6-methylheptadiene-1,5 and polyenes such as octatriene and dicyclopentadiene. Also ethylene-α-olefin-polyene-terpolymeres are useful. Useful α-olefins include propylene, butene, pentene, isoprene, hexene or their mixtures and useful polyenes include hexadiene-1,4, hexadiene-1,5, heptadiene-1,6, 2-methylpentadiene-1,4, octadiene-1,7, 6-methyl-heptadiene-1,5, octatriene, dicyclopentadiene. In cases where an ethylene copolymer is used, at least 50% by weight must be ethylene.
The polyolefin can also be comprised of polypropylene and its copolymers. Propylene copolymers must consist of over 50% by weight propylene and can be random- or block copolymers of propylene and ethylene. Also, other α-olefins can be used as co-monomers and also dienes such as hexadiene-1,4, hexadiene-1,5, heptadiene-1,6, 2-methylpentadiene-1,4, octadiene-1,7, 6-methylheptadiene-1,5 and polyenes such as octatriene and dicyclo-pentadiene.
The polyolefin can be in any form, but preferably in the form of pellets with a diameter of 0.5-10 mm. Particle forms of the polyolefin facilitate after treatment washing and drying.
Acrylate monomer
Suitable monomers are acrylates and methacrylates whose polymers have low glass temperatures, that is, they are rubber-like at and below room temperature, preferably at temperatures below −20° C. The glass temperature of the polyacrylate specifies the lower operating temperature of the material; below the glass temperature the polyacrylate is rigid and inelastic and the elastomeric properties of the material are lost. Suitable acrylates are alkylacrylates having 1 or preferably 2 or more carbon atoms in the alkyl chain. Methacrylates having a glass temperature low enough are alkylmethacrylates having 4 or more, preferably 8 or more, carbon atoms in the alkyl chain. These monomers can be used alone or in mixtures of two or more monomers. The glass temperature of the final product can be tailored by adding small amounts of monomers having fewer carbon atoms in the carbon chain to the above mentioned monomers. One can further use acrylates and methacrylates as co-monomers; which in addition to an ester bond have other polar groups such as alkcoxy or hydroxy groups. Examples of these are methoxy- and ethoxy-acrylate, hydroxyethyl- and hydroxypropyl-methacrylate. By using these co-monomers the oil resistance of the product can be improved. Also, small amounts of other non-acrylate monomers that are polymerizable by free radical polymerization techniques can be co-polymerized with the above mentioned acrylates and methacrylates.
Amount of Acrylate
In order to produce a material that is a thermoplastic elastomer the acrylate must be in the majority although the exact amount to be polymerized into the polyolefin depends on the exact polyolefin used and whether or not oil is added. Here, majority means at least 50%, preferably greater than 50%, more preferably at least 60%, yet more preferably at least 64%, and still more preferably at least 69%. According to this invention, a polypropylene based material needs 50-90% by weight acrylate when no oil or filler are added. Thus, the polypropylene represents 50-10% by weight. Without oil and filler addition the amount of acrylate can vary from 50-90% by weight for homopolyethylene, down to 20-90% by weight for polyethylene qualities which contain up to 30% by weight co-monomers. The Examples indicate the effect of the amount of acrylate on the softness of the final product.
Addition of Oil
Adding oil also softens the final product, thus reducing the amount of acrylate needed to obtain a particular softness. The amount of added oil can be 0-40% by weight in the final product and can be added with the acrylate and initiator, allowing penetration of the oil into the polyolefin-polyacrylate particles during the impregnation and/or polymerization. Alternatively, oil can be added to the reactor after the finalized polymerization and can be impregnated into the polyolefin-polyacrylate particles at an elevated temperature. Yet another way to introduce oil into the polyolefin-polyacrylate particles is in an extruder. Suitable oils are those normally used to soften rubber, e.g. paraffinic, naphthenic, aromatic and synthetic oils as well as plasticizers for thermoplastics such as dioctylphthalat.
Addition of Fillers
Fillers can be added to modify the final product's properties. For example, fillers can raise the operating temperature and rigidity. The filler can be added to the polyolefin-polyacrylate blend in the extruder or can be included with the polyolefin used as raw material for the polymerization. Conventional fillers such as talc, caolin, CaCO 3 and silica can be used and can be 0-70% by weight in the end product.
Composition of the End Product
The end product can also contain oil and fillers besides polyolefin and polyacrylate. Consequently, the amount of polyolefin and polyacrlate in the end product can vary within wide margins depending on the amount of oil and fillers used and also on the chosen polyolefin. If the polyolefin is polypropylene, the ratio of polypropylene/polyacrylate can be 0.1 to 2. If the polyolefin is polyethylene, the ratio can vary from from 0.1 to 5.
Crosslinking the Polyacrylate
Some acrylates spontaneously form gels without any diacrylate use, for example butylacrylate, and may eliminate the need to use diacrylate for crosslinking. The need for diacrylate also depends on the degree of adhesion between the discrete dispersed polyacrylate phase and the continuous polyolefin phase. As the adhesion between the phases increases the tendency of the dispersed polyacrylate to agglomerate and build bigger phase structures decreases. For example, if polyethylene, which contains polar groups, is used the adhesion can be so good that only small amounts or no diacrylate at all is needed. On the other hand, if a homopolyethylene or polypropylene is used, the adhesion between the phases is low and the polyacrylate must be crosslinked with diacrylate in order to enable processing of the dispersed polyacrylate without agglomeration and forming large polyacrlyate blocks. Low adhesion can also lead to phase invasion where the polyacrylate becomes a continuous or at least a co-continuous phase with the polyolefin. Crosslinking is preferably done in the reactor with an acrylate having two or more double bonds that can interact with different polyacrylate chains. Examples of suitable crosslinking agents are hexanediol diacrylate or dimethylacrylate. Generally the crosslinking agent is 0-15% by weight, based on the amount of acrylate. Other monomers having two or more double bonds, such as divinylbenezene, can also be used.
Initiator
Initiators conventionally used in free radical polymerization of vinyl monomers such as organic peroxides are suitable for the acrylate polymerization. Examples include benzoylperoxide,lauroylperoxide, t-butylperbenzoate, t-butyl-peroxy-2-ethylhexanate, t-butylperoxide, dicumylperoxide, di-t-butylperoxide, bis(t-butylperoxyisopropyl)benzene, t-butylperoxyisopropylcarbonate, 2,5-dimethyl-2,5-di-t-butylperoxyhexane, 2,5-dimethyl-2,5-di-(t-butylperoxy)hexyne-3, and azo compounds like azobisisobutyronitrile and azobisdimethylvaleronitrile.
More than one initiator can be used simultaneously so that the polymerization starts at a low temperature with a “low temperature initiator” and continues with a “high temperature initiator” at a higher temperature. The amount of the intiator can be between 0.001 and 2% by weight, preferably between 0.1 and 1% by weight, based on 100 weight parts of monomer.
Production, Including Impregnation and Polymerization
In principal, the production of this polyolefin-polyacrylate material can be made by the methods presented in the patent literature in which the acrylate and the initiator are first initiated into polyolefin particles and the acrylate is thereafter polymerized by elevating the temperature. The impregnation of the acrylate and the initiator can thus be made in the total absence of water, by adding some water, by adding water when more than half of the acrylate has been impregnated (these three methods are in principal described in the Finnish patents FI85496, FI86642 and FI88170) or in the presence of the total amount of water (as in US patent U.S. Pat. No. 4,412,938). Impregnation and polymerization can also be conducted simultaneously by slowly adding the acrylate and initiator to a water suspension containing polyolefin particles over the course of several hours and at an elevated temperature. (see German patent DE 2,907,662).
Finnish patent FI88170 presents an advantageous method whereby a maximum of about 65% by weight of acrylate is impregnated and polymerized into polyolefin in the polymerization stage. For softer elastomer, additional polyacrylate can be impregnated into the product obtained from the first polymerization stage, followed by a second polymerization. Using this approach the polyacrylate content can gradually be raised close to 100%. It is not necessary, however, to use totally independent or separate polymerizations. For example, near the end of the first polymerization, the temperature can be lowered to the impregnation temperature and the desired amount of acrylate and initiator can be pumped in. After these have been absorbed into the particles, the temperature is raised and the acrylate polymerized.
When polymerization is conducted in two or more stages and crosslinked polyacrylate is desired, the first polymerization is conducted without diacrylate. Here, the polyacrylate forms a discrete dispersed phase during the polymerization stage. During the other polymerization stage the added acrylate and diacrylate tend to migrate to the polyacrylate particles already formed in the polyolefin matrix, and crosslinking occurs there. This crosslinking is mainly between the added acrylate and diacrylate, but since this reaction occurs during polymerization in the presence of the existing polyacrylate particles, entanglements between the polymerizing and these preexisting particles are formed, creating physical crosslinks.
Properties of the Polymerization Product
The final product is a thermoplastic elastomer with a continuous phase of polyolefin crosslinked to a discrete dispersed phase of a rubber-like polyacrylate. The polyacrylate phase is in the majority. This final product maintains its two discrete phases during melt-processing. Other properties include: a Shore A hardness value greater than 50, preferably greater than 60, even more preferably greater than 70, 80 or 90 (test method is ISO 48), a modulus 100% of at least 0 Mpa, preferably greater than 1 Mpa, more preferably greater than 2 Mpa, even more preferably greater than 3 Mpa (test method is 37/1 mm/min), tensile strength of at least 1.9 MPa, preferably at least 3.2 MPa, more preferably at least 5.1 MPa, even more preferably at least 6.3, 7.1 or 8.4 MPa (test method is ISO 37), an elongation at break of at least 75%, preferably at least 107%, more preferably at least 209%, even more preferably at least 354%, 449% or 528% (test method is ISO 37), and a tear strength of at least 0 kN/m, preferably 2 kN/m, more preferably at least 8 kN/m, even more preferably at least 8 kN/m, 16 kN/m or 20 kN/m (test method is ISO 37).
The polymerization product has especially good oil resistance, weather resistance and ageing resistance due to the polyacrylate elastomer. The properties of the thermoplastic elastomers produced according to this patent depend on the polyolefin used: homo, block or random polypropylene, homopolyethylene or polyethylene containing co-monomers. The choice of polyeolefin especially influences temperature resistance, chemical resistance and adhesion properties. The acrylate type, amount and crosslinking density affect the hardness, toughness and elasticity of the final product. Ethylene based products are characterized by good heat and oil resistance. Fillers, which can be added to the starting polyolefin, allow tailoring of the product's properties.
Product Usage
The material produced of the current invention can be used in applications which other thermoplastic elastomers or conventional rubber is used, for example in the construction industry (sealing lists and packages), in the motor industry (protection bellow at power transmission points and interior material for instrument panels) and in the electrical industry (material for cables, contacts and different cases). This material can also be used for diverse mechanical articles like handles, wheels and sheaths.
The material can be processed by conventional processing methods used for thermoplastics, such as extrusion, injection molding and blow molding. Since polyolefin is the continuous phase, the material is well suited for co-extrusion with polyolefins. In processing, conventional additives like antioxidants, filler and oil can be added.
EXAMPLES
Polyolefin pellets, acrylate, initiator and, in some cases 1,6-hexanediole diacrylate, were added to the reactor. The reactor was filled and emptied three times with 7-8 bar nitrogen in order to remove oxygen from the reactor. After that, the temperature was raised to the impregnation temperature and kept there, stirring continuously, until the mojor port of the acrylate and the initiators were impregnated. The impregnation time was 1-3 hours depending on the polyolefin quality. Thereafter, the suspension water, also rinsed with nitrogen, was added. The suspension water contained tricalsiumphosphate and sodiumdodecylbenzenesulphonate as a suspension agent. The temperature of the suspension water was the same as the impregnation temperature. After the water addition the temperature was raised so much that the initiator started to decompose and initiate the polymerization. The polymerization took 7-12 hours depending on the polyolefin quality. After polymerization, the product was washed and dried. Several different polyolefin-polyacrylate materials were made according to this model, see Table 1. All polypropylene based materials having more than 50% by weight acrylate were made in two stages so that the product from the first stage contained 50% by weight acrylate. Experiment 9 was also made in two stages and experiment 10 was made in three stages. The structure with the dispersed polyacrylate domains can be seen from FIG. 1, where the product from the first polymerization stage of experiment 15 has been photographed by a transmission electron microscope. In the picture, the dark dispersed phase is polyacrylate and the light continuous phase is polypropylene. The diameter of the polyacrylate particles is about 0.5 μm.
TABLE 1
Experiments 1-16.
Exp
Polyolefine 1
Acrylate
Weight
Diacrylate 6
Initiator
Impre-
Polym.
Gel 2
Nr
quality
MI 3
type 4
%
w %
type 5
g.|C.
|C.
%
1
EVA28
5
EHA
40
—
AIBN, BPO
37
55-100
62
2
EVA18
5
EHA
50
—
AIBN, BPO
41
55-100
56
3
EVA18
10
EHA
50
—
BPO, BPIC
51
75-115
61
4
EVA9
8
EHA
50
—
BPIC
69
90-120
54
5
EBA27
4
EHA
50
—
AIBN, BPO
44
55-100
77
6
EBA17
7
EHA
50
—
BPO
72
70-100
70
7
EBA17
7
BA
50
—
BPIC
61
85-115
55
8
EBA17
7
BA
50
1.0
BPIC
69
85-115
60
9
EBA7
1
BA
64
0.5
t-BPB
86
90-120
83
10
LLDPE
65
BA
69
1.6
DHBP
101
110-135
53
11
Random PP
20
BA
50
0.1
DYBP
116
125-150
53
12
Random PP
20
BA
68.5
1.6
DYBP
112
130-150
74
13
Random PP
20
BA
67
3.1
DYBP
108
130-150
67
14
Random PP
20
BA
74
1.5
DYBP
117
130-150
74
15
Random PP
20
EHA
68.4
1.6
DYBP
116
130-150
64
16
Block PP
40
BA
67
3.0
DYBP
120
135-150
76
1) All polyolefines used are Neste*s commercial qualities.
2) Gel content was measured in boiling xylene under 16 hours.
3) Melt index is determined for polyethylene qualities at 190 | C. and 2.16 kg and for polypropylene at 230 | C. and 2.16 kg.
4) EHA = ethylexylacrylate, BA = butylacrylate
5) AIBN = azobisisobutyronitrile, BPO = benzoylperoxide, BPIC = tert-butylperoxyisopropylcarbonate, t-BPB = tert-butylperoxybenzoate, DYBP = 2,5-dimehtyl,2,5-di(tert-butylperoxy)-hexyne-3, DHBP = 2,5-dimethyl 2,5-di)tert-butylperoxy)hexane.
6) Diacrylate = 1,6-hexanedioldiacrylate
The polymer materials made according to Table 1 were injection moulded to sheets having the size of 80×80 mm and the thickness of 2 mm, at 165-205° C., depending on the polyolefine used. The necessary test bars were punched from the sheets. The mechanical properties are in Table 2. Elongation at break and tensile strength have been measured from test rods which are punched transverse to the flow direction of the injection moulding.
TABLE 2
Mechanical properties of the materials of the experiments 1-16.
Di-
elong.
tensile
Exp.
Polyolefine
Acrylate
Acr.
Gel
at break 1
strength 2
compr.
tension
Nr
quality
type
%
w %
%
%
MPa
IRHD 3
set 4 %
set 5 %
1
EVA28
EHA
40
—
62
158
5.5
65
—
24
2
EVA28
EHA
50
—
56
177
3.2
52
—
17
3
EVA18
EHA
50
—
61
107
2.7
61
—
20
4
EVA9
EHA
50
—
54
90
3.2
75
—
23
5
EBA27
EHA
50
—
77
75
1.9
56
—
16
6
EHA17
EHA
50
—
70
449
5.4
67
—
16
7
EBA17
BA
50
—
55
528
6.1
75
30
33
8
EBA17
BA
50
1.0
60
354
7.1
76
20
25
9
EBA7
BA
64
0.5
83
209
6.3
75
22
16
10
LLDPE
BA
69
1.6
73
175
5.1
82
38
37
11
Random PP
BA
50
0.1
53
198
8.4
97
—
66
12
Random PP
BA
68.5
1.6
74
169
7.3
90
43
40
13
Random PP
BA
67
3.1
67
142
8.9
92
31
32
14
Random PP
BA
74
1.5
74
128
5.6
81
26
16
15
Random PP
EHA
68.4
1.6
64
127
5.9
88
43
43
16
Block PP
EHA
72.5
3.5
1) Elongation at break measured by ISO 37
2) Tensile strength measured by ISO 37
3) Hardness, IRHD, measured by ISO 48
4) Compression set after 24 hours at room temperature by ISO 815
5) Tension set after 24 hours at room temperature by ISO 2285
The amount of polyacrylate has the biggest effect to the hardness of the product, the higher amount of polyacrylate the softer product, see experiments 1 and 2 and experiments 11-15. To the mechanical properties, the polyolefine quality also effects most to the hardness, compare 2, 3 and 4 as well as 5 and 6. The amount of diacrylate affects all mechanical properties. The higher amount of diacrylate improves strength, compression set and tension set but decreases the elongation at break, comare 7 and 8 as well as 12 and 13.
In table 3 the product from the experiment 7 is compared with commercial SBS-quality, Dexcos Vektor-2411D, at 55° C. These both have about the same hardness and the same highest operating temperature, 60-70° C. From the table it can be seen that SBS has considerably lower oil resistance than the product from the experiment 7. Also, in table 3 is compared the product from the experiment 13 with the thermoplastic elastomer Santopren 201-80 at 100° C. The product from the experiment 13 has polypropylene as a polyolefine and a continuous phase and it can therefor regarding to the temperature resistance, be compared with Santopren which also had polypropylene as a continuous phase. Santopren has ethylene-propylene-diene rubber as an elastomeric phase. The both have same hardness. From the table it can be seen that the product from the experiment 13 has considerably better oils resistance than Santopren in ASTM1- and ASTM2-oils. In ASTM3-oil Santopren is a little better.
TABLE 3
Oil resistance, measured as swelling, of the material made according to this invention
compared with commercial thermpolastic elastomers, by ISO 1817. For experiment 7 and SBS
was used 55 | C. and for experiment 13 and Santopren was used 100 | C..
ASTM1
ASTM2
ASTM3
Exp
Hardness
1 day
3 days
7 days
1 day
3 days
7 days
1 day
3 days
7 days
Nr
Material
IRHD
%
%
%
%
%
%
%
%
%
7
EBA17-PBA
75
8
14
16
14
28
34
51
89
—
SBS,
82
35
50
52
98
127
—
—
—
—
Vektor-2411D
13
PP-PBA
92
—
8
10
—
22
24
—
58
58
Santopren 201-80
91
—
18
19
—
31
31
—
52
54
The aging resistance of the material at high temperature was tested by aging the material at 70° C. during 168 hours. The elongation at break and tensile strength were measured for unaged and aged materials from test bars punched in flow direction. The material from experiment 7 was compared with a commercial SBS-quality, Enichem Europrene SOL T166, and with a commerical SEBS-quality, Neste polymer Compounds 6503. These three materials are comparable by hardness and operating temperature. From table 5 it can be seen that the material from experiment 7 has considerably better aging resistance at an elevated temperature. Apart from the fact that the material from experiment 7 was not stabilized with antioxidants. In the table there is also compared a polypropylene based material made according to example 13 with Santopren-quality 201-80.
TABLE 5
Changing of the elongation at break and tensile strength during aging at 70 | C. for 168
hours. The chance is given as percent chance between the unaged and aged materials.
Chance,
%
Expr
Hardness
Elongation
Tensile
Elongation
Tensile
Nr
Material
IRHD
at break %
strength MPa
at break
strength
7
EBA17-PBA
75
129
5.7
+4.9
+7.5
SBS 166
75
540
11.3
−15.2
−36.2
SEBS 6503
75
305
5.8
−21.0
−4.9
13
PP-BPA
91
126
10.3
−15.4
+5.1
Santopren 201-80
Experiments 17-20
A material made according to experiment 7 but with a diacrylate amount 0.5% by weight, was filled with three different fillers, 23-41% by weight in the end product, in a screw extruder at 200° C. From table 4 can be seen that hardness is rising together with a rising filler content. Other mechanical properties remain unchanged when compared with the unfilled material of experiment 17.
TABLE 4
Influence of fillers on the mechanical properties of the product of experiment 17.
Diacr.
Elong.
Compres-
Tension
Exp
Polyolefine
Acrylate
Weight
Gel
at break 1
Tensile
sion set 4
set 5
Nr
quality
type
%
%
%
%
str. 2 MPa
IRHD 3
%
%
17
EBA17
Ba
50
0.5
63
360
6.6
78
28
32
18 4
EBA17
BA
50
0.5
—
270
6.2
84
24
32
19 7
EBA17
BA
50
0.5
—
238
6.0
87
30
39
20 4
EBA17
BA
50
0.5
—
322
7.1
87
27
41
1) Elongation at break measured by ISO 37
2) Tensile strength measured by ISO 37
3) Hardness, IRHD, measured by ISO 48
4) Compression set after 24 hours at room temperature by ISO 815
5) Tension set after 24 hours at room temperature by ISO 2285
6) Added filler talc, Finntalk 20 10 vol % (23% by weight)
7) Added filler CaCO 3 Nordkrone 40 20 vol % (41% by weight)
8) Added CaCO 3 , Winnofil S 20 vol % (40% by weight)
Experiments 21, 22 and 23
To a material which is made exactly according experiment 13 was added 10% by weight oil and 0.3% by weight antioxidant, Irganox 1520, in a single-screw extruder at 205° C. A paraffin oil, Nypar 40 (Neste-Alfa Oy), and a naphthenic oil, Nytex 840 (Nyn Petroleum) were used as oils. The composition of the end product is thus 10% by weight oil, 63% by weight polybutylacrylate and 27% by weight polypropylene. The material was injection moulded to sheets from which test bars were punched at flow direction. From the results in table 6 can be seen that by oil addition the material has become softer without the loss of other mechanically good properties, compression set and tension set have even improved.
TABLE 6
Addition of 10% by weight oil to a polypropylene-polyacrylate material.
Tensile
% by
Elongation at
strength 2
Compression
Exp.
oil quality
weight
break 1 %
MPa
IRHD 3
set 4 %
Tension set 3 %
21
—
—
138
9.3
93
37
32
22
Nytex 840
10
131
8.0
88
33
27
23
Nypar 40
10
142
8.5
89
33
25
1) Elongation at break measured by ISO 37
2) Tensile strength measured by ISO 37
3) Hardness, IRHD, measured by ISO 48
4) Compression set after 24 hours at room temperature by ISO 815
50 Tension set after 24 hours at room temperature by ISO 2285
Experiments 24 and 25
These experiments were made in the same way as experiment 13 with the difference that to the reactor it was charged 6% by weight oil together with the acrylate in the second polymerisation stage. The whole amount of oil was absorbed into the pellets and the end product*s composition is thus 6% by weight oil, 70% by weight polybutylacrylate and 24% by weight polypropylene. From the test results in table 7 down can be seen that the material, compared to experiment 13 becomes considerably softer and compression set becomes a little better. Elongation at break and tensile strength decrease a little.
Experiment 26
This experiment was made in the same way as experiments 24 and 25 with the difference that oil was added in the both polymerisation stages, 6% by weight in the first and 11% by weight in the second polymerisation stage. This gives the final composition: 14% by weight oil, 30% by weight polypropylene and 56% by weight butylacrylate (inclusive 2.2% by weight diacrylate). Oil was Nytex 940. Test results can be seen in table 7 down.
Experiments 27 and 28
As starting material for oil and filler experiments was used a polypropylene based material which made according to experiment 13, with the difference that the amount of butylacrylate in the first polymerisation stage was 37% by weight and in the second polymerisation stage 34% by weight (+3% by weight). This gives an end composition of 60% by weight polybutylacrylate and 40, including 3% by weight diacrylate.
TABLE 7
Influence of oil and fillers to the properties.
PP
PBA
Filler
Elong. at
Tensile
Compression
Tension set 5
Exp.
Oil quality
w %
w %
w %
w %
break 1 %
str. 2 MPa
IRHD
set 4 %
%
24
Nypar 40
6
24
70
—
118
6.9
84
31
31
25
Nytex 840
6
24
70
—
126
7.5
85
27
29
26
Nytex 840
14
30
46
—
27
Nypar 40
20
28
Nypar 40
20
1) Elongation at break measured by ISO 37
2) Tensile strength measured by ISO 37
3) Hardness, IRHD, measured by ISO 48
4) Compression set after 24 hours at room temperature by ISO 815
5) Tension set after 24 hours at room temperature by ISO 2285 | The invention relates to a method for manufacturing a sealable and peelable polymer blend, in which method polystyrene and an ethylene copolymer are first melt blended and the obtained blend is further mixed with the same ethylene copolymer either by melt blending or dry blending so that the final polymer blend contains 1-50% by weight polystyrene and 99-50% by weight ethylene copolymer. Ethylene copolymer is preferably ethylene/methyl(meth)acrylate, ethylene/ethyl(meth)acrylate, ethylene/butyl(meth)acrylate or ethylene/vinylacetate copolymer. | 54,591 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority to U.S. Provisional Application 60/380,761 filed May 14, 2002; to U.S. Provisional Application 60/392,782 filed Jun. 28, 2002; and to U.S. Provisional application No. 60/422,933, filed Oct. 31, 2002, and to U.S. Provisional Application 60/428,033, filed Nov. 20, 2002, each of which are herein specifically incorporated by reference.
BACKGROUND OF THE INVENTION
[0002] In 1953, it was first recognized that ingestion of gluten, a common dietary protein present in wheat, barley and rye causes a disease called Celiac Sprue in sensitive individuals. Gluten is a complex mixture of glutamine- and proline-rich glutenin and prolamine molecules and is thought to be responsible for induction of Celiac Sprue. Ingestion of such proteins by sensitive individuals produces flattening of the normally luxurious, rug-like, epithelial lining of the small intestine known to be responsible for efficient and extensive terminal digestion of peptides and other nutrients. Other clinical symptoms of Celiac Sprue include fatigue, chronic diarrhea, malabsorption of nutrients, weight loss, abdominal distension, anemia, as well as a substantially enhanced risk for the development of osteoporosis and intestinal malignancies such as lymphoma and carcinoma. The disease has an incidence of approximately 1 in 200 in European populations and is believed to be significantly under diagnosed in other populations.
[0003] A related disease is dermatitis herpetiformis, which is a chronic eruption of the skin characterized by clusters of intensely pruritic vesicles, papules, and urticaria-like lesions. IgA deposits occur in almost all normal-appearing and perilesional skin. Asymptomatic gluten-sensitive enteropathy is found in 75 to 90% of patients and in some of their relatives. Onset is usually gradual. Itching and burning are severe, and scratching often obscures the primary lesions with eczematization of nearby skin, leading to an erroneous diagnosis of eczema. Strict adherence to a gluten-free diet for prolonged periods may control the disease in some patients, obviating or reducing the requirement for drug therapy. Dapsone, sulfapyridine, and colchicines are sometimes prescribed for relief of itching.
[0004] Celiac Sprue (CS) is generally considered to be an autoimmune disease and the antibodies found in the serum of the patients support the theory that the disease is immunological in nature. Antibodies to tissue transglutaminase (tTGase or tTG) and gliadin appear in almost 100% of the patients with active CS, and the presence of such antibodies, particularly of the IgA class, has been used in diagnosis of the disease.
[0005] The large majority of patients express the HLA-DQ2 [DQ(a1*0501, b1*02)] and/or DQ8 [DQ(a1*0301, b1*0302)] molecules. It is believed that intestinal damage is caused by interactions between specific gliadin oligopeptides and the HLA-DQ2 or DQ8 antigen, which in turn induce proliferation of T lymphocytes in the sub-epithelial layers. T helper 1 cells and cytokines apparently play a major role in a local inflammatory process leading to villous atrophy of the small intestine.
[0006] At the present time, there is no good therapy for the disease, except to avoid completely all foods containing gluten. Although gluten withdrawal has transformed the prognosis for children and substantially improved it for adults, some people still die of the disease, mainly adults who had severe disease at the outset. A leading cause of death is lymphoreticular disease, especially intestinal lymphoma. It is not known whether a gluten-free diet diminishes this risk. Apparent clinical remission is often associated with histologic relapse that is detected only by review biopsies or by increased EMA titers.
[0007] Gluten is so widely used, for example, in commercial soups, sauces, ice creams, hot dogs, and other foodstuffs, that patients need detailed lists of foodstuffs to avoid and expert advice from a dietitian familiar with celiac disease. Ingesting even small amounts of gluten may prevent remission or induce relapse. Supplementary vitamins, minerals, and hematinics may also be required, depending on deficiency. A few patients respond poorly or not at all to gluten withdrawal, either because the diagnosis is incorrect or because the disease is refractory. In the latter case, oral corticosteroids (e.g., prednisone 10 to 20 mg bid) may induce response.
[0008] In view of the serious and widespread nature of Celiac Sprue and the difficulty of removing gluten from the diet, better methods of treatment are of great interest. In particular, there is a need for treatment methods that allow the Celiac Sprue individual to eat gluten-containing foodstuffs without ill effect or at least to tolerate such foodstuffs in small or moderate quantities without inducing relapse. The present invention meets this need for better therapies for Celiac Sprue by providing new drugs and methods and formulations of new and existing drugs to treat Celiac Sprue. International Patent Application US03/04743, herein specifically incorporated by reference, discloses aspects of gluten protease stability and immunogenicity.
SUMMARY OF THE INVENTION
[0009] In one aspect, the present invention provides methods for treating Celiac Sprue and/or dermatitis herpetiformis and the symptoms thereof by administration of a tTGase (tissue transglutaminase) inhibitor to the patient. In one embodiment, the tTGase inhibitor employed in the method is a known small molecule-tTGase inhibitor selected from the group consisting of vinylogous amides, sulfonamides, 2-[(2-oxoalkyl)thio]imidazolium compounds, diazoketones, and 3-halo-4,5-dihydroisoxazoles. In another embodiment, the tTGase inhibitor is a dipeptide mimetic, a compound that mimics in structure a dipeptide selected from the group consisting of PQ, PY, QL, and QP.
[0010] In another aspect, the present invention provides novel tTGase inhibitors and methods for treating Celiac Sprue and/or dermatitis herpetiformis by administering those compounds. In one embodiment, the tTGase inhibitor is a peptide or peptidomimetic that has or contains within a longer sequence the structure of the peptide PQPQLPY or PQPELPY in which the E or the second Q is replaced by a glutamine mimetic that is an inhibitor of tTGase or in which a dipeptide selected from the group consisting of QP and LP is replaced by a constrained dipeptide mimetic compound. Such compounds are analogs of a sequence contained in gluten oligopeptides that are resistant to digestion and are believed to stimulate the autoimmune reaction that characterizes Celiac Sprue.
[0011] In another aspect, the invention provides pharmaceutical formulations comprising a tTGase inhibitor and a pharmaceutically acceptable carrier. In one embodiment, such formulations comprise an enteric coating that allows delivery of the active agent to the intestine, and the agents are stabilized to resist digestion or acid-catalyzed modification in acidic stomach conditions. In another embodiment, the formulation also comprises one or more glutenases, as described in U.S. Provisional Application 60/392,782 filed Jun, 28, 2002; and U.S. Provisional Application 60/428,033, filed Nov. 20, 2002, both of which are incorporated herein by reference. The invention also provides methods for the administration of enteric formulations of one or more tTGase inhibitors to treat Celiac Sprue.
[0012] In another aspect, the invention provides methods for screening candidate compounds to determine their suitability for use in the subject methods, by assessing the ability of a candidate agent for its ability to bind to, and/or to inhibit the activity of, tTGase. Candidate agents may also be screened for anti-allergic and anti-inflammatory activity by assessing their ability to bind to, and/or to inhibit the activity of, tTGase.
[0013] In another aspect, the tTGase inhibitors and/or pharmaceutical formulations of the present invention are useful in treating disorders where TGases are a factor in the disease etiology, where such disorders may include cancer, neurological disorders, wound healing, etc. These conditions include Alzheimer's and Huntington's diseases, where the TGases appear to be a factor in the formation of inappropriate proteinaceous aggregates that may be cytotoxic. In diseases such as progressive supranuclear palsy, Huntington's, Alzheimer's and Parkinson's diseases, the aberrant activation of TGases may be caused by oxidative stress and inflammation.
[0014] These and other aspects and embodiments of the invention and methods for making and using the invention are described in more detail in the description of the drawings and the invention, the examples, the claims, and the drawings that follow.
DETAILED DESCRIPTION OF THE EMBODIMENTS
[0015] Celiac Sprue and/or dermatitis herpetiformis are treated by inhibition of tissue transglutaminase. Therapeutic benefit can be enhanced in some individuals by increasing the digestion of gluten oligopeptides, whether by pretreatment of foodstuffs to be ingested or by administration of an enzyme capable of digesting the gluten oligopeptides, together with administration of the tTGase inhibitor. Gluten oligopeptides are highly resistant to cleavage by gastric and pancreatic peptidases such as pepsin, trypsin, chymotrypsin, and the like, and their prolonged presence in the digestive tract can induce an autoimmune response mediated by tTGase. The antigenicity of gluten oligopeptides and the ill effects caused by an immune response thereto can be decreased by inhibition of tissue transglutaminase. In another embodiment of the invention, by also providing a means for digestion of gluten oligopeptides with glutenase, gluten oligopeptides are cleaved into fragments, thereby contributing to the prevention of the disease-causing toxicity.
[0016] Methods and compositions are provided for the administration of one or more tTGase inhibitors to a patient suffering from Celiac Sprue and/or dermatitis herpetiformis. In some embodiments and for some individuals, the methods of the invention remove the requirement that abstention from ingestion of glutens be maintained to keep the disease in remission. The compositions of the invention include formulations of tTGase inhibitors that comprise an enteric coating that allows delivery of the agents to the intestine in an active form; the agents are stabilized to resist digestion or alternative chemical transformations in acidic stomach conditions. In another embodiment, food is pretreated or combined with glutenase, or a glutenase is co-administered (whether in time or in a formulation of the invention) with a tTGase inhibitor of the invention.
[0017] The subject methods are useful for both prophylactic and therapeutic purposes. Thus, as used herein, the term “treating” is used to refer to both prevention of disease, and treatment of a pre-existing condition. The treatment of ongoing disease, to stabilize or improve the clinical symptoms of the patient, is a particularly important benefit provided by the present invention. Such treatment is desirably performed prior to loss of function in the affected tissues; consequently, the prophylactic therapeutic benefits provided by the invention are also important. Evidence of therapeutic effect may be any diminution in the severity of disease, particularly diminution of the severity of such symptoms as fatigue, chronic diarrhea, malabsorption of nutrients, weight loss, abdominal distension, and anemia. Other disease indicia include the presence of antibodies specific for glutens, antibodies specific for tissue transglutaminase, the presence of pro-inflammatory T cells and cytokines, and degradation of the villus structure of the small intestine. Application of the methods and compositions of the invention can result in the improvement of any and all of these disease indicia of Celiac Sprue.
[0018] Patients that can benefit from the present invention include both adults and children. Children in particular benefit from prophylactic treatment, as prevention of early exposure to toxic gluten peptides can prevent development of the disease into its more severe forms. Children suitable for prophylaxis in accordance with the methods of the invention can be identified by genetic testing for predisposition, e.g. by HLA typing; by family history, and by other methods known in the arL As is known in the art for other medications, and in accordance with the teachings herein, dosages of the tTGase inhibitors of the invention can be adjusted for pediatric use.
[0019] Because most proteases and peptidases are unable to hydrolyze the amide bonds of proline residues, the abundance of proline residues in gliadins and related proteins from wheat, rye and barley can constitute a major digestive obstacle for the enzymes involved. This leads to an increased concentration of relatively stable gluten derived oligopeptides in the gut. These stable gluten derived oligopeptides, called “toxic oligopeptides” herein, interact with tTGase to stimulate an immune response that results in the autoimmune disease aspects of Celiac Sprue.
[0020] Such toxic oligopeptides include the peptide sequence PQPQLPY and longer peptides containing that sequence or multiple copies of that sequence. This peptide sequence is a high affinity substrate for the enzyme tissue transglutaminase (tTGase), an enzyme found on the extracellular surface in many organs including the intestine. The tTGase enzyme catalyzes the formation of isopeptide bonds between glutamine and lysine residues of different polypeptides, leading to protein-protein crosslinks in the extracellular matrix. The tTGase enzyme acts on the peptide sequence PQPQLPY to deamidate the second Q residue, forming the peptide sequence PQPELPY. The tTGase enzyme is the primary focus of the autoantibody response in Celiac Sprue. Gliadins, secalins and hordeins contain several of the PQPQLPY sequences or sequences similar thereto rich in Pro-Gin residues that are high-affinity substrates for tTGase. The tTGase catalyzed deamidation of such sequences dramatically increases their affinity for HLA-DQ2, the class II MHC allele present in >90% Celiac Sprue patients. Presentation of these deamidated sequences by DQ2 positive antigen presenting cells effectively stimulates proliferation of gliadin-specific T cells from intestinal biopsies of most Celiac Sprue patients, providing evidence for the proposed mechanism of disease progression in Celiac Sprue.
[0021] There are a number of known tTGase inhibitors that can be used in the methods of the invention. While known, these compounds have never before been used to treat Celiac Sprue effectively, because the compounds have not been administered to Celiac Sprue patients in the formulations and dosages required to deliver the active inhibitor to the small intestine in efficacious amounts. Known tTGase inhibitors include certain glutamine mimetic compounds, including compounds selected from the group consisting of vinylogous amides, sulfonamides, diazoketones, 3-halo-4,5-dihydroisoxazoles, and 1,2,4thiadiazoles. While the present invention is not to be bound by a mechanistic-theory, it is believed that these compounds provide an effective therapy-for Celiac Sprue by reversibly or irreversibly inhibiting the tTGase in the small intestine, thereby preventing it from acting on the oligopeptides comprising the PQPQLPY sequence.
[0022] PQPQLPY is a high affinity substrate for tTGase, because it has a structure that is highly complementary to the structure of the active site of the tTGase enzyme. In particular, the peptide bonds preceding Pro residues adopt trans configurations, thereby allowing the peptide to adopt an extended polyproline II helical structure. This polyproline II helical character is a general property of immunogenic gliadin peptides, and is an important determinant of their high affinity toward tTGase. Therefore, it has been exploited in the design of certain tTGase inhibitors of the invention. By administering compounds that bind to the active site of the tTGase enzyme and prevent either the binding of immunogenic gliadin peptides such as the 33-mer LQLQPFPQPQLPYPQPQLPYPQPQLPYPQPQPF, or their conversion to regioselectively deamidated products, a therapeutic benefit can be achieved in Celiac Sprue patients. In part, the present invention arises out of the discoveries that the dipeptides QP and LP play an important role in forming the structure that binds to the active site of the tTGase enzyme and that compounds that mimic the configurations of these dipeptides in a polyproline helix (i.e. where the imide bond adopts a trans configuration) can be used to inhibit tTGase and treat Celiac Sprue. Thus, in addition to the methods for administering the glutamine mimetic compounds described above, the present invention provides methods in which a small organic molecule that is a constrained mimetic of a dipeptide selected from the group consisting of PQ, QP, PE, PY, and LP is administered to a Celiac Sprue patient to treat celiac disease.
[0023] The tTGase inhibitors of the present invention that have structures that mimic the conformation of the key dipeptide moieties of the tTGase substrate can be thought of as “tTGase inhibitory motif” or “tTGase inhibitory moiety”. Human tTGase has a strong preference for peptide substrates with Type II polyproline character. This conformational preference is exploited by the selective tTGase inhibitors of the invention. Dipeptide moieties of interest have the formula XP, wherein X can be any amino acid but is preferably selected from the group consisting of Q, Y, L, E, or F. Inhibitors of the invention containing such moieties are referred to as “peptide mimetics” or “peptidomimetics”.
[0024] Examples of dipeptidomimetics based on the trans-PQPQLPY peptide are shown below.
trans-PQPQLPY (all X-P bonds in trans configuration)
[0025] Similar dipeptidomimetics can be identified based on sequences of other high-affinity gliadin peptide substrates of tTGase. Common constrained dipeptide mimetics useful for purposes of the invention also include quinozilidinone, pyrroloazepinone, indolizidinone, alkylbranched azabicyclo[X.Y.O]alkane amino acids (Gosselin et al., J. Org. Chem. 2000, 65, 2163-71; Polyak et al., J. Org. Chem. 2001, 66, 1171-80), 6,5-fused bicyclic lactam (Mueller et al., Tetrahedron Lett. 1994, 4091-2; Dumas, Tetrahedron Lett. 1994, 1493-6, and Kim, 1997, J. Org. Chem. 62, 2847-52 ), and lactam methylene linker.
[0026] The dipeptide mimetic tTGase inhibitor compounds, like the glutamine mimetic tTGase inhibitor compounds, are believed to provide a therapeutic benefit to Celiac Sprue patients by preventing tTGase from binding the toxic oligopeptide comprising the PQPQLPY sequence and converting it to the PQPELPY sequence, thus preventing the initiation of the autoimmune response responsible for the symptoms of the disease. Alternatively, these dipeptidomimetics can be incorporated into a PQPQLPY sequence or longer peptide or peptidomimetic containing that sequence in place of the corresponding dipeptide moiety. It is well understood in the pharmaceutical arts that the more selective a drug for its intended target, and the greater affinity of a drug for its intended target, the more useful the drug for the treatment of the disease relating to that target. Thus, while the glutamine and dipeptide mimetic inhibitors of the invention can be used to treat Celiac Sprue, there will in some instances be a need for or benefit from compounds with greater specificity for and affinity to tTGase. The present invention provides such compounds..
[0027] Thus, while beneficial therapeutic effect can be achieved by delivery of any tTGase inhibitor to the small intestine of a Celiac Sprue patient, in a preferred embodiment, the tTGase inhibitor is contained in a molecule that is a high affinity peptide or peptidomimetic substrate of tTGase or a peptidomimetic thereof. Thus, the inhibitors of tTGase provided by the present invention include modified high affinity peptide substrates for tTGase, where one or more glutamine residues of the peptide substrate are substituted with tTGase inhibitory moieties or one or more dipeptides in the substrate are substituted with a dipeptide mimetic or both. In either event, the peptide or peptidomimetic does not induce an autoimmune response in the Celiac Sprue patient.
[0028] High affinity peptide substrates for tTGase include the following peptides, and, with respect to the larger peptides shown, fragments thereof: PQPQLPY, PQPQLPYPQPQLP; LQLQPFPQPQLPYPQPQLPYPQPQLPYPQPQPF; QPQPFPPQLPYPQTQPFPPQQPYPQPQPQYPQPQ (from α1- and α6-gliadins); QQQPFPQQPIPQQPQPYPQQPQPYPQQPFPPQQPF (from B1 hordein); QPFPQPQQTFPQQPQLPFPQQPQQPFPQPQ (from γ-gliadin); VQWPQQQPVPQPHQPF (from γ-gliadin), VQGQGIIQPQQPAQ (from γ-gliadin), FLQPQQPFPQQPQQPYPQQPQQPFPQ (from γ-gliadin), FSQPQQQFPQPQQPQQSFPQQQPP (from γ-gliadin), and QPFPQPQQPTPIQPQQPFPQRPQQPFPQPQ. These peptides are resistant toward endo- and exo-proteolysis by gastric, pancreatic and small intestinal enzymes. Conservative amino acid substitutions, such as Y ->F, Q ->N/E, or L ->M, are also tolerated. Therefore, in accordance with the present invention, selective inhibitors of tTGase are provided by substituting either a glutamine that is deamidated by tTGase or a dipeptide contained in the peptide that binds in the active site of tTGase with a mimetic such that the resulting compound is an inhibitor of tTGase that does not stimulate the autoimmune response in a Celiac Sprue patient.
[0029] The reactive glutamines in the above proteolytically stable peptides include those glutamines identified as “(Q->E)”, E being the amino acid formed by deamidation of glutamine, in the following sequences: PQP(Q->E)LPY, PQP(Q->E)LPYPQPQLP; LQLQPFPQP(Q->E)LPYPQPQLPYPQP(Q->E)LPYPQPQPF, FSQP(Q->E)Q(Q->E)FPQPQQPQQSFP(Q->E)Q(Q->E)PP, VQGQGIIQP(Q->E)QPAQ, and FLQPQQPFP(Q->E)QP(Q->E)QPYPQQPQQPFPQ. Reactive glutamine residues in other peptides can be identified by standard HPLC-MS-MS procedures, and can be replaced by glutamine mimetics. The (Q->E) residues can be replaced by glutamine mimetics and/or the QP and LP dipeptides in these sequences can be replaced by dipeptidomimetics as discussed above. The novel tTGase inhibitors of the invention are peptides or peptidomimetic compounds in which either a reactive glutamine or a dipeptide that binds in the active site of tTGase or both has been replaced by a small molecule mimetic are referred to herein as “substituted peptides”. In one embodiment, the tTGase inhibitors useful in the methods and compositions of the present invention are those for which the affinity of the inhibitory moiety for the tTG active site increases (as measured by a decrease in K I or an increase in k inh /K I ) when presented in the context of a high affinity, proteolytically stable peptide substrate of the enzyme. This aspect of the invention is illustrated in the Examples below.
[0030] Such compounds of the invention are illustrated below by compounds in which a reactive glutamine is replaced by a tTGase inhibitory moiety. Various tTGase inhibitory moieties useful in the methods of the invention and that are incorporated into the novel substituted peptide and peptidomimetic tTGase inhibitors of the invention include the following compounds, which are shown with variable (designated R) groups to indicate that the compounds can be used directly as small molecule inhibitors or incorporated into a larger dipeptide mimetic or peptide or peptidomimetic tTGase inhibitory compound of the invention.
[0031] In the compounds shown above, R1, R2 and R3 are independently selected from H, alkyl, alkenyl, cycloalkyl, aryl, heteroalkyl, heteroaryl, alkoxy, alkylthio, arakyl, aralkenyl, halo, haloalkyl, haloalkoxy, heterocyclyl, and heterocyclylalkyl groups. R1 and R2 can also be an amino acid, a peptide, a peptidomimetic, or a peptidic protecting groups. Illustrative functional groups include: R 1 is selected from the group consisting of Cbz, Fmoc, Boc, PQP, Ac-PQP, PQPQLPYPQP, Ac-PQPQLPFPQP, QLQPFPQP, LQLQPFPQPLPYPQP, X 2-15 -P (where X 2-15 is a peptide consisting of any 2-15 amino acid residues followed by a N-terminal proline); and R 2 is selected from the group consisting of OMe, OtBu, Gly, Gly-NH 2 , LPY, LPF-NH 2 , LPYPQPQLPY, LPFPQPQLPF-NH 2 , LPYPQPQLP, LPYPQPQLPYPQPQPF, LP-X 2-15 (where X 2-15 is a peptide consisting of any 2-15 amino acid residues followed by a C-terminal proline).
[0032] Given the high selectivity of human tTGase for the peptide Ac-PQPQLPF-NH 2 , and
the intrinsic resistance of this peptide toward gastrointestinal proteolysis, the following tTGase inhibitors are provided by the present invention.
[0033] In each case, an inhibitor of the invention with greater specificity is provided by individual or combinatorial substitution of Q, L and F with alternative amino acids. In the case of sulfonamide inhibitors, the following analogs are also provided, where R is selected from an alkyl, alkenyl, cycloalkyl, aryl, heteroalkyl, heteroaryl, alkoxy, alkylthio, arakyl, aralkenyl, halo, haloalkyl, haloalkoxy, heterocyclyl, or heterocyclylalkyl group. Of particular interest are the sulfonyl hydrazides (R=NHR′) where R′ is H. alkyl, alkenyl, cycloalkyl, aryl, heteroalkyl, heteroaryl, alkoxy., alkylthio, arakyl, aralkenyl, halo, haloalkyl, haloalkoxy, heterocyclyl, or heterocyclylalkyl group.
[0034] In one preferred embodiment, R is a functional group whose corresponding amine is a preferred nucleophilic co-substrate of human tTGase. For example, the biological amine histamine is an excellent co-substrate of tTGase (kcat=20 min −1 , KM=40 μM). Consequently, the following compound is a preferred tTGase inhibitor of this invention:
[0035] The synthesis of such compounds of the invention can be carried out using methods known in the art for other purposes and the teachings herein. For example, the synthesis of vinylogous amides such as 1 (see the numbered structure shown below) containing an acrylamide function have been reported by Macedo et al. ( Bioorg. Med. Chem. (2002) 10, 355-360). Their ability to inhibit guinea pig tTG has been demonstrated (Marrano et al., Bioorg. Med. Chem. (2001) 9, 3231-3241). Illustrative vinylogous amide compounds of the invention include compounds in which a glutamine mimetic with an acrylamide motif such as 2 (see the numbered structure below) is contained in a peptide or peptidomimetic having the following structures: R 1 is selected from the group consisting of PQP, Ac-PQP, PQPQLPYPQP, Ac-PQPQLPFPQP, QPFPQP, LQLQPFPQPLPYPQP, or an amino acid protecting group, including but not limited to Boc and Fmoc; and R 2 is selected from the group consisting of LPY, LPF-NH 2 , LPYPQPQLPY, LPFPQPQLPF-NH 2 , LPYPQPQ, LPYPQPQLP, LPYPQPQLPYPQPQPF, or an amino acid protecting group, including but not limited to OtBu, OFm or additionally OBn or OMe.
[0036] The acrylamides can be incorporated into a high affinity peptide of the invention by fragment condensation as illustrated below in a synthetic method of the invention using intermediate compounds of the invention.
a) Boc 2 O, RT, 4 h, Na 2 CO 3 /dioxane, 95% b) C 6 H 5 l(OCOCF 3 ) 2 , pyridine, DMF/H 2 O, RT, 3 h, 80% c) acryl chloride, MeOH/TEA, 0° C.-RT, 12 h d) EDC, TEA, DCM e) LPF-NH 2 , RT, 12 h f) HCl (gaseous), DCM, RT, 4 h g) Ac-PQP, RT, 12 h.
[0037] The tTGase inhibitory compounds of the invention from the sulfonamides, diazoketones, 1,2,4 thiadiazoles, and isoxazoles can likewise be readily prepared using methods known in the art for other purposes and the teachings herein. To illustrate the invention with respect to such classes of compounds, the following amino acid analogs are employed: 4-sufonamido-2-amino-butyric acid (Sab), 6-diazo-5-oxo-norleucine (Don), and acivicin (Aci),. These compounds are useful tTGase inhibitors without further modification, and novel tTGase inhibitors of the invention comprise the structures of these compounds as part of a larger, high affinity inhibitor of tTGase, as illustrated by the structures above.
[0038] Any high affinity tTGase substrate can be used to provide the scaffold for presenting a tTGase inhibitor moiety. Moreover, compounds not known to be tTGase substrates can be identified by screening peptide libraries, for example on chips or beads or displayed on phages using reporter groups such as dansyl- or biotinyl-cadaverine, using procedures known in the art. Additionally, the tTGase inhibitors of the invention can include other moieties. As one example, in some embodiments, the tTGase inhibitor further comprise one or more proline residues C- and/or N-terminally of the glutamine mimetic-containing peptides to block exoproteolytic degradation.
[0039] To illustrate various tTGase inhibitors of the invention, a variety of relatively small and large inhibitors were synthesized and tested for inhibitory activity. As examples of small molecule inhibitors, Z-Don-OMe and Z-Sab-Gly-OH were synthesized. As examples of larger inhibitors, the compounds Ac-PQP-X-LPF-NH2, where X was Sab, a diazoketone, or acivicin, were synthesized.
[0040] Thus, Z-Don-OMe was synthesized as described (Allevi & Anatasia, Tetrahedron Asymmetry (2000) 11, 3151-3160; Pettit & Nelson, Can. J. Chem. (1986) 64, 2097-2102; Bailey & Bryans, Tetrahedron Lett. (1988) 29, 2231-2234). For the synthesis of Z-Sab-Gly-OH 33, commercially available racemic homocysteine thiolactone 24 was first protected to give 25 and subsequently saponified and acetylated in situ to give the free racemic acid 26 in high yield. Its coupling with the glycine benzyl ester 30 provided the dipeptide 31. Then, the conversion to the sulfonamide 32 was achieved via chlorination of the thioacetate moiety to a sulfonamide intermediate, followed by treatment with ammonia in CHCl 3 . Finally, the benzyl ester protecting group was removed by saponification with an aqueous NaOH solution.
[0041] The sulfonamide building block (Sab) 9 was incorporated into the Ac-PQP-X-LPF-NH 2 scaffold by fragment condensation as illustrated in the following scheme:
[0042] The diazo-ketone 10a motif was introduced into the same scaffold by post-synthetic modification of Ac-PQP-Glu-LPF-NH 2 40 to yield compound 41.
[0043] Incorporation of the acivicin moiety 12 into the high affinity PQPXLPY scaffold was achieved by Fmoc-protection of commercially available acivicin and Fmoc-compatible solid phase peptide chemistry as outlined below.
[0044] Synthesis of peptides containing 1,2,4 thiadiazoles is described by Marrano et al., Bioorg. Med. Chem. 9, 3231-3241 (2001). Because the carboxyl group of acivicin is not needed for tTG inhibition (Killackey et al., Mol. Pharmacol. (1989) 35, 701-706), the 3-chloro-4,5-dihydro-5-amino-isoxazole (Cai) group 13 was synthesized as described (Castelhano et al., Bioorg. Chem. (1988) 16, 335-340) and coupled C-terminally to a high-affinity peptide as depicted below:
[0045] The illustrative compounds of the invention described above were tested in a tTGase assay with recombinant human tissue transglutaminase, which was expressed, purified and assayed as described (Piper et al., Biochemistry (2001) 41, 386-393). Competitive inhibition with respect to the Cbz-Gln-Gly substrate was observed for all substrates; in all cases except for the Sab derivatives, irreversible inactivation of the enzyme was also observed. Importantly, all glutamine mimetics described above showed significant improved specificity within a tTG-specific peptide context. The results also demonstrated that, while the small molecule inhibitors can be used to inhibit tTGase, the larger compounds that present the glutamine mimetic tTGase inhibitor in the context of a peptide based on the PQPQLPY sequence tended to be better inhibitors.
[0046] Thus, the present invention provides a variety of different classes of known and novel tTGase inhibitors. To facilitate an appreciation of the invention, the tTGase inhibitors of the invention have in part been described above with structures containing variable “R” groups that are defined by reference to the various organic moieties that can be present at the indicated position in the structure. Below, brief definitions are provided for the phrases used to define the organic moieties listed for each R group.
[0047] As used herein, “alkyl” refers to a straight or branched hydrocarbon chain radical consisting solely of carbon and hydrogen atoms, containing no unsaturation, having from one to eight carbon atoms, and which is attached to the rest of the molecule by a single bond, e.g., methyl, ethyl, n-propyl, 1-methylethyl (isopropyl), n-butyl, n-pentyl, 1,1-dimethylethyl (t-butyl), and the like. Unless stated otherwise specifically in the specification, the alkyl radical may be optionally substituted by hydroxy, alkoxy, aryloxy, haloalkoxy, cyano, nitro, mercapto, alkylthio, —N(R 8 ) 2 , —C(O)OR 8 , —C(O)N(R 8 ) 2 or —N(R 8 )C(O)R 8 where each R 8 is independently hydrogen, alkyl, alkenyl, cycloalkyl, cycloalkylalkyl, aralkyl or aryl. Unless stated otherwise specifically in the specification, it is understood that for radicals, as defined below, that contain a substituted alkyl group that the substitution can occur on any carbon of the alkyl group.
[0048] “Alkoxy” refers to a radical of the formula —OR a where R a is an alkyl radical as defined above, e.g., methoxy, ethoxy, n-propoxy, 1-methylethoxy (isopropoxy), n-butoxy, n-pentoxy, 1,1-dimethylethoxy (t-butoxy), and the like. Unless stated otherwise specifically in the specification, it is understood that for radicals, as defined below, that contain a substituted alkoxy group that the substitution can occur on any carbon of the alkoxy group. The alkyl radical in the alkoxy radical may be optionally substituted as described above.
[0049] “Alkylthio” refers to a radical of the formula —SR a where R a is an alkyl radical as defined above, e.g., methylthio, ethylthio, n-propylthio, 1-methylethylthio (iso-propylthio), n-butylthio, n-pentylthio, 1,1-dimethylethylthio (t-butylthio), and the like. Unless stated otherwise specifically in the specification, it is understood that for radicals, as defined below, that contain a substituted alkylthio group that the substitution can occur on any carbon of the alkylthio group. The alkyl radical in the alkylthio radical may be optionally substituted as described above.
[0050] “Alkenyl” refers to a straight or branched hydrocarbon chain radical consisting solely of carbon and hydrogen atoms, containing at least one double bond, having from two to eight carbon atoms, and which is attached to the rest of the molecule by a single bond or a double bond, e.g., ethenyl, prop-1-enyl, but-1-enyl, pent-1-enyl, penta-1,4-dienyl, and the like. Unless stated otherwise specifically in the specification, the alkenyl radical may be optionally substituted by hydroxy, alkoxy, haloalkoxy, cyano, nitro, mercapto, alkylthio, cycloalkyl, —N(R 8 ) 2 , —C(O)OR 8 , —C(O)N(R 8 ) 2 or —N(R 8 )—C(O)-R 8 where each R 8 is independently hydrogen, alkyl, alkenyl, cycloalkyl, cycloalkylalkyl, aralkyl or aryl. Unless stated otherwise specifically in the specification, it is understood that for radicals, as defined below, that contain a substituted alkenyl group that the substitution can occur on any carbon of the alkenyl group.
[0051] “Aryl” refers to a phenyl or naphthyl radical. Unless stated otherwise specifically in the specification, the term “aryl” or the prefix “ar-” (such as in “aralkyl”) is meant to include aryl radicals optionally substituted by one or more substituents selected from the group consisting of hydroxy, alkoxy, aryloxy, haloalkoxy, cyano, nitro, mercapto, alkylthio, cycloalkyl, —N(R 8 ) 2 , —C(O)OR 8 , —C(O)N(R 8 ) 2 or —N(R 8 )C(O)R 8 where each R 8 is independently hydrogen, alkyl, alkenyl, cycloalkyl, cycloalkylalkyl, aralkyl or aryl.
[0052] “Aralkyl” refers to a radical of the formula -R a R b where R a is an alkyl radical as defined above and R b is one or more aryl radicals as defined above, e.g., benzyl, diphenylmethyl and the like. The aryl radical(s) may be optionally substituted as described above.
[0053] “Aralkenyl” refers to a radical of the formula -R c R b where R c is an alkenyl radical as defined above and R b is one or more aryl radicals as defined above, e.g., 3-phenylprop-1-enyl, and the like. The aryl radical(s) and the alkenyl radical may be optionally substituted as described above.
[0054] “Alkylene chain” refers to a straight or branched divalent hydrocarbon chain consisting solely of carbon and hydrogen, containing no unsaturation and having from one to eight carbon atoms, e.g., methylene, ethylene, propylene, n-butylene, and the like. The alkylene chain may be optionally substituted by one or more substituents selected from the group consisting of aryl, halo, hydroxy, alkoxy, haloalkoxy, cyano, nitro, mercapto, alkylthio, cycloalkyl, —N(R 8 ) 2 , —C(O)OR 8 , —C(O)N(R 8 ) 2 or —N(R 8 )C(O)R 8 where each R 8 is independently hydrogen, alkyl, alkenyl, cycloalkyl, cycloalkylalkyl, aralkyl or aryl. The alkylene chain may be attached to the rest of the molecule through any two carbons within the chain.
[0055] “Alkenylene chain” refers to a straight or branched divalent hydrocarbon chain consisting solely of carbon and hydrogen, containing at least one double bond and having from two to eight carbon atoms, e.g., ethenylene, prop-1-enylene, but-1-enylene, pent-1-enylene, hexa-1,4-dienylene, and the like. The alkenylene chain may be optionally substituted by one or more substituents selected from the group consisting of aryl, halo, hydroxy, alkoxy, haloalkoxy, cyano, nitro, mercapto, alkylthio, cycloalkyl, —N(R 8 ) 2 , —C(O)OR 8 , —C(O)N(R 8 ) 2 or —N(R 8 )C(O)R 8 where each R 8 is independently hydrogen, alkyl, alkenyl, cycloalkyl, cycloalkylalkyl, aralkyl or aryl. The alkenylene chain may be attached to the rest of the molecule through any two carbons within the chain.
[0056] “Cycloalkyl” refers to a stable monovalent monocyclic or bicyclic hydrocarbon radical consisting solely of carbon and hydrogen atoms, having from three to ten carbon atoms, and which is saturated and attached to the rest of the molecule by a single bond, e.g., cyclopropyl, cyclobutyl, cyclopentyl, cyclohexyl, decalinyl and the like. Unless otherwise stated specifically in the specification, the term “cycloalkyl” is meant to include cycloalkyl radicals which are optionally substituted by one or more substituents independently selected from the group consisting of alkyl, aryl, aralkyl, halo, haloalkyl, hydroxy, alkoxy, haloalkoxy, cyano, nitro, mercapto, alkylthio, cycloalkyl, —N(R 8 ) 2 , —C(O)OR 8 , —C(O)N(R 8 ) 2 or —N(R 8 )C(O)R 8 where each R 8 is independently hydrogen, alkyl, alkenyl, cycloalkyl, cycloalkylalkyl, aralkyl or aryl.
[0057] “Cycloalkylalkyl” refers to a radical of the formula -R a R d where R a is an alkyl radical as defined above and R d is a cycloalkyl radical as defined above. The alkyl radical and the cycloalkyl radical may be optionally substituted as defined above.
[0058] “Halo” refers to bromo, chloro, fluoro or iodo.
[0059] “Haloalkyl” refers to an alkyl radical, as defined above, that is substituted by one or more halo radicals, as defined above, e.g., trifluoromethyl, difluoromethyl, trichloromethyl, 2,2,2-trifluoroethyl, 1-fluoromethyl-2-fluoroethyl, 3-bromo-2-fluoropropyl, 1-bromomethyl-2-bromoethyl, and the like.
[0060] “Haloalkoxy” refers to a radical of the formula —OR c where R c is an haloalkyl radical as defined above, e.g., trifluoromethoxy, difluoromethoxy, trichloromethoxy, 2,2,2-trifluoroethoxy, 1-fluoromethyl-2-fluoroethoxy, 3-bromo-2-fluoropropoxy, 1-bromomethyl-2-bromoethoxy, and the like.
[0061] “Heterocyclyl” refers to a stable 3- to 15-membered ring radical which consists of carbon atoms and from one to five heteroatoms selected from the group consisting of nitrogen, oxygen and sulfur. For purposes of this invention, the heterocyclyl radical may be a monocyclic, bicyclic or tricyclic ring system, which may include fused or bridged ring systems; and the nitrogen, carbon or sulfur atoms in the heterocyclyl radical may be optionally oxidized; the nitrogen atom may be optionally-quatemized; and the heterocyclyl radical may be aromatic or partially or fully saturated. The heterocyclyl radical may not be attached to the rest of the molecule at any heteroatom atom. Examples of such heterocyclyl radicals include, but are not limited to, azepinyl, acridinyl, benzimidazolyl, benzthiazolyl, benzothiadiazolyl, benzoxazolyl, benzodioxolyl, benzodioxinyl, benzopyranyl, benzopyranonyl, benzofuranyl, benzofuranonyl, benzothienyl (benzothiophenyl), benzotriazolyl, carbazolyl, cinnolinyl, decahydroisoquinolyl, dioxolanyl, furanyl, furanonyl, isothiazolyl, imidazolyl, imidazolinyl, imidazolidinyl, isothiazolidinyl, indolyl, indazolyl, isoindolyl, indolinyl, isoindolinyl, indolizinyl, isoxazolyl, isoxazolidinyl, morpholinyl, naphthyridinyl, oxadiazolyl, octahydroindolyl, octahydroisoindolyl, 2-oxopiperazinyl, 2-oxopiperidinyl, 2-oxopyrrolidinyl, 2-oxoazepinyl, oxazolyl, oxazolidinyl, oxiranyl, piperidinyl, piperazinyl, 4-piperidonyl, phenazinyl, phenothiazinyl, phenoxazinyl, phthalazinyl, pteridinyl, purinyl, pyrrolyl, pyrrolidinyl, pyrazolyl, pyrazolidinyl, pyridinyl, pyrazinyl, pyrimidinyl, pyridazinyl, quinazolinyl, quinoxalinyl, quinolinyl, quinuclidinyl, isoquinolinyl, thiazolyl, thiazolidinyl, thiadiazolyl, triazolyl, tetrazolyl, tetrahydrofuryl, triazinyl, tetrahydropyranyl, thienyl, thiamorpholinyl, thiamorpholinyl sulfoxide, and thiamorpholinyl sulfone. Unless stated otherwise specifically in the specification, the term “heterocyclyl” is meant to include heterocyclyl radicals as defined above which are optionally substituted by one or more substituents selected from the group consisting of alkyl, halo, nitro, cyano, haloalkyl, haloalkoxy, aryl, heterocyclyl, heterocyclylalkyl, —OR 8 , -R 7 —OR 8 , —C(O)OR 8 , -R 7 —C(O)OR 8 , —C(O)N(R 8 ) 2 , —N(R 8 ) 2 , -R 7 —N(R 8 ) 2 , and —N(R 8 )C(O)R 8 wherein each R 7 is a straight or branched alkylene or alkenylene chain and each R 8 is independently hydrogen, alkyl, alkenyl, cycloalkyl, cycloalkylalkyl, aralkyl or aryl.
[0062] “Heterocyclylalkyl” refers to a radical of the formula -R a R e where R a is an alkyl radical as defined above and R e is a heterocyclyl radical as defined above, and if the heterocyclyl is a nitrogen-containing heterocyclyl, the heterocyclyl may be attached to the alkyl radical at the nitrogen atom. The heterocyclyl radical may be optionally substituted as defined above.
[0063] In the formulas provided herein, molecular variations are included, which may be based on isosteric replacement. “lsosteric replacement” refers to the concept of modifying chemicals through the replacement of single atoms or entire functional groups with alternatives that have similar size, shape and electro-magnetic properties, e.g. O is the isosteric replacement of S, N, COOH is the isosteric replacement of tetrazole, F is the isosteric replacement of H, sulfonate is the isosteric replacement of phosphate etc.
[0064] As used herein, compounds which are “commercially available” may be obtained from standard commercial sources including Acros Organics (Pittsburgh Pa.), Aldrich Chemical (Milwaukee Wiss., including Sigma Chemical and Fluka), Apin Chemicals Ltd. (Milton Park UK), Avocado Research (Lancashire U.K.), BDH Inc. (Toronto, Canada), Bionet (Cornwall, U.K.), Chemservice Inc. (West Chester Pa.), Crescent Chemical Co. (Hauppauge N.Y.), Eastman Organic Chemicals, Eastman Kodak Company (Rochester N.Y.), Fisher Scientific Co. (Pittsburgh Pa.), Fisons Chemicals (Leicestershire UK), Frontier Scientific (Logan Utah), ICN Biomedicals, Inc. (Costa Mesa Calif.), Key Organics (Cornwall U.K.), Lancaster Synthesis (Windham N.H., Maybridge Chemical Co. Ltd. (Cornwall U.K.), Parish Chemical Co. (Orem Utah), Pfaltz & Bauer, Inc. (Waterbury Conn.), Polyorganix (Houston Tex.), Pierce Chemical Co. (Rockford Ill.), Riedel de Haen AG (Hannover, Germany), Spectrum Quality Product, Inc. (New Brunswick, N.J.), TCI America (Portland Oreg.), Trans World Chemicals, Inc. (Rockville Md.), Wako Chemicals USA, Inc. (Richmond Va.), Novabiochem and Argonaut Technology.
[0065] As used herein, “suitable conditions” for carrying out a synthetic step are explicitly provided herein or may be discerned by reference to publications directed to methods used in synthetic organic chemistry. The reference books and treatise set forth above that detail the synthesis of reactants useful in the preparation of compounds of the present invention, will also provide suitable conditions for carrying out a synthetic step according to the present invention.
[0066] As used herein, “methods known to one of ordinary skill in the art” may be identified though various reference books and databases. Suitable reference books and treatise that detail the synthesis of reactants useful in the preparation of compounds of the present invention, or provide references to articles that describe the preparation, include for example, “Synthetic Organic Chemistry”, John Wiley & Sons, Inc., New York; S. R. Sandier et al., “Organic Functional Group Preparations,” 2nd Ed., Academic Press, New York, 1983; H. O. House, “Modem Synthetic Reactions”, 2nd Ed., W. A Benjamin, Inc. Menlo Park, Calif. 1972; T. L. Gilchrist, “Heterocyclic Chemistry”, 2nd Ed., John Wiley & Sons, New York, 1992; J. March, “Advanced Organic Chemistry: Reactions, Mechanisms and Structure”, 4th Ed., Wiley-Interscience, New York, 1992. Specific and analogous reactants may also be identified through the indices of known chemicals prepared by the Chemical Abstract Service of the American Chemical Society, which are available in most public and university libraries, as well as through on-line databases (the American Chemical Society, Washington, D.C., www.acs.org may be contacted for more details). Chemicals that are known but not commercially available in catalogs may be prepared by custom chemical synthesis houses, where many of the standard chemical supply houses. (e.g., those listed above) provide custom synthesis services.
[0067] “Optional” or “optionally” means that the subsequently described event of circumstances may or may not occur, and that the description includes instances where said event or circumstance occurs and instances in which it does not. For example, “optionally substituted aryl” means that the aryl radical may or may not be substituted and that the description includes both substituted aryl radicals and aryl radicals having no substitution.
[0068] “Pharmaceutically acceptable base addition salt” refers to those salts which retain the biological effectiveness and properties of the free acids, which are not biologically or otherwise undesirable. These salts are prepared from addition of an inorganic base or an organic base to the free acid. Salts derived from inorganic bases include, but are not limited to, the sodium, potassium, lithium, ammonium, calcium, magnesium, iron, zinc, copper, manganese, aluminum salts and the like. Preferred inorganic salts are the ammonium, sodium, potassium, calcium, and magnesium salts. Salts derived from organic bases include, but are not limited to, salts of primary, secondary, and tertiary amines, substituted amines including naturally occurring substituted amines, cyclic amines and basic ion exchange resins, such as isopropylamine, trimethylamine, diethylamine, triethylamine, tripropylamine, ethanolamine, 2-dimethylaminoethanol, 2-diethylaminoethanol, dicyclohexylamine, lysine, arginine, histidine, caffeine, procaine, hydrabamine, choline, betaine, ethylenediamine, glucosamine, methylglucamine, theobromine, purines, piperazine, piperidine, N-ethylpiperidine, polyamine resins and the like. Particularly preferred organic bases are isopropylamine, diethylamine, ethanolamine, trimethylamine, dicyclohexylamine, choline and caffeine.
[0069] The tTGase inhibitors, or their pharmaceutically acceptable salts may contain one or more asymmetric centers and may thus give rise to enantiomers, diastereomers, and other stereoisomeric forms that may be defined, in terms of absolute stereochemistry, as (R)- or (S)- or, as (D)- or (L) for amino acids. The present invention is meant to include all such possible isomers, as well as, their racemic and optically pure forms. Optically active (+) and (−), (R)- and (S)-, or (D)- and (L)- isomers may be prepared using chiral synthons or chiral reagents, or resolved using conventional techniques, such as reverse phase HPLC. When the compounds described herein contain olefinic double bonds or other centers of geometric asymmetry, and unless specified otherwise, it is intended that the compounds include both E and Z geometric isomers. Likewise, all tautomeric forms are also intended to be included.
[0070] The present invention provides the tTGase inhibitors in a variety of formulations for therapeutic administration. In one aspect, the agents are formulated into pharmaceutical compositions by combination with appropriate, pharmaceutically acceptable carriers or diluents, and are formulated into preparations in solid, semi-solid, liquid or gaseous forms, such as tablets, capsules, powders, granules, ointments, solutions, suppositories, injections, inhalants, gels, microspheres, and aerosols. As such, administration of the tTGase inhibitors is achieved in various ways, although oral administration is a preferred route of administration. In some formulations, the tTGase inhibitors are systemic after administration; in others, the inhibitor is localized by virtue of the formulation, such as the use of an implant that acts to retain the active dose at the site of implantation.
[0071] In some pharmaceutical dosage forms, the tTGase inhibitors are administered in the form of their pharmaceutically acceptable salts. In some dosage forms, the tTGase inhibitor is used alone, while in others, the tTGase is used in combination with another pharmaceutically active compounds. In the latter embodiment, the other active compound is, in some embodiments, a glutenase that can cleave or otherwise degrade a toxic gluten oligopeptide, as described in the Examples below. The following methods and excipients are merely exemplary and are in no way limiting.
[0072] For oral preparations, the agents are used alone or in combination with appropriate additives to make tablets, powders, granules or capsules, for example, with conventional additives, such as lactose, mannitol, corn starch or potato starch; with binders, such as crystalline cellulose, cellulose derivatives, acacia, corn starch or gelatins; with disintegrators, such as corn starch, potato starch or sodium carboxymethylcellulose; with lubricants, such as talc or magnesium stearate; and in some embodiments, with diluents, buffering agents, moistening agents, preservatives and flavoring agents.
[0073] In one embodiment of the invention, the oral formulations comprise enteric coatings, so that the active agent is delivered to the intestinal tract. Enteric formulations are often used to protect an active ingredient from the strongly acid contents of the stomach. Such formulations are created by coating a solid dosage form with a film of a polymer that is insoluble in acid environments and soluble in basic environments. Exemplary films are cellulose acetate phthalate, polyvinyl acetate phthalate, hydroxypropyl methylcellulose phthalate and-hydroxypropyl methylcellulose acetate succinate, methacrylate copolymers and cellulose acetate phthalate.
[0074] Other enteric formulations of the tTGase inhibitors of the invention comprise engineered polymer microspheres made of biologically erodable polymers, which display strong adhesive interactions with gastrointestinal mucus and cellular linings, can traverse both the mucosal absorptive epithelium and the follicle-associated epithelium covering the lymphoid tissue of Peyer's patches. The polymers maintain contact with intestinal epithelium for extended periods of time and actually penetrate it, through and between cells. See, for example, Mathiowitz et al. (1997) Nature 386 (6623): 410-414. Drug delivery systems can also utilize a core of superporous hydrogels (SPH) and SPH composite (SPHC), as described by Dorkoosh et al. (2001) J Control Release 71(3):307-18.
[0075] In another embodiment, the tTGase inhibitor or formulation thereof is admixed with food, or used to pre-treat foodstuffs containing glutens.
[0076] Formulations are typically provided in a unit dosage form, where the term “unit dosage form,” refers to physically discrete units suitable as unitary dosages for human subjects, each unit containing a predetermined quantity of tTGase inhibitor calculated in an amount sufficient to produce the desired effect in association with a pharmaceutically acceptable diluent, carrier or vehicle. The specifications for the unit dosage forms of the present invention depend on the particular complex employed and the effect to be achieved, and the pharmacodynamics associated with each complex in the host.
[0077] The pharmaceutically acceptable excipients, such as vehicles, adjuvants, carriers or diluents, are readily available to the public. Moreover, pharmaceutically acceptable auxiliary substances, such as pH adjusting and buffering agents, tonicity adjusting agents, stabilizers, wetting agents and the like, are readily available to the public.
[0078] Depending on the patient and condition being treated and on the administration route, the tTGase inhibitor is administered in dosages of 0.01 mg to 500 mg V/kg body weight per day, e.g. about 20 mg/day for an average person. Dosages are appropriately adjusted for pediatric formulation. Those of skill will readily appreciate that dose levels can vary as a function of the specific inhibitor, the diet of the patient and the gluten content of the diet, the severity of the symptoms, and the susceptibility of the subject to side effects. Some of the inhibitors of the invention are more potent than others. Preferred dosages for a given inhibitor are readily determinable by those of skill in the art by a variety of means. A preferred means is to measure the physiological potency of a given compound.
[0079] The methods of the invention are useful in the treatment of individuals suffering from Celiac Sprue and/or dermatitis herpetiformis, by administering an effective dose of a tTGase inhibitor, through a pharmaceutical formulation, and the like. Diagnosis of suitable patients may utilize a variety of criteria known to those of skill in the art. A quantitative increase in antibodies-specific for gliadin, and/or tissue transglutaminase is indicative of the disease. Family histories and the presence of the HLA alleles HLA-DQ2 [DQ(a1*0501, b1*02)] and/or DQ8 [DQ(a1*0301, b1*0302)] are indicative of a susceptibility to the disease. Moreover, as tTG plays an important role in other diseases, such as Huntington's disease and skin diseases in addition to dermatitis herpetiformis, a variety of formulated versions of the compounds of the invention (e.g. topical formulations, intravenous injections) are useful for the treatment of such medical conditions. These conditions include Alzheimer's and Huntington's diseases, where the TGases appear to be a factor in the formation of inappropriate proteinaceous aggregates that may be cytotoxic. In diseases such as progressive supranuclear palsy, Huntington's, Alzheimer's and Parkinson's diseases, the aberrant activation of TGases may be caused by oxidative stress and inflammation.
[0080] Therapeutic effect is measured in terms of clinical outcome, or by immunological or biochemical tests. Suppression of the deleterious T-cell activity can be measured by enumeration of reactive Th1 cells, by quantitating the release of cytokines at the sites of lesions, or using other assays for the presence of autoimmune T cells known in the art. Also both the physician and patient can identify a reduction in symptoms of a disease.
[0081] Various methods for administration are employed in the practice of the invention. In one preferred embodiment, oral administration, for example with meals, is employed. The dosage of the therapeutic formulation can vary widely, depending upon the nature of the disease, the frequency of administration, the manner of administration, the clearance of the agent from the patient, and the like. The initial dose can be larger, followed by smaller maintenance doses. The dose can be administered as infrequently as weekly or biweekly, or more often fractionated into smaller doses and administered daily, with meals, semi-weekly, and the like, to maintain an effective dosage level.
[0082] The following examples are put forth so as to provide those of ordinary skill in the art with a complete disclosure and description of how to make and use the present invention, and are not intended to limit the scope of what the inventors regard as their invention nor are they intended to represent that the experiments below are all or the only experiments performed. Efforts have been made to ensure accuracy with respect to numbers used (e.g., amounts, temperature), but some experimental errors and deviations may be present. Unless indicated otherwise, parts are parts by weight, molecular weight is weight average molecular weight, temperature is in degrees Centigrade, and pressure is at or near atmospheric.
EXAMPLE 1
Synthesis of Glutamine Mimetic tTGase Inhibitors
[0083] Synthesis of N-(Carbobenzyloxy)-D,L-homocysteine thiolactone (25). To a solution of DL-homocysteine thiolactone hydrochloride (1 eq.) in an aqueous solution of Na 2 CO 3 (10 eq.) and dioxane (v/v), cooled to 0° C., benzylchloroformate (1 eq) in dioxane is added. After 20 h at room temperature, the bulk of the dioxane is evaporated and the resulting aqueous solution extracted with AcOEt. The combined extracts are washed with brine, dried over sodium sulfate and evaporated. The crude product is triturated in ether and finally filtered. White solid. Yield 95%. 1 H NMR (CDCl 3 ) δ1.98 (m, 1H), 2.87 (m, 1H), 3,24-3.34 (m, 2H), 4. 31 (m, 1H), 5.12 (s, 2H), 7.35 (m, 5H)
[0084] Synthesis of S-acetyl-N-(carbobenzyloxy)-D,L-homocysteine (26). A solution of N-(Carbobenzyloxy) -D,L-homocysteine thiolactone 25 (1 eq.) in THF:H 2 O 1.5:0.5 was degassed three times. A solution of 6M aqueous degassed KOH (3 eq.), was added the thiolactone solution. After the solution was stirred at room temperature for 1.5 h, acetic anhydride (5.3 eq.) was then added dropwise with continued cooling (ice bath), maintaining a temperature of <27 ° C. After an additional 30 min. at room temperature, the reaction was acidified with 6N aqueous HCl to pH 4.3, and then concentrated in vacuo. The concentrate was acidified further with additional 6N aqueous HCl to pH 2.6. The product was extracted with EtOAc. The combined organic extracts were washed three times with saturated brine, dried (Na 2 SO 4 ), filtered, and concentrated under vacuum to afford a tacky white solid. The residue was azeotroped three times with toluene to remove residual acetic acid. The solid was collected by filtration using hexane:EtOAc 1:1 and dried to afford racemic 26, free acid form, as a white solid. Yield 85%. TLC R f 0.48 (EtOAC:AcOH 98:2). 1 H NMR (CDCl 3 ) δ1.99 (m, 1H), 2.08 (m, 1H), 2.29 (s, 3H), 2.86-2.98 (m, 2H), 4.14 (m, 1H), 5.12 (s, 2H), 7.35 (m, 5H).
[0085] Synthesis of (31). To a solution of the free racemic acid of S-acetyl-N-(carbobenzyloxy) -D,L-homocysteine 26 (1 eq.) in DCM at 0° C. was added 1-hydroxybenzotrizole hydrate (HOBt, 1.1 eq.), followed by 1-[3-(dimethylamino)propyl]-3-ethylcarbodiimide hydrochloride (EDPI, 1 eq.). The resulting suspension was stirred at 0° C. for 30 min and then a solution of glycine benzylester 30 (1 eq.) in DCM was added, followed by dropwise addition of a solution of 4-dimethylaminopyridine (DMAP, 1.2 eq.) in DCM. The resulting suspension was stirred at room temperature for 20 h. The reaction mixture was partitioned between EtOAc and 5% aqueous NaHPO 4 . The separated organic layer was then washed with 5% aqueous NaHPO 4 , satured aqueous Na 2 CO 3 , H 2 O, and brine, dried over Na 2 SO 4 , and filtered. Yhe filtrate was concentrated in vacuo, and the residu was flash chromatographed on a short silica gel column to afford the pure dipeptide 31 as a colorless oil. Yield 75%. 1 H NMR (CDCl 3 ) δ1.98 (m, 1H), 2.05-2.13 (m, 3H), 2.29 (s, 3H), 2.86 (m, 1H), 2.98 (m, 1H), 4.14 (m, 1H), 5.10-5.14 (m, 4H), 7.28-7.42 (m, 10H).
[0086] Synthesis of (32). A solution of 31 (1 eq.) and NaOAc (10 eq.) in HOAc:H 2 O 5:1 was stirred below 10° C. Gaseous chlorine was bubbled into the solution. After 10 min argon was blown through the yellow mixture for 10 min to remove excess Cl 2 and the solvent was evaporated. The residue was partitioned between EtOAc and H 2 O. The EtOAc solution was washed with brine, dried, and evaporated to the yellow oily sulfonylchloride. This product was used without further purification in the next stage. A solution of the crude sulfonylchloride (1 eq.) in CHCl 3 was stirred below 10° C. Gaseous ammoniac was bubbled into the solution. After 20 min, the mixture was stirred for 30 min, allowed to warm to room temperature, and evaporated to dryness. The residue was partitioned between EtOAc and H 2 O. The EtOAc solution was washed with brine, dried, and evaporated to a colorless oil. Yield 75%. 1 H NMR (CDCl 3 ) δ2.01 (m, 1H), 2.13 (s, 2H), 2.22-2.32 (m, 1H), 3.21-3.31 (m, 2H), 4.14 (m, 1H), 5.10-5.14 (m, 4H), 7.27-7.41 (m, 10 H).
[0087] Synthesis of (33). The benzyl ester 32 (1 eq.) was stirred for 2 h in a mixture of aqueous 1N NaOH:EtOH 1.2:3 (10 eq.). The reaction mixture was evaporated to dryness and the residue was dissolved in a small amount of H 2 O. The solution was filtered into a centrifuge tube and acidified to pH 3. The gelatinous precipitate was isolated by centrifugation, washed with CHCl 3 , and dried to a white solid. Yield 60%. MS m/z 372.3 [M-H − ] − .
[0088] Synthesis of Fmoc-Acivicin 45. 3.1 ml of a 0.75 M solution of Fmoc-N-hydroxysuccinimide in acetone was added to 0.4 g acivicin (2.25 mmol, Biomol) dissolved in 3.1 ml of a 10% Na 2 CO 3 aqueous solution. The slurry was stirring for 4 hours and the pH of was maintained at 9.0 by addition of Na 2 CO 3 . The solvent was removed by rotary evaporation, the residual solid was dissolved in 0.6 M HCL, extracted with ethyl acetate and concentrated to a yellow oil. Recrystallization from ethyl acetate: hexane yielded 0.62 9 (1.55 mmol, 70%) of the desired product as white crystals. R f (CH 2 Cl 2 : iPrOH: AcOH=100:3:1)=0.3 1 H (d 6 -acetone, 200 MHz) cpm=7.87 ArH (2H, d, J=7.4 Hz); 7.73 ArH (2H, d, J=7 Hz); 7.28-7.48 ArH (4H, m); 7.17 NH (1H, d, J=8 Hz); 5.22 CH 2 CHO (1H, m); 4.66 (1H, q, J=4.4 Hz); 4.2-4.4 (3H); 3.6-3.4 (2H). m [M-Na] + =423.4, 425.3 g/mol.
[0089] Synthesis of Pro-Gln-Pro-Aci-Leu-Pro-Tyr 46. PQPAciLPY was synthesized by standard Fmoc solid phase chemistry using Fmoc-acivicin and commercially available building blocks in a 25 μmol scale. Preparative reversed phase HPLC purification yielded 4 OD 275 (3.4 μmol, 14%). LC-MS: R t =12 min, [M+H] + =874.6.
[0090] Synthesis of Ac-Pr-Gl-Pr-DonLeu-Pr-PheNH 2 41. 72 mg (8.3 μmol) of HPLC-purified, lyophilized Ac-Pro-Gln-Pro-Glu-Leu-Pro-Phe-NH 2 in 1 ml THF and 15 μl (135μmol) N-methyl morpholine were mixed with 13 μl (100μmol) at 0° C., followed by addition of up to 0.5 mol of a saturated diazomethane solution in dry ether generated from Diazald as described by the supplier. After 1 hour the solvents were evaporated, the residual solid was extracted with ethyl ester and a 5% aqueous solution of NH 4 HCO 3 , and the combined aqueous phases were concentrated by rotary evaporation.. The crude product was purified by preparative reversed phase HPLC on a Beckman Ultrashpere C18 column (15×2.54 cm) using a 1% NH 4 HCO 3 as buffer A and 0.5% NH 4 HCO 3 , 80% acetonitrile as buffer B. The product eluting at 22.5% buffer B was concentrated yielding 16 mg (150 OD 275 ) of lyophyllized product. [M+Na] + =914.4.
[0091] Synthesis of (S)-2-Benzyloxycarbonylamino-4-suffamoyl-butyric acid ethyl ester (a) (Cbz-homocys) 2
[0092] 1.00 g (3.65 mmol) of L-homocystine (Bachem, Calif.) was dissolved in 15 ml of 1:1 (v/v) mixture of 1,4-dioxane and water, and NaOH (0.30 g, 2.0 eq) was added. To the solution cooled down to 0° C., benzyl chloroformate (1.27 ml, 2.3 eq) was added dropwise as the pH of the solution was maintained slightly basic by simultaneous addition of 1 N NaOH. After stirring for 1 hr, the solution was washed with ether, acidified with 6 N HCl and extracted with ethyl acetate. The organic layer was washed with brine and dried over Na 2 SO 4 . After filtration, the solvent was removed by evaporation and the residue was dried under vacuum to give the title compound as a white solid (1.83 g, 92%). 1 H NMR (DMSO-d 6 , 200 MHz): δ=7.59(d, 2H, J=8.0 Hz), 7.29-7.26(m, 10H), 4.96(s, 4H), 4.03-3.97(m, 2H), 2.70-2.62(m, 4H), 2.05-1.84(m, 4H) MS (ESl): m/z=536.9 [M+H] + , 559.1 [M+Na] + (b) (Cbz-homocys-OEt) 2
[0093] 1.00 g (1.86 mmol) of (Cbz-homocys) 2 was dissolved in 10 ml EtOH. To the solution cooled down to 0° C., SOCl 2 (0.33 ml, 2.4 eq) was added dropwise and the stirring was continued overnight at room temperature. The solvent was removed by evaporation and the residue was redissolved in ethyl acetate. The solution was washed with sat. NaHCO 3 solution and brine, and dried over Na 2 SO 4 . After filtration, the solvent was removed by evaporation and the residue was dried under vacuum to give the title compound as a white solid (1.10 g, quant.). 1 H NMR (CDC1 3 , 200 MHz): δ=7.30-7.27(m, 10H), 5.40(d, 2H, J=8.2 Hz), 5.04(s, 4H), 4.43-4.38(m, 2H), 4.15(q, 4H, J=7.0 Hz), 2.69-2.61(m, 4H), 2.20-1.94(m, 4H), 1.22(t, 3H, J =7.0 Hz) MS (ESl): m/z=592.9 [M+H] + , 615.2 [M+Na] + (c) (S)-2-Benzyloxycarbonylamino-4-sulfamoyl-butyric acid ethyl ester
[0094] 1.00 g (1.77 mmol) of (Cbz-homocys-OEt) 2 was dissolved in 12 ml of 2:1 (v/v) mixture of CCl 4 and EtOH. Cl 2 (g) was bubbled through the solution cooled down to 0° C. for 1 hr. Stirring was continued for 20 min at room temperature with Ar bubbling. The solvents were removed by evaporation and the residue was dried under vacuum.
[0095] This (S)-2-benzyloxycarbonylamino4-chlorosulfonyl-butyric acid ethyl ester was dissolved in 10 ml CH 2 Cl 2 and NH 3 (g) was bubbled through the solution at 0° C. for 30 min. The solvent was removed by evaporation and the residue was redissolved in ethyl acetate. The solution was washed with brine and dried over Na 2 SO 4 . After filtration, the solvent was removed by evaporation and the residue was purified by SiO 2 chromatography to give the title compound as a white solid (0.95 g, 82%). 1 H NMR (CDCl 3 , 200 MHz): δ=7.32-7.30(m, 5H), 5.49(d, 1H, J=8.4 Hz), 5.07(s, 2H), 4.71 (br, 2H), 4.50-4.45(m, 1 H), 4.18(q, 2H, J=7.2 Hz), 3.21-3.13(m, 2H), 2.42-2.14(m, 2H), 1.24(t, 3H, J=7.2 Hz) MS (ESI): m/z=367.1 [M+Na] +
[0096] Synthesis of (S)-2-Benzyloxycarbonylamino-4-hydrazinosulfonyl-butyrc acid ethyl ester (S)-2-benzyloxycarbonylamino-4-chlorosulfonyl-butyric acid ethyl ester, prepared from 0.10 g of (Cbz-homocys-OEt) 2 as above, was reacted with hydrazine monohydrate (38 μl, 2.2 eq) in 2 ml CH 2 Cl 2 for 1 hr. The solution was diluted with ethyl acetate and washed with 0.1 N HCl, sat. NaHCO 3 solution and brine. The solvents were evaporated and the residue was purified to by SiO 2 chromatography to give the title compound as clear oil (84 mg, 70%). 1 H NMR (CDCl 3 , 200 MHz): δ=7.30-7.28(m, 5H), 5.54(d, 1H, J=8.4 Hz), 5.05(s, 2H), 4.45-4.40(m, 1H), 4.16(q, 2H, J=7.0 Hz), 4.11(br, 3H), 3.24-3.08(m, 2H), 2.38-2.02(m, 2H), 1.22(t, 3H, J=7.0 Hz) MS (ESl): m/z=352.1 [M+Na] +
[0097] Synthesis of (S)-2-Benzyloxycarbonylamino-4-phenylhydrazinosulfonyl-butyric acid ethyl ester. According to the procedure described for the synthesis of (S)-2-Benzyloxycarbonylamino-4-hydrazinosulfonyl-butyric acid ethyl ester, the title compound was obtained from phenylhydrazine as slightly orange oil. 1 H NMR (CDCl 3 , 200 MHz): δ=7.29-7.15(m, 9H), 6.87(d, 2H, J=7.0 Hz), 6.09(s,1H), 5.31 (d, 1H, J=7.8 Hz), 5.02(s, 2H), 4.34-4.30(m, 1H), 4.10(q, 2H, J=7.2 Hz), 3.07-2.99(m, 2H), 2.36-2.04(m, 2H), 1.18(t, 3H, J=7.2 Hz) MS (ESl): m/z=458.0 [M+Na] +
[0098] Inhibition of tTG. tTG (9 μM) was inactivated in 200 mM MOPS, pH=7.1, 5 mM CaCl 2 , 1 mM ETDA at 30° C. containing 0-600 μM Pro-Gln-Pro-Aci-Leu-Pro-Tyr. Every 20 minutes a 40 μl aliquot was removed and residual tTG activity was assayed in 0.5 ml reaction containing 200 mM MOPS, pH=7.1, 5 mM CaCl 2 , 1 mM ETDA, 10 mM α-ketoglutarate, 180U/ml glutamate dehydrogenase (Biozyme laboratories) at 30° C. for 20 minutes by measuring the decrease of absorption at 340 nm. Residual activity was corrected by the corresponding uninhibited tTG reaction (0 μM inhibitor) and fitted to an exponential decay. Kinetic parameters were obtained by double-reciprocal plotting of the apparent second-order inactivation constant or, for sulfonamides and sulfonyl hydrazides, by fitting the data for reversible inhibitors to a standard Michaelis Menten equation with a competitive inhibition constant. The results of these inhibition experiments are shown in Tables 1, and 2 and 3 below.
TABLE 1 Kinetic parameters of catalysis and inhibition of tissue transglutaminase by reactive glutamine peptide analogs. The reactive glutamine (—X—) in the peptide substrate was substituted by the inhibitory residue acivicin (Aci) or 6-diazo-5-oxo-norleucine (DON). Reactive Gln Aci DON Motif: k cat K M k cat /K M k inh K I k inh /K I k inh K I k inh /K I Scaffold: [min −1 ] [M] [min −1 M −1 ] [min −1 ] [M] [min −1 M −1 ] [min −1 ] [M] [min −1 M −1 ] H—X—OH — >0.2 ≦2 0.015 0.087 0.17 0.025 0.13 0.2 Cbz-X— — >0.03 90 — — — 0.12 1.35 × 10 −4 890 OMe PQP—X— 28 3 × 10 −4 8.2 × 10 −4 0.014 7.8 × 10 −4 18 — — — LPY Ac—PQP— 40 4 × 10 −4 9.7 × 10 4 — — — 0.2 7 × 10 −8 2.9 × 10 6 X—LPF— NH 2
[0099]
TABLE 2
Kinetic parameters of catalysis and inhibition of
tissue transglutaminase by Sab and Z-Sab-Gly.
Compound
Sab
Z-Sab-Gly
K I [mM]
>200
8
k inh [min −1 ]
—
—
k inh /K I
—
—
[mM −1 min −1 ]
[0100]
TABLE 3
Tissue transglutaminase inhibition by
sulfonamides and sulfonyl hydrazides
tested compound
inhibition constant (M)
(S)-2-Benzyloxycarbonylamino-4-sulfamoyl-
4.4 × 10 −3
butyric acid ethyl ester
(S)-2-Benzyloxycarbonylamino-4-hydra-
2.2 × 10 −3
zinosulfonyl-butyric acid ethyl ester
(S)-2-Benzyloxycarbonylamino-4-phenyl-
1.3 × 10 −4
hydrazinosulfonyl-butyric acid ethyl ester
[0101] The above results demonstrate that the compounds tested have tTGase inhibitory activity.
[0102] All publications and patent applications cited in this specification are herein incorporated by reference as if each individual publication or patent application were specifically and individually indicated to be incorporated by reference.
[0103] The present invention has been described in terms of particular embodiments found or proposed by the present inventor 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. Moreover, due to biological functional equivalency considerations, changes can be made in protein structure without affecting the biological action in kind or amount. All such modifications are intended to be included within the scope of the appended claims. | A ministering an effective dose of a tTGase inhibitor to a Celiac or dermatitis herpetiformis patient reduces the toxic effects of toxic gluten oligopeptides, thereby attenuating or eliminating the damaging effects of gluten. | 76,789 |
[0001] This application claims benefit of Japanese Application No. 2008-108900 filed in Japan on Apr. 18, 2008 and Japanese Application No. 2008-161488 filed in Japan on Jun. 20, 2008, the contents of which are incorporated by this reference.
BACKGROUND OF THE INVENTION
[0002] The present invention relates generally to a wide-angle zoom lens including a wide-angle end having a large angle of view. Specifically, the invention relates to a wide-angle zoom lens used with electronic imaging devices such as CCDs or CMOSs. More specifically, the invention relates to a wide-angle zoom lens well suited for digital single-lens reflex cameras having a reflective surface at a back focus, and an imaging apparatus incorporating the same.
[0003] In recent years, the market for single-lens reflex cameras using electronic imaging devices such as CCDs or C-MOSs has grown steadily. However, there have not been many proposals of a superwide-angle zoom lens that has an angle of view of 100° or greater at a wide-angle end, is of small-format size and comprises fewer lenses. For instance, Patent Publications 1, 2 and 3 have come up with a superwide-angle zoom lens having an angle of view of about 102° and a zoom ratio of about 1.9, a superwide-angle zoom lens having an angle of view of about 110° and a zoom ratio of about 1.7, and a superwide-angle zoom lens having an angle of view of about 110° and a zoom ratio of about 1.5, respectively.
[0004] Patent Publication 1: JP(A)2004-21223
[0005] Patent Publication 2: JP(A)2007-94176
[0006] Patent Publication 3: JP(A)2001-166206
[0007] For the arrangement of such superwide-angle zoom lenses, it is general that there are a front lens group having negative refractive power and a rear lens group having positive refracting power. In this case, to image light beams incident at a wide range of angles within an electronic imaging device in a predetermined range, it is required to make the negative refracting power of the front group strong. Especially when it is attempted to set up the front group of negative refracting power with fewer lenses so as to reduce the size of the optical system, power loads on the respective lenses increase, rendering correction of aberrations difficult. Even when, in this case, it is intended to use aspheric surfaces to enhance the effect on aberration correction, lens configuration grows more complicated, offering problems such as difficulty of lens fabrication. For light incident on the electronic imaging device, it is desired to have telecentric capability, and it is required to make sure a certain flange back so as to insert various optical filters between the electronic imaging device and the optical system, which arises a problem that the total length of the optical system grows long. For that very reason, the diameter of lenses forming the front group having negative refracting power grows large, offering an obstacle to size reductions of the optical system.
[0008] With the superwide-angle zoom lens set forth in Patent Publication 1 (JP(A)2004-21223), superwide-angle design is achieved by using a lot of aspheric surfaces while the negative front group is simplified in construction. Because the power construction of the first lens that is an aspheric surface is not tight, however, that zoom lens is still less than satisfactory in both total length reductions and diameter reductions.
[0009] With the superwide-angle zoom lens disclosed in Patent Publication 2 (JP(A)2007-94176), the correction of aberrations necessary for superwide-angle design is implemented by applying aspheric surfaces to the negative second lens. For this reason, however, the first lens grows large, failing to achieve size reductions.
[0010] With the superwide-angle zoom lens shown in Patent Publication 3 (JP(A)2001-166206), the correction of aberrations necessary for superwide-angle design is implemented by applying aspheric surfaces to the first and second lenses having negative refracting power and incorporating a plurality of positive lens components in the first lens group. To this end, however, a lot more lenses of strong power are needed, rendering the optical system bulky. In addition, that zoom lens is generally unsatisfactory in terms of how to avoid decentration and slash cost.
[0011] Having been made with the aforesaid problems in mind, the invention has for its object the provision of a small-format, superwide-angle zoom lens that is well compatible with a lens interchangeable type single-lens reflex camera through the optimization of the construction of the first group, and an imaging apparatus incorporating the same.
SUMMARY OF THE INVENTION
[0012] According to the invention, the aforesaid object is accomplishable by the provision of a zoom lens consisting of, in order from its object side, a first lens group having negative refracting power and a second lens group having positive refracting power and designed to implement zooming by changing a distance between the lens groups upon zooming from a wide-angle end to a telephoto end, wherein said first lens group consists of, in order from its object side, a front unit having negative refracting power and a rear unit having negative refracting power, wherein said front unit consists of, in order from its object side, a first lens including a meniscus aspheric surface having negative refracting power and a second lens group including an aspheric surface having an absolute value of refracting power smaller than an absolute value of refracting power of said first lens, said rear unit consists of, in order from its object side, a third lens having negative refracting power, a fourth lens having negative refracting power and a fifth lens that is convex on its object side and has positive refracting power, and upon focusing from infinity to point-blank range, said rear unit draws near to the object side as the space between said front unit and said rear unit becomes narrow.
[0013] For single-lens reflex cameras that have to have a certain flange back, superwide-angle zooms that have a short real focal length and are of a retrofocus type negative-positive profile are frequently used so as to make sure the flange back.
[0014] The retrofocus type often relies upon the first lens group having negative refracting power, which is constructed of negative and positive units wherein the ensuing positive aberrations are corrected by negative refracting power. However, as a lens of positive refracting power is located for the correction of aberrations, negative refracting power that is in excess of that positive refracting power is needed to meet optical specifications (primarily focal length and flange back). This is not preferable for a superwide-angle lens having an angle of view greater than 100°, because of producing excessive higher-order aberrations with respect to light beams at large angles of view, and offering a large obstacle to size reductions as well. With these factored in, it is preferable to take on an arrangement comprising the front unit having negative refracting power and the rear unit having negative refracting power.
[0015] Referring here to the correction of aberrations, various aberrations in general, and coma and distortion in particular occur considerably at the first lens group having negative refracting power. These aberrations are effectively corrected by surfaces where light beams are separate; in view of optical performance, it is preferable to use an aspheric lens for the lens located on the object side. However, when it comes to a superwide-angle range having an angle of view of greater than 100°, the amount of distortion and coma produced increases to such large a degree that they cannot be corrected only by use of one aspheric lens.
[0016] Thus, at the front unit, distortion and coma in particular are corrected with the first, meniscus aspheric lens that is located on the object side and has negative refracting power, and a portion of coma that remains undercorrected with the first lens is corrected with the second lens having an absolute value of power smaller than that of the first aspheric lens.
[0017] At the rear unit, longitudinal aberrations produced at the front unit are primarily corrected. The fifth lens that is in the rear unit and has positive refractive power is only one positive lens in the first lens group, and that positive lens makes correction of positive aberrations produced not only in the rear unit but also in the first lens group.
[0018] Negative power is dispersed to the third lens having negative refracting power and the fourth lens having negative refractive power in the rear unit, thereby holding back the occurrence of aberrations in the rear unit. Note here that more lenses than that are not preferable, because of going against size reductions.
[0019] For size reductions of a superwide-angle lens, it is impeccable to keep low the position of an entrance pupil in general, and the position of an entrance pupil corresponding to a peripheral image height in particular. Although the first lens has strong negative power, it is not that preferable for the second lens group to have much stronger negative power. As already mentioned, imparting strong positive power to the second lens, too, is not preferable because there are higher-order aberrations produced, a factor for performance deterioration due to decentration.
[0020] Further, when it comes to a superwide-angle lens, strong field curvature occurs around in the positive direction upon focusing movement by letting out the first lens group. If, at this time, the space between the front unit and the rear unit is narrowed down while letting out the first lens group, it is then possible to produce field curvature in the negative direction, thereby making sure good peripheral performance even at point-blank range.
[0021] Aberrations from the aspheric surface in the front unit are corrected at so higher-order levels that aberrations from a floating mechanism due to decentration between the front unit and the rear unit are held back. Further, this mechanism enables the amount of the front unit let out to be relatively small with the result that it is possible to avoid any increase in the effective diameter of the lens in association with letting out the front unit, again contributing to size reductions.
[0022] The invention also provides an optical system consisting of, in order from its object side, a first lens group having negative refracting power and a second lens group having positive refracting power and designed to implement zooming by changing a distance between the lens groups upon zooming from a wide-angle end to a telephoto end, wherein said first lens group consists of, in order from its object side, a front unit having negative refracting power and a rear unit having negative refracting power, wherein said front unit consists of, in order from its object side, a first, meniscus aspheric lens having negative refracting power and a second, aspheric lens having an absolute value of refracting power smaller than an absolute value of refracting power of said first lens, and said rear unit consist of, in order from its object side, a third lens having negative refracting power, a fourth lens having negative refracting power and a fifth lens that is convex on its object side and has positive refracting power, with satisfaction of the following conditions (1) and (2):
[0000] −1.00 <R 01 — im /{( nd ol −1}× f 101 )}<−0.92 (1)
[0000] 0.40<( SAG 01 — im −SAG 01 — 0b )/ R 01 — im <0.48 (2)
[0000] where R 01 — im is the paraxial radius of curvature of the image side surface of said first lens,
[0023] nd 01 is the d-line refractive index of said first lens,
[0024] f 101 is the focal length of said first lens,
[0025] SAG 01 — im is the amount of sagging of the diameter of the image side surface of said first lens as a chief ray of the maximum image height passes upon focusing at infinity at the wide-angle end, and
[0026] SAG 01 — ob is the amount of sagging of the diameter of the object side surface of said first lens as a chief ray of the maximum image height passes upon focusing at infinity at the wide-angle end.
[0027] Condition (1) represents the power profile of the front and back surfaces of the first lens, indicating that the power profile of the first lens is substantially made up of the image side surface, and the object side surface is a convex one of weak power. Referring generally to a wide-angle lens, configuring the first surface into a concave shape is not preferable because there are some considerable higher-order aberrations produced. A conventionally often used shape convex on its object side may help reduce the occurrence of aberrations; however, it undermines the negative power itself of the first lens, giving rise to a diameter increase, an increase in the number of lenses involved, or an increase in the curvature on the image plane side, which may otherwise interfere with correction of aberrations.
[0028] For that reason, as the upper limit of −0.92 to condition (1) is exceeded, it causes the positive power of the first surface to grow large and the curvature of the image plane side to grow large, rendering good correction of aberrations difficult, and being short of the lower limit of −1.00 is not preferable for correction of aberrations, because there are higher-order aberrations growing large at the first surface.
[0029] More preferably, condition (1) is narrowed down to the following range.
[0000] −0.97 <R 01 — im /{( nd ol −1}× f 101 )}<−0.93 (1′)
[0030] Condition (2) is to normalize the amount of sagging of the front and back surfaces of said first lens in terms of the image-side radius of curvature. As already noted, the object side surface of the first lens has paraxially weak positive power: most of the negative power is substantially born by the image plane side. When it comes to an aspheric surface on the image plane side, that aspheric surface must function in a direction toward weakening negative power so as to correct aberrations occurring at an image height due to strong negative power. The spillover effect is that an effective diameter greater than the radius of curvature may be ensured with respect to the paraxial radius of curvature. When it comes to the amount of sagging, the ratio of the amount of sagging to the radius of curvature is going to be determined to some degrees from requirements for aberration correction and processing. When it comes to the aspheric surface on the object plane side, configuring it into shape having the amount of sagging in the direction toward the image plane is effective for correction of aberrations so as to hold back the occurrence of aberrations from incident light rays determined by superwide-angle specifications.
[0031] With these factored in, as the upper limit of 0.48 to condition (2) is exceeded, the effect of the aspheric surface on correction of aberrations is not satisfactorily achieved, rendering correction of aberrations, etc. difficult. Being short of the lower limit of 0.4 to condition (2) is not preferable, not only because the effect of that aspheric surface on correction of aberrations is hardly obtainable, but also because processing becomes much more difficult.
[0032] More preferably, condition (2) is narrowed down to the following range:
[0000] 0.40<( SAG 01 — im −SAG 01 — ob )/ R 01 — im <0.46 (2′)
[0033] Preferably, the second lens is a plastic lens. If a plastic lens is used as the second lens, mass production is then achievable at low costs. Note here that the plastic lens that is the second lens is preferably fabricated by molding.
[0034] It is also preferable to satisfy the following condition (3):
[0000] 2.95 <f 2 /f w <3.20 (3)
[0000] where f 2 is the focal length of the aforesaid second lens group, and
[0035] f w is the focal length of the whole zoom lens system at the wide-angle end.
[0036] Condition (3) is concerned with the focal length of the second lens group. As the lower limit of 2.95 to condition (3) is not reached, it is impossible to make sure any flange back, failing to obtain any function as an interchangeable lens for SLR. Being in excess of the upper limit of 3.20 to condition (3) is not preferable, because the focal length of the second lens group grows too long to interfere with size reductions of optical system.
[0037] More preferably, condition (3) is narrowed down to the range mentioned below.
[0000] 2.95 <f 2 /f w <3.10 (3′)
[0038] Further, it is preferable to satisfy the following condition:
[0000] 0.95 <|f 1 |/( f w ×f t ) 1/2 <1.10 (4)
[0000] where f 1 is the focal length of said first lens group,
[0039] f w is the focal length of the whole zoom lens system at the wide-angle end, and
[0040] f t is the focal length of the whole zoom lens system at the telephoto end.
[0041] Condition (4) is concerned with the focal length of said first lens group. Setting that focal length within the range defined by condition (4) helps maintain balances between changes in the total length of the zoom lens due to zooming movement. Being short of the lower limit of 0.95 to condition (4) is not preferable, because the total length grows long at the wide-angle end, resulting in increases in both the optical effective diameter and the total length of the zoom lens. As the upper limit of 1.10 to condition (4) is exceeded, the total length of the zoom lens grows long at the telephoto end, leading to an increase in the size of a lens barrel and rendering it difficult to make sure the focal length at the telephoto end.
[0042] More preferably, condition (4) is narrowed down to the range mentioned below.
[0000] 0.97 <|f 1 |/( f w ×f t ) 1/2 <1.05 (4′)
[0043] It is preferable that said front unit remains fixed and only the rear unit moves upon focusing. By limiting the focusing group to the rear unit, zoom lens fabrication is facilitated because of a simplified drive mechanism for focusing.
[0044] Further, it is preferable to satisfy the following condition:
[0000] −0.05 <f 101 /f 102 <0.05 (5)
[0000] where f 101 is the paraxial focal length of said first lens group, and
[0045] f 102 is the paraxial focal length of said second lens group.
[0046] Condition (5) is the ratio between the focal lengths of the first lens and the second lens. Being short of the lower limit of −0.05 to condition (5) is not preferable, because the power of the first lens grows too large for correction of higher-order aberrations, and being in excess of the upper limit of 0.05 to condition (5) is not preferable, because an entrance pupil position goes relatively far, rendering the diameter of the front lens too large for size reductions.
[0047] More preferably, condition (5) is narrowed down to the range mentioned below.
[0000] −0.03 <f 101 /f 102 <0.03 (5′)
[0048] Further, it is preferable to satisfy the following condition:
[0000] 0.31 <f 1 —G1a /f 1 —G1b <0.39 (6)
[0000] where f 1 —G1a is the combined focal length of said front unit, and
[0049] f 1 —G1b is the combined focal length of said rear unit.
[0050] Condition (6) is the ratio between the combined focal lengths of the negative front unit and the negative rear unit that form the first lens group. As the lower limit of 0.31 to condition (6) is not reached, it causes the negative power of the first lens group to be too biased in favor of the front unit, rendering aberration correction difficult. In addition, when the rear unit is allowed to function as a focusing unit, it is difficult to make sure the amount of letting out it. As the upper limit of 0.39 to condition (6) is exceeded, it causes off-axis light beams to gain height, resulting in an increase in the diameter of the front lens and rendering size reductions difficult.
[0051] More preferably, condition (6) is narrowed down to the range mentioned below.
[0000] 0.32 <f 1 —G1a /f 1 —G1b <0.36 (6′)
[0052] According to the invention as described above, it is possible to provide a wide-angle zoom lens for cameras using electronic imaging devices such as CCDs or C-MOSs, and a wide-angle zoom lens well fit for single-lens reflex cameras having a reflective surface at a back focus as well.
[0053] Still other objects and advantages of the invention will in part be obvious and will in part be apparent from the specification
[0054] The invention accordingly comprises the features of construction, combinations of elements, and arrangement of parts which will be exemplified in the construction hereinafter set forth, and the scope of the invention will be indicated in the claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0055] FIG. 1 is illustrative in lens arrangement sections of Example 1 of the inventive zoom lens at the wide-angle (a), in an intermediate setting (b) and at the telephoto end (c) upon focusing on an object at infinity.
[0056] FIG. 2 is illustrative, as in FIG. 1 , of Example 2 of the inventive zoom lens.
[0057] FIG. 3 is illustrative, as in FIG. 1 , of Example 3 of the inventive zoom lens.
[0058] FIG. 4 is illustrative, as in FIG. 1 , of Example 4 of the inventive zoom lens.
[0059] FIG. 5 is an aberration diagram for Example 1 upon focusing on an object point at infinity.
[0060] FIG. 6 is an aberration diagram for Example 1 upon focusing at 400 mm.
[0061] FIG. 7 is an aberration diagram for Example 1 upon focusing at 250 mm.
[0062] FIG. 8 is an aberration diagram for Example 2 upon focusing on an object point at infinity.
[0063] FIG. 9 is an aberration diagram for Example 2 upon focusing at 400 mm.
[0064] FIG. 10 is an aberration diagram for Example 2 upon focusing at 250 mm.
[0065] FIG. 11 is an aberration diagram for Example 3 upon focusing on an object point at infinity.
[0066] FIG. 12 is an aberration diagram for Example 3 upon focusing at 400 mm.
[0067] FIG. 13 is an aberration diagram for Example 3 upon focusing at 250 mm.
[0068] FIG. 14 is an aberration diagram for Example 4 upon focusing on an object point at infinity.
[0069] FIG. 15 is an aberration diagram for Example 4 upon focusing at 400 mm.
[0070] FIG. 16 is an aberration diagram for Example 4 upon focusing at 250 mm.
[0071] FIG. 17 is a sectional view of a single-lens reflex camera wherein the inventive zoom lens is used as an interchangeable lens.
DESCRIPTION OF EXEMPLARY EMBODIMENTS
[0072] The present invention is now explained in more details with reference to the examples shown in the accompanying drawings.
[0073] FIGS. 1 , 2 , 3 , and 4 are illustrative in lens arrangement sections of Examples 1, 2, 3, and 4 at the wide-angle end (a), in the intermediate setting (b) and at the telephoto end (c).
[0074] Throughout the drawings, the first lens group is indicated by G 1 , the second lens group by G 2 , the aperture stop by S, the front unit by Gf, the rear unit by Gr, and the image plane of a CCD or the like by I.
[0075] As shown in FIG. 1 , the zoom lens of Example 1 is made up of, in order from its object side, the first lens group G 1 of negative refracting power, the aperture stop S, and the second lens group G 2 of positive refracting power, and the first lens group is made up of, in order from its object side, the front unit Gf of negative refracting power and the rear unit Gr of negative refracting power.
[0076] Upon zooming from the wide-angle end to the telephoto end, the respective lens groups move as follows.
[0077] The first lens group G 1 moves toward the image side while the space between it and the second lens group G 2 becomes narrow from the wide-angle end to the intermediate setting, and moves toward the object side while the space between it and the second lens group G 2 becomes narrow from the intermediate setting to the telephoto end. At the telephoto end, the first lens group G 1 is positioned a little more on the image side than at the wide-angle end.
[0078] The aperture stop S and the second lens group G 2 move toward the object side while the space between them and the first lens group G 1 becomes narrow from the wide-angle end to the telephoto end.
[0079] Upon focusing from infinity to point-blank range, the rear unit Gr of the first lens group G 1 moves toward the object side while the space between it and the front unit Gf becomes narrow.
[0080] In order from the object side, the front unit Gf in the first lens group G 1 is made up of a first lens that is a negative meniscus lens convex on its object side and a second lens that is a negative meniscus lens convex on its object side, and the rear unit Gr in the first lens group G 1 is made up of a third lens that is a plano-concave lens concave on its image side, a third lens that is a plano-concave lens, a fourth lens that is a double-concave negative lens and a fifth lens that is a double-convex positive lens.
[0081] The second lens group G 2 is made up of a cemented lens of a double-convex positive lens and a double-concave negative lens, a cemented lens of a double-convex positive lens, a double-concave negative lens and a double-convex positive lens, a cemented lens of a double-convex positive lens and a double-concave negative lens, and a double-convex positive lens.
[0082] Six aspheric surfaces are used: two at both surfaces of the first lens and two at both surfaces of the second lens in the front unit Gf in the first lens group G 1 , and two at both surfaces of the double-convex positive lens in the second lens group G 2 .
[0083] As shown in FIG. 2 , the zoom lens of Example 2 is made up of, in order from its object side, the first lens group G 1 of negative refracting power, the aperture stop S, and the second lens group G 2 of positive refracting power, and the first lens group is made up of, in order from its object side, the front unit Gf of negative refracting power and the rear unit Gr of negative refracting power.
[0084] Upon zooming from the wide-angle end to the telephoto end, the respective lens groups move as follows.
[0085] The first lens group G 1 moves toward the image side while the space between it and the second lens group G 2 becomes narrow from the wide-angle end to the intermediate setting, and moves toward the object side while the space between it and the second lens group G 2 becomes narrow from the intermediate setting to the telephoto end. At the telephoto end, the first lens group G 1 is positioned a little more on the image side than at the wide-angle end.
[0086] The aperture stop S and the second lens group G 2 move toward the object side while the space between them and the first lens group G 1 becomes narrow from the wide-angle end to the telephoto end.
[0087] Upon focusing from infinity to point-blank range, the rear unit Gr in the first lens group G 1 moves toward the object side while the space between it and the front unit Gf becomes narrow.
[0088] In order from the object side, the front unit Gf in the first lens group G 1 is made up of a first lens that is a negative meniscus lens convex on its object side and a second lens that is a negative meniscus lens convex on its object side, and the rear unit Gr in the first lens group G 1 is made up of a third lens that is a plano-concave lens concave on its image side, a fourth lens that is a double-concave negative lens and a fifth lens that is a double-convex positive lens.
[0089] The second lens group G 2 is made up of a cemented lens of a double-convex positive lens and a double-concave negative lens, a cemented lens of a double-convex positive lens, a double-concave negative lens and a double-convex positive lens, a cemented lens of a double-convex positive lens and a double-concave negative lens, and a double-convex positive lens.
[0090] Six aspheric surfaces are used: two at both surfaces of the first lens and two at both surfaces of the second lens in the front unit Gf in the first lens group G 1 , and two at both surfaces of the double-convex positive lens in the second lens group G 2 .
[0091] As shown in FIG. 3 , the zoom lens of Example 3 is made up of, in order from its object side, the first lens group G 1 of negative refracting power, the aperture stop S, and the second lens group G 2 of positive refracting power, and the first lens group is made up of, in order from its object side, the front unit Gf of negative refracting power and the rear unit Gr of negative refracting power.
[0092] Upon zooming from the wide-angle end to the telephoto end, the respective lens groups move as follows.
[0093] The first lens group G 1 moves toward the image side while the space between it and the second lens group G 2 becomes narrow from the wide-angle end to the intermediate setting, and moves toward the object side while the space between it and the second lens group G 2 becomes narrow from the intermediate setting to the telephoto end. At the telephoto end, the first lens group G 1 is positioned a little more on the image side than at the wide-angle end.
[0094] The aperture stop S and the second lens group G 2 move toward the object side while the space between them and the first lens group G 1 becomes narrow from the wide-angle end to the telephoto end.
[0095] Upon focusing from infinity to point-blank range, the rear unit Gr of the first lens group G 1 moves toward the object side while the space between it and the front unit Gf becomes narrow.
[0096] In order from the object side, the front unit Gf in the first lens group G 1 is made up of a first lens that is a negative meniscus lens convex on its object side and a second lens that is a negative meniscus lens convex on its object side, and the rear unit Gr in the first lens group G 1 is made up of a third lens that is a negative meniscus lens convex on its object side, a fourth lens that is a double-concave negative lens and a fifth lens that is a double-convex positive lens.
[0097] The second lens group G 2 is made up of a cemented lens of a double-convex positive lens and a double-concave negative lens, a cemented lens of a double-convex positive lens, a double-concave negative lens and a double-convex positive lens, a double-convex positive lens, and a cemented lens of a double-concave negative lens and a double-convex positive lens.
[0098] Six aspheric surfaces are used: two at both surfaces of the first lens and two at both surfaces of the second lens in the front unit Gf in the first lens group G 1 , and two at both surfaces of the double-convex positive lens in the second lens group G 2 .
[0099] As shown in FIG. 4 , the zoom lens of Example 4 is made up of, in order from its object side, the first lens group G 1 of negative refracting power, the aperture stop S, and the second lens group G 2 of positive refracting power, and the first lens group is made up of, in order from its object side, the front unit Gf of negative refracting power and the rear unit Gr of negative refracting power.
[0100] Upon zooming from the wide-angle end to the telephoto end, the respective lens groups move as follows.
[0101] The first lens group G 1 moves toward the image side while-the space between it and the second lens group G 2 becomes narrow from the wide-angle end to the intermediate setting, and moves toward the object side while the space between it and the second lens group G 2 becomes narrow from the intermediate setting to the telephoto end. At the telephoto end, the first lens group Gt is positioned a little more on the image side than at the wide-angle end.
[0102] The aperture stop S and the second lens group G 2 move toward the object side while the space between them and the first lens group G 1 becomes narrow from the wide-angle end to the telephoto end.
[0103] Upon focusing from infinity to point-blank range, the rear unit Gr in the first lens group G 1 moves toward the object side while the space between it and the front unit Gf becomes narrow.
[0104] In order from the object side, the front unit Gf in the first lens group G 1 is made up of a first lens that is a negative meniscus lens convex on its object side and a second lens that is a negative meniscus lens convex on its object side, and the rear unit Gr in the first lens group G 1 is made up of a third lens that is a negative meniscus lens concave on its image side, a fourth lens that is a double-concave negative lens and a fifth lens that is a double-convex positive lens.
[0105] The second lens group G 2 is made up of a cemented lens of a double-convex positive lens and a double-concave negative lens, a cemented lens of a double-convex positive lens, a double-concave negative lens and a double-convex positive lens, a cemented lens of a double-convex positive lens and a double-concave negative lens, and a double-convex positive lens.
[0106] Six aspheric surfaces are used: two at both surfaces of the first lens and two at both surfaces of the second lens in the front unit Gf in the first lens group G 1 , and two at both surfaces of the double-convex positive lens in the second lens group G 2 .
[0107] Set out below are numerical data on the lenses in each examples.
[0108] Referring here to the numerical data on the lenses in each example, r is the radius of curvature of each lens surface, d is the thickness or spacing of each lens, nd is the d-line refractive index of each lens, vd is the d-line Abbe constant of each lens, K is the conic coefficient, A4, A6, A8, A10 and A12 are the aspheric coefficients, and E±N is ×10 ±N , with DO indicative of a spacing from the subject to the first surface.
[0109] Using each respective aspheric coefficient in each example, each aspheric configuration is given by the following equation:
[0000] Z =( Y 2 /r )/[1+{1−(1+ K )·( Y/r ) 2 } 1/2 ]+A 4 ×Y 4 +A 6 ×Y 6 +A 8 ×Y 8 +A 10 ×Y 10 +A 12 ×Y 12
[0000] where Z is the coordinates in the optical axis direction, and Y is the coordinates in the direction vertical to the optical axis.
[0110] The values of the conditions in each embodiment are the ones measured upon focusing on an object point at infinity. Full length is the on-axis distance from the entrance surface to the exit surface of the lens arrangement plus back focus, and the back focus is given on an air basis.
[0000]
Numerical Example 1
Unit mm
Surface data
Surface number
r
d
nd
νd
1(Aspheric)
232.63
3.20
1.58250
59.30
2(Aspheric)
11.38
11.00
3(Aspheric)
122.76
3.00
1.52540
55.80
4(Aspheric)
110.50
Variable
5
∞
1.30
1.60310
60.60
6
21.000
3.10
7
−63.640
1.20
1.58910
61.10
8
49.090
0.20
9
23.920
3.40
1.68890
31.10
10
−259.960
Variable
11(Stop)
∞
0.70
12
16.480
3.60
1.60340
38.00
13
−21.160
1.00
1.48750
70.20
14
257.160
0.40
15
27.350
2.70
1.48750
70.20
16
−20.760
1.20
1.88300
40.80
17
12.960
3.40
1.48750
70.20
18
−32.220
0.20
19
55.470
4.30
1.48750
70.20
20
−10.170
1.20
1.78590
44.20
21
68.620
0.30
22(Aspheric)
49.37
7.40
1.49640
81.50
23(Aspheric)
−12.38
Variable
Image plane
∞
Aspheric data
1st Surface
K = −22.852, A4 = 1.716E−05, A6 = −1.469E−07, A8 = 1.008E−12,
A10 = 3.616E−14, A12 = −3.740E−17
2nd Surface
K = −1.295, A4 = 9.699E−06, A6 = 1.551E−07, A8 = −7.650E−10,
A10 = 1.535E−12, A12 = −7.121E−15
3rd Surface
K = 0.000, A4 = −6.960E−05, A6 = 9.700E−08, A8 = 1.970E−09,
A10 = −7.310E−12, A12 = 8.152E−16
4th Surface
K = 0.000, A4 = 8.708E−06, A6 = 1.585E−07, A8 = 4.540E−09,
A10 = −2.818E−11, A12 = 1.659E−13
22th Surface
K = −7.984, A4 = −1.576E−05, A6 = 1.166E−07, A8 = 3.220E−09,
A10 = −2.190E−11, A12 = 0.000E−00
23th Surface
K = −0.182, A4 = 2.108E−05, A6 = 9.429E−08, A8 = −3.360E−10,
A10 = 1.709E−11, A12 = 0.000E−00
Various data
wide-angle
intermediate
telephoto
Focal length
9.165
12.709
17.655
F-number
4.14
4.82
5.71
Angle of view
102.70
82.90
64.60
Image height
11.15
11.15
11.15
Full lens length
112.62
109.62
112.56
(Upon focusing at infinity)
D0
∞
∞
∞
D4
5.07
5.07
5.07
D10
21.18
10.53
2.81
D23
33.56
41.21
51.87
(IO: Upon focusing at 400 mm)
D0
287.64
290.66
287.70
D4
3.71
3.71
3.71
D10
22.28
11.62
3.91
D23
33.56
41.21
51.87
(IO: Upon focusing at 250 mm)
D0
137.78
140.81
137.84
D4
2.53
2.53
2.53
D10
23.32
12.65
4.95
D23
33.56
41.21
51.87
Data on zoom lens group
Group
Start surface
Focal length
1
1
−12.483
2
12
27.483
Numerical Example 2
Unit mm
Surface data
Surface number
r
d
nd
νd
1(Aspheric)
254.51
3.20
1.58310
59.40
2(Aspheric)
11.31
11.00
3(Aspheric)
102.36
3.00
1.52540
55.80
4(Aspheric)
137.21
Variable
5
∞
1.30
1.60310
60.60
6
19.940
3.30
7
−67.950
1.20
1.60310
60.60
8
51.370
0.10
9
23.520
3.50
1.68890
31.10
10
−318.080
Variable
11(Stop)
∞
0.70
12
16.250
3.30
1.60340
38.00
13
−20.740
1.00
1.48750
70.20
14
235.140
0.40
15
26.130
2.80
1.48750
70.20
16
−20.500
1.20
1.88300
40.80
17
12.410
3.50
1.48750
70.20
18
−33.250
0.20
19
56.070
4.30
1.48750
70.20
20
−10.220
1.20
1.78590
44.20
21
66.600
0.30
22(Aspheric)
51.13
7.30
1.49700
81.50
23(Aspheric)
−12.25
Variable
Image plane
∞
Aspheric data
1st Surface
K = 0.000, A4 = 1.365E−05, A6 = −1.136E−08, A8 = 3.949E−12,
A10 = 1.589E−14, A12 = −1.508E−17
2nd Surface
K = −1.320, A4 = 9.964E−06, A6 = 5.843E−08, A8 = −7.707E−12,
A10 = −1.816E−12, A12 = 0.000E−00
3rd Surface
K = 0.000, A4 = −5.678E−05, A6 = 1.656E−07, A8 = 7.063E−10,
A10 = −3.993E−12, A12 = 0.000E−00
4th Surface
K = 0.000, A4 = 1.859E−05, A6 = 2.852E−07, A8 = 6.979E−10,
A10 = 6.880E−12, A12 = 0.000E−00
22th Surface
K = −5.090, A4 = −2.372E−05, A6 = 1.382E−07, A8 = 1.285E−09,
A10 = −8.015E−12, A12 = 0.000E−00
23th Surface
K = −0.450, A4 = 1.176E−06, A6 = 7.896E−10, A8 = −9.559E−10,
A10 = 9.801E−12, A12 = 0.000E−00
Various data
wide-angle
intermediate
telephoto
Focal length
9.151
12.712
17.662
F-number
4.08
4.82
5.72
Angle of view
102.80
83.00
64.60
Image height
11.15
11.15
11.15
Full lens length
112.69
109.46
112.23
(Upon focusing at infinity)
D0
∞
∞
∞
D4
5.05
5.05
5.05
D10
21.44
10.60
2.80
D23
33.53
41.14
51.72
(IO: Upon focusing at 400 mm)
D0
287.58
290.82
288.04
D4
3.73
3.73
3.73
D10
22.50
11.65
3.85
D23
33.53
41.14
51.72
(IO: Upon focusing at 250 mm)
D0
137.71
140.96
138.16
D4
2.61
2.61
2.61
D10
23.49
12.63
4.85
D23
33.53
41.14
51.72
Data on zoom lens group
Group
Start surface
Focal length
1
1
−12.871
2
12
27.502
Numerical Example 3
Unit mm
Surface data
Surface number
r
d
nd
νd
1(Aspheric)
266.41
3.20
1.58310
59.40
2(Aspheric)
11.68
11.20
3(Aspheric)
110.34
3.00
1.52540
55.80
4(Aspheric)
100.84
Variable
5
317.850
1.20
1.60310
60.60
6
19.560
2.90
7
−47.750
1.10
1.60310
60.60
8
37.850
0.20
9
21.880
4.50
1.63980
34.50
10
−68.080
Variable
11(Stop)
∞
1.20
12
17.270
3.30
1.57500
41.50
13
−18.410
2.00
1.48750
70.20
14
428.680
0.80
15
24.830
3.70
1.51630
64.10
16
−14.630
1.20
1.88300
40.80
17
11.310
3.40
1.48750
70.20
18
−158.960
0.20
19(Aspheric)
34.27
4.30
1.49640
81.50
20(Aspheric)
−16.14
0.40
21
−21.070
1.00
1.81600
46.60
22
47.870
5.70
1.48750
70.20
23
−12.510
Variable
Image plane
∞
Aspheric data
1st Surface
K = 92.742, A4 = 9.961E−06, A6 = −4.189E−09, A8 = 1.708E−12,
A10 = 3.195E−15, A12 = −8.084E−18
2nd Surface
K = −1.312, A4 = −2.870E−07, A6 = 1.001E−08, A8 = −3.825E−11,
A10 = 2.327E−13, A12 = −3.265E−15
3rd Surface
K = 0.000, A4 = −8.405E−05, A6 = 4.895E−07, A8 = −4.181E−11,
A10 = −4.410E−12, A12 = 0.000E−00
4th Surface
K = 0.000, A4 = −5.250E−08, A6 = 8.808E−07, A8 = 2.746E−09,
A10 = 2.641E−11, A12 = 0.000E−00
19th Surface
K = 0.000, A4 = 4.839E−06, A6 = 8.160E−08, A8 = 2.152E−09,
A10 = −5.264E−11, A12 = 0.000E−00
20th Surface
K = 0.000, A4 = 8.345E−05, A6 = 1.723E−08, A8 = 2.143E−09,
A10 = −6.931E−11, A12 = 0.000E−00
Various data
wide-angle
intermediate
telephoto
Focal length
9.170
12.750
17.720
F-number
4.07
4.82
5.71
Angle of view
102.80
83.20
64.70
Image height
11.15
11.15
11.15
Full lens length
114.61
110.66
112.88
(Upon focusing at infinity)
D0
∞
∞
∞
D4
4.55
4.55
4.55
D10
21.99
10.51
2.26
D23
33.57
41.10
51.57
(IO: Upon focusing at 400 mm)
D0
285.39
289.34
287.12
D4
3.51
3.52
3.52
D10
22.28
11.62
3.91
D23
33.56
41.21
51.87
(IO: Upon focusing at 250 mm)
D0
135.39
139.34
137.12
D4
2.42
2.48
2.45
D10
24.12
12.58
4.46
D23
33.57
41.10
51.57
Data on zoom lens group
Group
Start surface
Focal length
1
1
−13.345
2
12
28.099
Numerical Example 4
Unit mm
Surface data
Surface number
r
d
nd
νd
1(Aspheric)
325.73
3.20
1.58300
59.40
2(Aspheric)
11.63
10.90
3(Aspheric)
140.43
2.80
1.52540
55.80
4(Aspheric)
97.75
Variable
5
∞
1.30
1.61800
63.30
6
20.280
3.40
7
−70.550
1.20
1.61800
63.30
8
50.380
0.20
9
23.560
3.60
1.69900
30.10
10
−277.890
Variable
11(Stop)
∞
0.50
12
16.680
3.50
1.60340
38.00
13
−20.930
1.20
1.48750
70.20
14
239.150
0.40
15
26.910
2.70
1.48750
70.20
16
−19.280
1.20
1.88300
40.80
17
12.770
3.40
1.48750
70.20
18
−32.900
0.20
19
53.800
4.40
1.48750
70.20
20
−10.060
1.00
1.78590
44.20
21
65.760
0.40
22(Aspheric)
47.73
6.90
1.49640
81.50
23(Aspheric)
−11.64
Variable
Image plane
∞
Aspheric data
1st Surface
K = −22.229, A4 = 7.172E−06, A6 = −2.218E−09, A8 = 5.137E−12,
A10 = 6.362E−16, A12 = −4.101E−18
2nd Surface
K = −1.514, A4 = 2.495E−08, A6 = −3.004E−13, A8 = −7.721E−10,
A10 = 3.694E−12, A12 = −5.539E−15
3rd Surface
K = −2.521, A4 = −3.026E−05, A6 = 1.304E−07, A8 = 9.276E−11,
A10 = −1.120E−12, A12 = 0.000E−00
4th Surface
K = 72.860, A4 = 4.864E−05, A6 = 3.437E−07, A8 = 4.110E−21,
A10 = 7.213E−12, A12 = 0.000E−00
22th Surface
K = −16.668, A4 = −9.744E−06, A6 = 1.934E−08, A8 = 4.733E−09,
A10 = −3.792E−11, A12 = 0.000E−00
23th Surface
K = −0.461, A4 = 3.035E−06, A6 = −2.859E−08, A8 = −4.364E−10,
A10 = 1.102E−11, A12 = 0.000E−00
Various data
wide-angle
intermediate
telephoto
Focal length
8.660
12.010
16.690
F-number
4.07
4.82
5.71
Angle of view
105.92
85.36
67.51
Image height
11.15
11.15
11.15
Full lens length
119.98
108.58
111.06
(Upon focusing at infinity)
D0
∞
∞
∞
D4
5.66
5.66
5.66
D10
20.77
10.00
2.20
D23
33.48
40.85
51.13
(IO: Upon focusing at 400 mm)
D0
288.29
291.70
289.21
D4
4.35
4.35
4.35
D10
21.81
11.03
3.24
D23
33.48
40.85
51.13
(IO: Upon focusing at 250 mm)
D0
138.42
141.85
139.35
D4
3.24
3.24
3.24
D10
22.79
11.99
4.21
D23
33.48
40.85
51.13
Data on zoom lens group
Group
Start surface
Focal length
1
1
−12.335
2
12
27.125
[0111] FIGS. 5 , 6 and 7 are aberration diagrams for Example 1 upon focusing on an object point at infinity, at 400 mm and 250 mm. In these aberration diagrams, (a), (b) and (c) are indicative of spherical aberrations, astigmatisms, distortion and chromatic aberrations of magnification at the wide-angle end, in the intermediate setting and at the telephoto end, respectively. Likewise, FIGS. 8 , 9 and 10 are aberration diagrams for Example 2 upon focusing on an object point at infinity, at 400 mm and 250 mm; FIGS. 11 , 12 and 13 are aberration diagrams for Example 3 upon focusing on an object point at infinity, at 400 mm and 250 mm; and FIGS. 14 , 15 and 16 are aberration diagrams for Example 4 upon focusing on an object point at infinity, at 400 mm and 250 mm.
[0112] Tabulated below are the values of conditions (1) to (6) in each of the above examples.
[0000]
Cond.
Example 1
Example 2
Example 3
Example 4
(1)
−0.946
−0.951
−0.952
−0.961
(2)
0.418
0.455
0.430
0.446
(3)
2.998
3.005
3.064
3.131
(4)
1.001
1.012
1.046
1.026
(5)
0.0090
−0.027
0.0084
0.0331
(6)
0.337
0.370
0.332
0.337
[0113] Each example may be modified or varied as follows.
[0114] To cut off unessential light such as ghosts and flares, it is acceptable to rely on a flare stop other than the aperture stop. That flare stop may then be located somewhere on the object side of the first lens group, between the first and the second lens group, and between the lens group located nearest to the image plane side and the image plane. A frame member or other member may also be located to cut off flare rays. For that purpose, the optical system may be directly printed, coated or sealed in any desired shape inclusive of round, oval, rectangular, polygonal shapes or a shape delimited by a function curve. Further, just only a harmful light beam but also coma flares around the screen, etc. may be cut off.
[0115] Only the upper or the lower limit of the respective conditions may be varied as already noted.
[0116] FIG. 16 is a sectional view of the single-lens reflex camera that operates as an electronic imaging apparatus wherein the inventive zoom is used and a small-format CCD or C-MOS or the like is used as the imaging device. In FIG. 16 , reference numeral 1 is the single-lens reflex camera, 2 the imaging lens system mounted in a lens barrel having zooming and focusing mechanisms, and 3 a mount portion of the lens barrel that enables the imaging lens system 2 to be attached to or detached from the single-lens reflex camera 1 . For that mount, a screw type mount, a bayonet type mount or the like may be used. In this example, the bayonet type mount is used.
[0117] Reference numeral 4 is the imaging device plane, 5 is a quick return mirror interposed between the lens system and the imaging device plane 4 on an optical path 6 through the imaging lens system 2 , 7 a finder screen located in an optical path taken by light reflected off the quick return mirror 5 , 8 a penta prism, 9 a finder, and E the eye of the viewer (eye point).
[0118] The inventive zoom lens exemplified by Example 1, 2, 3, and 4, for instance, may be used as the imaging lens system 2 of the single-lens reflex camera 1 arranged as mentioned above.
[0119] According to the invention as described above, it is possible to achieve a zoom lens that is used as an interchangeable lens fit for a single-lens reflex type digital camera, and makes sure brightness with reduced fluctuations during or upon zooming. It is then possible to achieve a zoom lens that easily makes sure the angle of view and zoom ratio at the wide-angle end even in bright environments. | A zoom lens consists of, in order from its object side,
a first lens group of negative refracting power, and a second lens group of positive refractive power wherein zooming from a wide-angle end to a telephoto end is implemented by changing a distance between the respective lens groups.
The first lens group consists of, in order from its object side,
a front unit of negative refracting power, and a rear unit of negative refracting power.
The front unit consists of, in order from its object side,
a first lens that has negative refracting power and meniscus shape, and includes an aspheric surface, and a second lens that is smaller than the first lens in terms of an absolute value of refracting power, and includes an aspheric surface.
The rear unit consists of, in order from its object side,
a third lens of negative refracting power, a fourth lens of negative refracting power, and a fifth lens that has positive refracting power and is convex on its object side, and upon zooming from infinity to point-blank range, the rear unit moves in such a way as to draw nearer to the object side as the space between the front unit and the rear unit becomes narrow. | 86,359 |
BACKGROUND OF THE INVENTION
[0001] 1. The Field of the Invention
[0002] This invention relates to carbonated compositions for cleaning textile fibers. More particularly this invention relates to carbonated compositions containing carbonate salt and an acid with a low solubility for delaying the production of carbon dioxide.
[0003] 2. The Relevant Art
[0004] There are innumerable cleaning compositions for cleaning textile fibers such as carpets, upholstery, drapery, and the like. Each type of cleaning composition is formulated to loosen and disperse the soil from the textile fibers either physically or by chemical reaction. The soil can then be solubilized or suspended in such a manner that it can be removed from the fibers being cleaned.
[0005] Most of these cleaningcompositions are based on soaps or detergents, both of which are generically referred to as “surfactants”. By “detergent” is meant a synthetic amphipathic molecule having a large non-polar hydrocarbon end that is oil-soluble and a polar end that is water soluble. “Soap” is also an amphipathic molecule made up of an alkali salt, or mixture of salts, of long-chain fatty acids wherein the acid end is polar or hydrophilic and the fatty acid chain is non-polar or hydrophobic. Detergents are further classified as non-ionic, anionic, or cationic. Anionic or nonionic detergents are the most common.
[0006] These surfactants function because the hydrophobic ends of the molecules coat or adhere to the surface of soils and oils and the water soluble hydrophilic (polar) ends are soluble in water and help to solubilize or disperse the soils and oils in an aqueous environment.
[0007] There are several problems associated with the use of surfactants for cleaning fibers, such as carpeting and upholstery. First, large amounts of water are generally required to remove the surfactants and suspended or dissolved particles. This leads to long drying times and susceptibility to mildew. Second, surfactants generally leave an oily hydrophobic coating on the fiber surface. The inherent oily nature of the hydrophobic end of the surfactants causes premature resoiling even when the surfaces have a surfactant coating which is only a molecule thick. Third, surfactants can sometimes cause irritation or allergic reactions in people who are sensitive to these chemicals. Fourth, several environmental problems are associated with the use of soaps and detergents; some are non-biodegradable and some contain excessive amounts of phosphates, which are also environmentally undesirable.
[0008] In an attempt to solve at least some of these problems, numerous cleaning compositions have been developed. A significant improvement in the art of cleaning textile fibers, and carpets and upholstery teaches that when detergent solutions are carbonated and applied to the fibers, the solution rapidly penetrates the fibers and, through the effervescent action of the carbonation, quickly lifts the suspended soil and oil particles to the surface of the fiber from which they can be removed by vacuuming or transfer to an absorptive surface. Moreover, effervescent action requires less soap or other surfactant applied to the fibers. Because less soap or other surfactant is needed, less water is needed to affect the cleaning, and therefore, the fibers dry more rapidly than do fibers treated with conventional steam cleaning or washing applications, and little residue is left on the fibers. This results in less resoiling due to the reduced residue and a decreased likelihood of brown out because of the more rapid drying of the fibers. Although this effervescent action process is clearly advantageous over prior art methods, it still requires the use of some surfactant and, in some instances, added phosphates, which are undesirable in today's environmentally conscious society.
[0009] Generally, carbon dioxide, and thus the carbonation, is created by mixing a powdered carbonate with an acid. Because gases, including carbon dioxide, are much less soluble in hot water than cold water, it has generally been advised to mix the cleaning solution (the powdered product, which is powdered carbonate and powdered acid) in cold water to help preserve higher levels of carbonation in the cleaning solution. It is between the mixing of the powdered product with water, and before the container containing the mixture is capped, that some of the carbon dioxide is released and lost into the surrounding atmosphere. If hot water is used to make the cleaning solution, an even greater amount of carbon dioxide can escape before the lid is secured. On the other hand, cleaning solutions generally clean more effectively when they are at elevated temperatures.
[0010] Accordingly systems have been created, which hold the acid and carbonate salt in separate reservoirs and individually heat the solutions before being combined into a third container, or before being sprayed onto the textile. The result is a complex and expensive system requiring numerous reservoirs, valves, nozzles, hoses, solutions, etc.
[0011] Thus, it can be clearly recognized that there is a need for a cleaning composition formulated in a single reservoir with hot water, carbonate salt, and an acid with low solubility, which produces a delayed high level of carbonation for an extended period of time.
SUMMARY OF THE INVENTION
[0012] The various elements of the present invention have been developed in response to the present state of the art, and in particular, in response to the problems and needs in the art that have not yet been fully solved by currently available cleaning compositions. Accordingly, the present invention provides an improved internally carbonated cleaning solution using an acid with low water solubility.
[0013] More particularly, the present invention relates to an internally carbonated aqueous cleaning composition for textiles comprising about 20 to 60%, in percent by weight, of at least one carbonate salt, about 20 to 60%, in percent by weight, of at least one acid, the acid having a solubility less than two grams per 100 grams of water at about twenty five degrees Celsius. An aqueous medium is added to the carbonate salt and the acid to produce carbon dioxide.
[0014] In another embodiment, the composition comprises about 40 to 60% of the acid and about 35 to 50% of the carbonate salt.
[0015] In one embodiment, the solid acid is either fumaric acid or adipic acid.
[0016] In another embodiment, the carbonate salt is selected from the group consisting of sodium carbonate, sodium percarbonate, sodium bicarbonate, lithium carbonate, lithium percarbonate, lithium bicarbonate, potassium carbonate, potassium percarbonate, potassium bicarbonate, ammonium carbonate, sodium sesquicarbonate, potassium sesquicarbonate, lithium sesquicarbonate, and ammonium sesquicarbonate, and ammonium bicarbonate, or any other effective carbonate salt.
[0017] In another embodiment, the aqueous medium is added to the carbonate salt and the acid at a temperature above thirty two degrees Celsius.
[0018] In another embodiment, when the composition is mixed with the aqueous medium to form a solution, the composition concentration resulting from the carbonate salt and acid in the solution is between about 0.5 to 3%.
[0019] In another embodiment, the present invention relates to a method of cleaning textile fibers comprising the steps of applying to the fibers, an internally-carbonating cleaning composition, the composition being prepared by admixing 20 to 60%, in percent by weight, a carbonate salt and 20 to 60%, in percent by weight, an acid with a solubility less than two grams per 100 grams of water at twenty five degrees Celsius, and wherein when the carbonate salt and the acid are mixed in an aqueous medium, the carbonate salt and acid react to produce carbon dioxide.
[0020] Additional features and advantages of the present invention will become more fully apparent from the following description and appended claims, or may be learned by the practice of the invention as set forth hereinafter.
BRIEF DESCRIPTION OF THE DRAWINGS
[0021] In order that the advantages of the invention will be readily understood, a more particular description of the invention briefly described above will be rendered by reference to specific embodiments that are illustrated in the appended drawings. Understanding that these drawings depict only typical embodiments of the invention and are not therefore to be considered to be limiting of its scope, the invention will be described and explained with additional specificity and detail through the use of the accompanying drawings, in which:
[0022] FIG. 1 illustrates a comparison graph showing the response of carbon dioxide production versus time for fumaric and citric acid; and
[0023] FIG. 2 illustrates a comparison graph showing the response of carbon dioxide production versus time for fumaric and tartaric acid.
DETAILED DESCRIPTION OF THE INVENTION
[0024] Reference throughout this specification to “one embodiment,” “an embodiment,” or similar language means that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment of the present invention. Thus, appearances of the phrases “in one embodiment,” “in an embodiment,” and similar language throughout this specification may, but do not necessarily, all refer to the same embodiment.
[0025] Furthermore, the described features, structures, or characteristics of the invention may be combined in any suitable manner in one or more embodiments. One skilled in the relevant art will recognize, however, that the invention can be practiced without one or more of the specific details, or with other methods, components, materials, and so forth. In other instances, well-known structures, materials, or operations are not shown or described in detail to avoid obscuring aspects of the invention.
[0026] In a first embodiment, a solid acid and carbonate salt are prepared and admixed in a single container and then diluted with a desired amount of water. The carbonate salt may be any one of, or a combination of the group consisting of sodium carbonate, sodium percarbonate, sodium bicarbonate, lithium carbonate, lithium percarbonate, lithium bicarbonate, potassium carbonate, potassium percarbonate, potassium bicarbonate, ammonium carbonate, sodium sesquicarbonate, potassium sesquicarbonate, lithium sesquicarbonate, and ammonium sesquicarbonate, and ammonium bicarbonate, or any other effective carbonate salt. The solid acid, preferably, has a low solubility, with a maximum solubility of approximately two grams of acid per one hundred grams of water at twenty five degrees Celsius. Examples of solid acids with low solubility include Fumaric acid, with a solubility of 0.63 grams per one hundred grams of water at twenty five degrees Celsius, and Adipic acid, with a solubility of about 1.44 grams per one hundred grams of water at twenty five degrees Celsius. Other solid acids with low solubility will also work.
[0027] The solid acids and carbonate salts are mixed or ground together to form a solid mixture. The solid mixture contains from about 20% to 60% carbonate salts and about 20% to 60% of a natural solid acid with a low solubility. The most preferable mixture contains 35% to 50% carbonate salt and 40% to 60% acid.
[0028] Additionally, in a preferred embodiment, the water temperature exceeds forty eight degrees Celsius. However, it is recognized that the water temperature may be as low as room temperature. Preferably, the temperature is not below thirty two degrees Celsius as the time for the acid to mix with the water may be excessively long. When the water is added to the solid mixture of acid and carbonate salt, the ingredients react to form the carbon dioxide, which creates effervescent bubbles.
[0029] The solution is preferably applied to the textiles as a spray; however, other known methods of applying the solution may be used. When sprayed, for example, through a wand from a pressurized container, the pressure is released when the solution is exposed to the atmosphere, and the carbonated cleaning solution breaks into a myriad of tiny effervescent bubbles.
[0030] The combined carbonation action and the cleaning solution results in a low water volume. Specifically, the soils or oil on the fibers being cleaned are surrounded by a complex of carbon dioxide bubbles and polar and non-polar ended molecules that bind with and suspend the soil. The cleaning solution then can be lifted from the fibers into the surrounding carbonating aqueous environment. By “aqueous” it is meant that there is a certain amount of water, but that does not suggest that copious amounts of water are present. In fact, it has been found that only a slight dampening of the fiber may be sufficient to promote the lifting action of the effervescent carbonated solution to loosen or dislodge the soil or oil particles from the fiber. Additionally, it has been found that the active salts, created by the carbonate/bicarbonate mix, and carbon dioxide interactive substance or complex, hold the soil particles in suspension for a time sufficient for them to be removed from the fiber by means of vacuuming or adsorption onto a textile pad, toweling or similar adsorbent material.
[0031] Typically, the acid, carbonate salt, and water ingredients are mixed in a single container. Advantageously, because the acid has a low solubility, the creation of carbonation is delayed longer than high solubility acids. This delayed carbonation provides the user with sufficient time to mix the ingredients together and seal the container before any considerable amount of the carbonation is lost to the atmosphere.
[0032] FIG. 1 illustrates a comparison graph showing the response time of carbon dioxide production for fumaric and citric acid. To quantify these results, a sample of carbonate salt solution was prepared at a concentration of 0.01 Molar and at 120 degrees Fahrenheit. A carbon dioxide ion selective electrode (previously calibrated at 120 degrees Fahrenheit) was placed in the solution and initial readings were taken for about one hundred seconds. In the first test, an effective amount of citric acid crystals, (0.0067 Molar citrate solution, enough to neutralize all of the carbonate salt solution) were mixed with the carbonate salt solution. The carbon dioxide electrode began to detect carbon dioxide almost immediately after mixture. As illustrated, the carbon dioxide reached a maximum concentration of 0.0082 Molar within about forty five seconds of adding the acid. The carbon dioxide level then began to drop after holding a maximum concentration for about fifteen seconds.
[0033] The previous experiment was repeated using a sample of fumaric acid. An effective amount of fumaric acid was mixed with a sample of carbonate salt solution, which was at a concentration of 0.01 Molar and at 120 degrees Fahrenheit. As shown in the figure, the initial production of carbon dioxide was delayed slightly when compared to the production of carbon dioxide for citric acid. The carbon dioxide reached a maximum concentration of 0.0095 Molar within about 120 seconds of mixing. The carbon dioxide level then began to drop after holding a maximum concentration for about thirty seconds, approximately twice as long as the reaction with citric acid.
[0034] FIG. 2 illustrates a comparison graph showing the response of carbon dioxide production for fumaric and tartaric acid. After approximately 80 seconds of initial readings with the carbon dioxide ion selective electrode, an effective amount of tartaric acid was combined with a sample of carbonate solution at a concentration of 0.01 Molar and at 120 degrees Fahrenheit. A maximum level of carbon dioxide production occurred almost immediately and maxed out at approximately 0.0085M. With fumaric acid as the acidulent, the carbon dioxide reached a maximum concentration of 0.0095 M within about 120 seconds of adding the acid.
[0035] Tartaric acid is a closer relative to fumaric acid than citric acid. Like fumaric acid, tartaric acid is a diprotic acid with very similar acid strengths for each acidic proton. The main characteristic of these acids is their difference in water solubility. Fumaric acid is about two hundred time less soluble than tartaric acid in water at room temperature.
[0036] Using fumaric acid as the acidulent, the nearly two minute delay in maximum carbon dioxide level production will allow a user to mix the cleaning solution in a single container, with hot water, and cap the container without losing a great deal of carbonation.
[0037] In practice, 227 grams of fumaric acid is admixed to 190 grams of sodium carbonate, and mixed with five gallons of hot water, around 120 degrees Fahrenheit. The amounts of fumaric acid and sodium carbonate may be increased or decreased approximately five to ten grams. Similarly, 252 grams of adipic acid is admixed with 165 grams of sodium carbonate and mixed with five gallons of hot water, around 120 degrees Fahrenheit. The amounts of adipic acid and sodium carbonate may be increased or decreased approximately five to ten grams.
[0038] It is understood that the above-described arrangements are only illustrative of the application of the principles of the present invention. 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 only 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.
[0039] For example, it is envisioned that other additives commonly found in commercial cleaning compositions may be added without departing from the scope of this invention provided they do not interfere with the interaction of the acids and carbonates and the creation of carbon dioxide. These include, but are not limited to, bleaches, optical brighteners, fillers, fragrances, antiseptics, germicides, dyes, stain blockers, preservatives, and similar materials.
[0040] It is also envisioned that the components (carbonate, acid, and water) of the cleaning composition may be applied to the textile simultaneously, e.g. mixed immediately before application, or during application. In the alternative the components of the cleaning composition may be applied, and thus mixed, in any desired order. For example, a solution of acid can be applied directly on the textile followed by the carbonate solution. Alternatively, the carbonate solution could be sprayed first and then the solution containing the acid. Either procedure works well because solutions with a pH which is not neutral tend to clean much better than those that are neutral.
[0041] Thus, while the present invention has been fully described above with particularity and detail in connection with what is presently deemed to be the most practical and preferred embodiment(s) of the invention, it will be apparent to those of ordinary skill in the art that numerous modifications, including, but not limited to, variations in size, materials, shape, form, function and manner of operation, assembly and use may be made, without departing from the principles and concepts of the invention as set forth in the claims. | Carpeting, upholstery, drapery and other textile fibers are cleaned by applying to the fibers an aqueous, chemically carbonated cleaning solution prepared by mixing a carbonate salt and a low soluble acid with hot water, such that the low soluble acid delayedly reacts with the carbonate salt to produce carbon dioxide before being applied to the textile fibers. The delayed production of carbon dioxide helps prevent the loss of carbon dioxide before the carbon dioxide is lost. The hot water increases cleaning capability of the cleaning solution. | 20,180 |
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the priority and benefit of U.S. Provisional Application No. 60/176,535, as well as U.S. Provisional Application No. ______, entitled “SYSTEM AND METHOD FOR THE AUTOMATED PRESENTATION OF HEALTH DATA TO, AND ITS INTERACTION WITH, A COMPUTER MAINTAINED DATABASE, TO GENERATE INFORMATION REGARDING POSSIBLE REMEDIES, THERAPIES, PROBLEM SOLUTIONS AND BENEFICIAL PRACTICES, TO IMPROVE USER HEALTH” filed on Sep. 15, 2000, Attorney Docket No. 2761.100, Sidney M. Baker, Inventor, the disclosures of each of which are hereby incorporated herein in their entirety.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates generally to the fields of data mining, expert systems, and system theory. In particular, the preferred embodiment relates to interactive data mining regarding the health of a human organism, described as a system.
[0004] General System Theory was introduced in the early twentieth century by the German/Canadian Biologist Ludwig Von Bertalanffy. Classical science, and its diverse disciplines, be they chemistry, biology, psychology, or the social sciences, tended to isolate individual elements of the observed universe, such as chemical compounds and enzymes, cells, elementary sensations, freely competing individuals, etc. and assumed that by putting theses elements together again, either conceptually or experimentally the whole or system under consideration—i.e., the cell, mind, or society—would result and be intelligible. In engineering terminology this approach was equivalent to reducing every system to the linear response of its various components and superposing or aggregating those linear responses to monitor the system as a whole. The problem with such an approach, or opistimology, is the fact that a whole is often more than the sum of its parts. There is often nonlinear and non-intuitive interaction and interdependence between the so called “components” of any system. General system theory is the scientific exploration of wholes and wholeness. General system theory assumes that for a true understanding of any system comprehension not only of the elements is required but of their varied interaction and interrelations as well. This requires exploration of systems in their own right and specificities.
[0005] The application of general systems theory to medicine would require nonlinear medical thinking. It mostly has to do with the approach one takes towards understanding what has caused and event, such as a symptom or a collection of symptoms, signs, and lab tests which are referred to as an illness. As present most medical thinking remains linear. Doctors and patents alike are tempted by the idea that an illness has a single cause that can be treated with a single remedy; such as a pill or a surgical procedure. General systems theory, when applied to medicine, presents ideas about causality in which a web of interactions produces a result that is not easy to pin on a single causative facture. Therefore the resolution of medical problems, or health is sustained by achieving a state of balance among countless strands of the web of genetic, physiologic, psychic, developmental, environmental factors all of which contribute to the state of well being, or lack thereof of human beings. When something goes wrong with ones health, it makes sense to pay attention of all aspects of this web that can be addressed with reasonable cost and risk.
[0006] The notion of systems is not unknown to traditional medical thinking. However, its meaning is quite different from the sense it is acquired among the inheritance of general systems theory. Traditionally, medical education is organized via various bodily systems such as the cardiovascular, nervous, immune, reproductive, gastrointestinal, integumentary (skin), musculoskeletal, endocrine, reticuloendothelial and hematologic. It is theses systems that serve as the basis for classifying disease. Upon graduation from medical school novice doctors are expected to choose a particular system and become a specialist. On the other hand, systems theory as applied to medicine provides a unifying model of how things operate, and allows the viewing of biological systems as interconnected and interacting unity of their various components. As a result, one can make functional—as opposed to anatomical—divisions, as overall balances assessed within the system. The theory that has dominated medical science for the greater part of the twentieth century is that people get sick because they are the victims of disease. A better theory is that people get sick because of a disruption of the dynamic balance that exists between themselves and their environment. This latter theory works just as well to describe what happens when one gets chicken pox as it does when there is a more complex problem in which many genetic, environmental, and nutritional factors interact.
[0007] Because of the prevailing disease oriented approach of medical language the illusion is created that if one possesses the name of a disease responsible for a patients complaints, then one can solve that patients health problem. A better mental model would be one in which all of the details of a person's problem are preserved as opposed to abstracting our theoretical based notions of important as opposed to unimportant “symptoms”. Such a language would allow the totality of the information content of the state of a person's health at a given time be preserved. All that would remain needed is the means to extract it and to analyze it.
[0008] Digital computers are particularly adapted to such a task. Portraits of a human health status, including reported symptoms, observant indications and laboratory reports can be constructed in such a way so as to preserve the totality of information contained in such a health “snapshot” while still using the names commonly used in medical science to describe the main features of illness. Computers are utilized to make complex pictures out of human health data. If the data is detailed, accurate and structured, the pictures will reflect reality and allow patterns to emerge which are not necessarily visible to the naked eye. The computer can be used as a “microscope” for viewing large patterns as much as the microscope is used to view the exceedingly small.
[0009] In order to use a digital computer in such a way, a format must be created that can be easily encoded into digital data, processed, and decoded into a meaningful output. Users' verbal descriptions of their medical states must be carefully guided into precise and orthogonal categories which can each be assigned a number value, resulting in a multidimensional set of numbers representative of each user's health snapshot. Each dimension would represent some medical attribute. The presence of absence of some condition, sensation, or state, the severity, frequency, or character of the condition, and the duration, onset in correlation to other states or user activities of the problem, to name some general examples.
[0010] 2. Related Art
[0011] Related art in the field of the invention is sparse. Although there are numerous medical database/medical information computer programs and websites, accessible via a local computer, the Internet or other data network, all offering the user the ability to search for a variety of information, none offers the user an opportunity to express the totality ofhis or her current health snapshot using system provided categories and divisions of the semantic plane. As a result these sites function as efficient and highly accessible medical encyclopedias. Noting more. There is no actual interaction between knowledge stored in the websites server and the health snapshot of the user to generate information that the user would not otherwise know.
[0012] In fact, across the gambit of medical web sites and related and equilivent interactive informational tools, the “mental map” or “semantic plane” and the corresponding technical language or taxonomy, by means of which both the queries are posed to, and the information, or output is generated from, the system database—is the traditional disease based singular cause and effect model discussed above. Therefore, one can at these sites and their equilivent, learn the “causes” and treatments, of a variety of “diseases”. As well, one can learn the “disease” causing ones reported symptomology usually, but one cannot discover what percentage of other persons reporting similar symptomology also have similar problems as the user which are not commonly considered to be part of the symptomology of the “disease”. For example, suppose someone reports a shortness of breath. Because the medical informational tools currently available to the public do not dynamically interact with the information reported by a user (to the extent that they extensively query the user at all) a given user cannot know that eighty three percent (83%) of persons reporting or seeking the assistance of the medical website also had a strange rash on the soles of their feet. Or, as another example, persons reporting shortness ofbreath could acquire a variety of information about cardiovascular health and potential problems, but could never know how many people reported a folic acid deficiency and poor night vision as well.
[0013] It is only through the articulation of the totality of events (in reality a reasonable tractable representative set thereof) indicative of a human organisms health, including the various mental, biochemical, physical and other processes that completely describes the system as a whole that ones health “system” can be objectively described.
[0014] What is therefore desired or needed to truly exploit the massive automated information extraction and handling and processing capabilities of the digital computer, and by extension, a network of digital computers, is the creation of (i). A carefully constructed taxonomy that facilitates the exhausts of mapping of a human organisms health snapshot into words (ii). System of querying the user so as to translate his or her responses into the categories of said taxonomy that would allow complete mapping of their health snapshot, (iii). A means of encoding information content of the user health snapshot into numerical values that can be manipulated by digital computer, and finally (iv) a method of processing the encoded information representing a user's health snapshot so as to allow the interaction of that user's health snapshot with a database of other user's health snapshots so as to generate meaningful inferences and analysis of the user's health snapshot so as to output meaningful information to the user.
SUMMARY OF THE INVENTION
[0015] A system and method are presented for the articulation, in data structures which can be operated upon by digital computers, of the health snapshot of a human being, and the interaction of that human's health snapshot with a database of other system users' health snapshots so as to obtain information and meaningful problem solving approaches with regard to the state of the human being's health. Although the techniques described can be applied to any comprehensive description of an organic or other system (e.g., horses, a chemical manufacturing system, an automobile) and any database cataloging events and problems experienced by, possessed by, or involving such systems, in the preferred embodiment the system under consideration is the mental and physical health of the human organism, and the database of systems and their events is a collection of the comprehensive descriptions of the health of a multitude of people. Each such health snapshot, or systemic description, comprehensively describes a persons health in terms of system common categories.
BRIEF DESCRIPTION OF THE DRAWINGS
[0016] The present invention will be more readily understood from a detailed description of the preferred embodiments taken in conjunction with the following figures. Many of the drawings consist of screen shots of an exemplary embodiment of the invention adapted to the World Wide Web. In this embodiment the trade name “Medigenesis” is used to denote the system, and as such, appears on many of the screenshots.
[0017] [0017]FIG. 1 is a screenshot of an exemplary system homepage;
[0018] [0018]FIG. 1A depicts the system structure and data flow;
[0019] [0019]FIG. 1B depicts a simplified version of the system structure and data flow;
[0020] [0020]FIG. 1C depicts the descending levels of abstraction of user events;
[0021] [0021]FIG. 1D depicts the fields of a Patient Description Vector;
[0022] [0022]FIG. 1E depicts the clustering concept;
[0023] [0023]FIG. 2 is a screenshot of an exemplary “What is Medigenesis” informational page;
[0024] FIGS. 3 - 3 C depict an exemplary “Your Privacy and Security” page;
[0025] [0025]FIG. 4 depicts an exemplary “New Member Information” box from the account signup page;
[0026] [0026]FIG. 5 depicts an exemplary “What's News” screen;
[0027] [0027]FIG. 6 depicts an exemplary “Contact Us” screen;
[0028] [0028]FIG. 7 depicts an exemplary “Provider Resourses” screen;
[0029] [0029]FIG. 8 depicts an exemplary “Reading Room” screen;
[0030] [0030]FIG. 8A depicts a fuller view of the exemplary “Reading Room” screen;
[0031] [0031]FIGS. 9 and 9A depict an exemplary “Discussion” screen;
[0032] [0032]FIG. 10 depicts an exemplary “Glossary” screen;
[0033] [0033]FIG. 11 depicts an exemplary “Help” screen;
[0034] [0034]FIGS. 12 and 12A depict an exemplary “Member Homepage” screen;
[0035] [0035]FIGS. 13 and 13A depict an exemplary “Recommended Groups” screen;
[0036] [0036]FIG. 14 depicts an exemplary “Infertility>Subscribe” screen;
[0037] [0037]FIG. 15 depicts an exemplary “Discussion>Subscribed Groups” screen;
[0038] FIGS. 16 - 17 depict an exemplary “Event Locator” shown for a child female user;
[0039] FIGS. 18 - 22 depict the “Event Locator”, shown for an adult male user;
[0040] [0040]FIG. 23 depicts an exemplary “Locate a Treatement” screen;
[0041] [0041]FIG. 24 depicts an exemplary “Locate a Treatment Screen” with a list of antibiotics displayed;
[0042] [0042]FIGS. 25 & 25A depict an exemplary “Treatment Details” screen;
[0043] FIGS. 26 - 32 depict examples of the help screens;
[0044] [0044]FIG. 33 is an exemplary depiction of
[0045] [0045]FIG. 33 is an exemplary depiction of the Member Homepage;
[0046] [0046]FIG. 34 is an exemplary depiction of the Your Health Profile page;
[0047] [0047]FIG. 35 is an exemplary depiction of the Member Information page;
[0048] [0048]FIG. 36 is an exemplary depiction of the Treatments page;
[0049] [0049]FIG. 37 is an exemplary depiction of the Primary Problems interface;
[0050] FIGS. 38 - 41 are an exemplary depiction of a Medical Summary Report; and
[0051] [0051]FIG. 42 is an exemplary depiction of the Diagnostic Tests page.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0052] You are chatting with an old friend at a party. After catching up on the latest baseball scores, your progress on a new project at work, an interesting recipe you tried recently for pasta premivera, and you mentioned you are worried about your oldest son. He is fourteen (14) years old, has developed acne, and his egama has gotten worse. He is really self-concious about his skin; one knows how children are at that age. That may account for why he has been getting such terrible stomach aches and headaches lately. The doctor wants to start him on antibiotics for the acne. You hate the though of him taking that stuff but what else can you do? “That's funny” replies your friend, as it turns out his cousin has a thirteen (13) year old daughter with strikingly similar problems; as it turns out she has developed an allergy to dairy products. Your friend continues, that simply by cutting most milk, cheese, and ice cream out of her diet her acne, eczema and stomach problems cleared up in less than one month.
[0053] Take that scenario and multiply it by thousands and thousands of people, and you have the idea of the preferred embodiment of the present invention. The system allows the user to tell it, via an automated graphical interface, about his or her medical problems, symptoms, lab test results, history, intuitive vague feelings about his or her health—in short, all the details that make a person, medically speaking, who they are—then automatically guides the user through a comprehensive questionnaire to take the user's comprehensive health description. Handing the acquired data to an information processing module the system then matches up the user with others within the system database that medically speaking “look just like the user”, on the assumption that what has worked for them has a solid chance of working for the user.
[0054] The system of the preferred embodiment of the invention is therefore a tool of efficiency. It takes into account everything that makes the user who he or she is, mines the data inherent in the system database, and uses that interaction to generate a report that lists a variety of proposed therapies that have given other similarly situated users benefit. The system is also a tool of empowerment. It helps its users take better care of themselves and their families. After interacting with the system database, a user will be able to generate a medical profile of themselves, their child, or their parent, to share with their doctor. This allows the user to become a better informed patient of his or her doctor, thereby increasing the effiencies of physician provided therapies, as well as being able to ask the relevant questions, having been mentally prepared and informed by the system of the preferred embodiment of the invention well in advance.
[0055] In the past, medical databases were available only to medical professionals. The data they contained were in a language commonly spoken only by such professionals. By contrast, the system of the present invention uses ordinary language to interface with its users. It describes symptoms in the same words that a user might utter when talking to their doctor. It can be used by anyone, for anyone, at any time. Since it avails itself of widely accessible computer networks linking multitudes of individuals, such as the Internet, and is completely scaleable, the database can easily accommodate hundreds of thousands, or even millions, of users. The vast scale of the invention implies that there are bound to be a significant number of other users who look, medically speaking, very similar to the user. This offers him or her the benefit of the medical experiences and data of these other “medically similar” users. In effect, the system of the preferred embodiment of the invention is the largest continually operating cocktail party ever known.
[0056] However, in the case of the preferred embodiment of the invention, what the user finds transcends the best of imaginable cocktail parties. The system functions as an expert system that knows how to, most efficiently and comprehensively, query each attendee at the virtual cocktail party so as to coax them to articulate a comprehensive and complete expression of their medical state of being. Further, and at the same time, functioning like the stereotypical cocktail party gadabout, the system immediately communicates all useful information contained in the totality of the minds, bodies, and experiences of all of the other guests at the cocktail party to the user, so as to better inform and empower the user as to the state of their health and well being.
[0057] The system of the preferred embodiment of the present invention is constructed to accomplish three (3) functions. Information acquisition, information processing, and information output. Between the steps of information extraction and information processing there is an additional step of information encoding, and subsequent to the information processing step is another step of information decoding. While these coding/encoding steps are fundamental, they are simply means to interface the information between the user and the processing capability of a digital computer; in that sense they are secondary functions to the three main objectives of the preferred embodiment of the present invention.
[0058] [0058]FIG. 1B illustrates a simplified overall process flow, illustrative of these three phases. The three phases are delineated by the horizontal lines dividing the chart into three parts. The information acquisition phase comprises obtaining the User Provided Data 1B10. The information processing phase comprises (a) generating the Patient Description Vector, or PDV 1 B 20 , which is how the system “sees” the user, and (b) the generation of the cluster of similar users 1 B 30 in a “medical distance” sense, where greater similarity generates a larger score. Finally, the information processing phase comprises analysis of the cluster of medically similar users and the generation of reports 1 B 40 to the original querying user.
[0059] The information extraction phase consists of obtaining a complete and comprehensive snapshot of the individual user's health picture. In the language of system theory, a complete description of the system state is here elucidated. This is accomplished using the system's unique taxonomy. The taxonomy is a language or lexicon that is detailed enough so as to allow the system to store a comprehensive description of the user which facilitates finding medically meaningful similar users, and at the same time comprises language that is natural enough to allow even the uneducated and unsophisticated user to meaningfully articulate his or her own medical state of being.
[0060] The information processing functionality is a unique method of what is known in the art as data mining or knowledge discovery. It involves a two (2) step process: (i) statistical processing of the system database to locate a set of other users similar to the querying user, and (ii) analysis of the set of similar users to find hidden patterns and useful remedies, possible solutions, therapies, and information. A simple example of such remedies would be the idea avoiding of dairy products which was exchanged between the two attendees to the example cocktail party discussed above. In the system of the preferred embodiment of the invention, however, this would not be a random, anecdotal, and unquantified piece of information exchanged between people chatting at a cocktail party. Rather, a statistically significant correlation between persons in the system database similar enough to the querying user to provide meaningful health analogies.
[0061] Knowledge Discovery In The Preferred Embodiment Of The Present Invention
[0062] Before describing in detail the three stages of the system of the preferred embodiment of the invention and the detailed interactions with it which a user would undergo, it is first necessary to understand what the actual goal or functionality of the system is. This requires some appreciation of the underlying analytical techniques that support knowledge discovery from the system database. Because the system of the preferred embodiment of the invention is interdisciplinary in nature, i.e. it touches on the areas of semantics and the creation of a linguistic version of an orthogonal basis set, system theory, medicine and healthcare, and finally, data mining, knowledge discovery, and statistical analysis, it is felt necessary to provide some general conceptual background.
[0063] Next described, therefore, is what was termed above the information processing step of the preferred embodiment of the present invention, which relates to the general discipline of statistical analysis and data mining.
[0064] Different data mining methods can be employed to provide a “microscopic view” of the data which enable the detection of invisible patters among large numbers of recorded user histories. Using an assortment of data mining techniques users will be able to have a direct “knowledge exchange” with a structured database containing records of other users, their symptoms, and what medical options have worked for them. A key knowledge extraction technique that is employed in the preferred embodiment of the present invention is cluster analysis, sometimes known in the art as proximity analysis, or nearest neighbor analysis. Cluster analysis is an exploration of a data set of vectoral representations of database members, or entities, for the identification of natural groupings. The resulting natural groupings class similar entities together, and within a group the entities share similarities in the attributes that characterize them. In such cluster analysis no assumption is made about the number of underlying groups or any other structural aspect. Grouping is done after defining an appropriate similarity or distance measure. Typical example applications of clustering are customer segmentation and database marketing. Once the customers are divided into homogenous clusters, each cluster can be identified by cluster profiles or average cluster behavior. In the system of the present invention users are characterized in term of a representational vector, where the vector represents the user's medical situation/experiences, or what has been termed herein the “medical state of being.”
[0065] As those who are skilled in the art will readily understand, this technique is sometimes referred to as nearest neighbor analysis. In nearest neighbor analysis an algorithm is constructed to find the nearest neighbors in a certain class or universe to which a given element belongs. In the system of the preferred embodiment of the present invention, not just the nearest neighbor is desired, but an entire set, or cluster, of nearest neighbors is desired to provide medical analogies for the query user. The set of nearest neighbors is defined by a dynamic algorithm which decides how near the set of nearest neighbors must be to the querying user in the multidimensional vectoral space which is the conceptual computing environment of the system. As will be readily obvious to those skilled in the art, one of the operands of the nearest cluster algorithm will be the “medical distance” measure assigned to the distance in the multidimensional vector space between the querying user and each of the other users in the database. This distance metric algorithm is itself dynamic and will be continually self optimizing so as to more and more optimally articulate the distance, in a meaningful medical/health sense (measured as the capability to provide useful treatment or diagnostic analogies and guidance) between any two users in the system database.
[0066] Another data mining technique that is often employed is the discovery of association rules. Association rules discover the correlations between attributes, such as, the presence of one particular attribute implying the presence of other attributes for an entity. An example of an association rule is that “whenever a given customer purchases salmon and mussels he also buys white wine”. In commercial contexts, association rules are often used in cross marketing, store layout planning, catalog design, and the like. For two (2) sets of items x and y, an association rule is usually denoted as x˜y to convey that the presence of the attribute x in a transaction implies the presence of y. The role of associations would be complementary to clustering (once the clusters are determined, mining for association rules within the cluster would provide useful information on the medical experiences of the cluster members).
[0067] These two primary techniques, clustering analysis and association rule discovery, are further extended in the system of the preferred embodiment of the present invention to include classification approaches, where real time classifiers are run to answer user posed questions. Classification deals with sorting a given set of observations into two (2) or more classes. The emphasis is on deriving a rule that can be used to assign a new observation to one of the classes, i.e., future predication. A classic example of classification is depiction of a disease. A classifier can be calibrated using a data set containing disease present and non-present vectors. Then it can be used to predict whether new patient vectors have the disease or not. Another example, from recent medical literature in the area of autism, is the detection of an environmental factor or factors significantly increasing the risk of autism. As is well known in the medical community dealing with autism, there has been established, in a statistically significant sense, a connection between children receiving the combined MMR vaccine (mumps, measles, and rubella) and the incidence of autism. Thus, a classifier could then be calibrated using a data set from the system database of autistic children containing those who received the combined MMR vaccine and those that did not. Then the classifier can be used to predict whether new users who received the combined MMR vaccine have, or, have a risk of developing, the disease or not.
[0068] [0068]FIG. 1A depicts the data flow in the preferred embodiment of the invention. Beginning with the User Reported Data 1 A 01 , a user logs on to the site, and via an anatomical user interface and a comprehensive questionnaire, as described below in connection with the user interface, reports all relevant data to his health snapshot. Conceptually, this data allows the system to comprehensively describe the user's health “system” (to analogize to system theory), or her comprehensive medical state of being. This report is in the language of, and is stored in, the system databases allocated to each user, as a series of User Reported Problems/Events. How this information is elicited from the user is fully described below in connection with the user interface, and relates to the information acquisition aspect of the preferred embodiment.
[0069] Exhibit A-1 is an example listing of all user reportable or identifiable Problems/Events that are possible in the preferred embodiment, entitled EVENT LOCATOR. This list is dynamic, however, and can be modified as warranted by the continual internal system monitoring, for efficiency, clarity and comprehensiveness. As its name implies, the listing is oriented towards the Anatomical User Interface and the Questionnaire, as described below, and thus is organized first by the anatomical location on the body where the problem or attribute is manifested. This listing, having some 32,000 possible ailments or attributes, is simply too large to be used to represent the user in the system. Thus, it must be collapsed into more general groupings. Exhibit A-2, entitled “Medex_Formal Problem”, is such an example distillation. This Exhibit has three columns. The middle column, MEDEXNAME, contains 5,597 unique user events, to which the entire 32,000 symptom aliases can be mapped. The third column (rightmost) describes whether the event is a medical problem, such as, for example, a spine injury or an allergy to latex, or simply a pertinent medical fact, termed an “attribute”, such as, for example, having had a certain standard vaccine, or having traveled to a particular foreign country. The first (leftmost) column of Exhibit A-2 is the SFWID, which is an example set of 2204 possible System Function Where (“SFW”) combinations. The SFWs, as more fully explained below, are the orthogonal categories by which a user is comprehensively represented in the system. FIG. 1C illustrates the increasing level of abstraction (going down the page) moving from the circa 32,000 symptom aliases to the circa 5600 problem names to the some 2200 SFWs.
[0070] Obviously there are two levels of abstraction ending up at the same place—the 2200 SFWs. Why? One purpose of the symptom alias is that it provides for members to describe a specific problem ‘in their own words’. The example that always seems to get used to demonstrate this was ‘stinky poop’ versus ‘smelly feces’ versus wickedly pungent excrement. All say the same thing, yet each uses different words reflective of the user's soci-economic stratum and linguistic habits. Thus the some 32,000 symptom aliases have significant synonymy and semantic redundance.
[0071] The other reason for duplication is that a symptom can appear, as shown below, in more than one place in the event locator—a person may click on arm, then skin, then ‘eczema on the arm’, or they may click on skin, then ‘eczema on the arm’.
[0072] SFW—System Function Where:
[0073] the Central Data Structure of the System
[0074] SFWs are organized not by location (visually perceived spatial orientation), but much more efficiently by bodily system and function (conceptually perceived functionality), the latter being the reported problem or condition. The lowest level of abstraction of the SFW is the Where element, and identifies where anatomically that particular system's particular ailment or condition is manifest.
[0075] Exhibit A-3 contains an example listing of a set of 2204 SFWs, comprising an orthogonal basis set of medical conditions and facts by which a user's health state of being can be thoroughly expressed. The information processing module of the system of the preferred embodiment sees each user as a vector comprising an age component, a gender component, and N SFW components, where N is the number of all SFWs possible in the system. In the example listing of Exhibit A-3, N=2204. FIG. 1B depicts the increasing levels of abstraction between Exhibits A- 1, A-2, and A-3.
[0076] Because an individual user may report data a number of times, but is represented by only one data structure within the system, multiple occurrences of a user event are collapsed into one value for that particular SFW, using an equation that maps one value to the SFW in question, including information regarding the number of occurrences and the severity of each occurrence. Referring again to FIG. 1, the reported information by the user 1 A 01 , and the severity parameters 1 A 02 , are distilled and combined to create the Patient Description Vector, or “PDV”, which, as described above, is how the user is “seen” by the system's information processor.
[0077] An example of an SFW component of the PDV encoding the fact that a user has Eczema on the arm would be, in the example of Exhibits A, coded as “Skin-Inflammation-Not Specified” as is shown on the top record of page 110 of Exhibit A-2. Similarly, every member problem (or, synonymously, member event) from Exhibit A-1 has a corresponding SFW in Exhibit A-3.
[0078] PDV—Patient Description Vector
[0079] The PDV is a row of numbers that collectively define the point the relevant user occupies in the multi-dimensional hyperspace of all possible (considered) medical conditions. Each column in the row corresponds to a dimension in the hyperspace, and columns will be set aside for the following pieces of information, with reference to FIG. 1D: user's age, gender, and a column for each valid SFW.
[0080] Column 1: Gender=Male and Column 2: Gender=Female
[0081] The members' gender information will be encoded by placing a 1 in the appropriate column. No information (equivalently, a zero) will be placed in the other column.
[0082] Columns 3-17: Age
[0083] The age information will be encoded by placing a 1 in the appropriate column, and zero in the other columns. Each column will represent an age range of 7 years. So, if the member is younger than 7 a 1 will be placed in the first column, if they are younger than 14 (but older than 7) a 1 will be placed in the second column, etc.
[0084] Columns 18-2221: SFWs
[0085] As per Exhibit A-3, in an example of the preferred embodiment there are 2204 different, valid combinations of SFWs. Each of these will be assigned an identification number (an ‘SFWid’), and each SFWid will in turn be assigned a ‘column’ in the PDV vector. Thus, the total columns in the vector in such an example are 2221, 17 for storage of the age and gender information, and 2204 for the SFWs.
[0086] The value which will be placed in the column corresponding to a given sfwid is given by the following equation.
PDV sfwid = 1 + U pperB · [ 1 - ( 1 a ) i ( 1 b ) j ( 1 c ) k ( 1 d ) l ]
[0087] Where:
[0088] PDV sfivid =The number to be placed into the PDV vector for this sfwid. The parameters allow multiple occurrence information, as well as severity information (since there is no separate SFW for a severe, mild, or medium occurrence of the same event) to be encoded in the SFW value. These parameters operate as follows:
[0089] UpperB this parameter bounds the maximum that can be reached in an entry. (The actual maximum that can be reached is 1+UpperB);
[0090] a—parameter that controls the rate at which each extra ‘mild’ event (classified within this particular sfwid) brings the entry towards the upper bound;
[0091] b—parameter that controls the rate at which each extra ‘moderate’ or ‘variable’ event (classified within this particular sfwid) brings the entry towards the upper bound;
[0092] c—parameter that controls the rate at which each extra ‘severe’ event (classified within this particular sfwid) brings the entry towards the upper bound;
[0093] d—parameter that controls the rate at which each extra ‘variable’ event (classified within this particular sfwid) brings the entry towards the upper bound;
[0094] Input numbers (dependent on user data)
[0095] i,j,k,l—these numbers count the number of (respectively) mild, moderate, severe, and variable events that the given member has had, or currently has, which are classified to fall within this sfwid.
[0096] These severity parameters (which include the multiple occurrence information) are shown as an operand to the PDV in FIG. 1A, item 1 A 02 .
[0097] These equations operating on the user provided data will lead to the generation of a vector 1 A 05 with reference to FIG. 1, where the number of columns, or the dimensionality of the hyperspace (n), will be on the order of 2200. Basically the PDV is simply a format to describe the member in a way conducive to ‘proximity analysis’. Once the PDV is generated in the above fashion, it will be stored in the database for later retrieval, and for usage in reporting/debugging purposes.
[0098] Metric Calculation
[0099] Having To find the similarity between two members (as represented by their respective PDVs) a ‘metric calculation’ is undertaken. This metric operates as a variation on the dot product (which is a scalar measure of the extent that one vector lies along the direction of another, itself a measure of similarity; the dot product of a vector with itself is thus unity). The metric can be weighted to take into account that the dimensions, being word based and subject to interpretation, may not be absolutely orthogonal, or independent, and thus the coincidence of two different SFWs may actually deserve a significant similarity rating.
[0100] Calculation of the Metric
[0101] A crucial part of the system is the calculation of the ‘similarity’ between two PDV vectors. This step is shown as 1 A 10 in FIG. 1 A. In the preferred embodiment, the formula used to calculate the ‘similarity’ between two PDV vectors, x, and y is given by:
similarity_measure = ∑ i = 0 n - 1 ∑ j = 0 n - 1 w ij · x i · y i
( ∀ i , j : w ij > τ )
[0102] Basically, the system multiplies every non-zero entry in x against every non-zero entry in y, using the corresponding component of the appropriate weighting factor matrix W, 1 A 06 . The system then sums the result, completing the medical distance calculation 1 A 10 .
[0103] However, where the weighting term (w) is zero, or when w is less than some (adjustable) threshold tau, that term is not counted in the summation, and no similarity is credited for the coincidence of the two SFW fields involved.
[0104] The above medical similarity metric 1 A 11 is actually a variation, or extension, of the well known ‘dot product’. Obviously, it is dynamic, and can be easily changed so as to optimize the meaningfulness and usefulness of the medical similarity concept. The calculation of the metric can be understood, by considering, first, the ‘dot product’. If we have two vectors in an n-space (in 2-space we might consider the closeness between two directions, or between two 2-D vectors), the simple dot product of those two vectors, x, and y, is given by:
= ∑ i = 0 n - 1 x i · y i
[0105] In the case that W in the metric discussed above had all ones in the diagonal, then the metric reduces to a normal dot product. That is, if
W = [ 1 0 0 0 0 1 0 … 0 0 … 0 0 … 0 1 ]
[0106] then the metric is simply a straightforward dot product.
[0107] The way that the similarity metric calculation works can be adjusted by adjusting the parameters in W. It can also be adjusted, more easily, by changing the threshold tau.
[0108] Finding the cluster
[0109] By repeated application of the metric (or some optimized equivalent) it will be possible to find the n members who are ‘closest’ to the current member 1 A 15 . This list of ‘cluster buddies’ (having the highest scores on the similarity metric) will then be stored temporarily, for use in subsequent calculations.
[0110] Storage and retrieval
[0111] The system of the preferred embodiment supports the storage and retrieval of data relating to cluster analysis. PDV information in particular, being multiple thousands of columns wide, needs to be stored in a data-compressed way, and yet, be retrievable in a vector format. The primary data stores include the following.
[0112] PDVs (the latest PDV for every member, including the calculated length of that PDV);
[0113] Similarity matrix information (the matrix of similarities calculated between PDV's, or equivalently, members, being of size M×M,where M is the number of members, or alternatively, a vector of 1×M for each member, stroing his or her similarity measure from all of the others); and
[0114] Supporting information for the metric calculation (the weighting matrix W).
[0115] Performance
[0116] A good part of the accuracy for this method of measuring ‘similarity’ between members depends on the exact values chosen for the weights matrix W, and for the threshold Tau. A high threshold (or a lot of zeros in W) leads to less dimensionality in the calculation and consequently more tractability in trying to find similar members. On the other hand, a low threshold tau (or a lot of high numbers in W) is equivalent to saying that all factors in the body are tightly interrelated, and consequently a high dimensionality in the calculation. The same trade off applies to the question of whether the UpperBound, and the a, b, c, d parameters are set high or low during the generation of the PDV. Therefore, it is expected that the method for generating W, and the choice of optimum values for the other parameters will evolve to higher precision and better predicatability. The method of the preferred embodiment for achieveing this evolution is to define one or more success measures, and create a genetic algorithm to automatically periodically diagnose system performance in terms of the one or more success measures, and automatically modify the various equations for the similarity metric, for W, and for the severity and multiple occurrence parameters.
[0117] Determining The Optimal Number Of People To Display (Creating Dynamic Clusters)
[0118] In basic applications of clustering, groups (or clusters) are formed a priori in the metric space, and a new individual is mapped to the closest group. In the approach of the preferred embodiment, the distance (metric) of the new person to each of the persons (historical) in the database is calculated, and we select people that are “close” to him in a ranked manner. In such a scheme, the question arises: How many people are “close enough” to the new person? One logic would be to show the people that closer than a certain threshold (these people would then be showed in a ranked manner, closest to the farthest). Similarly, a certain fixed number of cluster buddies or a percentage of the total number of database members could be chosen. Optimally, it is desirable to let the data itself determine the natural boundary. Other users in the vicinity are included in the cluster until a gap is encountered that is bigger than a gap threshold. The logic can be visualized in the plot shown in FIG. 1E:
[0119] In FIG. IE, the points lying in the Region A are considered close, and the points lying outside region B are considered “not close”.
[0120] Consider the following series of distances:
[0121] Distances: 1, 1.2, 2, 2.5, 3.0, 4.0, 7.0, 8.0, 8.5
[0122] The gaps between successive prospective “cluster buddies” are then:
[0123] Gaps: 0.2, 0.8, 0.5, 0.5, 1.0, 3.0, 1.0, 0.5
[0124] Gap Moving Averages:
Moving Average 1=0.2;
Moving Average 2=(0.2+0.8)/2=0.5
Moving Average 3=(0.2+0.8+0.5)/3=0.5
Moving Average 4=(0.2+0.8+0.5+0.5)/4=0.5
Moving Average 5=(0.2+0.8+0.5+0.5+1.0)/5=0.6
[0125] At this stage, the next gap (=3.0) is significantly greater (order of magnitude=5) than the current gap moving average of 0.6. Hence the point may not be desired to be included in the group, and the cluster is restricted to the first 5 cluster buddies.
[0126] User Interface and Data Acquisition
[0127] What has been described above relates to the information processing aspect of the preferred embodiment of the invention. Temporally, this information processing stage occurs after the information acquisition stage, where the complete systemic description of a user's medical/health state of being is elicited, and mapped to the SFW's comprising the Patient Description Vector, PDV. What will next be described is the information acquisition aspect of the preferred embodiment.
[0128] The system of the preferred embodiment of the present invention is implemented on a computer network, such as the Internet. The user's gateway to the system is the Home Page, as shown in FIG. 1. Clicking on button 101 leads to a mission statement page, as shown in FIG. 2. Clicking on button 102 leads to the Your Privacy and Security page, shown in FIGS. 3 - 3 C.
[0129] Clicking on button 104 accesses the Account Signup page, as shown in FIG. 4, and the New Member Information box appears as therein depicted. The user fills out the interactive box and receivesaccessto the site. Button 105 leads to the What's News? page, as shown in FIG. 5, and button 106 leads to the Contact Us page, as shown in FIG. 6. Finally, button 107 leads to the Provider Resources page and subpages, as shown in FIGS. 7 - 7 B. The menu bar, which is always at the bottom of the system screen, wherever one is in the system, will now be described, still with reference to FIG. 1. Menu Item 108 leads to the Reading Room, as shown in FIGS. 8 and 8A, Item 109 leads to the Discussion Area, as shown in FIGS. 9 and 9A. Item 110 leads to the Glossary, depicted in FIG. 10. Recall that one of the functions of the site and the system is to educate the user in the terms used to describe his or her health, so the glossary is quite an important tool. Item 111 , Help, displays the help informational screen as shown in FIGS. 26 - 32 .
[0130] Item 112 leads the user to a system search screen.
[0131] The critical interactions between the user and the system of the invention occur in the information acquisition phase, which occurs when the user, interacting with the system interface, describes his detailed state of health, the treatments he is taking, his primary and secondary problems, and the results of lab tests.
[0132] The interface operates as follows. From the system Home page, shown in FIG. 1, upon clicking on the Member Home Page button 113 , the user is taken to the Member Home Page, and sees the screen depicted in FIG. 33.
[0133] Upon clicking on the Your Health Profile button 3301 , or the “go” sign to the right of it, the user is taken to the Your Health Profile page, and sees the screen depicted in FIG. 34.
[0134] There are six categories of information which can be entered and managed (i.e., edited) by the user at this page. Member Information, Treatments, Primary Problems, Secondary Problems, and Diagnostic Tests. The Medical Summary category cannot be edited, inasmuch as it represents the output from the system to the user, or for the benefit of the user's physician, but new summaries can be run by the user at any time, and are intended tobe run if any of the other data has changed. Clicking Member Information 3401 takes the user to that page, and displays the screen depicted in FIG. 35.
[0135] At this juncture the user can modify or add to any desired information that has already been stored, and then click at the button labeled Return to: Your Health Profile to return to the Your Health Profile page.
[0136] With regard to Treatments, listed as the second category on the Your Health Profile page, Clicking on Add Treatment brings the user to the Add Treatment page, and the text and interactive box appears as depicted in FIG. 36:
[0137] The function of this screen is for the user to tell the system database which treatments, meaning primarily medications, that he or she is currently taking. This information is necessary to obtain the true picture of the user's health. With reference to FIG. 23, the user sees the Locate a Treatment interactive box, and can either search for a treatment by typing in a text string in the type-in box 2305 , or choose a treatment category 2306 , by clicking the menu selector 2307 , and clicking on the list button 2304 . The latter action will bring up the Health Option List for the selected type, as in FIG. 24, where a list 2403 of the chosen type, here antibiotics, is shown. Clicking on a particular listed treatment, such as, for example, the antibiotic Zyvox 2402, brings the user to the treatment details screen.
[0138] FIGS. 25 - 25 B also depict this screen. Here, with reference to FIG. 25A, the user discloses the date the user stopped taking the medication 25 AO 1 , the good response descriptor 25 A 02 , or the bad response descriptor 25 AO 3 , comments for either good or bad responses, 2SAOS and 2SAO6,respectively, whether the treatment should be displayed on the progress report 25 AO 4 and any further comments 25 AO 7 . The information is saved by clicking on “Save” 25 AO 8 . The response descriptors for good and bad are shown in FIG. 25B, in box 25 BO 1 , and range from mildly bad (good), somewhat bad (good), bad (good), to seriously bad (good). After completing the information for the treatment, the screen depicted in FIG. 37 is next seen.
[0139] The user either adds a new treatment and repeats the process just described, or continues with the health profile of the six information categories found at the “Your Health Profile” page, the most important are the Primary Problems and the Secondary Problems. These will be next described in detail.
[0140] From the Your Health Profile screen a user accesses the primary problems screen by either clicking on the Add Primary Problem or the manage primary problem links. This takes the user to the Event Locator, as shown in FIGS. 16 and 17, for a young female child, and in FIGS. 18 - 22 for an adult male. The user clicks on the body of the Event Locator FIG. 1801 in FIG. 18, and a part of the body is highlighted. Alternatively, the user clicks on one of the words located around the figure. In either case the chosen body part or topic appears at the top 1805 of the interactive box on the right of the screen, and a list of “aliases” or sub categories of the chosen category appear for choosing and adding to the problem list shown in the Chosen Problem List box 1802 . The user continues in this fashion until all the primary problems are chosen. The user then returns to the Your Health Profile page by clicking on the save and return button 1806 , and sees the modified Primary Problems section as depicted in FIG. 37.
[0141] Secondary Problems are queried by an exhaustive questionnaire. Sample pages of the questionnaire are provided as Exhibit B-1. The questions seek to elicit the various problems a user has, and track the Exhibit A-1 set of all possible problems in all possible phrasings inherent in the system. As described above, the critical information gleaned is mapped to the SFWs and stored in the user's PDV.
[0142] Clicking on the “Run a new Medical Summary Report” link from section 5 of the Your Health Profile page generates a report, an example of which is shown in FIGS. 38 - 41 . With reference to FIG. 1A, this is step 1 A 20 . The report, inter alia, is characterized by an informational display similar to the following example text:
[0143] Your Cluster 1
[0144] Number of people in your cluster: 23 Defining symptoms in your cluster
[0145] Within your cluster, the following percentage of people have experienced symptoms exactly like, or similar to your problems . . .
Your Cluster 1 Exact 2 Similar 3 0% . . . 100% number of people in your cluster: 23 Defining symptoms in your cluster: Within your cluster, the following percentage of people have experienced symptoms exactly like, or similar to your problems . . . >>headaches 4 10% 30% (Bar Chart) >>staph 30% 40% (Bar Chart) Other people in your cluster also had . . . >>allergy to gluten 5 70% (Bar Chart) >>red hair 60% Treatments in your cluster People within your cluster have reported good responses to . . . >>magnesium 70% 6 (Bar Chart) People within your cluster have reported bad responses from . . . >>trepanning 20% (Bar Chart) Common discussion forums for people in your cluster If you wish to share information, or collaborate with others who are ‘like you’ then you will be interested to know the forums they are subscribed to: >>staph infections forum 70% (Bar Chart) <<subscribe>> 7 >>headaches forum 20% (Bar Chart) Already subscribed
[0146] Note that the report summarizes the reported problems, provides the benefit of the system's statistical analysis, and can even suggest, based upon such analysis, further diagnostic tests. As well, the report draws on all the information stored in the system, and not just that information encoded in the PDV. Thus, if the user complies with the suggested diagnostic tests, assumably she will report the results of the diagnostic test to the system, generate a new medical summary report, and both she, and the knowledge inherent in the system, will obtain further useful information. Clicking on the Manage Diagnostic Tests link at section 6 of the Your Health Profile Page displays the screen shown in FIG. 42.
[0147] The system thus serves as the direct recipient of laboratory tests, and reports the results back to the user. Clicking on the link 4201 at the top right, or using the go button 4203 and menu bar 4204 returns the user to the Your Health Profile page.
[0148] To use a signal processing analogy, the bandwidth of the information acquired in the information acquisition phase is simply too great to be processed in real time by the information processor. Thus, for the purposes of generating a cluster, the signal is downsampled, and high frequency information is discarded. Once, however, the cluster is found, and computation does not require all the users in the system database to be operands to the processing algorithms, the bandwidth can again be increased to the original bandwidth, and all information, no mater how complex, available in the system regarding the user, and the other members of the cluster, is available for analysis in generating the user reports. With reference to FIG. 1A, the cluster 1 A 15 , and all of its users' complete records, as well as the user's complete original records, collectively 1 A 16 , are available as operands to the report generating algorithms.
[0149] Thus, once the cluster closest to the new user is arrived at, additional analysis such as data mining using association rules is employed to derive useful information for the nearest users, as above. One of the data mining techniques employed is the discovery of association rules. Association rules discover the correlations between attributes, such as the presence of a particular attribute implying the presence of other attributes for a user. As described above, for the sake of analytical tractability, many auxiliary dimensions, elicited in the user interface from the user, but not encoded in the SFWs, were omitted from the original clustering. These dimensions, such as aggravating factors, alleviating factors, etc. (see Exhibits A-1 and A-2) hold rich information that has, in the SFW encoding and cluster generation process, been unexplored.
[0150] An example of an association rule is that “whenever a patient has disease X, the common aggravating factor is wheat”. For two sets of items X and Y, an association rule is usually denoted as x˜y to convey that the presence of the attribute X in a vector implies the presence of Y. The role of associations would be complementary to clustering (once the clusters are determined, mining for association rules within the cluster provides useful information on the medical experiences of the clusters).
[0151] Primary Scenario
[0152] To summarize the operation of the system of the preferred embodiment,the flow of events, in the usual case, is as follows.
[0153] 1. A member accesses the system, and completes the steps in the Your Health section. (Detailing their Primary Problems, Treatments, and taking the Questionnaire, all as described above).
[0154] 2. The User (Member) chooses to generate a new Report.
[0155] 3. The original User's record is mapped to a PDV, based on the medical information that the user has entered. This discards some information in the User's record for the purposes of generating the cluster.
[0156] 4. The PDV, and supporting user choices from the Exhibit A-1 list, as well as the formal problems of the A-2 list that the A-1 list choices are mapped to, is stored for later retrieval.
[0157] 5. The PDV is compared against all existing PDVs in the database to find a cluster of members (users) who are ‘close’ to this member.
[0158] 6. Queries are generated against the top ‘n’ members to determine their most common discussion groups, defining problems and good/bad treatments. All available information in the system is used at this stage.
[0159] 7. This information is presented to the user in a table, or other meaningful and efficient formats.
[0160] 8. Reports can be sent electronically, or via hard copy, to a User's doctor or other designated parties. FIG. 1A 30 .
[0161] Event Locator and Questionnaire Design Issues:
[0162] The design issues behind, and the functionalities of, the Questionnaire, will next be discussed.
[0163] The capacity of databases to permit new methods of viewing patterns of information and finding matches is not worth much without ways to capture accurate, detailed, and structured input.
[0164] The user is the original, most reliable and most efficient source of most information about symptoms, life events, environmental exposures, past illness, operations, allergies, and family history. The user has a story—referred to medically as the medical, social, environmental, family history. The system database has rows and columns waiting to receive the story. The interface between the input and storage of this data fulfills the following criteria:
[0165] 1. Engaging;
[0166] 2. Intuitive;
[0167] 3. Uses everyday language;
[0168] 4. Codes the data on entry.
[0169] Questionnaires in current medical use have narrow or superficial areas of interest in information that can expand in the context of a personal interview. There does not now exist a method for the free-form capture of detailed coded data in a system that begins with the same kind of question one would ask when sitting down with a patient for the first time: “Please tell me what is bothering you?” The Event Locator (FIGS. 16 - 22 , and the listings in Exhibit A-1 which can all be addressed in the Event Locator and/or follow up Questionnaire) starts from that point and leads to a questionnaire that follows up on symptoms and other events captured in the event locator, as described above.
[0170] A database providing vernacular descriptions of most medical symptoms and events matched to their coded dimensional meanings provides the foundation for the preferred embodiment of the present invention's capacity to encode natural language descriptions.
[0171] The present invention's first device is a graphic representation of a figure corresponding to the user's gender and age group (adult, child, toddler). The screen presented to the user shows the figure on the left. See FIGS. 16 - 22 . Moving a mouse over the figure, the user sees the names of various body areas or organs pop up in text boxes (leg, liver, intestines, nose, face, etc) and a mouse click then gives the user a list in one of the three boxes on the right side of the screen the top 15 symptoms associated with that area (precisely, it is the upper left hand box on the right half of the screen, labeled “areas”).
[0172] The user finds that selecting a small area (e.g. nose) will produce a list of problems whose associations are restricted to the nose, whereas selection of face will beget a list that includes nose problems along with eyes, mouth, chin, lips, etc. A substantial subset of symptoms can be addressed simply by reference to a part of or place on the body. Other problems may be identified by identifying the function (e.g. pain, itching) or the cause (allergy, trauma) of the symptom to be described. Thus a user with a headache may click on “pain,” or “head” to reach a list from which his or her type of headache can be selected. A person with itching on the elbows and knees may select “itching” or click first on elbows and then knees bringing them sequentially to elbow itching and knee itching.
[0173] All possible primary events in the invention's database can be found by at least one, and usually several redundant clicking choices. A primary event is one that is susceptible of being considered as a problem that would be described in response to the question, “Please tell me what is bothering you” and which would then populate the primary problem list. Thus the user can locate all sorts of trauma, allergies, pains, itching, and other disturbances of function as well as important toxic exposures and life events. Linkage of all the symptoms is assured by a table maintained in the database denoting which symptoms are grouped under subgroups (e.g., nose) and bigger groups (e.g., face). The following options appear after the top 15 symptoms (associated with the user designated area, function or trauma) list appears on the right side of the screen:
[0174] 1. The user may select a symptom from the list.
[0175] 2. The user may expand the list to include all the choices (i.e. beyond the top 15) in a scrollable enlargement of the top 15 list.
[0176] 3. The user may compact the symptom list by clicking to its left, on the human figure, on a location (e.g. nose, ear, mouth) representing a narrowing of the choices in a bigger groups (e.g. face). Similarly, for say, Life Events, the user may narrow its list by choosing the type of Life Event he or she wishes to select as a primary problem (death, job change, family change).
[0177] The user adds a problem to his or her primary problem list by clicking on the words that best describe one of his or her difficulties. The process may be repeated until the user has described all symptoms and events.
[0178] Once the graphic device has permitted the capture of the free form aspect of a medical interview in which the top of the user's problem list can be obtained thanks to the users incentive to input his or her main problems the user moves to the primary problem list screen for rating (assigning a numerical value representing the relative importance of each problem to the user), scoring (indicating whether the symptom is mildr moderate severe, or variable in its intensity) and describing (with drop down table choices) the onset, frequency, and episodic duration (when you get the headache how long does that episode last?) of each problem.
[0179] After the primary problems have been dealt with, the system moves the user on to describing her secondary problems. As described above, this occurs via the medium of the questionnaire.
[0180] The Questionnaire
[0181] The questionnaire allows for an inventory of other remaining difficulties that add detail to the sketch of primary problems and thus results in a true portrait of the user's unique combination of symptoms (events) stored in a manner that allows it to be matched with other individuals in the database as they are represented by statistical clusters. The key to the questionnaire is its presentation of branching, from general questions such as “Do you have any muscles spasms, tics, cramps, or tension?” to a specific list of symptoms that fall naturally into such a group. Questionnaire logic that recognizes symptoms entered in the primary problem list acknowledges previous answers (“We see that you have problems with headache; please tell us more about the factors influencing your headaches”), or builds from previous responses: (“We see that you have itchy elbows, please tell us if you have other itches that are important.”)
[0182] The lexicon or taxonomy referred to above, i.e. the listings of Exhibit A-1 is the foundation of the questionnaire. The lexicon gives the invention the capacity to exchange information with users in a language that is at the same time vernacular, yet coded in ways that preserve the detailed individuality of each user. Unlike a paper questionnaire, in which the device of e.g., “If ‘no’ skip to question 161”, has obvious limitations to one level of logical branching, an Internet or other data network accessed questionnaire has the capacity for many layers of branching that permit drilling down from a very general question. For example, from the general question “Do you have any skin problems or changes of any kind in your skin?” to (if yes) a group of more specific header questions which (if yes) permit the presentation of very specific skin symptoms. The more specific skin header questions have been formulated so that the vernacular terms used reflect the realities of medical dialog while their clusterings within each header question reflect functional (pain, itching, disruption, dryness) distinctions allowing for the specific questions at the third layer of branching to be of the same general type.
[0183] The questions found in an example questionnaire cover all of the issues contained in the Exhibit A-1 listing. The preferred embodiment has approximately 7400 of them. Primary Problem categories are asked to nearly everyone, termed “header questions”, and specific follow ups only to those indicating the presence of the problem. In this manner, the system “drills down” from the general to the specific, and thus hones in with great detail on the user's particular problems. Exhibit B-1 contains sample pages from the on screen version of an example questionnaire as seen by a user, depicting the skin header (or general) questions.
[0184] The skin header questions (Exhibit B-1), show how a complete inventory of skin questions was built from the lexicon by grouping words commonly expressed by patients to describe related problems.
[0185] Muscular problems provide another example of the way that the data in the database generates the terms used in the questionnaire. The question: “Do you have any tics, cramps, twitches, spasms, or muscle tension?” is a concatenation of terms joined by the functional pathology having to do with an abnormal increase in the normal function of muscles, to contract. It would not, however, due to ask a patient “Do you have an abnormal increase in the tendency of your muscles to contract?”, because that description is too far from the vernacular. On the other hand, to design a questionnaire entirely on the basis of being able to think up all the variations of how people express such categories of symptoms without reference to a lexicon of how they actually did so would be impossibly tedious. With each question the user is presented with the appropriate modifiers of severity, onset, frequency, episodic duration, and overall duration (for problems that ended in the past).
[0186] After completing the questionnaire, the user may promote problems uncovered in the questionnaire process to be primary problems if he or she appreciates during the questionnaire process that such and such a problem is, in fact, of sufficient concern to be rated among the ones that he or she mentioned in the primary problem phase (Event Locator, FIGS. 16 - 22 ).
[0187] Coding Examples
[0188] In what follows, examples of possible coding are presented to illustrate one implementation of key system computational functionalities. Numerous variations are obviously possible, and the following examples are for illustration only, and in no way are intended to limit or restrict the multiplicity of possible embodiments of the invention covered by the claims.
[0189] The key steps of the preferred embodiment are:
[0190] 1—Calculate the weightings matrix W;
[0191] 2—Generate a PDV for a particular member;
[0192] 3—Calculate medical similarity of this PDV to the other members; and
[0193] 4—Find the cluster of nearest N members (dynamic calculation based upon moving averages not shown; considered a trivial extension of the example depicted given the discussion in the specification above).
[0194] 1. Calculate weightings matrix
[0195] This is done as a two step process:
[0196] Firstly the following code runs as a stored procedure and creates the ‘first pass’ approximation for the most common cases. Basically it gives a weighting of 1 if only s,f, or w are shared between two columns. 2 if two things are shared and 3 if all three are shared (ie they are the same column).
<CODE> insert into clusterweightings select c1.clusterColumnId, c2.clusterColumnId, case when (sfw1.systemId = sfw2.systemId and sfw1.functionId = sfw2.functionId and sfw1.whereId = sfw2.whereId) then 3 when ((sfw1.systemId = sfw2.systemId and sfw1.functionId = sfw2.functionId) or (sfw1.functionId = sfw2.functionId and sfw1.whereId = sfw2.whereId) or (sfw1.systemId = sfw2.systemId and sfw1.whereId = sfw2.whereId)) then 2 else 1 end from (clusterColumn as c1 inner join sfw as sfw1 on c1.sfwid = sfw1.sfwId) cross join (clusterColumn as c2 inner join sfw as sfw2 on c2.sfwid = sfw2.sfwId) where sfw1.systemId = sfw2.systemId or sfw1.functionId = sfw2.functionId or sfw1.whereId = sfw2.whereId </CODE>
[0197] Then, to refine the weightings matrix we pass over the columns again using VB code, the purpose of which is to deal with the situation that different Systems, or Functions , e.g. CNS and Behaviour are actually somewhat related, and should have some “closeness” score.
[0198] updateSystemSFW(“X”, “X”, 1) for all columns that have the same system, i.e. “X” in two different columns.
[0199] The last stage downgrades the weight (by 1) when the where value that is shared is “not specified” (as opposed to e.g. “leg”).
<CODE> Call updateSystemSFW(“CNS”, “Behavior”, 0.8) Call updateSystemSFW(“Craving”, “Behavior”, 0.6) Call updateSystemSFW(“Development”, “Behavior”, 0.6) Call updateSystemSFW(“Emotion”, “Behavior”, 0.8) Call updateSystemSFW(“Neuromuscular”, “Behavior”, 0.2) Call updateSystemSFW(“Speech”, “Behavior”, 0.4) Call updateSystemSFW(“Vascular”, “Blood”, 0.2) Call updateSystemSFW(“Metabolic”, “Blood chemistry”, 0.4) Call updateSystemSFW(“Digestive”, “Body weight”, 0.4) Call updateSystemSFW(“Metabolic”, “Body weight”, 0.4) Call updateSystemSFW(“Nutrition”, “Body weight”, 0.2) Call updateSystemSFW(“Vascular”, “Cardiovascular”, 0.6) Call updateSystemSFW(“Development”, “CNS”, 0.4) Call updateSystemSFW(“Emotion”, “CNS”, 0.6) Call updateSystemSFW(“Hearing”, “CNS”, 0.2) Call updateSystemSFW(“Immune”, “CNS”, 0.4) Call updateSystemSFW(“Neuromuscular”, “CNS”, 0.2) Call updateSystemSFW(“Speech”, “CNS”, 0.4) Call updateSystemSFW(“Vision”, “CNS”, 0.2) Call updateSystemSFW(“Eating”, “Craving”, 0.8) Call updateSystemSFW(“Emotion”, “Craving”, 0.4) Call updateSystemSFW(“Metabolic”, “Craving”, 0.2) Call updateSystemSFW(“Nutrition”, “Craving”, 0.6) Call updateSystemSFW(“Life Event”, “Development”, 0.2) Call updateSystemSFW(“Eating”, “Digestive”, 0.8) Call updateSystemSFW(“Exocrine”, “Digestive”, 0.2) Call updateSystemSFW(“Immune”, “Digestive”, 0.4) Call updateSystemSFW(“Nutrition”, “Digestive”, 0.6) Call updateSystemSPW(“Emotion”, “Eating”, 0.2) Call updateSystemSFW(“Nutrition”, “Eating”, 0.8) Call updateSystemSFW(“Metabolic”, “Endocrine”, 0.6) Call updateSystemSFW(“Reproductive”, “Endocrine”, 0.6) Call updateSystemSFW(“Metabolic”, “Energy”, 0.6) Call updateSystemSFW(“Warmth”, “Energy”, 0.4) Call updateSystemSFW(“Skin”, “Hair”, 0.6) Call updateSystemSFW(“Immune/lymph”, “Immune”, 1) Call updateSystemSFW(“Warmth”, “Metabolic”, 0.4) Call updateSystemSFW(“Skin“, “Nails”, 0.6) Call updateSystemSFW(“Skeletal-joint”, “Neuromuscular”, 0.2) Call updateFunctionSFW(“Abnormal color”, “Abnormal”, 1) Call updateFunctionSFW(“Abnormal growth”, “Abnormal”, 1) Call updateFunctionSFW(“Abnormal lab test”, “Abnormal”, 1) Call updateFunctionSFW(“Abnormal odor”, “Abnormal”, 1) Call updateFunctionSFW(“Abnormal PE”, “Abnormal”, 1) Call updateFunctionSFW(“Abnormal rhythm”, “Abnormal”, 1) Call updateFunctionSFW(“Abnormal sensation”, “Abnormal”, 1) Call updateFunctionSFW(“Abnorrnal sound”, “Abnormal”, 1) Call UpdateNotSpecifiedWhere (1) </CODE>
[0200] 2. Generate PDV for a particular member
[0201] This is all implemented in a class called “BoundedPDv.java.” The method works as follows:
<CODE language=“java” doctored=“heavily doctored”> public void generatePdvColumns() throws DomainException { getPdvColumns().clear(); generateGenderColumns(memberId); generateAgeColumns(memberId); generateSfwColumns(memberId); } /** retrieve gender information from member * object and update corresponding columns */ private void generateGenderColumns(Long memberId) throws DomainException { Member member = new Member(new MemberIdKey(memberId)); String gender = member.getGender(); if (“m”.equalsIgnoreCase(gender)) { Long columnId = new Long(MALE_COLUMN_ID); setColumn(columnId, 1); return; } if (“f”.equalsIgnoreCase(gender)) { Long columnId = new Long(FEMALE_COLUMN_ID); setColumn(columnId, 1); return; } Log.write(Log.ERROR,“could not determine gender of member, got gender:” + gender + “ for memberId” + memberId + “- continuing silently”, this); } /** retrieve age information from member * object and update corresponding columns */ private void generateAgeColumns(Long memberId) throws DomainException { Member member = new Member(new MemberIdKey(memberId)); int maxAge = NUM_AGE_COLUMNS*YEARS_IN_AGE_BRACKET; // 15*7=105 int lastAgeColumn = NUM_AGE_COLUMNS+FIRST_AGE_COLUMN−1; //15+3−1=17 (columnId,17) at the mo int age = member.getAge().intValue(); // find the highest age bracket in which the member // exceeds minimum age int bracketMin = maxAge; for (int columnId=lastAgeColumn; columnId>=FIRST_AGE_COLUMN; columnId−−) { bracketMin=bracketMin−YEARS_IN_AGE_BRACKET; if (age>=bracketMin) { // NB.. if older than maxAge, they end up in the highest bracket setColumn(new Long(columnId),1); return; } } } /** call a stored procedure (for speed) * to get the columns relating to SFW information, calculate * corresponding value and call setColumn to update into pdv column list */ private void generateSfwColumns (Long memberId) throws DomainException { String retrieveQuery = “{call cluster_event_seventies_sp(“ + memberId + ”)}”; while (resultSet.next()) { rowCount++; // retrieve the severity info int i = resultSet.getInt(“i”); int j = resultSet.getInt(“j”); int k = resultSet.getInt(“k”); int l = resultSet.getInt(“l”); // calculate value for column from these severities // lose accuracy at this, the last point, in equation float value = (float)calculateSfwValue(i, j, k, l); // and update/add this value into pdvColumnList Long columnId = new Long (resultSet.getLong(“columnId”)); setColumn(columnId, value); } } // calculate these values once per each initialisation of the instance private double aInv=1/ClusterParam.a; private double bInv=1/ClusterParam.b; private double cInv=1/ClusterParam.c; private double dInv=1/ClusterParam.d; private double calculateSfwValue(int i, int j, int k, int l) throws DomainException { return 1 + ClusterParam.upperB * (1− (Math.pow(aInv, i) * Math.pow(bInv, j) *Math.pow(cInv, k) *Math.pow(dInv, l))); } } </CODE> for completeness the stored procedure which gets the severity i, j, k, l for the member's events is defined as follows: <CODE language=“TSQL”> CREATE PROCEDURE cluster_event_severities_sp ( @MemberId INT ) AS DECLARE @num_mild int, @num_moderate int, @num_severe int, @num_variable int, @column_id int, @sfw_id int create table #temp(columnId int, SFWId int, I int, J int, K int, L int) declare cluster_col_cursor cursor for select distinct cc.ClusterColumnId, cc.SfwId from ClusterColumn cc, FormalProblem fp, Event e where e.MemberId = @MemberId and e.FormalProblemId = fp.FormalProblemId and fp.SFWId = cc.SFWId and cc.ClusterColumnType = ‘Sfw’ and e.OnsetSeverity in (‘mild’, ‘moderate’, ‘severe’, ‘variable’) open cluster_col_cursor fetch next from cluster_col_cursor into @column_id, @sfw_id while @@FETCH_STATUS = 0 begin select @num_mild = count(*) from Event e, FormalProblem fp where e.FormalProblemId = fp.FormalProblemId and e.MemberId = @MemberId and fp.SfwId = @sfw_id and e.OnsetSeverity = ‘mild’ select @num_moderate = count(*) from Event e, FormalProblem fp where e.FormalProblemId = fp.FormalProblemId and e.MemberId = @MemberId and fp.SfwId = @sfw_id and e.OnsetSeverity = ‘moderate’ select @num_severe = count(*) from Event e, FormalProblem fp where e.FormalProblemId = fp.FormalProblemId and e.MemberId = @MemberId and fp.SfwId = @sfw_id and e.OnsetSeverity = ‘severe’ select @num_variable = count(*) from Event e, FormalProblem fp where e.FormalProblemId = fp.FormalProblemId and e.MemberId = @MemberId and fp.SfwId = @sfw_id and e.OnsetSeverity = ‘variable’ insert into #temp values(@column_id, @sfw_id, @num_mild, @num_moderate, @num_severe, @num_variable) fetch next from cluster_col_cursor into @column_id, @sfw_id end close cluster_col_cursor deallocate cluster_col_cursor select * from #temp drop table #temp GO </CODE>
[0202] 3. Calculate similarities from this PDV to other members.
[0203] This is all done inside the database.
[0204] The key code that does this is the bits of sql that follow, essentially it just implements the formula that is in the spec.
<CODE lanquage=“TSQL”> CREATE PROCEDURE cluster_calculate_similarities_sp ( @PdvIdIn int, @Tau float ) AS DECLARE @PdvIdOut int declare cluster_potential_cursor cursor for select distinct PdvIdOut from cluster_find_potential_pdv_list_view where PdvIdIn = @PdvIdIn and Tau > @Tau delete from clusterMetric where pdvId=@pdvIdIn open cluster_potential_cursor fetch next from cluster_potential_cursor into @PdvIdOut while @@FETCH_STATUS = 0 begin insert into ClusterMetric(PdvId, PdvId2, AmendDate, Val) select @PdvIdIn, @PdvIdOut, getdate(), sum(cw.weighting * pd.Val * pd2.Val) from PdvDetail pd, ClusterWeightings cw, PdvDetail pd2 where cw.ClusterColumnId = pd.ClusterColumnId and cw.ClusterColumnId2 = pd2.ClusterColumnId and pd.PdvId = @PdvIdIn and pd2.PdvId = @PdvIdOut and cw.Weighting > @Tau fetch next from cluster_potential_cursor into @PdvIdOut end close cluster_potential_cursor deallocate cluster_potential_cursor GO </CODE>
[0205] The above code depends on “cluster_find_potential_pdv_list_view” which is a view used, for speed purposes only, to create virtual subset of all pdvs. (Ie only the pdv-pdv matches where the similarity is >0 get a value inserted)
[0206] That view is defined as follows:
<CODE language=“TSQL”> CREATE PROCEDURE cluster_find_potential_pdv_list_sp ( @PdvId int, @Tau float ) AS insert into #potential_pdv select distinct p2.PdvId from Pdv p, PdvDetail pd, ClusterWeightings cw, PdvDetail pd2, Pdv p2 where pd.PdvId = p.PdvId and cw.ClusterColumnId = pd.ClusterColumnId and cw.ClusterColumnId2 = pd2.ClusterColumnId and pd2.PdvId = p2.PdvId and p.PdvId = @PdvId and p2.isDefault=‘Y’ and cw.Weighting > @Tau GO </CODE>
[0207] 4. Find the top N members:
[0208] This is pretty simple really . . . Essentially we just iterate through the list of pdvs starting at the most similar until we get to the nth member. At that point we have a value which can be used to select out the speific members via code which says basically “get all members where the similarity value >@calculatedMinValue” to get our N members.
<CODE language=“TSQL”> CREATE PROCEDURE cluster_find_value_sp @pdvID INT, @n INT AS declare @tmpVal as float, @curVal as float, @cnt as int set @curval = 0 set @cnt = 0 --create cursor DECLARE val_cursor CURSOR FOR SELECT val from clustermetric WHERE pdvid = @pdvID ORDER BY val desc --search for nth value --search for null values?? OPEN val_cursor FETCH NEXT FROM val_cursor INTO @curVal SET @cnt = @cnt + 1 while @@FETCH_STATUS = 0 AND @cnt < @n−1 begin FETCH NEXT FROM val_cursor INTO @curVal SET @cnt = @cnt + 1 end print @curVal CLOSE val_cursor DEALLOCATE val_cursor return @curVal GO </CODE>
[0209] The foregoing description of the preferred embodiments of this invention has been presented for purposes of illustration and description. It is not intended to be exhaustive or to limit the invention to the precise form disclosed, and obviously, many modifications and variations are possible, such as different listings (and thus divisions of the semantic plane) of the SFW's, available reportable problems and formal problems, different subject matter than human medical systemic states of being being encoded and mined, etc. Such modifications and variations that may be apparent to persons skilled in the art are intended to be included within the scope of this invention as defined by the accompanying claims. | A system and method are provided for extracting a set of data from a system user descriptive of the complete health snapshot of the user's to interact with a database of numerous other users so as to generate a cluster of similar user's exhibiting a similar (within some system defined distance metric) health snapshot. The system guides the user to present his or her data via a complex questionnaire based upon a novel descriptive taxonomy, based upon the principles of “cyberhealth” as opposed to the standard medical “disease oriented” singular cause and effect model. The system generates the cluster of similar users, analyzes the cluster to obtain a ranked list of possible remedies or therapies to assist the user in dealing with health problems. The system further creates a computer networked virtual community of users with common health problems/interests, facilitates online chat, discussion groups, and the trading of health information. Additionally, the system provides listings of and links to health care providers and medical testing laboratories who are able to assist users of the system. | 91,863 |
TECHNICAL FIELD
[0001] This invention is a tissue regenerative biological composition. More specifically, a composition at least in part formed from bone marrow and a method of manufacture and use of said composition with an acellular mixture.
BACKGROUND OF THE INVENTION
[0002] In the area of tissue regeneration or repair, the use of stem cell therapy has been widely touted.
[0003] Often, these inventions describe isolating the stem cells, purifying and culturally expanding mesenchymal stem cells. In U.S. Pat. No. 5,837,539, entitled “Monoclonal Antibodies For Human Mesenchymal Stem Cells”, Arnold Caplan et al. reported that the cells are preferably culturally expanded, but suggest it is possible to use the stem cells without culture expansion. Caplan also describes a way to isolate stem cells.
[0004] A major technological hurdle to producing a safe allogeneic composition with viable cells has been the need to approach a fraction of risk approaching zero by removing all antigenic properties that lead to inflammation factors in a separation to yield only a certain stromal cell type. This has proven both difficult and degrading the quantity of viable cells that can be effectively harvested.
[0005] The present invention has yielded a biological composition that is safe and achieves and does so in a method that allows the resultant mixture to be recovered from bone marrow wherein the mixture unexpectedly exhibits evidence of viability independent of mesenchymal cells in the dose and sustains a legacy or memory of the lineages from where the acellular biological composition came which retain the ability to support the emergence of new tissue forms including bone and other tissues.
[0006] These and other benefits of the present invention and the method of preparing it are described hereinafter.
SUMMARY OF THE INVENTION
[0007] A biological composition has a mixture of mechanically selected allogeneic biologic material derived from bone marrow. The mixture has non-whole cellular components including vesicular components and active and inactive components of biological activity, cell fragments, cellular excretions, cellular derivatives, and extracellular components. The mixture including non-whole cell fractions including one or more of exosomes, transcriptosomes, proteasomes, membrane rafts, lipid rafts. The mixture is compatible with biologic function.
[0008] The mixture of mechanically selected material derived from bone marrow. The biological composition preferably has bone particles. The bone particles can be added to the mixture derived from bone marrow. The bone particles include a mixture of cortical bone particles and cancellous bone particles.
[0009] The combination of non-whole cell components with a select number of non-whole cell fractions sustains pluripotency in the cells. In a preferred embodiment, the biological composition is predisposed to demonstrate or support elaboration of active volume or spatial geometry consistent in morphology with that of endogenous bone. The biological composition extends regenerative resonance that compliments or mimics tissue complexity. The mixture is treated in a protectant or cryoprotectant prior to preservation or cryopreservation or freeze drying. The composition can be maintained at ambient temperature prior to freeze drying. The protectant or cryoprotectant creates a physical or electrical or chemical gradient or combination thereof for tissue regeneration. The gradient can have a physical characteristic of modulus or topography, such as charge density, field shape or cryo or chemo toxic tendencies. The gradient can have a chemical characteristic of spatially changing compositions of density or species of functional molecules, wherein the molecules can offer a fixed catalytic function as a co-factor. Also, the gradient can have an electrical characteristic of charge based or pH based or electron affinities that confer metastability in biologic potential.
[0010] The bone marrow mixture which is derived from a cadaver has separation-enhanced non-whole cell fractions vitality including one or more of the following: separating the fractions from cells heightens their vitality, reversing “arrest” of donors, responsive molecular coupling, matrix quest in neutralizing inflammation or satience by balancing stimulus for repair. The protectant or cryoprotectant is a polyampholyte. The regenerative resonance occurs in the presence or absence of a refractory response. When using a cryoprotectant, the cryopreservation occurs at a temperature that is sub-freezing wherein the cryopreservation temperature is from 0 degrees C. to −200 degrees C. The protection may also be achieved by non-cryogenic means.
[0011] The biological composition's non-whole cellular component also can include organelle fragments and the active and inactive components of biological activity which can also include extants of the human metabolome.
[0012] A method of making a biological composition of the present invention has the steps of: collecting, recovering and processing bone marrow from a cadaver donor; mechanically separating the cellular or non-cellular components or a combination thereof of bone marrow from cadaverous bone; concentrating by centrifugation and filtering; separation by density gradient centrifugation; collecting non-cellular fractions or non-cellular components or a combination thereof of predetermined density; washing the non-whole cellular fractions or non-cellular components or a combination thereof to create the mixture; quantifying concentrations of non-cellular fractions components at a non-zero entity; suspending to a predetermined concentration in a polyampholyte cryoprotectant; freezing the mixture at a predetermined controlled rate; and packaging a bone blend having particles in the size range of 100 to 300 μm of demineralized cortical bone, mineralized cortical bone and mineralized cancellous bone either within the mixture or separate. These particle size ranges can vary higher or lower depending on the application. At the time of use, the mixture is thawed by immersion in a warm water bath for 2-3 minutes at 37 degrees C. It is diluted in saline without spinning; and then the diluted mixture, with or without the bone blend being intermixed, can be implanted by packing, injection, scaffolding or any other suitable means into a patient.
DEFINITIONS
[0013] DNase—deoxyribonuclease is any enzyme that catalyzes the hydrolytic cleavage of phosphodiester linkages in the DNA backbone, thus degrading DNA.
[0014] DMEM, DMEM/LG—Dulbecco's Modified Eagle Medium, low glucose. Sterile, with: Low Glucose (1 g/L), Sodium Pyruvate; without: L-glutamine, HEPES (4-(2-hydroxyethyl)-1-piperazineethanesulfonic acid)
[0015] DPBS—Dulbecco's Phosphate Buffered Saline.
[0016] CBT-MIXER—Mixing blade for Cancellous Bone Tumbler Jar.
[0017] Cold Media—Media used during the preparation of vertebral bodies for initial processing.
[0018] Cryopreserved—Tissue frozen with the addition of, or in a solution containing, a cryoprotectant agent such as glycerol, or dimethylsulfoxide, or carboxylated poly-1-lysine.
[0019] Freeze Dried/Lyophilized—Tissue dehydrated for storage by conversion of the water content of frozen tissue to a gaseous state under vacuum that extracts moisture.
[0020] Normal Saline—0.9% Sodium Chloride Solution.
[0021] Packing Media—Media used during initial processing and storage of the processed vertebral bodies prior to bone decellularization.
[0022] PBS—Phosphate Buffered Saline.
[0023] Processing Media—Media used during bone decellularization that may contain DMEM/Low Glucose no phenol red, Human Serum Albumin, Heparin, Gentamicin and DNAse.
BRIEF DESCRIPTION OF THE DRAWINGS
[0024] The invention will be described by way of example and with reference to the accompanying drawings in which:
[0025] FIG. 1 shows a photograph of a cut vertebral body taken from a spine of a cadaver donor.
[0026] FIG. 2 shows a photograph of the vertebral body after being cut into cubic pieces and immersed in a packing media.
[0027] FIG. 3 shows a photograph of the bulk bone material after being ground and immersed in packing media and placed in a jar for later tumbling.
[0028] FIG. 4 shows a photograph of the jar with a CBT-Mixer connected to a tumbler.
[0029] FIG. 5 is a photograph of an exemplary sieve device having sieves sized to separate the solid material.
[0030] FIG. 6 shows a photograph of two 50 ml vials, the one on the left being prior to centrifuging with the Ficoll that is commercially available at the bottom and the material above it. The 50 ml vial on the right is after centrifuging showing the non-whole cell fraction interface layer.
[0031] FIG. 7 is a photograph showing the four tumbling steps 1 - 4 by exemplary collection and Ficoll separation of the decanted fluids, the fluid in tumble 1 being completely discarded to remove unwanted debris.
[0032] FIG. 8 shows a photograph of two 50 ml vials, the one on the left being prior to centrifuging with a sucrose gradient that is commercially available at the bottom and the material above it. The 50 ml vial on the right is after centrifuging showing the non-whole cell fraction above the interface layer.
[0033] FIG. 9 is a representative photograph of the final packaging.
[0034] FIG. 10 is a photograph showing the ground bone.
DETAILED DESCRIPTION OF THE INVENTION
[0035] With reference to the present invention which is a tissue regenerative biological composition 100 made from bone marrow 200 , it is believed best understood by the methods used to process and recover the biological composition, as illustrated in the FIGS. 1-6 .
[0036] The first steps are to collect, recover and process bone marrow 200 from a cadaver donor. To do this, the spine is removed aseptically from the cadaver and the resultant spine segment is covered by cold media. The cold media has 0.5 ml of Heparin; 10,000 units/ml per 500 ml of DMEM. DMEM is a sterile solution with low glucose (1 g/L), Sodium Pyruvate; without L-glutamine, or HEPES. This cold media is used for packaging the spine segments for later processing. At this point the spine segment includes a plurality of vertebral bodies 202 . The clinical technician must remove as much soft tissue as possible and cut each vertebral body 202 with a saw. These vertebral bodies 202 , once cleaned, of all adherent soft tissue around the cortical surfaces will look as shown in FIG. 1 .
[0037] Once a cleaned vertebral body 202 is obtained, the next step involves cutting each vertebral body 202 into pieces, each piece 204 roughly 1 cm 3 . The cut pieces 204 being immersed in a packing media 400 . The exemplary packing media can be DMEM with 0.5 mlHeparin and 1.25 ml of DNAse added.
[0038] Once all the vertebral bodies 202 have been cut, the pieces 204 are taken to the bone grinder. The bone is ground into 4-10 mm pieces using packing media 400 to help the pieces go through the grinder. The ground bone 206 (bulk cortical-cancellous crushed) and all of the packing media 400 , estimated volume of 500 ml are transferred into a jar 300 where 0.5-1.0 ml of Gentamicin is added to the jar 300 with ground bone 206 and packing media 400 . At this point, the crushed bone 206 , including cellular soft marrow 200 , is intermixed.
[0039] The step of mechanically separating these cellular components of bone marrow 200 from the cadaverous bone is next performed. Transferring the bulk cortical-cancellous bone chips into a new jar with a CBT-Mixer in the jar. The bulk cortical-cancellous bone chips 206 will go through four cycles as summarized in the table below. Each cycle, after cycle 1 , contains three steps using a bone tumbler 500 and sieve set 600 . The sieve set 600 has screens 602 of various sizes, for example 500 μm and 180 μm, as shown in FIG. 5 .
[0000]
Step
Cycle 1
Cycle 2
Cycle 3
Cycle 4
Bone
30 minutes.
30 minutes
30 minutes
30 minutes
Tumbler
Using
Using
Using
Using
500 mL
500 mL
500 mL
400 mL
Processing
Processing
Processing
Processing
Media
Media
Media
Media
Sieve Set
Use the 500-
Use the 500-
Use the 500-
Use the 500-
μm and the
μm, 180-μm
μm, 180-μm
μm, 180-μm
bottom pan
and bottom
and bottom
and bottom
sieve.
pan sieve.
pan sieve.
pan sieve.
Discard
Collect
Collect
Collect
decanted
decanted
decanted
decanted
fluid.
fluid.
fluid.
fluid.
Centrifuge
N/A
Use decanted
Use decanted
Use decanted
fluid.
fluid.
fluid.
[0040] In cycle 1 , the decanted fluid 210 is discarded. To best understand this, an exemplary FIG. 7 shows conical tubes with the decanted fluids after each cycle followed by Ficoll separation. Tumble 1 or Cycle 1 has most of the unwanted cells and debris as evidenced by its dark and red appearance whereas each subsequent cycle 2 , 3 and 4 are progressively cleared. This FIG. 7 is only to illustrate the effects of multiple tumbles 1 - 4 and the value in discarding the decanted liquid 210 after the first tumble 1 .
[0041] After each subsequent sieving of the bulk bone material 206 , the decanted fluid 212 , 214 , 216 containing the mixture with whole cells is collected and put into a collection jar. When the next three cycles are complete and the decanted fluid is all placed in the collection jar comingling the fluids 212 , 214 and 216 to form a decanted fluid 220 . Then the centrifugation of the combined decanted fluid 220 occurs by placing the fluid 220 in a number of 250 ml conical tubes using a 100 ml pipette. The centrifuge is programmed to 280×g for 10 minutes at room temperature, preferably about 20 degrees C. The fluid 220 is passed through a blood filter to further remove any bone or spicules or clumps from the suspended cells. This completes the step of centrifuging and filtering. At this point, the mixture including whole cells 240 has been separated from the soft marrow tissue 200 and the remaining cancellous and cortical bone is discarded.
[0042] After this as shown in FIG. 6 , the step of separating the cells 240 from the non-whole cellular components by a density centrifugation occurs. The whole cells 240 are in the interface and the non-whole cell components are in the supernatant above the interface. The mixture including is placed in 50 ml conical tubes 20 with Ficoll 800 and undergoes a Ficoll-Paque separation under centrifugation wherein a cell density gradient is established by spinning at 400×g for 30 minutes at room temperature, preferably about 20 degrees C. The mixture includes cellular or non-cellular components or a combination thereof. All fluid 211 above the interface is removed include the desired non-whole cell components which exclude the whole cells 240 , 250 .
[0043] Typically, non-whole cell fragments, or membrane components have a diameter of 40-100 nm and can be separated within a density of 1.13-1.19 g/mL in a sucrose solution, and can be sedimented by centrifugation at 100,000 g. In fact, these fragments, or cell fractions, or microvesicles, have been collectively referred to as exosomes. Ranging in size from 20-1000 nm in diameter, they have been similarly referred to as nanoparticles, microparticles, shedding microvesicles, apoptotic blebs, and human endogenous retroviral particles. There are few firm criteria distinguishing one type of microvesicle from the other.
[0044] Following removal of the cell fraction, the supernatant is further filtered through 0.45 and 0.2 μm filters. Exosomes are further collected and separated within the suspension in multiple centrifugation steps with increasing centrifugal strength to sequentially pellet cells (300 g), microvesicles (10,000 g) and ultimately exosomes (100,000 g). Cells are deliberately removed to achieve the non-whole cell fragments and microvesicles.
[0045] Subsequent separation using density gradient-based isolation, using sucrose or commercially available prep can be applied to obtain more pure exosome preparations. Recent reports encouraging the use of iodixanol-based gradients for improved separation of exosomes from viruses and small apoptotic bodies are considerations left open to be adopted or adapted in refinement. Differing from sucrose, iodixanol forms iso-osmotic solutions at all densities, thus better preserving the size of the vesicles in the gradient, and both technologies are available to best isolation technology. In addition to these traditional isolation techniques, easy-to-use precipitation solutions, such as ExoQuick™ and Total Exosome Isolation™ (TEI), that have been commercialized reduce the need for expensive equipment or technical know-how. Although their mode-of-action has not been disclosed or validated, these kits are commonly used.
[0046] Once the mixture is completed, the method can include additional steps. This leads to the use of a bone blend 102 shown in FIG. 10 , preferably from the same vertebral bone or at least bone from the same donor.
[0047] When the mixture is prepared, it can have whole cells or even no whole cells, but will have the mechanically selected non-whole cellular components including vesicular components and active and inactive components of biological activity, cell fragments, cellular excretions, cellular derivatives, and extracellular components.
[0048] In one embodiment, the composition includes the whole cells in the mixture. In that embodiment, it is possible to provide bone particles with the mixture either in the mixture or separately to be combined at the time of use.
[0049] In one embodiment, the bone is ground to a particle size of 100-300 μm, see FIG. 11 . The bone mixture has 1.5 cc of mineralized cancellous bone 104 , 1.5 cc of mineralized cortical bone 105 and 2.0 cc of demineralized cortical bone 106 yielding 30 percent, 30 percent and 40 percent respectively of the total 5 cc (5 gram) of bone material 102 . The ranges coincide with the 1 cc of mixture when resuspended in 3 cc of saline to provide a bone particle and mixture for implantation, which can be by packing, injection, scaffolding or any other suitable means, into a patient in a fracture healing procedure, by way of example.
[0050] Other ranges of bone particle sized and mixture can be employed depending on the application which, in this example, was bone regeneration. Lower volumes and concentrations may be more suited for less intrusive bone repairs or more if larger if larger amounts of material are needed as in a hip defect or repair.
[0051] Variations in the present invention are possible in light of the description of it provided herein. While certain representative embodiments and details have been shown for the purpose of illustrating the subject invention, it will be apparent to those skilled in this art that various changes and modifications can be made therein without departing from the scope of the subject invention. It is, therefore, to be understood that changes can be made in the particular embodiments described, which will be within the full intended scope of the invention as defined by the following appended claims. | A biological composition has a mixture of mechanically selected allogeneic biologic material derived from bone marrow. The mixture has non-whole cellular components including vesicular components and active and inactive components of biological activity, cell fragments, cellular excretions, cellular derivatives, and extracellular components. The mixture including non-whole cell fractions including one or more of exosomes, transcriptosomes, proteasomes, membrane rafts, lipid rafts. The mixture is compatible with biologic function. | 22,141 |
TECHNICAL FIELD OF THE INVENTION
The invention relates generally to the use of databases. The invention relates preferably to a method and a system associated with the use of databases with mobile terminals.
BACKGROUND ART OF THE INVENTION
The following notions are used in this application:
“Data management system” is an entity, which comprises one or more databases and/or data management systems, whereby the system is responsible for reading the data structures contained in the databases and/or data management systems and for changing these data structures.
“Database” is an information structure, which comprises one or more data elements, and the use of which is controlled by the data management system. The invention is applicable both in relational databases and in databases of other forms, such as in object oriented databases.
“Data element” is an information structure, which can comprise other data elements or such data elements, which can be construed as atomary data elements. For instance, in a relational database data elements are represented by tables comprising rows. The rows comprise fields, which are typically atomary data elements.
“Database operation” is an event, during which data elements are read from the database, during which data elements of the database are modified, during which data elements are removed from the database, and/or during which data elements are added to the database.
“Transaction” is a plurality of database operations acting on the data elements. A transaction can also comprise further transactions.
“Database Catalog” is a logical database within a database instance. A physical database can manage data of multiple database catalogs. Each database catalog can act as an independent master or replica database node in a database synchronization environment.
“Database Schema” is the structure of a database system, described in a formal language supported by the database management system (DBMS). In a relational database, the schema defines the tables, the fields in each table, and the relationships between fields and tables.
“Master database” is a database catalog in a database synchronization system that contains the official version of synchronized/distributed data. A master database can have multiple replica databases.
“Replica database” is a database catalog in a database synchronization system that contains a full or partial tentative copy of the master data.
“Synchronization” is operation between replica and master database catalogs in which changed data is exchanged between the catalogs. In one known embodiment, this means propagation of Intelligent Transactions from replica to master and/or subscription of changed data of publications from master to replica.
“Publication” is a set of data in a database catalog that has been published in master database for synchronization to one or multiple replica databases.
There are presently some software push technologies available that are capable of pushing a set of software files to terminals and keeping the once-installed configuration up-to-date by pushing upgrade files to the terminal on an as-needed basis. This means that the software that is stored and run locally in the terminal can be managed remotely.
However, this technology does not address the requirements of mobile users and wireless communities where it is important to manage a potentially large, dynamically changing set of applications. For instance, the list of services available to that terminal, i.e, the “desktop” of the terminal, is relatively static and cannot be easily changed to reflect different roles and locations of the user of the terminal.
Many web portals allow personalization of their home pages so that different users can have different view to the list of services provided by the portal. This perzonalization data is separate for each portal and it cannot be utilized when using another portal. Moreover, web portal personalization techniques are applicable only to web-based applications, i.e. services that are provided by a server that resides in the network.
For these reasons, the current web service personalization technology that operates on isolated and proprietary user profile data is not feasible in environments, where there are potentially a very large number of application service providers, e.g. one per each wireless base station, which all need to conform with the personal preferences of the user and capabilities of the current terminal of the user.
SUMMARY OF THE INVENTION
The objective of this invention is to present a method and a system which allows managing a large dynamically changeable set of applications in mobile Internet.
The objectives of the invention are attained by specifying user preferences with an identity server, and matching the preferences with applications of a community server. The result of the match is stored in a service assembly point. This invention also introduces the concept of Identity Data, which is maintained in the Identity Server, and is an essential part in process of joining to a new community. Examples of Identity Data may include name, address, age, size, weight, sex, profession, hobbies, personal interests, etc.
The invention provides a service matchmaking method that efficiently matches the users preferences and available services of a community into a list of local and web-based services that is of interest to the user.
The invention thus provides a solution to the problem of managing services and configuration of smart network node in environments where the services and their content data need to be managed remotely from multiple remote sources in a dynamic manner based on preferences of the user and capabilities of the currently used terminal. The related service data may include the availability, registered users, application binary files, configuration, parameter requirements, classification, etc.
A typical example of a dynamically configurable smart network node according to the invention is a so-called smart phone. The user of a smart phone has different roles in different communities depending on location, time of day and personal preferences. For example, during workdays from 8 AM to 5 PM, a person can have a “Boss” role in a “Work” community. In his role, Me person wants to have access to corporate intraweb, e-mail and chat applications through his terminal. Outside business hours, this same person may want to use applications that are available to him via the “Dad” role in his “Home” community. The services may run in the network servers or alternatively, they can run locally in the smart terminals. To ensure ease of use of the terminal, managing the “desktop”, i.e. determining the services available to the user in his current role, should be done centrally in each of the communities. No or minimal amount of user interaction is necessary to manage the configuration of the terminal.
With the present invention it is possible to remotely manage software configuration and content data of a terminal from various community servers and keep the terminal data automatically in synchronization with the community server's data by using a known, generic relational and transactional data synchronization mechanism. Also the distinction between Community Data and Identity Data is possible.
The communication between the client terminal and the servers is preferably at least in part wireless communication in order to provide a mobile terminal, but the communication can also be wireline communication. The “Service Assembly Point” (SAP) may be a server or a client terminal with a wireless or wireline connection to the Community Server.
The method according to the invention for managing data in a system comprising at least one community, at least one user, at least one community system comprising at least one database, and at least one application, at least one service assembly point (SAP) comprising at least one database, and means for communication between a community system and a service assembly point, is characterized in that
at least one service assembly point is a member of at least one community, the users can be members in a community with different profiles, and the users may use applications of a community according to said profiles.
The invention also relates to a storage media comprising a stored, readable computer program, which is characterized in that the program comprises instructions for controlling a data management system or components thereof to implement the method according to the invention.
The invention further relates to a data management system comprising at least one community and at least one user, at least one community system comprising at least one database and at least one application, at least one service assembly point (SAP) comprising at least one database, and means for communication between a community system and the service assembly point, which is characterized in that
at least one service assembly point is a member of at least one community, the users of the SAPs can be members in a community with different profiles, and the users of the SAPs may use applications of a community according to said profiles.
The invention further relates to a community server for a data management system, the community server comprising at least one community, at least one database, at least one application, and means for communication between the community system and a service assembly point (SAP) of the data management system, which is characterized in that the community server comprises
means for joining service assembly points into communities, means for providing the users of the SAPs that are members in a community with different rights of use, means for allowing the users of the SAPs to use applications of a community according to said rights of use.
Some preferred embodiments of the invention are described in the dependent claims.
BRIEF DESCRIPTION OF THE DRAWINGS
Below the invention is described in more detail with reference to preferred embodiments shown as examples and to the enclosed figures, in which:
FIG. 1 shows some parts of an examplary system according to the invention;
FIG. 2 shows the basic units of an examplary system according to the invention;
FIG. 3 shows a flow diagram of examplary steps for joining a community and a producing a set of applications to the client in a method according to the invention;
FIG. 4 shows a flow diagram of examplary steps for downloading and installing an application in a method according to the invention;
FIG. 5 shows a flow diagram of examplary steps for running an application in a method according to the invention; and
FIG. 6 shows two examplary publications in a system according to the invention.
DETAILED DESCRIPTION
FIG. 1 shows an example of parts of a system 100 according to the invention. The user has a locally runnable software and content of a smart terminal 120 , which is in communication with the “Community Client”, which is managed by one or multiple application and content management servers, “Community Server” 101 , 107 , and “Content Server”, 103 , 105 , 109 , respectively. The applications and pointers to web based applications are stored in the managed data storage, e.g, relational database, of the Community Servers. The content data of the applications may be managed and distributed using Content Servers. The identity data, such as User ID, name, access keys etc., of the user of the Community Client is maintained in the User Identity Client 130 of the Community Client terminal 120 . The identity data may also be maintained in a separate Identity Server that is synchronized with the identity clients of the user (not shown in FIG. 1 ). The profile information of the users can be maintained in the Identity Server. The community replicas are stored in the databases 121 , 123 , 125 , 127 , 129 of the client terminal. The smart terminals can maintain a full or partial copy (replica) of the servers' data using suitable data synchronization technology, such as functionality disclosed in patent application document EP 0 860 788.
FIG. 2 shows an examplary mobile Internet system according to the invention that consists of three main components: Community Server 201 for managing and classifying Services, Identity Server 202 for managing User Identity and Service Assembly Point (SAP) 220 that is typically a Smart Terminal but can also reside in any other type of network node. Such a network node may be e.g. a base station controller, access router, optical network router, etc. The invention provides a solution for the problem of bringing a user of the SAP a subset of locally executable or network based services that match the published user preferences and terminal capabilities of the currently used terminal.
Community Server
In the mobile Internet, there can potentially be a very large number of sources for the services. In this invention, these sources of services are called Mobile Communities. A service of the community can be network-based (i.e. it runs on a server that resides in the network) or it can be run locally in the Service Assembly Point.
The nature of the services can be described by classifying them using commonly agreed service classes. The service classes describe the nature of the service at different levels of detail. For instance, a commonly known “Tetris” game can belong to “TETRIS”, “SPEED GAMES”, “UNINTELLIGENT GAMES”, “GAMES” and “EVERYTHING” service classes.
In the invention, the services and their classifications are preferably managed by an entity called Community Server.
Identity Server
Each user of the Mobile Internet has his/her own identity. The Identity Data of the user can contain for instance following categories of data:
Basic Identification Information has the unique identifier of the user, name and address information of the user, currently active role of the user etc.; Service Preference Information contains the list of service classes that are of interest to the user; Access Keys to facilitate secure access to those services that require heightened security; Location and Service Usage History of the user, i.e. current and past locations where the user has been; and Terminals of the user, such as PCs, mobile phones, communicators & information appliances.
In the invention, the User Identity is preferably managed by an entity called Identity Server. The identity server can synchronize its data with the identity clients of one or multiple Service Assembly Points. Another possibility is to maintain the Identity Data only in the Service Assembly Point if there is no need to share identity information across devices.
Service Assembly Point
The Service Assembly Point is a node in the network, typically a Smart Terminal, where the list of services that is of interest to the user, which can be provided through the terminal that's currently in use, is stored.
When a user wants to assemble a service list from a community server to be used in a Service Assembly Point, following steps are taken:
1) To ensure that the Service Assembly Point has the most recent version of the user identity data, it synchronizes its Identity Database Replica with the Identity Database Master that runs in the Identity Server. This step is not necessary if the SAP's version of the user's identity data is known to be the most recent version. 2) The Service Assembly Point establishes a connection with the Community Server's master database and creates a local replica of the database to the SAP. This step is not needed if the replica for that Community Server has been created earlier. 3) The Service Assembly Point publishes user's preference and terminal property data to the Community Server and invokes the service matchmaking process in the Community Server for instance by using data synchronization techniques such as SOLID Intelligent Transaction disclosed in document EP 0 860 788. 4) The service matchmaking process produces a list of services in the Community Server that is synchronized back to the community replica database of the Service Assembly Point. 5) The list of services is shown to the User. 6) To invoke a service, the User selects the service from the list. 7) If the service is to be executed locally in the Service Assembly Point, the service binaries and resources are downloaded from the Community Server to the local replica of the community using e.g. data synchronization techniques such as publications, unless downloaded already earlier. If the service is located by a network-based application server, the service is located and invoked by using the Uniform Resource Locator (URL) of the service.
Whenever the User needs to refresh the list of available services (e.g. when he/she changes preferences) or services of the community are changed, this can be done by re-executing steps 3–5 of the above sequence of steps.
FIG. 3 shows a flow diagram of examplary steps for joining a community in a method according to the invention. The logical terminal 342 can establish a relationship with a new Community Server by registering itself with the server. At registration, 361 , the database management system of the Community Client reserves a new area (e.g. database catalog) for the data of the new Community Server, 362 . After creating the database catalog, the Community Client authenticates itself with the Community Server database, 363 – 367 , using the locally maintained identity data and downloads meta-data about the Community Server's database to the new database catalog of the terminal. The meta-data contains information necessary to create the replica database schema, 365 , and to synchronize the replica database later with the master database of the Community Server, 368 .
Once the registration and meta-data download has successfully completed, the terminal database creates a database schema to the newly created catalog using scripts that have been sent from the community server to the terminal database as part of meta-data. Finally the preferences and terminal properties are matched with service classification and terminal requirements, 369 , in a Service matchmaking process. The service matchmaking efficiently matches the user's preferences and available services of a community into a list of local and web-based services that is of interest to the user. After this, the new replica catalog can download community and application's header data from the community server's database by subscribing to Community publication.
FIG. 4 shows a flow diagram of examplary steps for downloading and installing an application in a method according to the invention. The smart terminal can build its “desktop” i.e. links to its available services based on the data it has synchronized from the Community Server. This can be done for example by selecting a catalog from the Community Client's database, selecting a current role from the roles table of the catalog and listing the applications of the selected role in the user interface. The binary code, resources and installation scripts of the applications can be downloaded to the terminal, 470 , separately by subscribing to a separate Application (APPLICATION_ID) publication, 471 . In his publication, the APPLICATION_ID identifies the application whose binaries, resources and installation scripts are to be downloaded.
If the downloaded application requires a local Content database that is possibly synchronized with another database, the downloaded application's meta-data can contain scripts that create a separate database catalog, 472 – 474 , for the content data of the application and register this new catalog with the master database of the Content Server. These scripts are executed, 475 , after successful subscription of the APPLICATION publication.
FIG. 5 shows a flow diagram of examplary steps for running an application in a method according to the invention. The user of the terminal can run an application by selecting the application from the user interface, 581 . This invokes the application loader program that instantiates the selected application from the database tables to the main memory of the terminal, 582 , and executes the program, 583 , 584 . Because the applications reside in the synchronizable local database, their consistency is always guaranteed by the generic data synchronization mechanism of the data management components of the Community Client and Server nodes. When application configuration is changed in the Community Server database, the new version is automatically downloaded to the Community Client when the databases are synchronized next time.
When the user does not need the services of the Community any more, the service suite of that Community can be deleted from the terminal simply by unregistering The replica database and by dropping the catalog and its content from the database.
FIG. 6 shows a publication which can be used in implementing the present invention. Publication comprises a set of data in a database catalog that has been published in master database for synchronization to one or multiple replica databases. In the publication the USERS_APPS(user_ID) identifies the member user 692 , the applications of the user 693 and the applications 694 , In the publication, the APPLICATION(app_ID) 695 identifies the application 696 whose binaries 697 , resources 698 and installation scripts 699 are to be downloaded to the client terminal.
A system according to the invention can be implemented by a person skilled in the art with state of the art information technology and communication technology components. A person skilled in the art can implement the functions according to the invention by arranging and programming such components to realize the inventive functions.
For example, it is preferable to implement the invention to work in a telecommunication system, which is compliment with at least one of the following: TCP/IP, CDMA, GSM, GPRS, WCDMA, UMTS, Teldesic, Iridium, Inmarsat, WLAN and imode,
It is also preferable to use a standardized operating system in the terminals and servers. The operating system of a terminal can be, for example, Unix, MS-windows, EPOC, NT, MSCE, Linux, PalmOS and GEOS. The community server and/or the identity server may have at least one of the following operating systems: Unix, MS-windows, NT and Linux.
To a person skilled in the art it is obvious that in order to have an illustrative description the above presented exemplary embodiments have a structure and a function which are relatively simple. By applying the model presented in this application it is possible to design different and very complicated systems which, in obvious ways to the expert, utilise the inventive idea presented in this application. | The invention relates generally to the use of databases. Preferably the invention relates to a method and a system associated with the use of databases with mobile terminals. The objective of this invention is to present a method and a system which allows managing a large dynamically changeable set of applications in the mobile Internet. The objectives of the invention are attained by determining user profiles within communities, and the rights for using applications of a community server depends on the profiles of the user within the community. The identity information is preferably maintained in an identity server. The invention provides a solution to the problem of managing services and configuration of smart network node in environments where the services and their content data need to be managed remotely from multiple remote sources in a dynamic manner. | 23,501 |
[0001] This is a continuation application of prior application Ser. No. 09/950,743, filed on Sep. 12, 2001, which is hereby incorporated by reference.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] This invention relates to a media pack that can be removably mounted in a printer, a printer and a camera with the printer that can removably receive the media pack.
[0004] 2. Prior Art
[0005] In general, in order to form an image with an excellent picture quality on a recording surface of a recording medium by an ink jet recording apparatus, it is required to use ink, which is suited to a kind of the recording medium, for example. To meet this requirement, a media pack which can be removably mounted in the body of a recording apparatus was disclosed e.g. in Japanese Laid-Open Patent Publication (Kokai) No. 11-254700 (where the media pack is referred to as a media cartridge). The use of the media pack or media cartridge makes it possible to positively provide ink suitable for use on the recording medium.
[0006] The media cartridge is comprised of a cassette section in which a stack of a plurality of recording medium sheets are contained, an ink tank section for holding ink suitable for recording on the recording medium sheets, and a waste ink tank section for collecting and holding used ink which has been used in a recovery process for a recording head. The media cartridge is replaced by a new one when the recording medium sheets and/or the ink held therein are used up. Also, when recording medium sheets of a different kind are required to be used, the media cartridge is replaced by another media cartridge holding the desired kind of recording medium sheets and ink suitable for the recording medium sheets.
[0007] However, when the above conventional type of media cartridge is used, it is required to change the media cartridge each time recording medium sheets and/or ink held in the media cartridge are used up, which results in higher running costs than when a media cartridge can be refilled with recording medium sheets and/or ink.
[0008] Further, when it is required to use a plurality of media cartridges each holding a different kind of recording medium sheets and ink while replacing them with each other, some media cartridges can be left unused over a long time period. Recording medium sheets and/or ink in a media cartridge purchased long ago can have changed in quality and deteriorated to such an extent that they are no longer suitable for use. However, a user might use the media cartridge without being aware of the fact that the media cartridge was purchased long ago. Deterioration of recording medium sheets and/or ink in the media cartridge makes it impossible to output an image with a desired picture quality, which causes the inconvenience that the user has to perform printing again by using a new media cartridge.
[0009] Further, a camera with a printer is conventionally known, which is capable of storing in its memory information related to an image picked up by an electronic imaging means, such as a CCD, and printing out image information at any time.
[0010] In general, a fusion thermal transfer printer, a sublimation thermal transfer printer or an ink jet printer can be used for the camera of the above kind. Among these printers, the ink jet printer is most advantageous in terms of running costs, reduction of the size, power management, and output speed, and hence particularly suitable for a camera of a camera-printer combination type of which portability is required.
[0011] In the above combination-type camera with a printer, it is preferred that an image picked up by the camera is printed in a state of the camera being placed on a horizontal or level support surface, but printing is possible even when the camera is being carried so long as the camera is held in a predetermined state. However, e.g. when a photographer is moving with the camera in his/her hands, the camera is shaken up and down or left and right, together with the printer incorporated in the camera. When printing is performed in the state of the camera being shaken up and down or left and right, if a big shake occurs, the print operation of the printer is hindered, which makes it impossible to obtain a desired print output. As a result, a print output comes to nothing.
[0012] Further, the photographer cannot make a determination as to the degree or magnitude of a shake which is tolerable for print operation, which degrades the ease of use of the combination-type camera.
SUMMARY OF THE INVENTION
[0013] It is a first object of the present invention to provide a media pack which can be removably mounted in a printer, and which allows a consumable article or articles contained therein for use by the printer to be refilled, and enables the printer to easily recognize whether there is a possibility of degradation of the consumable article(s) due to a long time period elapsing after refilling of the consumable article(s).
[0014] It is a second object of the present invention to provide a printer and a camera with a printer which make it possible to easily recognize whether there is a possibility of degradation of the consumable article(s) of a media pack due to a long time period elapsing after refilling of the consumable article(s), when the media pack is used.
[0015] It is a third object of the present invention to provide a media pack which can be used for time-related management of information related to operations of a printer.
[0016] It is a fourth object of the present invention to provide a printer and a camera with a printer which are capable of performing time-related management of information related to operations of the printer by using a memory arranged in a media pack when the media pack is used.
[0017] It is a fifth object of the present invention to provide a camera with a printer which enables time-related management of a media pack mounted therein by utilizing clock information for recording a date and time in association with an image during image recording by a camera.
[0018] It is a sixth object of the present invention to provide a media pack which makes it possible to read characteristic change information indicative of a change in characteristics of a consumable article or articles of a media pack, to thereby enable easy recognition of the change in characteristics of the consumable article(s).
[0019] It is a seventh object of the present invention to provide a printer which is capable of easily recognizing a change in characteristics of a consumable article or articles of a media pack when the media pack is used.
[0020] It is an eighth object of the present invention to provide a camera with a printer which is capable of optimally controlling a print operation performed in a condition where a blur can occur, and which is easy for a user to handle, and enables reduction of the size of the whole apparatus through sharing a single sensor for a shake sensor for the camera and a blur sensor for controlling printing by the printer.
[0021] To attain the first object, according to a first aspect of the invention, there is provided a media pack that can be removably mounted in a printer, the media pack comprising a pack body containing at least ink and a print medium for use with the printer, and a memory arranged within the pack body, for storing data related to the at least ink and a print medium, the data including at least first information of a year and month at which at least ink and a print medium was filled or produced.
[0022] This arrangement not only allows the media pack to be refilled with the consumable article for use by the printer, but also enables the printer to easily recognize whether there is a possibility of degradation of the consumable article due to a long time period having elapsed after refilling of the consumable article.
[0023] Preferably, the first information is updated when the media pack is refilled with the print medium.
[0024] Preferably, the memory also stores second information of a year and month at which the ink was filled or produced.
[0025] Preferably, the first information is stored in association with the second information.
[0026] Preferably, the memory stores third information relating to a change in characteristics of the ink dependent on a time period elapsed after the filling or producing of the ink.
[0027] According to this preferred embodiment, the printer reads third information stored in the memory, whereby the compensation for the degradation of the ink can be easily filled or produced.
[0028] To attain the second object, according to a second aspect of the invention, there is provided a printer comprising a mounting mechanism capable of removably mounting a media pack comprising a pack body containing ink and a print medium for use in printing, and a memory capable of storing data related to the print medium, the data including at least first information of a year and month at which print medium was filled or produced, and a detector capable of detecting an elapsed time period based on the first information read out from the memory.
[0029] According to this printer, when using the media pack, it is possible to easily determine whether or not there is a possibility of degradation of the consumable article due to a long elapsed time period.
[0030] Preferably, the memory also stores second information of a year and month at which the ink was filled or produced, and the printer includes an acquisition circuit capable of acquiring characteristic change third information relating to a change in characteristics of the ink dependent on a time period elapsed after the filling or producing of the ink.
[0031] Preferably, the third information is stored in the memory of the media pack.
[0032] Preferably, the third information is stored in a memory.
[0033] Preferably, the printer further includes an image processing circuit capable of executing image processing of image data, by using coefficients, and a coefficient-changing circuit capable of changing the coefficients used in the image processing, based on the third information.
[0034] According to this preferred embodiment, the compensation for degradation of the ink can be easily carried out.
[0035] To attain the second object, according to a third aspect of the invention, there is provided a printer comprising a mounting mechanism capable of removably mounting a media pack at least one kind of containing consumable article and including a memory capable of storing at least first information of a year and month at which the consumable article was filled or produced, a mode setting circuit capable of setting a print mode for performing a print operation, and a detector capable of detecting an elapsed time period based on the first information, when the media pack is mounted in the mounting mechanism and when the print mode is set.
[0036] According to this printer, when using a media pack, it is possible to easily determine whether or not there is a possibility of degradation of the consumable article due to a long time period having elapsed after the filling or production of the consumable article.
[0037] Preferably, the printer further includes a display capable of displaying a result of detection performed by the detector when the media pack is mounted, in a first display form, and displaying a result of detection performed by the detector when the print mode is set, in a second display form different from the first display form.
[0038] According to this preferred embodiment, it is possible to carry out warning of degradation of the consumable article in a user-friendly manner.
[0039] To attain the second object, according to a fourth aspect of the invention, there is provided a camera with a printer, comprising a printer, an image sensor capable of picking up an image, a timer capable of setting date information, a recorder capable of recording the image picked up by the image sensor, in association with the date information set by the timer, a mounting mechanism capable of removably mounting a media pack containing at least one kind of consumable article for use in printing by the printer and including a memory capable of storing at least first information of a year and month at which the consumable article was filled or produced, and a detector capable of detecting a time period elapsed after the filling or producing of the consumable article, based on the first information stored in the memory and the date information set by the timer.
[0040] According to this camera with a printer, it is possible to determine easily whether or not there is a possibility of degradation of the consumable article due to a long elapsed time period.
[0041] Preferably, the camera with a printer includes an acquisition circuit capable of acquiring third information relating to a change in characteristics of the consumable articles dependent on a time period elapsed after the filling or producing of the consumable article.
[0042] Preferably, the third information is stored in the memory of the media pack.
[0043] Preferably, the third information is stored in a memory.
[0044] Preferably, the camera with a printer includes an image processing circuit capable of executing image processing of image data, by using coefficients, and a coefficient-changing circuit capable of changing the coefficients used in the image processing, based on the acquired third information.
[0045] According to this preferred embodiment, compensation for the degradation of the consumable article can be easily carried out.
[0046] Preferably, the camera with a printer includes a mode setting circuit capable of setting a print mode for performing a print operation, and the detector detects a time period elapsed after the filling or producing of the consumable articles when the media pack is mounted in the mounting means and when the print mode is set.
[0047] Preferably, the camera with a printer includes a display capable of displaying a result of detection performed by the detector when the media pack is mounted, in a first display form, and displays a result of detection performed by the detector when the print mode is set, in a second display form different from the first display form.
[0048] According to this preferred embodiment, it is possible to carry out warning of degradation of the consumable article(s) in a user-friendly manner.
[0049] To attain the third object, according to a fifth aspect of the invention, there is provided a media pack that can be removably mounted in a printer, the media pack comprising a pack body containing at least one kind of consumable article for use by the printer, and a memory arranged within the pack body, the memory being capable of storing information relating to operations of the printer in association with date information at least in a state of the media pack being mounted in the printer.
[0050] According to this media pack, it is possible to utilize the media pack for time-related management of the information related to operations of the printer.
[0051] To attain the fourth object, according to a sixth aspect of the invention, there is provided a printer comprising a mounting mechanism capable of mounting a media pack containing at least one kind of consumable article, and printing means capable of performing a print operation by using the consumable article contained in the media pack, the media pack including a pack body containing the consumable article, and a memory arranged within the pack body, the memory being capable of storing information relating to the print operation in association with date information at least in a state of the media pack being mounted in the mounting mechanism, the information wherein relating to the print operation including error information of an error in the print operation.
[0052] According to this printer, when the media pack is used, it is possible to perform time-related management of the information related to operations of the printer by using the memory arranged in the media pack.
[0053] Preferably, the camera with a printer comprises a connector for connecting the printer to the camera.
[0054] According to this camera with a printer, when the media pack is used, it is possible to perform time-related management of the information related to operations of the printer by using the memory arranged in the media pack.
[0055] To attain the fifth object, according to a seventh aspect of the invention, there is provided a camera with a printer, comprising a printer, an image sensor capable of picking up an image, a timer capable of setting date information, a recorder capable of recording the image picked up by the image sensor, in association with the date information set by the timer, a mounting mechanism capable of removably mounting a media pack containing consumable articles for use in printing by the printer and including a memory capable of storing, and a controller that writes the date information set by the timer, in the memory of the media pack.
[0056] According to this camera with a printer, date information for use in recording a date and time in association with an image during image recording by the camera can be utilized for time-related management of the media pack.
[0057] Preferably, the at least one kind of consumable article contained in the media pack comprises ink and/or a print medium.
[0058] Preferably, the memory of the media pack further stores information related to the consumable articles.
[0059] Preferably, the controller writes the date information set by the timer and the information related to operations of the printer in association with each other in the memory of the media pack.
[0060] To attain the sixth object, according to an eighth aspect of the invention, there is provided a media pack which can be removably mounted in a printer, the media pack comprising a pack body containing at least one kind of consumable article for use by the printer, and a memory arranged within the pack body, the memory being capable of storing data related to information indicative of a change in characteristics of the consumable article dependent on a time period elapsed after the filling or producing of the consumable article.
[0061] According to this media pack, it is possible to read the characteristic change information indicative of a change in characteristics of the consumable article, thereby easily recognizing the change in characteristics of the consumable articles.
[0062] To attain the seventh object, according to a ninth aspect of the invention, there is provided a printer comprising a mounting mechanism capable of mounting a media pack including a pack body containing at least one kind of consumable article for use in printing, and a memory arranged within the pack body, the memory being capable of storing data relating to information indicative of a change in characteristics of the consumable article dependent on a time period elapsed after filling or producing of the consumable article, and an acquisition circuit for acquiring the information from the memory of the media pack.
[0063] According to this printer, when using the media pack, it is possible to easily recognize the change in characteristics of the consumable article within the media pack.
[0064] Preferably, the printer includes an image processing circuit capable of executing image processing of image data by using coefficients, and a coefficient-changing circuit capable of changing the coefficients used in the image processing, based on the acquired information.
[0065] According to this preferred embodiment, it is possible to easily compensate for degradation of the consumable article.
[0066] To attain the eighth object, according to a tenth aspect of the invention, there is provided a camera with a printer comprising a camera body, a printer integrally combined with the camera body, a shake sensor capable of detecting a shake of the camera body, a correction circuit capable of correcting a blur of a captured image according to an output from the shake sensor, and a controller for controlling operation of the printer according to the output from the shake sensor.
[0067] According to this camera with a printer, it is possible to optimally control the print operation performed in a condition where a blur can occur, and a user can handle the apparatus with ease. Further, the shake sensor for the camera can also be utilized as a blur sensor for controlling printing by the printer, which contributes to reduction of the size of the whole apparatus.
[0068] Preferably, the printer includes a recording head reciprocally movable in a scanning direction, and the camera includes a head position sensor capable of detecting a position of the recording head, the controller stopping a scanning operation of the recording head at a predetermined scanning position according to the output from the shake sensor.
[0069] Preferably, the printer includes a recording head movable in a predetermined scanning direction, and the controller controls operation of the recording head in the predetermined scanning direction according to a shake amount in the predetermined scanning direction.
[0070] Preferably, the printer is capable of scanning in a scanning direction, and the controller controls a scanning speed of the recording head in the scanning direction according to the shake amount in the main scanning direction.
[0071] Preferably, the printer feeds a print medium sheet in a sub-scanning direction while moving the recording head in a main scanning direction, and the controller determines the shake amount in the sub-scanning direction based on the output from the shake sensor, and controls movements of the recording head and the print medium in the sub-scanning direction relative to each other according to the shake amount in the sub-scanning direction.
[0072] Preferably, the date information includes hour and minute data.
[0073] The above and other objects, features, and advantages of the invention will become more apparent from the following detailed description taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0074] FIG. 1 is a front view of a camera with a printer to which the present invention is applicable;
[0075] FIG. 2 is a perspective view of the FIG. 1 camera, as viewed diagonally from front;
[0076] FIG. 3 is a perspective view of the FIG. 1 camera, as viewed diagonally from rear;
[0077] FIG. 4 is a perspective view of a media pack mountable in the FIG. 1 camera;
[0078] FIG. 5 is a perspective view showing the arrangement of essential parts within the FIG. 1 camera;
[0079] FIG. 6 is a perspective view of a printer section in the FIG. 5 arrangement;
[0080] FIG. 7 is a perspective view of the FIG. 6 printer section with a portion thereof dismounted;
[0081] FIG. 8 is a perspective view of a carriage in the FIG. 6 printer section;
[0082] FIG. 9 is a perspective view showing the construction of a print media feeder system of the FIG. 6 printer section;
[0083] FIG. 10 is a block diagram schematically showing the arrangement of a camera section A 100 and that of the printer section B 100 ;
[0084] FIG. 11 is a functional block diagram useful in explaining image signal processing by the camera section A 100 ;
[0085] FIG. 12 is a functional block diagram useful in explaining image signal processing by the printer section B 100 ;
[0086] FIG. 13 is a functional block diagram useful in explaining antivibration control in a photographing mode and carriage control in a print mode, carried out by the camera section;
[0087] FIG. 14 is a functional block diagram useful in explaining power supply control in which a DC-to-DC converter 150 for firing of a photographing flash by a photographing flashing light-emitting device is utilized as a power source for boosting a voltage applied to a recording head 207 for printing or ink pumping;
[0088] FIGS. 15A to 15 F collectively form a timing chart showing timings in outputs of respective drive signals S 1 to S 4 in the FIG. 14 power supply control;
[0089] FIG. 16 is a flowchart showing an operating procedure of the camera with a printer;
[0090] FIG. 17 is a continued part of the flowchart;
[0091] FIG. 18 is a continued part of the flowchart;
[0092] FIG. 19 is a continued part of the flowchart;
[0093] FIG. 20 is a flowchart showing a procedure of replenishment (refilling) of the media pack C 100 with consumable articles; and
[0094] FIG. 21 is a flowchart showing an operating procedure of a camera with a printer, according to another embodiment of the invention.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0095] The present invention will now be described in detail with reference to the drawings showing embodiments thereof.
[0096] A term “print” or “printing” (or “recording”), as used throughout the present specification is intended to mean not only an operation for forming intended information including characters and figures, but also a wide range of operations for forming images, patterns, or the like on a print medium, regardless of whether or not the images or patterns are intended and whether or not they are made apparent so as to allow humans to visually perceive them, and operations for processing a print medium.
[0097] Further, the “print medium” is intended to mean not only paper used by an ordinary printer, but also a wide range of materials allowing reception of ink, such as cloth, a plastic film, a metal plate, glass, ceramic, wood, or the like.
[0098] Moreover, the “ink” (also referred to as “liquid”), should be interpreted in its broad sense, similarly to the above term “print”, and is intended to mean a liquid applied onto the print medium so as to form images, patterns, or the like, process the print medium, or be subjected to processing (such as coagulation or insolubilization of a coloring material contained in the ink applied onto the print medium) of the ink.
[0099] First, the basic mechanical construction of an apparatus according to the present embodiment will be described with reference to FIGS. 1 through 9 . The apparatus is formed as a camera with a printer. A body A 001 of the apparatus incorporates a printer section (recorder section) B 100 arranged on a rear side of a camera section A 100 in a manner integrated with the camera section A 100 . It should be noted that the printer section B 100 may be removable from the camera section A 100 . In this case, the blocks A 100 and B 100 are provided with interactive communication contacts, which can be directly connected to each other when the block B 100 is mounted in the apparatus body A 001 . The printer section B 100 records images by using ink and a print medium supplied from a media pack C 100 . According to the construction of the present embodiment, as is apparent from FIG. 5 showing the apparatus body A 001 with a housing thereof removed, as viewed from the rear, the media pack C 100 is fitted in the right-hand side, as viewed in the figure, of the apparatus body A 001 , and the printer section B 100 is arranged on the left-hand side, as viewed in the figure. To perform recording by the printer section B 100 , the apparatus body A 001 can be set into a recording position in which the apparatus body A 001 is placed with a liquid crystal display section A 105 , referred to hereinafter and a lens A 101 positioned below. When the apparatus body A 001 is in this recording position, a recording head B 120 , referred to hereinafter, of the printer section B 100 is brought into a position for ejecting the ink downward. The recording position, however, is not limited to the position described above, but can be identical to a position in which the apparatus body A 001 is placed for photographing operation by the camera section A 100 . However, it is preferred from the viewpoint of stability of recording operation that the apparatus body A 001 is set into the above recording position allowing the ink to be ejected downward.
[0100] Next, the basic construction of the apparatus according to the present embodiment will be described more in detail with respect to the following separate three sections: A “CAMERA SECTION”, B “MEDIA PACK”, and C “PRINTER SECTION”.
[0000] A. “Camera Section”
[0101] The camera section A 100 basically forms an ordinary digital camera. The camera section A 100 is integrated into the apparatus body A 001 together with the printer section B 100 , described in detail hereinafter, whereby a digital camera incorporating a printer, which has appearances shown in FIGS. 1 to 3 , is formed. In these figures, reference numeral A 101 designates the lens, A 102 an optical viewfinder, A 102 a a finder window, A 103 a photographing flashing light-emitting device, A 104 a release button, and A 105 the liquid crystal display section (external display section). As described in detail hereinafter, the camera section A 100 processes data representative of an image picked up by an imaging element, such as a CCD or MOS, stores the image data in a compact flash memory card (e.g. a CF card) A 107 , processes a signal for displaying the image, and performs transmission and reception (interactive communication) of various kinds of data to/from the printer section B 100 . Reference numeral A 109 designates a discharge port from which a print medium C 104 , referred to hereinafter, printed with an image obtained by photographing is discharged. The discharge port A 109 has a lid, not shown, provided thereon. Reference numeral A 108 appearing in FIG. 5 designates a battery serving as a power source for the camera section A 100 and the printer section B 100 .
[0000] B. “Media Pack”
[0102] The media pack C 100 is removable from the apparatus body A 001 . In the present embodiment, a lid A 002 (see FIG. 3 ) covering an insertion section, not shown, of the apparatus body A 001 is opened, and the media pack C 100 is inserted through the insertion section whereby the media pack C 100 is mounted in the apparatus body A 001 as shown in FIG. 1 . The insertion section is closed by the lid A 002 , as shown in FIG. 3 , when the media pack C 100 is not mounted in the apparatus body A 001 , and opened only when the media pack C 100 is mounted. FIG. 5 shows the apparatus body A 001 having the media pack C 100 inserted therein, in a state of the housing thereof being removed. The media pack C 100 has a pack body C 101 which has a shutter C 102 mounted thereon in a manner slidable in directions indicated by a double-headed arrow D shown in FIG. 4 . When the media pack C 100 is not mounted in the apparatus body A 001 , the shutter C 102 is biased in a position indicated by two-dot chain lines in FIG. 4 by a spring, not shown, whereas when the media pack C 100 is mounted in the apparatus body A 001 , the shutter C 102 slides into a position indicated by solid lines in FIG. 4 against the urging force of the spring.
[0103] The pack body C 101 contains ink packs C 103 and a print medium 104 . In FIG. 4 , the ink packs C 103 are received below the print medium C 104 . In the embodiment, the number of the ink packs C 103 provided in the pack body C 101 is three, and inks of Y (yellow), M (magenta) and C (cyan) are contained separately in the respective ink packs C 103 . Further, the print medium C 104 is sheets of paper in the present embodiment, and will be hereinafter also referred to as “print medium sheets” where necessary. A stack of approximately twenty print medium sheets C 104 are contained in the pack body C 101 . The inks and the print medium sheets C 104 are selected as an optimal combination for desired image recording and received in the identical media pack C 100 . Therefore, various media packs C 100 are provided which contain different combinations of inks and print medium sheets, e.g. media packs for ultrahigh image quality, for normal image quality, for seals (split seals), for glossy paper, for recycled paper, for acid-free paper, etc., to thereby allow users to selectively mount one of the media packs C 100 in the apparatus body A 001 according to the kind of an image to be recorded and the use of the print medium sheets having the image formed thereon. This makes it possible to positively record a desired image by using an optimal combination of inks and print medium sheets. Further, the media pack C 100 is provided with a non-volatile memory as a memory, referred to hereinafter, such as an EEPROM (identification IC). The EEPROM stores the kinds and remaining amounts of inks and print medium sheets contained in the media pack, information on the date and time of refilling or production of the inks and the print medium sheets, and history data including detailed error data and date information concerning occurrence of abnormal conditions as well as data of aging change of color characteristics of the inks and the print medium sheets, as described in detail hereinafter.
[0104] When the media pack C 100 is mounted in the apparatus body A 001 , the ink packs C 103 are each connected to an ink supply system, referred to hereinafter, of the apparatus body A 001 via a corresponding one of three joints C 105 corresponding to the respective inks of the colors Y, M and C. On the other hand, the print medium sheets C 104 are each taken out by a sheet feed roller C 110 (see FIG. 9 ), referred to hereinafter, while being separated one sheet from another by a separating mechanism, not shown, followed by being each fed or advanced in a direction indicated by an arrow C. A driving force for driving the sheet feed roller C 110 is supplied to the same from a feed motor M 002 (see FIG. 9 ), referred to hereinafter, arranged in the apparatus body A 001 , via a connection section C 110 a.
[0105] Further, the pack body C 101 is provided with a wiper C 106 for wiping the recording head, referred to hereinbelow, of the printer section to clean the same and an ink absorber C 107 for absorbing waste ink discharged from a waste liquid joint, not shown, of the printer section. The recording head of the printer section reciprocates in the main scanning direction indicated by a double-headed arrow A, as described hereinafter. When the media pack C 100 is removed from the apparatus body A 001 , the spring, not shown, urges the shutter C 102 to slide into the position indicated by the two-dot chain lines in FIG. 4 , for protection of the joints C 105 , the wiper-C 106 and the ink absorber C 107 .
[0000] C. “Printer Section”
[0106] The printer section B 100 of the apparatus of the present embodiment is a serial type using an ink jet recording head. The printer section B 100 will be described with respect to the following three separate sections, C-1. “PRINT OPERATION SECTION”, C-2. “PRINT MEDIA FEEDER SYSTEM” and C-3. “INK SUPPLY SYSTEM”.
[0000] C-1. “Print Operation Section”
[0107] FIG. 6 is a perspective view showing the whole of the printer section B 100 , while FIG. 7 is a perspective view with some portions of the printer section B 100 removed.
[0108] As shown in FIG. 5 , a leading end portion of the media pack C 100 mounted in the apparatus body A 001 is positioned at a predetermined location within the body of the printer section B 100 . A print medium sheet C 104 fed from the media pack C 100 in the direction indicated by the arrow C in FIG. 6 is fed on a platen B 103 in a sub-scanning direction (direction orthogonal to the main scanning direction A) indicated by an arrow B in a state sandwiched between an LF roller B 101 and an LF pinch roller B 102 of a print media feeder system described hereinbelow. Reference numeral B 104 designates a carriage moved along a guide shaft B 105 and a lead screw B 106 in a reciprocating manner in the main scanning direction A.
[0109] As shown in FIG. 8 , the carriage B 104 is provided with a bearing B 107 for the guide shaft B 105 and a bearing B 108 for the lead screw B 106 . At a predetermined location in the carriage B 104 , there is mounted a screw pin B 109 (see FIG. 7 ) via a spring B 110 in a manner projecting inward of the bearing B 108 . The screw pin B 109 has an end thereof fitted in a spiral groove formed in the outer peripheral surface of the lead screw B 106 , whereby rotational motion of the lead screw B 106 is converted into reciprocating motion of the carriage B 104 in the directions A.
[0110] Further, mounted on the FIG. 8 carriage B 104 are the ink jet recording head B 120 capable of emitting inks of colors Y, M and C and an auxiliary tank, not shown, containing the inks to be supplied to the recording head B 120 . The recording head B 120 is formed with a plurality of ink jet orifices B 121 (see FIG. 8 ) arranged in a direction intersecting the main scanning direction A (direction orthogonal to the main scanning direction A in the present embodiment). The ink jet orifices B 121 each form a nozzle which is capable of emitting ink supplied from the auxiliary tank. Means for generating energy for causing emission of ink can be implemented by an electrothermal converter provided for each nozzle. The electrothermal converter is driven for being heated to thereby generate bubbles in ink within the corresponding nozzle, and bubbling energy of the bubbles causes ink droplets to jet from the corresponding ink jet orifice B 121 .
[0111] The capacity of the auxiliary tank is smaller than the total capacity of the ink packs C 103 held in the media pack C 100 , and the auxiliary tank contains respective amounts of inks of the colors required for recording an amount of image corresponding to at least one print medium sheet C 104 . The auxiliary tank is formed therein with ink reservoirs for storing the respective inks of the colors Y, M, C, and each of the ink reservoirs is formed with an ink supply section and a negative pressure-introducing section. The ink supply sections are each connected to a corresponding one of three hollow needles B 122 , while the negative pressure-introducing sections are connected to a common supply air port B 123 . As described in detail hereinafter, the auxiliary tank constructed as above is supplied with ink from each of the ink packs C 103 in the media pack C 100 when the carriage B 104 is brought to its home position shown in FIG. 6 .
[0112] In FIG. 8 illustrating the carriage B 104 , reference numeral B 124 designates a needle cover. When the needles B 122 and the joints C 105 (see FIG. 4 ) of the media pack are not connected to each other, the needle cover B 124 is urged downward by the urging force of a spring, not shown, into a position for protecting the needles B 122 , whereas when the needles B 122 and the joints C 105 are connected to each other, the needle cover B 124 is pushed upward against the urging force of the spring to release the needles B 122 from the protected state. A position of the carriage B 104 in the direction A is detected by cooperation of an encoder sensor B 131 arranged in the carriage B 104 and a linear scale B 132 (see FIG. 6 ) arranged in the body of the printer section B 100 . Further, when the carriage B 104 is brought into its home position, this fact is sensed by cooperation of an HP (home position) flag B 133 attached to the carriage B 104 and an HP sensor B 134 (see FIG. 7 ) arranged in the body of the printer section B 100 .
[0113] In FIG. 7 , the guide shaft B 105 has opposite ends thereof each formed with a spindle, not shown, at a location off the central axis of the shaft B 105 . The guide shaft B 105 is pivotally moved about the spindles to adjust the position of the carriage B 104 , whereby the distance between the recording head B 120 and a print medium sheet C 104 on the platen B 103 (so-called “head-to-paper distance”) is adjusted. The lead screw B 106 is driven for rotation by a carriage motor M 001 via a screw gear B 141 , an idler gear B 142 and a motor gear B 143 . Reference numeral B 150 designates a flexible cable for electrically connecting between a control system, referred to hereinafter, and the recording head B 120 .
[0114] The recording head B 120 shown in FIG. 8 jets ink from the ink jet orifices B 121 in response to image signals while moving in the main scanning direction A together with the carriage B 104 , to thereby record a one-line portion of an image on a print medium sheet on the platen B 103 . This one-line recording operation by the recording head B 120 and a feed operation by the print media feeder system, described in detail hereinbelow, for feeding or advancing the print medium sheet by a predetermined amount in the sub-scanning direction B are repeatedly carried out, whereby the image is recorded on the print medium sheet line by line.
[0000] C-2. “Print Media Feeder System”
[0115] FIG. 9 is a perspective view showing the construction of the print media feeder system in the printer section B 100 . In FIG. 9 , reference numeral B 201 designates a pair of sheet discharge rollers. The upper one of the sheet discharge rollers B 201 in the figure is driven by the feed motor M 002 via a sheet discharge roller gear B 202 and a relay gear B 203 . Similarly, the LF roller B 101 , referred to hereinbefore, is driven by the feed motor M 002 via an LF roller gear B 204 and the relay gear B 203 . As the feed motor M 002 performs normal rotation, a driving force generated by the normal rotation of the feed motor M 002 causes the sheet discharge roller B 201 and the LF roller B 101 to feed a print medium sheet C 104 in the sub-scanning direction B.
[0116] On the other hand, when the feed motor M 002 performs reverse rotation, a platen head B 213 and a lock mechanism, not shown, are driven via a switching slider B 211 and a switching cam B 212 , and at the same time a driving force generated by the reverse rotation of the feed motor M 002 is transmitted to the sheet feed roller C 110 of the media pack C 100 . More specifically, when the feed motor M 002 performs reverse rotation, the driving force of the feed motor M 002 causes the platen head B 213 to move through a window C 102 A (see FIG. 4 ) of the shutter C 102 of the media pack C 100 to press a stack of the print medium sheets C 104 in the media pack C 100 downward as viewed in FIG. 4 . As a result, the lowermost one of the print medium sheets C 104 appearing in FIG. 4 is pressed onto the sheet feed roller C 110 within the media pack C 100 . Further, the lock mechanism, not shown, is brought into an operative state by the driving force generated by the reverse rotation of the feed motor M 002 , to lock the media pack C 100 in the apparatus body A 001 , thereby inhibiting removal of the media pack C 100 . At the same time, the driving force generated by the reverse rotation of the feed motor M 002 is transmitted to the sheet feed roller C 110 of the media pack C 100 to cause the same to feed the lowermost print medium sheet C 104 in the direction C.
[0117] As described above, with reverse rotation of the feed motor M 002 , only one print medium sheet C 104 is fed out from the media pack C 100 in the direction C in FIG. 9 , and then when the feed motor M 002 performs normal rotation, the sheet is fed out in the direction B.
[0000] C-3. “Ink Supply System”
[0118] The joints C 105 of the media pack C 100 mounted in the printer section B 100 are positioned below the needles B 122 (see FIG. 8 ) of the carriage B 104 shifted to its home position. In the body of the printer section B 100 , there are formed joint forks, not shown, at a location below the joints C 105 . The joint forks move the joints C 105 upward, whereby the joints C 105 are connected to the needles B 122 . Thus, ink supply passages are formed between the ink packs C 103 of the media pack C 100 and the ink supply sections of the auxiliary tank in the carriage B 104 . Further, the body of the printer section B 100 has a supply joint, not shown, formed at a location below the supply air port B 123 (see FIG. 8 ) of the carriage B 104 shifted to its home position. The supply joint is connected via a supply tube, not shown, to a pump cylinder of a pump, not shown, which functions as a negative pressure source. The supply joint is moved upward by a joint lifter, not shown, to be connected to the supply air port B 123 of the carriage B 104 , whereby a negative pressure-introducing passage is formed between the negative pressure-introducing section of the auxiliary tank within the carriage B 104 and the pump cylinder. The joint lifter is driven by the the driving force of a joint motor M 003 to move up and down the supply joint and the joint forks together.
[0119] The negative pressure-introducing section of the auxiliary tank is provided with a thin-film air-liquid separating member, not shown, allowing passage of air and blocking passage of ink. The air-liquid separating member permits passage of air drawn by suction from the auxiliary tank through the negative pressure-introducing passage, whereby the auxiliary tank is replenished with ink from the media pack C 100 . Then, when the auxiliary tank is fully filled with ink to such an extent that the ink reaches the air-liquid separating member, the air-liquid separating member blocks passage of the ink, whereby supply of ink is automatically stopped. The air-liquid separating member is provided in the ink supply section of each ink reservoir within the auxiliary tank so as to stop supply of ink automatically on a reservoir-by-reservoir basis.
[0120] Further, the body of the printer section B 100 is provided with a suction cap, not shown, which is capable of capping the recording head B 120 (see FIG. 8 ) on the carriage B 104 shifted to its home position. The suction cap is capable of sucking ink from the ink jet orifices B 121 of the recording head B 120 (head recovery process) by utilizing a negative pressure introduced thereinto from the pump cylinder through a suction tube, not shown. Further, the recording head B 120 emits ink non-contributive to image recording into the suction cap as required (preliminary emission process). The ink emitted into the suction cap is discharged from the pump cylinder into the ink absorber C 107 within the media pack C 110 through a waste liquid tube, not shown, and a waste liquid joint, not shown.
[0121] The pump cylinder is cooperatively associated with a pump motor, not shown, for driving the same for reciprocating motion, and other component parts, to form a pump unit. The pump motor also functions as a drive source for vertically moving a wiper lifter, not shown. The wiper lifter moves upward the wiper C 106 of the media pack C 100 mounted in the printer section B 100 , to shift the same to a position for wiping the recording head B 120 .
[0122] Next, the basic construction of a signal processing system of the apparatus including the control system will be described with respect to the following section D “SIGNAL PROCESSING SYSTEM” with reference to FIGS. 10 to 20 .
[0000] D. “Signal Processing System”
[0123] FIG. 10 is a schematic block diagram showing the arrangement of the camera section A 100 and that of the printer section B 100 .
[0124] In the camera section A 100 , reference numeral 101 designates a CCD as an imaging element. Needless to say, another type of imaging element (such as a MOS image sensor) may be employed in place of the CCD. Reference numeral 102 designates a microphone for use in voice input, 103 an ASIC (Application-Specific Integrated Circuit) for executing hardware processing, 104 a first memory for temporary storage of image data, etc., 105 a CF card (corresponding to the “CF card A 107 ”) as a removable image memory for storing a photographed image, 106 an LCD (corresponding to the “liquid crystal display section A 105 ”) for displaying a picked-up or reproduced image, 107 a lens unit (corresponding to the “lens A 101 ”), and 108 a shake compensation mechanism for optically compensating for a camera shake which occurs at the time of photographing. In the present embodiment, the shake compensation mechanism is comprised of transparent flat plates arranged in a manner parallel to each other and inclined by a predetermined angle with respect to the optical axis, and the inclination angle is changed in a direction in which a camera shake is suppressed, according to the amount and direction of the shake. It should be noted that the shake compensation mechanism may be alternatively implemented by a variable apical angle prism or so-called electronic antivibration (technique of reducing blur due to a camera shake by temporarily storing a picked-up image signal in an image memory and then shifting a reading area in the memory from which the signal is read, according to the amount of the camera shake). Reference numeral 109 designates an acceleration sensor or the like as a shake-detecting sensor for detecting the amount of a camera shake, 111 a photographing flashing light-emitting device (corresponding to the “photographing flashing light-emitting device A 103 ”), reference numeral 112 an SW group of various switches (including the “release button A 104 ”), 113 a speaker for generating operation sounds, warning sounds, and so forth, 120 a first CPU controlling the camera section A 100 , and 150 a DC-to-DC converter as a booster circuit for causing the photographing flashing light-emitting device 111 to emit the flashing light. It should be noted that in the present embodiment, part of boosted output voltage of the booster circuit for the photographing flashing light-emitting device 111 is used as a predetermined DC voltage to be supplied to a pumping motor or the recording head in the printer section, for ink pumping operation or for print operation, respectively, which contributes to reduction of the size of the whole apparatus.
[0125] Further, the camera section A 100 includes a clock TM for counting date information to be recorded in association with each photographed image. The ASIC 103 performs synchronizing control related to various kinds of times and hours both in the camera section and the printer section, based on the counts of the clock TM.
[0126] In the printer section B 100 , reference numeral 210 designates an interface between the camera section A 100 and the printer section B 100 , 201 an image processing section (including a binarization processing section for binarizing an image), 202 a second memory for use in image processing, 203 a band memory control section, 204 a band memory, 205 a mask memory, and 206 a head control section, reference numeral 207 a recording head (corresponding to the “recording head B 120 ”). Reference numerals 208 , 209 designate an encoder corresponding to the encoder sensor B 131 and an encoder counter, respectively. Further, reference numeral 220 designates a second CPU controlling overall operation of the printer section B 100 , 221 a motor driver, 222 a motor (including the “motors M 001 , M 002 , M 003 ”), 223 a sensor group (including the “HP sensor B 134 ”), 224 an EEPROM incorporated in the media pack C 100 , which may be any type insofar as it is a rewritable non-volatile memory, 230 a voice encoder section, and 250 a power source (corresponding to the “battery A 108 ”) for supplying electric power to the whole apparatus.
[0127] FIG. 11 is a functional block diagram useful in explaining image signal processing performed by the camera section A 100 . In a photographing mode, an image picked up by the CCD 101 through the lens 107 is subjected to signal processing (CCD signal processing) by the ASIC 103 to be converted to a YUV (luminance-two color difference) signal. Then, the signal is resized to one with a predetermined resolution and JPEG-compressed, followed by being recorded on a CF card 105 . Whenever an image is recorded onto a CF card 105 , date information (e.g. time, day, month, year) automatically determined by the clock TM is also recorded in association with the recorded image. Voices are inputted through the microphone 102 and recorded onto the CF card 105 via the ASIC 103 . Voices can be recorded simultaneously with photographing or alternatively after photographing by postrecording. In a reproduction mode, a JPEG image is read from the CF card 105 and JPEG-extended by the ASIC 103 , and then further resized to an image with a resolution suitable for display, followed by being displayed on the LCD 106 .
[0128] FIG. 12 is a functional block diagram useful in explaining image signal processing performed by the printer section B 100 .
[0129] An image reproduced by the camera section A 100 , i.e. an image read from a CF card 105 is JPEG-extended by the ASIC 103 , as shown in FIG. 11 , and resized to one with a resolution suitable for printing. Then, the resized image data (YUV) is sent to the printer section B 100 via the interface 210 appearing in FIG. 10 . As shown in FIGS. 10 and 12 , in the printer section B 100 , the image processing section 201 executes image processing of the image data sent from the camera section A 100 , conversion of the image data to an RGB signal, input γ correction according to the characteristics of the camera, color correction and color conversion by using a lookup table (LUT), and conversion of the RGB signal to a binary signal for printing. The color correction using the lookup table (LUT) may be performed by the CPU based on color correction data stored in the EEPROM 224 within the media pack, as described hereinafter.
[0130] In the binarization process, the second memory 202 is used as an error memory for execution of an error diffusion (ED) process. Although in the present embodiment, the binarization processing section of the image processing section 201 carries out the error diffusion process, it is also possible to execute other processing such as binarization processing using dither patterns. The binarized print data is temporarily stored in the band memory 204 via the band memory control section 203 . Whenever the carriage B 104 having the recording head 207 and the encoder 208 mounted thereon moves a predetermined distance, an encoder pulse is delivered to the encoder counter 209 of the printer section B 100 from the encoder 208 . In synchronism with inputting of the encoder pulse, the print data is read from the band memory 204 and the mask memory 205 , and the head control section 206 controls the recording head 207 , based on the print data, for recording.
[0131] Next, band memory control in FIG. 12 will be described.
[0132] The plurality of nozzles of the recording head 207 are arranged in an array such that the density of e.g. 1200 dpi is maintained. In order to enable the recording head 207 to perform recording operation during a single main scanning operation by the carriage in the direction A shown in FIGS. 6 to 9 , it is required to prepare recording data in an amount corresponding to the number of the nozzles with respect to the sub-scanning direction (direction B in FIGS. 6 to 9 ) and in an amount corresponding to a recording area (i.e. corresponding to one scanning operation) with respect to the main scanning direction. Recording data is generated by the image processing section 201 and then temporarily stored in the band memory 204 by the band memory control section 203 . When recording data in the amount corresponding to one scanning operation is stored in the band memory 204 , the carriage is driven in the main scanning direction for scanning. During this main scanning operation of the carriage, encoder pulses inputted from the encoder 208 are counted by the encoder counter 209 . The recording data is read from the band memory 204 according to the encoder pulses, and the recording head 207 jets ink droplets based on the read image data. When a two-way recording method is employed in which image recording is carried out both in the forward scanning operation and return scanning operation of the recording head 207 in the direction A (i.e. forward path recording and return path recording are performed), image data is read from the band memory 204 in dependence on the direction of scanning by the recording head 207 . For instance, during a forward path recording operation of the recording head 207 , the address of image data read from the band memory 204 is sequentially incremented, whereas during a return path recording operation of the recording head 207 , the address of image data read from the band memory 204 is sequentially decremented.
[0133] Actually, when image data (formed of the colors C, M, Y) generated by the image processing section 201 has been-written to the band memory 204 to provide one band of image data, scanning by the recording head 207 is permitted. Then, the recording head 207 scans, whereby the image data is read from the band memory, and the recording head 207 records an image based on the image data. During the recording operation, image data to be recorded next is prepared by the image processing section 201 and written onto an area of the band memory 204 corresponding to the recording position of the image.
[0134] As described above, the band memory control is executed while being switched between the operation of writing recording data (colors C, M, Y) generated by the image processing section 201 into the band memory 204 and the operation of reading the recording data from the same in synchronism with the scanning operation by the carriage so as to send the same to the head control section 206 .
[0135] Next, a description will be given of mask memory control in FIG. 12 .
[0136] The mask memory control is required when a multi-path recording method is adopted. In this method, a single line of recording image having a width corresponding to the length of a nozzle row is recorded in a plurality of scanning operations by the recording head 207 . More specifically, the amount of a single feed of a print medium sheet, which is fed intermittently in the sub-scanning direction, is set to 1/N of the length of a nozzle row. As a result, e.g. when N=2 holds, a single line of a recording image is recorded by two scanning operations each time a corresponding divisional portion thereof is recorded (two-path recording), and when N=4 holds, a single line of a recording image is recorded by four scanning operations each time a corresponding divisional portion thereof is recorded (four-path recording). Similarly, when N=8 holds, eight-path recording is performed, and when N=16 holds, 16-path recording is performed. Thus, in the multi-path recording method, one line of a recording image is recorded by a plurality of scanning operations each time a corresponding divisional portion thereof is recorded by the recording head 207 .
[0137] Actually, the mask memory 205 stores mask data for use in allocating image data to a plurality of scanning operations by the recording head 207 , and based on AND data of the mask data and the image data, the recording head 207 ejects ink to record the image.
[0138] Further, as shown in FIG. 11 , voice data stored in a CF card 105 is sent by the ASIC 103 to the printer section B 100 via the interface 210 , similarly to image data. The voice data sent to the printer section B 100 is encoded by the voice encoder 230 , and then subjected to a predetermined modulation, followed by being embedded in a print image as “watermark” information in the form of two-dimensional barcode. When it is not necessary to input voice data into a print image or when an image having no voice data is printed, voice data in the form of two-dimensional barcode is not printed, but only the image is printed.
[0139] In the present embodiment, there are carried out media pack consumable article management control for coping with degradation of consumable articles (i.e. ink and print medium sheets) within a media pack C 100 , antivibration control in the photographing mode and carriage control in a print mode both performed by using the shake-detecting sensor (acceleration sensor) 109 , and power supply control for using the boost-type DC-to-DC converter 150 provided for the photographing flashing light-emitting device of the camera section A 100 , as a power supply for printing operation by the recording head 207 of the printer section B 100 or ink pumping operation carried out for the recording head 207 .
[0140] First, the media pack consumable article management control will be described. FIG. 20 is a flowchart which shows a procedure of replenishing (refilling) the media pack C 100 with consumable articles.
[0141] The media pack C 100 according to the present embodiment can be replenished with ink and print medium sheets as consumable articles. Further, the media pack C 100 incorporates the EEPROM 224 to which data concerning the consumable articles and the replenishment of the media pack C 100 therewith can be written. The date data of a remaining quantity of the consumable articles and a date of replenishment or production of the media pack C 100 are written in the EEPROM 224 and updated whenever the quantity of the consumable articles is reduced or the media pack C 100 is replenished (refilled) or produced. The updated data are used for management of the consumable articles within the media pack C 100 .
[0142] When it is required to replenish the media pack C 100 with consumable articles, the media pack C 100 is brought to a factory or a print shop, where consumable articles are filled into the media pack C 100 manually by workers of the factory or the print shop. In the refilling operation, as shown in FIG. 20 , first at a step S 101 , ink packs C 103 of the respective colors (Y, M, C) within the media pack C 100 are each refilled with a corresponding ink, and at a step S 102 , print medium sheets C 104 are refilled. Then, data of the date (month and year and/or day and time) of the replenishment (refilling) or reproduction of the consumable articles, data of the characteristics of the refilled inks (including color characteristic data and data of viscosity), data of the remaining quantity of ink, data of characteristics of the print medium sheets (including data concerning the quality of the print medium sheets which can be classified e.g. into glossy paper, acid-free paper, recycled paper, or the like, and data of the ground color of the print medium sheets), data of the remaining number of the print medium sheets, and degradation characteristic data of the inks (including lookup table data representing the relationship between elapsed days, months or years and the change of each color as a linear matrix coefficient) are written in the EEPRON 224 within the media pack C 100 by a memory writing device at a step S 103 . In this case, the lookup table data itself may not be stored in the EEPROM 224 , but a method may be employed in which a plurality of kinds of lookup tables for color correction are stored in advance in the lookup table appearing in FIG. 12 , and data for enabling selection of one of the tables according to the degree of degradation of the consumable articles is stored in the EEPROM 224 , a memory within the camera section, or a memory within the printer section.
[0143] When the replenishment (refilling) of the media pack C 100 with the consumable articles is completed by execution of the above steps, the media pack C 100 is sent or directly handed to the user. It should be noted that identical data to the data mentioned above are stored in each media pack C 100 shipped as an article from factories.
[0144] Thus, when a media pack C 100 is in actual use, the data concerning the consumable articles are read from the EEPROM 224 , and management of the consumable articles is performed based on the read data. Consequently, it is possible to estimate the degree of degradation of the consumable articles, based on the above data, and carry out processing for warning, color correction, and the like, based on the result of the estimation.
[0145] Next, a description will be given of the antivibration control in the photographing mode and the carriage control in the print mode. FIG. 13 is a functional block diagram useful in explaining antivibration control performed by the camera section in the photographing mode and the carriage control in the print mode performed by the same.
[0146] According to the present embodiment, in the photographing mode, the antivibration control for suppressing blur of an image due to a camera shake is executed based on an output signal from the acceleration sensor 109 . In the antivibration control, the amount and direction of the camera shake are detected based on the output signal from the acceleration sensor 109 , and then the amount of correction by the shake compensation mechanism 108 is controlled based on the detected amount and direction of the camera shake. More specifically, a control variable for changing an incident light path with respect to the lens 107 in such a direction as will suppress the blur of the image due to the camera shake is calculated as a correction amount, and the shake compensation mechanism 108 is operated based on the correction amount. As a result, the blur of the image due to the camera shake is corrected to obtain a clear image data.
[0147] Further, in the print mode, the amount of the camera shake is detected based on the output signal from the identical acceleration sensor 109 , and carriage control for temporarily suspending print operation is carried out in dependence on the detected amount of the camera shake. More specifically, in the carriage control, when the detected amount of the camera shake is larger than a predetermined amount, a command for stopping the carriage 225 at a predetermined position (main scanning start position or main scanning end position) is delivered to the printer section B 100 . In the printer section B 100 , when the command is received, a motor driving the carriage 225 is controlled to temporarily stop the carriage 225 at the predetermined position.
[0148] Next, a description will be given of the power supply control for using the boost-type DC-to-DC converter 150 provided for the photographing flashing light-emitting device, as the power supply for printing operation by the recording head 207 of the printer section B 100 or ink pumping operation carried out for the recording head 207 . FIG. 14 is a functional block diagram useful in explaining the power supply control, while FIG. 15 is a timing chart showing timing of generation of drive signals SG 1 to SG 5 by the power supply control.
[0149] As shown in FIG. 14 , the DC-to-DC converter 150 is comprised of a transformer 151 having a primary side to which is applied a voltage from the power source 250 via a switch (SW) 14 , an oscillation circuit 152 , a charging circuit 154 for generating a predetermined voltage to be supplied from a secondary side of the transformer 151 to the photographing flashing light-emitting device 111 and charging the same, and a trigger 155 for applying a predetermined trigger voltage to the photographing flashing light-emitting device 111 . The secondary side of the transformer 151 outputs the voltage to be applied to the charging circuit 154 , a drive voltage to be applied to the recording head 207 of the printer section B 100 through a rectifying circuit RT, and a drive voltage to be applied to the motor 228 for pumping ink for the recording head through a rectifying circuit RT′ via respective output terminals. The drive voltage for driving the recording head 207 is supplied to the recording head 207 via a switch (SW) 13 , and the drive voltage for driving the pumping motor 228 is supplied to the motor 228 via a switch (SW) 13 ′.
[0150] The operations of the SW 13 , SW 13 ′ and SW 14 , the charging circuit 154 and the trigger 155 are controlled according to the power supply control by the CPU 120 of the camera section A 100 . More specifically, when a power switch (SW) 11 of the camera with a printer is turned on, the drive signal SG 1 is delivered to the SW 14 , whereby the SW 14 is turned on (see FIG. 15B ). Then, based on an output from a mode switching switch (SW) 12 , it is determined whether the present mode is a camera mode or a printer mode. If the SW 12 is in a state switched to a side “a”, it is determined that the camera mode is set, while if the SW 12 is in a state switched to a side “b”, it is determined that the printer mode is set. In the present embodiment, as shown in FIG. 15A , when the SW is turned on, the camera mode is set by default.
[0151] When the camera mode is set, the drive signal SG 2 instructing the charging circuit 154 to start preliminary operation for lighting the photographing flashing light-emitting device 111 is delivered to the charging circuit 154 (see FIG. 15C ). Then, the drive signal SG 3 for causing the photographing flashing light-emitting device 111 to emit a flashing light is delivered to the trigger 155 in predetermined photographing timing (see FIG. 15D ), whereby the photographing flashing light-emitting device 111 emits the flashing light.
[0152] When the user wants to print out a photographed image, he/she operates the SW 12 to set the printer mode (see FIG. 15A ). When the printer mode is set, a drive signal S 4 is delivered to the SW 13 in accordance with the timing of print operation by the recording head 207 (see FIG. 15E ). As a result, the SW 13 is turned on, the drive voltage is supplied to the recording head 207 from the DC-to-DC converter 150 through the rectifying circuit RT. Further, when a drive signal S 5 is delivered to the SW 13 ′ for ink pumping operation (see FIG. 15F ), the SW 13 ′ is turned on, whereby a drive voltage is supplied to the pumping motor 228 from the DC-to-DC converter 150 through the rectifying circuit RT′.
[0153] As described above, when the printer mode is set, since the DC-to-DC converter 150 supplies the drive voltage for printing to the recording head 207 or the drive voltage for pumping ink from the recording head 207 to the motor 228 , the printer section B 100 is not required to be additionally provided with a drive voltage supply circuit for printing by the recording head 207 or for pumping ink for the same, which makes it possible to simplify the construction of the printer section B 100 and to largely reduce the size of the apparatus.
[0154] Next, the operation of the present apparatus will be described. FIGS. 16 to 19 are flowcharts which show an operating procedure of the camera with a printer.
[0155] As shown in FIG. 16 , when the camera power source is turned on, first, it is detected at a step S 1 whether or not a media pack is loaded, based on an output from a media pack loading detection switch, not shown. If the presence of the media pack is detected, the program proceeds to a step S 2 , wherein various data stored in the memory (EEPROM M 224 ) within the media pack are read. Then, the program proceeds to a step S 3 , wherein it is determined whether or not the reading of the data was successfully performed.
[0156] If the reading of the data was failed, i.e. if communication with the memory within the media pack failed (e.g. when the data within the memory could not be properly read due to a faulty mechanical connection between electric contacts of the media pack and electric contacts of the camera body, or when in spite of proper electrical connection, it is determined that communication failed, due to noise introduced into the data from the memory), the program proceeds to a step S 4 , wherein the present date (including e.g. day, month, year (and time, if required)) is stored in the memory within the media pack, and at the same time error information is stored in the same in association with the date data. In this case where the communication failed, occurrence of the communication error is stored as error information.
[0157] Then, the program proceeds to a step S 5 , wherein an error flag is written to the memory within the media pack. At the following step S 6 , the error information is displayed on the LCD 106 in a first display form. In the first display form, predetermined marks, characters, or the like are used to express e.g. error information. Then, the program proceeds to a step S 11 in FIG. 17 .
[0158] If there was no communication error at the step S 3 , the program proceeds to a step S 7 , wherein it is determined whether or not there is any error flag contained in the data read from the memory within the media pack. In the present embodiment, if there occurs at least one of a case where there is no ink, a case where there is no paper as a print medium, a case where a predetermined time period has elapsed since loading of ink and/or paper, and others, an error flag is written to the memory within the media pack together with the error information.
[0159] If an error flag was detected at the step S 7 , error information corresponding to the error flag is displayed on the LCD 106 in the first display form at a step S 6 , followed by the program proceeding to the step S 11 in FIG. 17 .
[0160] If no error flag was detected at the step S 7 , it is judged that the data read from the memory within the media pack is normal, and the program proceeds to a step S 8 . At the step S 8 , the date (e.g. day, month, year) of refilling the media pack with ink and/or a print medium, such as paper sheets, or the date of production of the ink or print medium is detected, and the date of refilling or production is compared with a date (e.g. day, month, year) determined by the clock TM in the camera body. Then, at the following step S 9 , it is determined whether or not a result of the comparison (difference between the two dates) is larger than a predetermined value Ta (e.g. two years). If the difference between the two dates is larger than the predetermined value, i.e. if more than two years have passed after refilling the media pack with ink and/or print medium production of the ink or print medium, it is judged that ink as a consumable article and/or a print medium such as paper sheets as consumable articles were deteriorated, and the program proceeds to the step S 4 , wherein error information that the degradation of the ink and/or print medium has occurred is stored in the memory within the media pack, and at the same time the date determined by the clock TM of the camera section is also stored in the same in association with the error information. Then, at the step S 5 , an error flag is written to the memory within the media pack, and at the following step S 6 , the error information is displayed in the first display form on the LCD 106 as display means, followed by the program proceeding to the step S 11 in FIG. 17 .
[0161] If it is determined that the difference is equal to or smaller than the predetermined value Ta at the step S 9 , the program proceeds to the step S 11 in FIG. 17 . Further, if it is detected at the step S 1 that no media pack is loaded, the fact is displayed on the LCD 106 in the first display form. The notice displayed in the first display form at this step is one at the same warning level as the one displayed in the first display form at the step S 6 .
[0162] At the step S 11 , it is determined whether or not the present mode is the printer mode. If the present mode is the printer mode, the program proceeds to a step S 12 , wherein it is determined whether or not there is an error flag in the memory within the media pack. If an error flag exists, the program proceeds to a step S 13 , wherein the corresponding error information is displayed on the LCD 106 in a second display form, and at the same time, a warning sound is generated. The second display form is distinguished from the first one in that its warning level is set to be higher than the latter such that the user can notice the warning more easily. For example, when error information is expressed by using the same kind of mark or characters as in the first display form, the mark or characters are displayed in a larger size such that the error information can be recognized more easily, and further, a sound is used to attract an operator's attention more easily. Needless to say, when a sound is used in the first display form, the second display form requires the use of a sound increased in volume, for example, so that the user can notice it more easily. Then, the program returns to the step S 11 . On the other hand, if no error flag was detected at the step S 12 , the program skips over the step S 13 to a step S 14 .
[0163] At the step S 14 , it is determined again whether or not a media pack is loaded. If a media pack is not loaded, the program proceeds to a step S 15 , wherein the fact is displayed in the second display form (i.e. in the display form using a mark or characters of a larger size and/or a sound for easier recognition). Then, the program returns to the step S 14 , wherein loading of a media pack is awaited.
[0164] If it was detected at the step S 14 that a media pack is loaded, the program proceeds to a step S 16 , wherein a cap is removed from each ink pack in the media pack, and then a negative pressure nozzle is connected to each of the ink tanks for preliminary print operations including a recovery pumping operation. In the present embodiment, the preliminary operations are carried out after setting the print mode, so that wasteful consumption of electric power and ink can be significantly reduced, compared with a case where operations similar to those performed at the step S 16 are carried out when a media pack is loaded or when the main power source of the camera is turned on.
[0165] Then, the program proceeds to a step S 17 , wherein depression of a print button is awaited. When the button is depressed, the program proceeds to a step S 18 , wherein the sheet feed roller is driven, thereby feeding a single print medium, such as paper sheets, from the media pack. Then, the program proceeds to a step S 19 , wherein the number of paper sheets as the print medium stored in the memory within the media pack is decremented by 1. Then, at a step S 20 , linear matrix conversion of print colors is performed by using the coefficient data of the color correction matrix stored in the memory of the media pack. Characteristics of changes in respective ink colors (e.g. yellow, cyan, magenta) dependent on elapsed time (months and years (or days)) after refilling or production of the inks are measured in advance, and linear matrix coefficients (e.g. 3×3=9 matrix coefficients for use in matrix operation of data of yellow, cyan, magenta before correction) for correcting the change characteristics are stored in the memory within the media pack in the form of a lookup table. Alternatively, as described hereinbefore, a plurality of lookup tables are stored in the lookup table appearing in FIG. 12 , and data for enabling selection of one of the tables according to the degree of degradation of the inks is stored in the EEPROM 224 , the memory within the camera section, or the memory within the printer section. Therefore, when the number of the elapsed months or years (or days) after refilling of the media pack with the inks is determined at the step S 9 , optimal printing can be performed by using ink colors whose characteristics of change were corrected according to the number of the elapsed months or years (or days). Although in the above embodiment and an embodiment described hereinafter, the date data information includes information of day, month and year and time information, it goes without saying that the date data information is not necessarily required to include information of time and day, but the date data information may be any time information such as year information alone, month and year information, day, month and year information, or information containing all of month, year, day, hour, minute, and second.
[0166] Then, the program proceeds to a step S 21 , wherein it is determined whether or not the remaining number of paper sheets as the print medium updated at the step S 19 is equal to zero. If the remaining number is equal to zero, the program proceeds to a step S 22 , wherein error information indicative of the fact as error information is written to the memory within the media pack together with an error flag. Further, a date (day, month, year, (time, if required)) determined by the clock TM within the camera section at this time point is also stored in association with the error information, followed by the program proceeding to a step S 23 in FIG. 18 . On the other hand, if the remaining number of the print medium sheets is not equal to zero, the program skips over the step S 22 to the step S 23 .
[0167] At the step S 23 , a print operation is started, and at the following step S 24 , it is detected by the acceleration sensor 109 whether or not a camera shake is larger than a predetermined amount. If the camera shake is larger than the predetermined amount, the program proceeds to a step S 25 , wherein the print operation is temporarily suspended. In this case, the printer section B 100 is controlled such that the print operation is temporarily suspended with the carriage 225 in the printer section B 100 being positioned at a main scanning end. The print operation is held in this state until the camera shake is reduced. Consequently, when the print operation is resumed after reduction of the camera shake, there occurs no conspicuous printing shift.
[0168] If the camera shake is equal to or smaller than the predetermined amount at the step S 24 , the program proceeds to a step S 26 , wherein it is determined whether or not the print operation is temporarily halted. If the print operation is in a temporary halt, the print operation is resumed, followed by the program proceeding to a step S 28 , whereas if the print operation is not temporarily halted, the program skips over the step S 27 to the step S 28 . At the step S 28 , it is determined whether or not printing on one sheet has been completed. If the printing has not been completed, the program returns to the step S 24 . If the printing has been completed, the program proceeds to a step S 29 , wherein data of the remaining quantity of ink within the memory in the media pack is updated. More specifically, the data is updated to a value obtained by subtracting an ink jet amount (which is obtained not by measuring the amount of ink actually ejected, but by calculating the amount of each color ink to be used based on image data, by arithmetic operation) and the amount of ink sucked into the auxiliary tank within the recording head 207 (which is set to a substantially fixed amount) from data of the ink remaining amount stored in the memory within the media pack.
[0169] Next, the program proceeds to a step S 30 , wherein it is determined whether or not any one of the color inks has been used up (which means not only a state of the remaining amount thereof being reduced to zero, but also a state of the remaining amount being smaller than a predetermined amount). If any one of the color inks has been used up, the program proceeds to a step S 31 , wherein error information indicative of the fact is written, together with the error flag. At the same time, the date (day, month, year (and time, if required)) determined by the clock TM of the camera section at this time point is also stored in association with the error information.
[0170] At a step S 32 , it is determined whether or not there has occurred any abnormality (such as a failure caused by abortion of printing e.g. due to a camera shake or a big vibration, an inability to print a specific color e.g. due to clogging of the recording head, or the like) in the present print operation. If no abnormality has occurred, the program proceeds to a step S 33 , wherein information indicative of success of printing is written to the memory within the media pack, together with the date (hour) determined by the clock TM within the camera section at this time point in association with the information. Then, the fact that the printing has been normally completed is displayed on the LCD 106 at the following step S 34 , followed by the program returning to the step S 11 .
[0171] On the other hand, if occurrence of any abnormality in the printing operation was detected at the step S 32 , the program proceeds to a step S 35 , wherein information indicative of the abnormality is written to the memory within the media pack. At the following step S 36 , an error flag is stored in the same, and the date (day, month, year (and time)) determined by the clock TM within the camera section at this time point is also stored in association with the error information and error flag. Then, at a step S 37 , the error information is displayed on the LCD 106 , followed by the program returning to the step S 11 .
[0172] As described above, according to the present embodiment, information indicative of a detected one of various kinds of errors is stored in the memory within the media pack in association with a date (day, month, year, and time) determined by the clock TM within the camera section. Therefore, in the case of recovering the media pack later or in the case of using the same repeatedly, it is possible to carry out repair of the media pack or correction of data properly. Moreover, it is also possible to collect information for improvement of a media pack.
[0173] If it is determined at the step S 11 ( FIG. 17 ) that the present mode is not the printer mode but the camera mode, the program proceeds to a step S 38 in FIG. 19 , wherein a lens barrier, not shown, arranged on the front of the lens 107 is released by a plunger. Then, at the following step S 39 , depression of the release button into a first stroke position, which means that the SW 1 is turned on, is awaited. When the SW 1 of the release button is turned on, the program proceeds to a step S 40 , wherein measuring operations, such as a metering operation, a color measuring operation, and a distance measuring operation, are carried out.
[0174] Then, the program proceeds to a step S 41 , wherein depression of the release button into a second stroke position, which means that the SW 2 is turned on, is awaited. When the SW 2 is not turned on, the program returns to the step S 39 , whereas when the SW 2 is turned on, the program proceeds to a step S 42 . At the step S 42 , a shake amount and a shake direction are detected based on the output from the acceleration sensor 109 , and then it is determined whether or not there is a camera shake, dependent on whether the detected shake amount is larger than a predetermined amount. If there is a camera shake, at a step S 43 , the shake compensation mechanism 108 is operated according to the shake amount and the shake direction to thereby correct a shift of the image, and then the program proceeds to a step S 44 . On the other hand, if there is no camera shake, the program skips over the step S 43 to the step S 44 .
[0175] At the step S 44 , an exposure operation is carried out by controlling an aperture and a shutter, whereby the CCD 101 is exposed to a predetermined amount of light. Then, the program proceeds to a step S 45 , wherein image processing operations, such as white-balance calibration, gamma correction, color correction and compression, are performed, and at a step S 46 , the image is stored in the CF card 105 . At the same time, information of a date determined by the clock TM within the camera section at this time point is also stored in association with the image.
[0176] Then, the program proceeds to a step S 47 , wherein it is determined whether or not the present mode is the camera mode. If the present mode is the camera mode, the program returns to the step S 39 , whereas if not, the program returns to the step S 11 after closing the lens barrier at a step S 48 .
Another Embodiment
[0177] A second embodiment of the present invention will be described with reference to FIG. 21 . FIG. 21 is a flowchart which shows an operating procedure of the camera with a printer, according to the second embodiment.
[0178] The present embodiment is distinguished from the above described embodiment in that in carriage control executed by using the acceleration sensor 109 , the running speed of the carriage 225 and sheet feed are controlled according to the amount of a camera shake in a predetermined direction.
[0179] More specifically, as shown in FIG. 21 , a print operation is started at a step S 240 (corresponding to the step S 23 in FIG. 18 ), and at the following step S 250 , a shake amount and a shake direction are detected by the acceleration sensor 109 . Then, at a step S 260 , a shake component amount in the main scanning direction is calculated from the detected shake amount and direction, and it is determined whether or not the shake component amount is larger than a predetermined amount. If the shake component amount in the main scanning direction is larger than the predetermined amount, the program proceeds to a step S 270 , wherein the present running speed of the carriage 225 is reduced according to the shake component amount in the main scanning direction. More specifically, a deceleration amount by which the carriage 225 is to be decelerated is set according to the shake component amount in the main scanning direction, and the running speed of the carriage 225 is controlled according to the set deceleration amount. In this case, if the shake component amount is medium, a smaller deceleration amount is set to thereby minimize a decrease in printing efficiency. On the other hand, if the shake component amount is large, a larger deceleration amount is set to limit the influence of the shake on deviation of the scanning speed within a predetermined range, thereby reducing an error in a hitting position of ink ejected onto a paper sheet from the recording head 207 to an amount which is equal to or smaller than a predetermined amount.
[0180] Then, the program proceeds to a step S 280 , wherein the present position of the recording head 207 is detected, and it is determined whether or not the recording head is at the main scanning end. If the recording head is not at the main scanning end, the program returns to the step S 250 , wherein a shake amount is detected again. On the other hand, if the recording head is at the main scanning end, the program proceeds to a step S 290 , wherein the carriage 225 is temporarily stopped, and thereby temporarily suspending the main scanning. Then, the program proceeds to a step S 310 , wherein a shake component in the sub-scanning direction is determined from a shake amount, and it is determined whether or not the shake component is larger than a predetermined amount.
[0181] If the shake component in the sub-scanning direction is larger than the predetermined amount at the step, the program proceeds to a step S 330 , wherein sheet feed is stopped. Then, the program returns to the step S 250 , wherein a shake amount is detected again. On the other hand, if the shake component in the sub-scanning direction is equal to or smaller than the predetermined amount at the step S 310 , the program proceeds to a step S 320 , wherein the paper sheet is fed by a predetermined amount. Then, at the following step S 340 , it is determined whether or not printing on one sheet has been completed according to whether or not the recording position has reached a sub-scanning end. If the recording position has not reached a sub-scanning end, which means that printing has not been completed, the program returns to the step S 250 , wherein a shake amount is detected again.
[0182] If the shake component amount in the main scanning direction is equal to or smaller than the predetermined amount at the step S 260 , the program proceeds to a step S 300 , wherein the carriage 225 is driven at a normal speed. In other words, the main scanning is carried out at the normal speed. If the running speed of the carriage 225 is being currently decelerated, the running speed is increased again to the normal speed. Thereafter, at steps S 310 to 330 , sheet feed is stopped or continued according to the shake amount in the sub-scanning direction.
[0183] When it is determined at the step S 340 that the printing on one sheet is completed, the program returns to the step S 29 in FIG. 18 , and then the steps S 29 et seq. are repeatedly carried out.
[0184] Although in the above described embodiments, the camera is comprised of the camera section a 100 and the printer section B 100 which are integrated in a one-piece body, this is not limitative, but even when the camera section A 100 and the printer section B 100 are formed in two separate bodies, which are interconnected via the interface 210 , it is possible to realize similar functions to those described above. | There is provided a media pack which can be removably mounted in a printer, and which allows a consumable article or articles contained therein for use by the printer, and enables the printer to easily recognize whether there is a possibility of degradation of the consumable article(s) due to a long time period elapsing after filling or producing of the consumable article(s). A pack body contains ink and a print medium for use by the printer, and a memory is arranged within the pack body, for having readably written therein data related to the print medium, which includes at least information of a year and month at which the print medium was filled or produced. | 96,621 |
TECHNICAL FIELD
[0001] This disclosure relates generally to the processes of fabricating various petroleum-based fuels, and more specifically, to hydrogenation processes for obtaining petroleum distillate from light Fischer-Tropsch liquids.
BACKGROUND INFORMATION
[0002] Fischer-Tropsch synthesis is known to yield a broad mixture of products including primarily paraffins, and some olefins. The individual compounds of such mixture can contain up to about 200 carbons, the number of carbons between about 20 and about 150, with average number about 60 being typical. Certain quantities of oxygenated products and trace amounts of sulfur- or nitrogen containing products or aromatic compounds can be also present.
[0003] Some Fischer-Tropsch processes yield mixtures enriched with C 5 -C 30 alkanes and also containing a significant quantity of olefins and oxygenated compounds such as alcohols or acids. Such mixtures are known as “light Fischer-Tropsch liquids” or “LFTL.” Light Fischer-Tropsch liquids are frequently used as a raw material for obtaining various petrochemical products, such as, e.g., petroleum distillates, or diesel fuels, among others.
[0004] To make LFTL useful and suitable as blending stock for diesel fuel, olefins and oxygenated compounds contained therein are removed, typically by the saturation of olefins and by conversion of oxygenated compounds into water via hydrogenation also known as hydrotreating, which involves the processes of hydrogenation of LFTL in the presence of hydrogen and a catalyst.
[0005] Despite its many advantages, hydrotreating of LFTL is characterized by a number of drawbacks and deficiencies. For example, the process usually requires using very high pressures and temperatures. In addition, while traditional hydrotreating does allow for removal of olefins and oxygenated compounds, the final product often has a cloud point that is too high, limiting the amount of the product that can be blended into diesel fuels.
[0006] To avoid or lessen the effects of the above-mentioned deficiencies, as well as for the purposes of improvement of the overall process efficiency, better processes are needed to be used with light Fischer-Tropsch liquids.
SUMMARY
[0007] We provide methods for obtaining a petroleum distillate product. One method comprises subjecting an untreated light Fischer-Tropsch liquid to a first hydrogenation in the presence of a first catalyst to obtain a hydrotreated light Fischer-Tropsch liquid composite and subjecting the hydrotreated light Fischer-Tropsch liquid composite to a second hydrogenation in the presence of a second catalyst to obtain and recover the petroleum distillate product.
[0008] The light Fischer-Tropsch liquid subject to hydrogenation may be an untreated light Fischer-Tropsch liquid having the degree of unsaturation characterized by the bromine number of about 200 or below. The light Fischer-Tropsch liquid subject to hydrogenation may be also an untreated light Fischer-Tropsch liquid containing between about 1 mass % and about 20 mass % of oxygen.
[0009] The first catalyst, i.e., the catalyst used in the first step of hydrogenation process, may be a metallic composition embedded within an inorganic oxide or a zeolitic substrate, the composition comprising a base metal, e.g., a nickel-molybdenum composition or a cobalt-molybdenum composition. The metallic composition comprising the first catalyst may also include at least one noble metal, such as platinum or palladium.
[0010] The second catalyst, i.e., the catalyst used in the first step of hydrogenation process, may be a metallic composition embedded within an inorganic oxide or a zeolitic substrate, the composition comprising a base metal, e.g., a nickel-molybdenum composition or a cobalt-molybdenum composition. The metallic composition comprising the second catalyst may also include at least one noble metal, such as platinum or palladium. The first and the second catalysts may be the same or different.
[0011] We also provide a system for obtaining a petroleum distillate that subjects an untreated light Fischer-Tropsch liquid to a first hydrogenation and yields a hydrotreated light Fischer-Tropsch liquid composite, and a second hydrogenating unit that subjects the hydrotreated light Fischer-Tropsch liquid composite to a second hydrogenation and yields the petroleum distillate product.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] FIG. 1 illustrates schematically a system for hydrogenating of light Fischer-Tropsch liquids according to one embodiment of the present invention.
[0013] FIG. 2 illustrates schematically a system for hydrogenating of light Fischer-Tropsch liquids according to another embodiment of the present invention.
DETAILED DESCRIPTION
[0014] The following definitions and abbreviations are used below, unless otherwise described:
[0015] The term “a light Fischer-Tropsch liquid” or the abbreviation “LFTL” is defined as a mixture comprised of n-paraffins having the number of carbons between about 5 and about 50, the mixture containing a substantial portion of C 5 -C 30 alkanes and also containing olefins and oxygenated compounds.
[0016] The term “a hydrocarbon” is defined as an organic compound, the molecule of which consists only of carbon and hydrogen.
[0017] The terms “a paraffin” and “alkane” are used interchangeably and refer to a hydrocarbon identified by saturated carbon chains, which can be normal (straight), branched, or cyclic (“cycloparaffin”), and described by a general formula C n H 2n+2 , where n is an integer. Paraffins or alkanes are substantially free of carbon-carbon double bonds (C═C).
[0018] The term “an olefin,” also known as “alkene” is defined as a hydrocarbon containing at least one carbon-carbon double bond, and described by a general formula C n H 2n , where n is an integer.
[0019] The terms “hydrogenation” and “hydrotreating” are used interchangeably and refer to a process of addition of hydrogen to unsaturated organic compounds, such as olefins (alkenes), typically, in a presence of a suitable catalyst, to obtain saturated organic compounds, such as alkanes, as a result.
[0020] The term “a catalyst” is defined as substance that changes the speed or yield of a chemical reaction without being itself substantially consumed or otherwise chemically changed in the process.
[0021] The term “a noble metal” refers to a metal that is highly resistant to corrosion or oxidation, and does not easily dissolve, as opposed to most base metals. Examples include, but are not limited to, platinum, palladium, gold, silver, tantalum, or the like.
[0022] The team “a base metal” refers to any non-precious metal that is capable of being readily oxidized. Examples include, but are not limited to, nickel, molybdenum, tungsten, cobalt, or the like.
[0023] The term “a bromine index” or “bromine number” indicates the degree of aliphatic unsaturation and is defined as the amount of bromine in grams absorbed by 100 grams of a sample containing an unsaturated compound, such as an olefin.
[0024] The term “a cloud point” refers to a temperature at which fuel starts congealing and starts becoming cloudy due to the appearance of wax crystals, when the fuel is tested in accordance with the American Society for Testing and Materials (ASTM) Specification D2500. The cloudiness increases as the temperature is lowered further.
[0025] The term “diesel fuel” is defined in accordance with the specifications described in the ASTM Specification D975 and refers to a petroleum fraction having containing primarily C 10 -C 24 hydrocarbons and having distillation temperatures of about 160° C. at the 10% recovery point and about 340° C. at the 90% recovery point.
[0026] The term “API gravity” refers to American Petroleum Institute's measure of the density of a petroleum product relative to the density of water.
[0027] The abbreviation “WABT” means “weighted bed average temperature” and refers to an average temperature on the bed of catalyst.
[0028] The abbreviation “LHSV” means “liquid hourly space velocity” and refers to a ratio between the hourly volume of feedstock used in the process of hydrogenation and the volume of catalyst used.
[0029] The abbreviations “IBP” and “EBP” refer to the temperatures that are the initial boiling point of a product and the ending boiling point, respectively.
[0030] A petroleum distillate product may be obtained by using a two-stage process of hydrogenation. At the first stage, where most of the hydrotreating occurs, an untreated light Fischer-Tropsch liquid may be subjected to hydrogenation, which includes reacting the untreated LFTL with gaseous hydrogen, at an elevated temperature and elevated pressure, in the presence of a catalyst. During hydrogenation, the olefins that are present in the untreated LFTL react with hydrogen and become saturated by forming alkanes. If the original LFTL contained some quantity of cycloolefins, in addition cycloalkanes may be also formed. As a result, a hydrotreated light Fischer-Tropsch liquid composite is formed and water is released as a by-product.
[0031] The hydrotreated light Fischer-Tropsch liquid composite obtained as described above is then further hydrogenated to complete the process. Again, the second stage of hydrogenation includes reacting the hydrotreated LFTL, at an elevated temperature and elevated pressure, in the presence of a catalyst. Upon the completion of the process of hydrogenation, the final petroleum distillate product may be recovered. The final product is a diesel range material that may be substantially devoid of olefins and oxygenated products and may be suitable for blending with diesel fuels.
[0032] Both stages of hydrogenation may be carried out in a hydrotreating unit, or in two separate hydrogenating units, as desired. The temperature at which hydrogenation is carried out may be between about 200° C. and about 370° C., such as about 315° C. The pressure at which hydrogenation is carried out may be between about 1 MPa and about 15 MPa, for example, about 4 MPa. A desired rate of supply of hydrogen gas can be selected. For example, hydrogen gas can be supplied at a rate between about 170 and about 840 m 3 per 1 m 3 of the untreated LFTL at the first stage of hydrogenation or per 1 m 3 of the hydrotreated LFTL at the second stage.
[0033] Each stage of hydrogenation can be carried out under the same conditions, such as temperature, pressure, and the rate of hydrogen supply, or under the different conditions so long as the temperature and pressure are within the respective ranges disclosed above.
[0034] The process of hydrogenation can be described by the exemplary reaction schemes (1) (for straight-chained olefins such as methylbutene) and (2) (for cycloolefins such as cyclopentene):
[0000]
[0035] As can be seen from the reaction schemes (1) and (2), the process of hydrogenation is carried out in the presence of a catalyst. An appropriate catalyst can be selected from a variety of available options known in the art. For example, the catalyst that can be used is a base metal composition, such as a nickel-molybdenum composition, a cobalt-molybdenum composition, or the like. Alternatively, or a noble metal composition comprising, for example, platinum, palladium, or the like can be employed. The same catalyst or different catalysts can be utilized at the first and second stages of hydrogenation as discussed above.
[0036] Hydrotreating is frequently a catch-all term for numerous processes that entail treating products with hydrogen. Hydrotreating includes processes such as hydrodeoxygenation, hydroisomerization, hydrocracking, and hydrodewaxing to name a few. To one skilled in the art, it is generally apparent which particular hydrotreating process is being employed when one is studying the fluids being treated, and the resulting products, as well as operating conditions. The preferred process is briefly described in order to clarify specific hydrotreating steps in the process of producing a high grade blending stock from Fischer-Tropsch liquids.
[0037] In a preferred process, the present invention uses a two step hydrotreating procedure. The first step involves hydrotreating the LFTL over a first catalyst for the purpose of hydrodeoxygenation and partial saturation of unsaturated hydrocarbon compounds. The first catalyst is an amorphous catalyst having a metal embedded therein. The removal of oxygen from the LFTL provides protection for catalysts used in the further processing of the hydrotreated LFTL. The hydrotreated LFTL is further processed over a second catalyst for isomerization and some cracking of the hydrocarbon compounds within the hydrotreated LFTL. The second catalyst is a zeolite having a metal embedded therein. The second step comprising isomerization and some cracking improves the pour and cloud points of the liquid allowing for blending into a diesel pool or, depending on the desired degree of cracking, can produce a high quality jet fuel.
[0038] In a normal process for multistage hydrotreating of a Fischer-Tropsch liquid, the process entails hydrotreating the Fischer-Tropsch liquid over an amorphous catalyst with the primary purpose of oxygen removal from the liquid. The second step of hydroisomerization is also performed with an amorphous catalyst to provide an isomerized and deoxygenated Fischer-Tropsch liquid. This can be seen in U.S. Pat. No. 6,602,402, where the process of Benazzi et al. use amorphous catalysts for the first hydrotreating step, and the hydroisomerization step. Benazzi et al. further requires an additional step for dewaxing the hydrotreated and hydroisomerized Fischer-Tropsch liquid. The present invention does not have a hydrodewaxing step as in Benazzi et al., but overcomes drawbacks to Benazzi's second step of hydroisomerization by using a zeolitic catalyst for generating a blending stock and eliminating Benazzi's third step of dewaxing as this is accomplished in our second reactor.
[0039] Any LFTL can be used as feedstock as the starting product in the hydrogenation processes described above, including a variety of commercially available light Fischer-Tropsch liquids. The starting untreated LFTL may have distillation temperatures of about 90° C. at the 10% recovery point and about 370° C. at the 90% recovery point.
[0040] An acceptable LFTL that can be used may include a substantial quantity of paraffins, which may include one or more straight-chained paraffin(s) and may in addition include at least one branched paraffin. Such straight-chained and branched paraffin(s) are the principal components of the untreated starting LFTL. In addition to straight-chained paraffin and branched paraffin(s) the paraffin composition can further comprise at least some quantity of cycloparaffin(s).
[0041] Furthermore, the starting LFTL may have the contents of olefins that is characterized by the bromine number greater than about 10. In addition, the starting LFTL may include a quantity of oxygenated products that is characterized by the total oxygen contents between about 1 mass % and about 20 mass %. Not more than just trace amounts of any aromatic compounds, including alkyl aromatic compounds and polyalkyl aromatic compounds, may be present in the original LFTL.
[0042] The final product of the entire process of hydrogenation can be for blended with diesel fuels and with jet oil, may have the cetane number of at least about 50, and may have a cloud point of about 5° C. or less.
[0043] Various systems and apparatuses can be used for conducting our processes. One embodiment of such a system that can be used is shown by FIG. 1 and can be described as follows. FIG. 1 illustrates the system 100 comprising three hydrotreatment reactors 4 , 11 , and 19 . All three reactors may be the same or different. In the exemplary system 100 shown by FIG. 1 , the reactors 4 and 11 may use a nickel/molybdenum catalysts such as KF-647 or KF-846, and the reactor 19 may utilize a platinum/palladium catalyst. The catalysts are described in more detail in the “Examples” portion of the application, below.
[0044] The LFTL feed 1 can be mixed with the hydrogen gas 2 that can be supplied at a rate between about 170 and about 840 m 3 per 1 m 3 of the LFTL. The LFTL/H 2 mixture can be then pre-heated to the desired temperature (e.g., 200° C. and about 370° C., such as about 315° C.) and can be then directed to the first hydrotreatment reactor 4 . The process of hydrogenation then occurs inside the reactor 4 and includes the reaction of the LFTL with hydrogen gas on a bed, such as a fixed bed, of a catalyst (not shown). As hydrogen is consumed during this process, hydrogen may be replenished from a make-up source of hydrogen 3 , and hydrogen provided from this source may contain some amount of H 2 S. The process may be carried out at a pressure between about 1 MPa and about 15 MPa, for example, about 4 MPa. The required pressure can be generated and maintained using the compressor 7 .
[0045] The exothermic reactions occurring in reactor 4 may lead to a temperature increase. In order to control the temperature in the reactor the reacting fluid may be cooled (quenched). Such quenching can be achieved by supplying cool hydrogen via the by-pass line 5 . Upon completion of this stage of hydrogenation, the partially hydrogenated product then may exit the reactor 4 and be directed into the separator 6 , where water is separated as the stream 13 . The product may exit the separator 6 via the line 8 , and may then be directed to the second hydrotreatment reactor 11 , using the pump 9 .
[0046] In the second reactor 11 , the process of hydrogenation may be continued using additional hydrogen that may be supplied via the line 10 . The conditions for the second stage hydrogenation may be the same as those used for the hydrogenation in the reactor 4 , as described above.
[0047] The hydrogenated product then may exit the reactor 11 and be directed into the separator 12 , where water is separated as the stream 13 , and the product may exit the separator 12 via the line 14 , and may then be directed to the stripper 15 , where the H 2 S gas is removed as the stream 16 , and the product may exit the stripper 15 via the line 17 , and may then be directed to the third hydrotreatment reactor 19 , using the pump 18 .
[0048] The final stage of the process of hydrogenation then occurs inside the reactor 19 and includes the reaction of the partially treated LFTL with hydrogen gas on a bed, such as a fixed bed, of a catalyst (not shown). As hydrogen is consumed during this process, hydrogen may be replenished from a make up source of hydrogen 20 , where hydrogen may be typically free of H 2 S. The process may be carried out at a pressure between about 1 MPa and about 15 MPa, for example, about 4 MPa. The required pressure can be generated and maintained using the compressor 23 .
[0049] The exothermic reactions occurring in reactor 19 may lead to a temperature increase. In order to control the temperature in the reactor the reacting fluid may be cooled (quenched). Such quenching can be achieved by supplying cool hydrogen via line 21 . Upon completion of this stage of hydrogenation, the partially hydrogenated product then may exit the reactor 19 via the line 22 , then may be directed to the separator 24 . After the process of separation, the final product can exit the system 100 as the stream 25 and then may be directed to fractionation.
[0050] Another embodiment of a system that can be used is shown by FIG. 2 illustrating the system 200 comprising two hydrotreatment reactors 29 and 40 . These reactors may be the same or different. In the exemplary system 200 shown by FIG. 2 , the reactor 29 may use a nickel/molybdenum catalysts such as KF-647 or KF-846, and the reactor 40 may utilize a platinum/palladium catalyst.
[0051] The LFTL feed 26 can be mixed with the hydrogen gas 27 that can be supplied at a rate between about 170 and about 840 m 3 per 1 m 3 of the LFTL. The LFTL/H 2 mixture can be then pre-heated to the desired temperature (e.g., 200° C. and about 370° C., such as about 315° C.) and can be then directed to the first hydrotreatment reactor 29 .
[0052] The process of hydrogenation then occurs inside the reactor 29 and includes the reaction of the LFTL with hydrogen gas on a bed of a catalyst (not shown). Hydrogen may be replenished from a make-up source of hydrogen 28 , and hydrogen supplied from this source may contain some amount of H 2 S. The process may be carried out at a pressure between about 1 MPa and about 15 MPa, for example, about 4 MPa. The required pressure can be generated and maintained using the compressor 33 .
[0053] The exothermic reactions occurring in reactor 29 may lead to a temperature increase. In order to control the temperature in the reactor the reacting fluid may be cooled (quenched), which can be achieved by supplying cool hydrogen via line 30 . The partially hydrogenated product then may exit the reactor 29 and be directed via the line 31 into the separator 32 , where water is separated as the stream 37 . The product may exit the separator 32 via the line 34 , and may then be directed to stripper 35 , where the H 2 S gas is removed as the stream 36 . The product may then exit the stripper 35 via the line 38 , and may then be directed to the second hydrotreatment reactor 40 , using the pump 39 .
[0054] A later stage of the process of hydrogenation then occurs inside the reactor 40 and includes the reaction of the partially treated LFTL with hydrogen gas on a bed of a catalyst (not shown). As hydrogen is consumed during this process, hydrogen may be replenished from a make up source of hydrogen 41 , where hydrogen may be typically free of H 2 S. The process may be carried out at a pressure between about 1 MPa and about 15 MPa, for example, about 4 MPa. The required pressure can be generated and maintained using the compressor 42 .
[0055] The exothermic reactions occurring in reactor 40 may lead to a temperature increase. In order to control the temperature in the reactor the reacting fluid may be cooled (quenched) by supplying cool hydrogen via the by-pass line 44 . Upon completion of this stage of hydrogenation, the partially hydrogenated product then may exit the reactor 40 via the line 43 , then may be directed to the separator 45 . After the process of separation, the final product can exit the system 200 as the stream 46 and then may be directed to fractionation.
EXAMPLES
[0056] The following examples are provided to further illustrate the advantages and features of our processes and systems, but are not intended to limit the scope of this disclosure.
Example 1
Starting Material
[0057] The starting material that was used as a feed in hydrogenation was a commercially available light Fischer-Tropsch liquid and had the properties and characteristics shown in Table 1. In Table 1, the data for distillation temperatures show the boiling temperature at the beginning and the end of the recovery (by mass %) range. For example, the entry “10/20” in the property column and “100/142” in the value column signifies the boiling temperature of about 100° C. at the 10% mass recovery point and about 142° C. at the 20% mass recovery point.
[0000]
TABLE 1
Properties of Starting Untreated LFTL
Property
Value
Specific gravity, g/cm 3
0.7884
API Gravity
47.98
Sulfur Contents, ppm* ) , mass
Less than 1
Nitrogen Contents, ppm* ) , mass
10
Oxygen Contents, mass %
5.9
Bromine Index
56
Acid Number
25.9
Distillation Temperature** ) , ° C.
IBP/5
21/86
10/20
100/142
30/40
167/190
50/60
418/454
70/80
266/296
90/95
336/373
EBP
469
Contents of Aromatic Compounds, mass %
One Ring
0.8
Two Rings
0.2
Three or More Rings
1.5
* ) parts per million
** ) determined in accordance with ASTM Specification D2887
*** ) determined in accordance with Institute of Petroleum Test IP-391
Example 2
Hydrogenation of the Starting LFTL
[0058] The starting untreated LFTL described in Example 1 was subjected to hydrogenation. The process was carried out in a two reactor (R-1 and R-2) configuration, with the removal of water between reactors. Nickel/molybdenum catalysts KF-647 and KF-846 were used in reactors R-1 and R-2, respectively. The catalysts were obtained from Albemarle Corp. of Baton Rouge, La.
[0059] The process yielded hydrotreated LFTL composite. The conditions of the process of hydrogenation are shown in Table 2, and the properties of the product are shown in Table 3.
[0000]
TABLE 2
Operating Conditions Used for Hydrogenating LFTL
Operating Condition
Reactor 1 (R-1)
Reactor 2 (R-2)
Pressure, MPa
4.14
4.14
WABT* ) , ° C.
316
316
LHSV** ) , hr −1
2.5
1.67
Overall LHSV** ) , hr −1
1.00
Recycle Gas to Reactor 1, m 3
337
per 1 m 3 of LFTL
* ) weighted bed average temperature
** ) liquid hourly space velocity
[0000]
TABLE 3
Properties of Hydrotreated LFTL Composite
Property
Value
Specific Gravity, g/cm 3
0.7387
API Gravity
60.04
Hydrogen Contents, mass %
15.39
Bromine Index
Less than 10
Oxygen Contents, mass %
Less than 0.02
Acid Number
0.005
Distillation Temperature* ) , ° C.
IBP/5
−9/66
10/20
88/126
30/40
152/175
50/60
197/218
70/80
255/287
90/95
331/369
EBP
510
Distillation Temperature** ) , ° C.
IBP/5
48/85
10/20
103/128
30/40
148/167
50/60
189/214
70/80
239/Solidified
90/95
N/A (Solidified)
EBP
N/A (Solidified)
* ) determined in accordance with ASTM Specification D2887
** ) determined in accordance with ASTM Specification D86, fractions are in volume %
[0060] The product obtained as described above and having properties shown in table 3 was then fractionated into two fractions to separate naphtha from diesel fuel. The first fraction (i.e., the naphtha fraction) had the IBP of about 149° C., and the second fraction (i.e., the diesel fraction) had the IBP above 149° C. The properties of the diesel fraction are provided in Table 4.
[0000]
TABLE 4
Properties of the Diesel Fraction (IBP > 149° C.)
Property
Value
API Gravity
53.9
Cloud Point, ° C.
12.2
Flash Point, ° C.
57.2
Distillation Temperature* ) , ° C.
IBP/5
168/181
10/20
184/192
30/40
203/216
50/60
232/249
70/80
268/293
90/95
N/A//N/A (Solidified)
EBP
N/A (Solidified)
* ) determined in accordance with ASTM Specification D86, fractions are in volume %
[0061] As can be seen from Tables 3 and 4, in the process described above, it was not possible to complete the distillation according to ASTM Specification D86, and the diesel fraction had the cloud point which was quite high (about 12° C.), thus limiting the amount of the hydrotreated LFTL that can be used for blending into a diesel fuel. The following example demonstrates improvement of the process illustrated in Example 2.
Example 3
Further Processing of the Hydrotreated LFTL Composite
[0062] The product described in Table 3, obtained as discussed in Example 2 above (prior to fractionating the hydrotreated LFTL composite into the naphtha and diesel fractions), was further processed by additional hydrogenation, as follows.
[0063] The hydrotreated LFTL composite described in Table 3 was hydrogenated over a catalyst comprising about 0.45 mass % of platinum and about 0.45 mass % of palladium embedded on a support comprising a zeolite. The processing conditions for the process of hydrogenation are described in Table 5.
[0000]
TABLE 5
Conditions for Processing the Hydrotreated LFTL Composite by
Hydrogenation over a Platinum/Palladium Catalyst
Operating Condition
Value
Pressure, MPa
6.9
LHSV, hr −1
1.0
Hydrogen Flow, m 3 per 1 m 3 of LFTL
1,011
Temperature, ° C.* )
265.6
291.7
* ) two separate experiments
[0064] As can be seen from Table 5, the process of hydrotreating was carried out at two different temperatures. Using the lower temperature, i.e., 265.6° C., may be suitable for improving the quality of the diesel fraction, while using the higher temperature, i.e., 291.7° C., may be beneficial if the product is to be used in the manufacturing of jet fuel with enhanced properties.
[0065] The product obtained under conditions shown in Table 5 was then fractionated and the light and the heavy naphtha fractions were removed by distillation. The properties of the remaining fraction are provided in Tables 6 and 7. Table 6 shows the properties of the diesel fraction that remained, as obtained after the hydrogenation carried out at the lower hydrogenation temperature of about 265.6° C.
[0000]
TABLE 6
Properties of the Diesel Fraction After Processing the Hydrotreated
LFTL Composite by Hydrogenation over a Platinum/Palladium Catalyst
at 265.6° C.
Stream
Liquid Product
IBP/85° C.
85° C./143° C.
143° C./EBP
Yield, g
9,357
779
1,865
6,642
Yield, mass %
N/A
8.4
20.1
71.5
API Gravity
59.8
84.5
69.6
54.6
Specific Gravity, g/cm 3
0.7397
0.6550
0.7036
0.7602
Hydrogen Contents, mass %
N/A
N/A
15.78
15.33
Flash Point, ° C.
N/A
N/A
2.8
53.9
Cloud Point, ° C.
N/A
N/A
N/A
3.9
Pour Point, ° C.
N/A
N/A
N/A
−6.1
Viscosity at −20° C., cSt
N/A
N/A
1.185
N/A
Iron Contents, mass %
N/A
N/A
<0.00002
<0.00002
Reid Vapor Pressure, Pa
N/A
N/A
9,928.5
896.3
Micro Research Octane
N/A
N/A
<40
N/A
Number
Micro Motor Octane
N/A
N/A
<40
N/A
Number
Cetane Number
N/A
N/A
N/A
73.7
Distillation Temperatures* ) , ° C.
IBP
−1.1
−9.4
63.9
139.4
5
66.7
17.8
87.2
149.4
10
96.7
30.0
96.7
150.0
20
126.1
33.3
98.3
173.9
30
151.1
35.6
99.4
195.0
40
173.9
56.7
105.6
207.2
50
196.1
67.2
118.9
223.3
60
216.7
69.4
126.7
243.9
70
246.7
70.0
127.8
270.0
80
273.9
70.6
128.9
288.3
90
316.1
70.6
129.4
329.4
95
356.1
87.2
141.1
366.7
EBP
500.6
97.2
149.4
475.6
Distillation Temperatures** ) , ° C.
IBP
N/A
N/A
103.9
166.7
5
N/A
N/A
107.2
178.3
10
N/A
N/A
108.3
178.3
20
N/A
N/A
109.4
186.7
30
N/A
N/A
111.1
196.1
40
N/A
N/A
112.8
208.3
50
N/A
N/A
115.0
222.2
60
N/A
N/A
117.2
238.3
70
N/A
N/A
120.0
257.2
80
N/A
N/A
123.3
279.4
90
N/A
N/A
127.2
315.6
95
N/A
N/A
130.6
N/A
EBP
N/A
N/A
143.9
354.4
Recovery, mass %
N/A
N/A
98.7
93.9
* ) simulated, determined in accordance with ASTM Specification D2887
** ) Engler distillation, determined in accordance with ASTM Specification D86
[0066] As can be seen from the data presented in Table 6, the cloud point has been substantially improved compared with that of the diesel fraction recovered from the hydrotreated LFTL composite (see Table 4 for comparison of the respective cloud points), and the cetane number is quite high. Thus, the diesel fraction characterized in Table 6 may be used for blending with various diesel fuels. It may be also noticed that the difficulties previously experienced with the ASTM D86 distillation were eliminated.
[0067] Table 7 shows the properties of the kerosene/jet fuel fraction that remained, as obtained after the hydrogenation carried out at the higher hydrogenation temperature of about 291.7° C., and demonstrates that the product can be used as a high quality jet fuel blending component.
[0000]
TABLE 7
Properties of the Kerosene/Jet Fuel Fraction After Processing the
Hydrotreated LFTL Composite by Hydrogenation over a
Platinum/Palladium Catalyst at 291.7° C.
Stream
Liquid Product
IBP/85° C.
85° C./135° C.
135° C./EBP
Yield, g
4,995
649
1,307
2,965
Yield, mass %
N/A
13.2
26.6
60.3
API Gravity
65.1
85.2
70.0
58.3
Specific Gravity, g/cm 3
0.7197
0.6530
0.7022
0.7456
Hydrogen Contents, mass %
N/A
N/A
15.78
15.44
Total Sulfur Contents, mass ppm
N/A
N/A
<0.05
0.07
Flash Point, ° C.
N/A
N/A
1.0
43.0
Cloud Point, ° C.
N/A
N/A
N/A
−35.0
Pour Point, ° C.
N/A
N/A
N/A
−57.0
Smoke Point, mm
N/A
N/A
N/A
39
Freeze Point, ° C.
N/A
N/A
N/A
−56.6
Viscosity at −20° C., cSt
N/A
N/A
1.137
3.250
Iron Contents, mass %
N/A
N/A
<0.00002
<0.00002
Reid Vapor Pressure, Pa
N/A
N/A
10,824.8
1,930.5
Micro RON
N/A
N/A
<40
N/A
Micro MON
N/A
N/A
<40
N/A
Distillation Temperatures* ) , ° C.
IBP
−22.2
−12.2
63.3
123.3
5
33.9
16.7
85.0
140.6
10
72.8
18.3
87.2
142.3
20
97.8
32.2
97.2
151.1
30
117.8
34.4
98.9
165.0
40
131.7
52.8
100.0
174.4
50
151.7
57.2
115.0
186.7
60
167.8
66.1
117.8
196.7
70
187.2
68.3
125.6
208.3
80
205.0
69.4
127.2
221.1
90
227.8
70.0
128.3
238.9
95
245.0
83.9
131.1
253.9
EBP
286.7
95.6
148.9
286.1
Distillation Temperatures** ) , ° C.
IBP
N/A
N/A
101.1
156.1
5
N/A
N/A
103.9
164.4
10
N/A
N/A
105.0
163.9
20
N/A
N/A
106.7
168.3
30
N/A
N/A
107.8
172.2
40
N/A
N/A
109.4
177.2
50
N/A
N/A
111.1
184.4
60
N/A
N/A
113.3
191.7
70
N/A
N/A
116.1
201.1
80
N/A
N/A
119.4
212.2
90
N/A
N/A
123.9
229.4
95
N/A
N/A
128.3
247.2
EBP
N/A
N/A
141.1
248.3
Recovery, mass %
N/A
N/A
97.0
95.8
* ) simulated, determined in accordance with ASTM Specification D2887
** ) Engler distillation, determined in accordance with ASTM Specification D86
[0068] Although our methods and systems have been described with reference to the above-discussed reactions and structures, it will be understood that modifications and variations are encompassed within the spirit and scope of the disclosure as defined in the appended claims. | A method for obtaining a petroleum distillate product is provided, the method includes subjecting an untreated light Fischer-Tropsch liquid to a two-step hydrogenation process, each step to be carried in the presence of a catalyst comprising an amorphous substrate having a metallic composition embedded therein. After the first step of hydrogenation, an intermediate hydrotreated light Fischer-Tropsch liquid is obtained, followed by the second step of hydrogenation thereof, obtaining the petroleum distillate product as a result. An apparatus for carrying out the method is also provided. | 58,108 |
TECHNICAL FIELD
[0001] The present invention relates to a game machine that is applied to a game system which progresses a game between a plurality of terminals connected via a communication line, that can function as one of the plurality of terminals, and a control method used therefor and a computer program used thereof.
BACKGROUND ART
[0002] There are game machines in which a plurality of players alternately operates each operating unit in tune with a rhythm of music. Of the game machines, there has been known a game machine which is played by a plurality of players, and in which each player alternately operates each operating unit while deciding a next player to operate each operating unit through an operation of each operating unit (for example, see Patent Literature 1).
[0003] Patent Literature 1: Japanese Patent Application Laid-Open (JP-A) No. 2003-236243.
SUMMARY OF INVENTION
Technical Problem
[0004] In the game machine disclosed in Patent Literature 1, one player's operation result affects progress of the game of the other player directly. Therefore, the game progresses via the common game screen. In the game machine like this, there is not assumed a game which has to use a game screen different from opponents. As a game like this, for example, there is assumed a case which executes a game with difficulty level differing from opponents. That is, in the game machine disclosed in Patent Literature 1, a play using a game with different difficulty level cannot be actualized.
[0005] In this regard, an object of the present invention is to provide a game machine which can actualize a play between games having difficulty level differing from each other, a control method therefor, and a computer program.
Solution to Problem
[0006] A game machine of the present invention is a game machine which is applied to a game system progressing a game between a plurality of terminals connected through a communication line, based on play acts by a player of each terminal, and which is capable of functioning as one of the plurality of terminals, wherein the game machine comprises: a reference timing data storage device adapted and configured to store two or more pieces of reference timing data in which reference timings at which the play acts should be performed in the game are described so that contents of the reference timings differ from each other; a reference timing teaching device adapted and configured to teach the reference timings for own game machine, based on a piece of the reference timing data differing from a piece of the reference timing data used in another game machine functioning as another terminal of the game system, among the two or more pieces of reference timing data; an other machine information acquiring device adapted and configured to acquire other machine information relating to the play acts on the other game machine; and a condition determination device adapted and configured to determine whether or not a predetermined reflection condition has been met based on the other machine information acquired by the other machine information acquiring device, and wherein the reference timing teaching device reflects the other machine information to a teaching aspect for teaching the reference timings for the own game machine, when the predetermined reflection condition has been met based on a determination result of the condition determination device.
[0007] According to the present invention, there is provided a game using pieces of reference timing data differing between the own game machine and the other game machine. That is, the game having different contents progress between the own game machine and the other game machine. Due to this, it is possible to provide the game having different difficulty levels between the own game machine and the other game machine. Further, a result of one play act is reflected to a teaching aspect of reference timings of the other, between the own game machine and the other game machine using different reference data, using a predetermined reflection condition. That is, even if games having different difficulty levels are played, it is possible to use one play act for progress of the game of the other, using the predetermined reflection condition. Due to this, it is possible to actualize a play between games having different difficulty levels.
[0008] The contents of the two or more pieces reference timing data may differ from each other in any way. For example, in an aspect of the game machine according to the present invention, the two or more pieces of reference timing data may differ from each other, due to a difference of number of the described reference timings.
[0009] In an aspect of the game machine according to the present invention, the play acts may include two or more kinds of acts, the condition determination device may determine that the predetermined reflection condition has been met when number of specific kind of acts reaches at a predetermined number, based on the specific kind of acts among the two or more kinds of acts included in the other machine information. In this case, it is possible to use one specific kind of act as an act influencing the other.
[0010] In the aspect using predetermined number of specific kind of acts as the predetermined reflection condition, number according to a ratio between number of the reference timings described in the piece of the reference timing data used in the own game machine and number of the reference timings described in the piece of the reference timing data used in the other game machine may be used as the predetermined number. In this case, one specific kind of act is reflected to the progress of the game of the other at a ratio according to number of reference timings. When number of the reference timings is large, since this means that the play acts to be performed are many, the difficulty level is higher in many cases than the case in which number of that is little. That is, the difference of number of the reference timings relates to the difference of the difficulty level. Accordingly, in this case, it is possible to try to adjust the difference of the difficulty level more appropriately, since it is possible to reflect one specific kind of act to the other at a ratio according to the difficulty level of the game.
[0011] Any kind of acts may use as the specific kind of act. For example, in an aspect using the specific kind of act, acts of a case in which each play act is not executed by each player within predetermined time, or an inappropriate case as each play act may be used as each specific kind of act.
[0012] In an aspect of the game machine according to the present invention, the game machine may further comprise: an input apparatus including at least one operation unit for inputting the play acts; and a display apparatus that displays a game screen, wherein the reference timing data storage device may store two or more pieces of sequence data in which operation timings for the one operation unit are described as the reference timings so that contents of the operation timings differ from each other, as the two or more pieces of reference timing data, the other machine information acquiring device may acquire operation information for the one operation unit of the other game machine, as the other machine information, the condition determination device may determine whether or not the predetermined reflection condition has been met based on the operation information acquired by the other machine information acquiring device, wherein the reference timing teaching device may comprises; a game region presenting device adapted and configured to display a game region to which a plurality of reference portions arranged apart from each other are set, on the game screen, and a mark display control device adapted and configured to teach the operation timings, by displaying operation indication marks for indicating the operations on the one operating unit while moving the operation indication marks in the game region so that each operation indication mark arrives at at least one of the plurality of the reference portions along any one of moving paths connecting the reference portions with each other at each operation timing indicated by a piece of the sequence data differing from a piece of the sequence data used in the other game machine, and wherein the mark display control device may reflect the operation information of the other game machine to a teaching aspect for teaching the own operation timings, by using the operation information of the other game machine for selecting at least one moving path of at least one operation indication mark to be displayed on the own game machine when the predetermined reflection condition has been met, based on a determination result of the condition determination device. In this case, in a game in which operation indication marks move between reference portions for teaching operation timings, it is possible to actualize a play using sequence data having different difficulty levels between the own game machine and the other game machine.
[0013] In an aspect of the game machine according to the present invention, when a special operation indication mark displayed at a case in which a predetermined display condition has been met is displayed on the game screen of the other game machine as the operation indication mark, the mark display control device may display the special operation indication mark on the game screen of the own game machine as the operation indication mark corresponding to any one of the operation timings, and may reflect the operation information for the special operation indication mark on the other game machine to the special operation indication mark on the own game machine, separately from the predetermined reflection condition. In this case, it is possible to reflect operation information for one special operation indication mark to the moving path of the special operation indication mark of the other, separately from the different of the difficulty level. That is, it is possible to use one special operation indication mark as a means influencing the progress of the game directly.
[0014] In an aspect of the game machine according to the present invention, the game machine may further comprise: an audio output apparatus that reproduces and outputs a sound; a music data storage device adapted and configured to store music data used to reproduce music; and a music reproducing device adapted and configured to reproduce the music through the audio output apparatus based on the music data, and wherein timings in the music may be used as the reference timings. In this case, it is possible to actualize the play between the games having the different difficulty levels, in a music game.
[0015] A control method of controlling a computer of the present invention is a control method of controlling a computer incorporated into a game machine which is applied to a game system progressing a game between a plurality of terminals connected through a communication line, based on play acts by a player of each terminal, which is capable of functioning as one of the plurality of terminals, and which comprises a reference timing data storage device adapted and configured to store two or more pieces of reference timing data in which reference timings at which the play acts should be performed in the game are described so that contents of the reference timings differ from each other, and wherein the control method of controlling the computer comprises the steps: a reference timing teaching step that teaches the reference timings for own game machine, based on a piece of the reference timing data differing from a piece of the reference timing data used in another game machine functioning as another terminal of the game system, among the two or more pieces of reference timing data; an other machine information acquiring step that acquires other machine information relating to the play acts on the other game machine; and a condition determination step that determines whether or not a predetermined reflection condition has been met based on the other machine information acquired by the other machine information acquiring device, and wherein the reference timing teaching step further includes a step that reflects the other machine information to a teaching aspect for teaching the reference timings for the own game machine, when the predetermined reflection condition has been met based on a determination result of the condition determination device.
[0016] Further, a computer program for a game machine of the present invention is a computer program for a game machine which is applied to a game system progressing a game between a plurality of terminals connected through a communication line, based on play acts by a player of each terminal, which is capable of functioning as one of the plurality of terminals, and which comprises a reference timing data storage device adapted and configured to store two or more pieces of reference timing data in which reference timings at which the play acts should be performed in the game are described so that contents of the reference timings differ from each other, and wherein the computer program for the game machine is configured so as to cause a computer which is incorporated into the game machine to function as: a reference timing teaching device adapted and configured to teach the reference timings for own game machine, based on a piece of the reference timing data differing from a piece of the reference timing data used in another game machine functioning as another terminal of the game system, among the two or more pieces of reference timing data; an other machine information acquiring device adapted and configured to acquire other machine information relating to the play acts on the other game machine; and a condition determination device adapted and configured to determine whether or not a predetermined reflection condition has been met based on the other machine information acquired by the other machine information acquiring device, and wherein the computer program for the game machine is configured so as to cause the reference timing teaching device to further function as a device adapted and configured to reflect the other machine information to a teaching aspect for teaching the reference timings for the own game machine, when the predetermined reflection condition has been met based on a determination result of the condition determination device. It is possible to actualize a game machine of the present invention by executing the computer program or the control method of controlling a computer of the present invention.
Advantageous Effects of Invention
[0017] As described above, according to the present invention, there is provided a game using pieces of reference timing data differing between own game machine and the other game machine. That is, it is possible to provide the game having different difficulty levels between the own game machine and the other game machine. Further, even if games having different difficulty levels are played, it is possible to use one play act for progress of the game of the other, using the predetermined reflection condition. Due to this, it is possible to actualize a play between games having different difficulty levels.
BRIEF DESCRIPTION OF DRAWINGS
[0018] FIG. 1 is a diagram illustrating a game system to which a game machine according to an embodiment of the present invention is applied.
[0019] FIG. 2 is a diagram illustrating physical configuration of a game machine.
[0020] FIG. 3 is a functional block diagram of a game machine.
[0021] FIG. 4 is a diagram schematically illustrating a game screen of a music game which is played through game machines.
[0022] FIG. 5 is a diagram for describing a region of an object.
[0023] FIG. 6 is a diagram illustrating an example of each game screen displayed on each game machine during a play using a same music in which difficulty levels are different from each other.
[0024] FIG. 7 is a diagram illustrating an example of contents of sequence data.
[0025] FIG. 8 is a diagram illustrating an example of contents of sequence data corresponding to high difficulty level.
[0026] FIG. 9 is a functional block diagram of a game control unit 11 for actualizing a play using pieces of music with different difficulty levels.
[0027] FIG. 10 is a diagram illustrating an example of a flowchart of an operation detection process routine.
[0028] FIG. 11 is a diagram illustrating an example of a flowchart of a sequence process routine.
[0029] FIG. 12 is a diagram illustrating an example of a flowchart of a path determination process routine.
[0030] FIG. 13 is a diagram illustrating an example of a flowchart following FIG. 12 .
DESCRIPTION OF EMBODIMENTS
[0031] Hereinafter, an embodiment of a game machine according to the present invention will be described. FIG. 1 is a diagram illustrating a game system to which the game machine according to an embodiment of the present invention is applied. In the game system 1 , a plurality of game machines 2 and a center server 3 are connected to a network 5 via routers 4 . The center server 3 is not limited to this example configured by a single physical apparatus. For example, the single logical center server 3 may be configured by a server group that consists of a plurality of physical apparatuses. Each game machine 2 functions as a terminal apparatuses (or client) of the game system 1 , by being connected to the network 5 . As the network 5 , the internet is used. Incidentally, the network 5 is not limited to the internet, as far as a communication line is used. Also, as the communication line, either wired line or wireless line may be used.
[0032] Each game machine 2 is configured as an arcade game machine which allows a play of a game in predetermined range in exchange for payment of play fee. An appropriate number of these game machines 2 are installed in each of several commercial facilities such as stores 6 or the like. Each router 4 is associated with and installed in each store 6 and the center server 3 . The game machines 2 in the same store 4 are connected to the network 5 via the common router 4 . Incidentally, a local server may be installed between the game machines 2 and each store 4 . And, the game machines 2 may be connected to the center server 3 via the local server, so as to be able to communicate to the center server 3 .
[0033] A control unit (not illustrated) is provided in the center server 3 . The control unit is configured as a computer unit comprising a microprocessor and an internal storage (not illustrated) including: a read only memory (ROM) storing a program such as operating system or the like which should be executed by the microprocessor; a random access memory (RAM) providing a work area for the microprocessor, or the like. Further, an external storage (not illustrated) is connected to the center server 3 . In the external storage, there are stored various server program to be executed by the control unit, and various data referred to by the server program.
[0034] FIG. 2 is a diagram illustrating physical configuration of the game machine 2 . The game machine 2 includes a casing 7 , and a monitor 8 serving as a display apparatus arranged, obliquely toward a player P side, on the top surface of the casing 7 . A transparent touch panel 9 is superimposed on the surface of the monitor 8 . The touch panel 9 is a known input apparatus that outputs a signal corresponding to a contact position when the player P contacts the touch panel 9 with his/her finger or the like. In addition to the above apparatuses, the game machine 1 includes various kinds of input apparatuses and output apparatuses provided in a typical arcade game machine such as a button used to make a selection or a decision, a power switch, a volume operation switch, and a power lamp. However, they are not illustrated in FIG. 2 .
[0035] FIG. 3 is a functional block diagram of the game machine 2 . As illustrated in FIG. 3 , a control unit 10 serving as a computer is provided in the casing 7 . The control unit 10 includes a game control unit 11 serving as a control host, a display control unit 12 and an audio output control unit 13 which operate according to an output from the game control unit 11 . The game control unit 11 is configured as a unit in which a microprocessor is combined with various kinds of peripheral apparatuses such as an internal storage (for example, a ROM or a RAM) necessary for operations of the microprocessor. The display control unit 12 causes a predetermined image to be displayed on the monitor 8 by rendering an image corresponding to image data provided from the game control unit 11 in a frame buffer and then outputting a video signal corresponding to the rendered image to the monitor 8 . The audio output control unit 13 causes a predetermined sound (including music or the like) to be reproduced from a speaker 14 by generating an audio reproduction signal corresponding to audio reproduction data provided from the game control unit 11 and then outputting the generated audio reproduction signal to the speaker 14 serving as an audio output apparatus connected to the control unit 10 .
[0036] The game control unit 11 is connected with an external storage 20 . As the external storage 20 , there is used a storage medium in which data remains stored even when power is not supplied, such as an optical storage medium including a digital versatile disc-read only memory (DVD-ROM) and a compact disc-read only memory (CD-ROM) or the like, or a non-volatile semiconductor memory apparatus including an electrically erasable programmable read-only memory (EEPROM) or the like.
[0037] A game program 21 and game data 22 are stored in the external storage 20 . The game program 21 is a computer program necessary for the game machine 2 to execute a music game according to a predetermined procedure. When the game machine 1 is activated, the game control unit 11 executes various kinds of initial settings necessary to operate as the game machine 2 by executing an operation program stored in an internal storage thereof. And then, the game control unit 11 sets an environment for executing the music game according to the game program 21 by reading the game program 21 and then executing the game program 21 from the external storage 20 . The game control unit 11 is a logical apparatus actualized by a combination of computer hardware and a computer program. The game control unit 11 executes processes necessary for the music game such as a process of instructing the player to make an operation in tune with reproduction of music (musical composition) selected by the player, and a process of generating a sound effect in response to the player's operation. Furthermore, as a part of the processes, the game control unit 11 executes also a process of evaluating the player's operation and then controlling a game based on an evaluation result, or the like.
[0038] The game data 22 includes various pieces of data to be referred to when the music game is executed according to the game program 21 . As examples of such various pieces of data, the game data 22 includes music data 25 , sound effect data 26 , and the image data 27 . The music data 25 is data necessary to cause music which is a target of the game to be reproduced and output from the speaker 14 . FIG. 3 illustrates a single kind of music data 25 , but the player can actually select the music to be played from among a plurality of pieces of music. These pieces of the music data 25 are recorded with information for identifying each piece of music, in the game data 22 . The external storage 20 functions as a music data storage device, by storing the music data 25 .
[0039] The sound effect data 26 is data in which each of one or more types of sound effects to be output from the speaker 14 in response to the player's operation is recorded in association with a unique code for each of the sound effects. The sound effect includes sounds of musical instruments and various kinds of sounds. Pieces of sound effect data which are equal in number to a predetermined octave number and have different musical pitches according to each of kinds of sounds may be prepared. The image data 27 is data used to cause a background image, various kinds of objects or icons, and the like in a game screen to be displayed on the monitor 8 .
[0040] The game data 22 further includes sequence data 28 serving as reference timing data. The sequence data 28 is data used to define operations to be indicated to the player. At least a piece of the sequence data 28 is prepared for a single music data. The details of the sequence data 28 will be described later. The external storage 20 functions as a reference timing data storage device, by storing the sequence data 28 .
[0041] Next, an outline of the music game executed by the game machines 2 will be described. The game machines 2 are configured as music game machines of a match-up type which competes for a result by operation timings of two players (including a case in which the game machine 2 functions as the other player) when the two players execute an operation in tune with music. Further, through such a music game, the game machines 2 are configured so that one game player of one game machine itself can play with the other players of the other game machines 2 connected to the one game machine via the network 5 .
[0042] Before the game is started, there is sent matching request requiring an opponent, from each game machine 2 to the center server 3 via the network 5 . The center server 3 makes a match between two players playing with each other, based on the matching request from each game machine 2 . When the opponent is determined based on designation of the center server 3 , between the players, there is started the play using communication between the game machines 2 .
[0043] FIG. 4 is a diagram schematically illustrating a game screen of the music game which is played through the game machines 2 . The game screen 50 includes a game region 52 for teaching operation timings to the player, and an information region 53 for displaying game information including scores of two players in which a match has been made, or the like. The game region 52 is formed as a quadrilateral. A first reference portion 55 A and a second reference portion 55 B serving as reference portions are arranged on near both ends of the game region 52 in a longitudinal direction (the vertical direction of the FIG. 4 ) so as to face each other. Each of the reference portions 55 A and 55 B extends in the form of a straight line in a direction orthogonal to the longitudinal direction of the game region 52 .
[0044] Each of the reference portions 55 A and 55 B is used as a reference of a current time on the game by the both players of two game machines 2 in which a match has been made. Specifically, the first reference portion 55 A functions as a mark indicating a reference of a current time of the player of the one game machine (who may be hereinafter referred to as the first player). And, the second reference portion 55 B functions as a mark indicating a reference of a current time of the player of the other machine who becomes the opponent (who may be hereinafter referred to as second player). Here, in the example of FIG. 4 , the game screen 50 is illustrated so that the near side is at the bottom and the far side is at the top in view of the player side. Further, at each of the reference portions 55 A and 55 B, different colors are used for distinguishing each player. In the example of FIG. 4 , a red straight line is used as the first reference portion 55 A, and a blue straight line is used as the second reference portion 55 B. Further, the information region 53 is arranged around the game region 52 . One end side of the game region 52 in the longitudinal direction is used for displaying a score and the like of the one player. And, the other end side thereof is used for displaying a score and the like of the other player.
[0045] Each of the reference portions 55 A and 55 B includes a plurality of rebounding points arranged at predetermined intervals. As illustrated in the diagram as broken lines, the plurality of rebounding points R 1 included in the first reference portion 55 A and the plurality of rebounding points R 2 included in the second reference portion 55 B are connected with each other through a plurality of paths W. Specifically, on the first reference portion 55 A, there are provided the plurality of paths W reaching from one rebounding point R 1 to the rebounding points R 2 included in the second reference portion 55 B. In the same way, on the second reference portion 55 B, there are provided the plurality of paths W reaching from one rebounding point R 2 to the rebounding points R 1 included in the first reference portion 55 A. Incidentally, in the FIG. 4 , there are illustrated only a part of rebounding points R 1 and R 2 . However, many rebounding points R 1 and R 2 exist actually at predetermined intervals along reference portions 55 A and 55 B.
[0046] The plurality of paths W extending from the rebounding point R 1 of the first reference portion 55 A extends to upper side end portion 52 U at the side of the second reference portion 55 B while passing through the rebounding point R 2 . Further, the plurality of paths W extending from the rebounding point R 2 of the second reference portion 55 B extends to underside end portion 52 B at the side of the first reference portion 55 A while passing through the rebounding point R 1 . When one rebounding point R 1 of the first reference portion 55 A is focused on, for the one rebounding point R 1 , as the plurality of paths W, there are provided three paths W 1 , W 2 , and W 3 extending from the one rebounding point R 1 toward three rebounding point R 2 included in the second reference portion 55 B. During execution of the music game, that is, during the progress of reproduction of music, objects 60 serving as operation indication marks indicating operations are displayed on the paths W connecting the rebounding points R 1 with the rebounding points R 2 according to the sequence data 28 . Incidentally, in FIG. 4 , for convenience of description, the paths W 1 , W 2 , and W 3 are denoted by the dashed lines. However, none of the plurality of paths W is displayed on the actual game screen 50 .
[0047] The objects 60 appear at the rebounding points R 1 or the rebounding points R 2 at appropriate timings in music. Further, according to the progress of the music, the objects 60 move along the paths W extending from the rebounding points R 1 or R 2 at the appearance positions, toward the other of the rebounding points R 1 and R 2 positioned at the opposite side from one of the rebounding points R 1 and R 2 at the appearance positions. And, when appropriate operations are executed in tune with the arrival of the objects 60 , the objects 60 disappear. In exchange for this disappearance of the objects 60 , next objects 60 appear at the rebounding points R 1 and R 2 on each reference portion 55 A or 55 B at which the appropriate operations have been executed. That is, when the appropriate operations have been executed, arrival positions (the rebounding points) of the objects 60 function as the appearance positions of the next objects 60 . Incidentally, each of objects 60 moves along any one of the paths W which is set at each rebounding point R 1 (or R 2 ). Steps for selecting one path W from the paths W are further described later.
[0048] The objects 60 which have appeared at the appearance positions move from the appearance positions toward the rebounding points R 1 or R 2 located in the other side. For this reason, when the appropriate operations have been executed, the objects 60 repeatedly move between the reference portions 55 A and 55 B so as to alternately rebound at the rebounding points R 1 and R 2 . On the other hand, when the appropriate operations have not been executed, the objects 60 pass through each reference portion 55 A or 55 B, and move to the upper side end portion 52 U or the underside end portion 52 B along paths W. And, the arrival positions of the objects 60 at the upper side end portion 52 U or the underside end portion 52 B function as the appearance positions of the next objects 60 . For this reason, when the appropriate operations have not been executed, the objects 60 change moving directions at each end portion 52 U or 52 B toward each reference portion located in the other side so as to alternately rebound at each end portion 52 U or 52 B. As the moving paths of the objects 60 after rebounding at the end portions 52 U and 52 B, there are set paths in which the distance to the rebounding points to be arrived at will become shortest without going through side walls 52 L and 52 R.
[0049] As the appropriate operations described above, each player is required to perform a touch operation of touching the position of the reference portion 55 A or 55 B at which the objects 60 have arrived in tune with the arrival of the objects 60 at the reference portion 55 A or 55 B. When each player performs the touch operation, there is detected a time difference between a time when the objects 60 match each of the reference portions 55 A and 55 B and a time when each player has performed the touch operation. The smaller the time difference is, the higher an operation of the player is evaluated. Further, a sound effect is reproduced from the speaker 14 in response to the touch operation. A well-known method may be used as the method of reproducing the sound effect. For example, as the well-known method of reproducing a sound effect, there exist a method of adding a sound effect from music while reproducing the music, and a method of reproducing a sound effect corresponding to a miss operation while muting the music when missed. Further, for example, there also exists a method in which when music is divided in parts, each part is assigned to each operation timing, and the appropriate operations are executed, a part of the music assigned to the corresponding operation timing is played back (a method of forming the music by the appropriate operation at each operation timing. For this reason, when a miss operation is made, a part of the music to which the operation timing is assigned is not reproduced).
[0050] In the example of FIG. 4 , the object 60 moves toward the rebounding point R 2 of the second reference portion 55 B along the path W 1 . In this case, it is preferable that the second player performs the touch operation at the position of the second reference portion 55 B displayed on the other game machine (the second player's own game machine) at which the object 60 arrives, in tune with the arrival at the second reference portion 55 B. Further, the object 60 is displayed in color corresponding to the reference portion 55 A or 55 B of a destination toward which the object 60 is currently moving. In other words, in the example of FIG. 4 , the object 60 is displayed in blue until arriving at the rebounding point R 2 of the second reference portion 55 B, and the next object 60 appearing at the rebounding point R 2 at the arrival position is displayed in red. In this embodiment, a plurality of operating units are configured by a combination of each of the reference portions 55 A and 55 B on the monitor 8 and the touch panel 9 superimposed thereon. Incidentally, in the following, each of the reference portions 55 A and 55 B may be used as a term representing the operating unit. Further, the second reference portion 55 B is the reference portion corresponding to the operating unit of the opponent player's game machine (the other machine).
[0051] The paths W along which the objects 60 move are determined based on positions of the objects 60 when the reference portion 55 A or 55 B is touched. In order to make a comparison of position easy, each object 60 is divided into a plurality of regions. FIG. 5 is a diagram for describing regions of each object 60 . In FIG. 5 , dashed lines represent the paths W 1 , W 2 , and W 3 . And, an alternate long and short dash line 62 represents the boundary between the regions.
[0052] In the example of FIG. 5 , the object 60 is divided into four regions. In the four regions, there are included a contact region S, right region R, left region L, and remaining region O. The contact region S is a region near a contact point at which the object 60 first comes in contact with each reference portion 55 A or 55 B. The right and left regions R and L are regions located at the right and left side of the contact region S. And, according to the touch operation of the player to any one of regions, there is selected the path W along which the object 60 should move next. Specifically, as the path along which the object 60 moves, when near the contact region S or the remaining region O (including each region) are touched, the straight line path W 2 reaching to R 1 at the shortest distance is selected. Further, the first right path W 3 reaching to R 1 through the right side wall 52 R of the game region 52 in the longitudinal direction is selected, when near the left region L (including this region) is touched. And, the first left path W 1 reaching to R 1 through the left side wall 52 L of the game region 52 in the longitudinal direction is selected, when near the right region R (including this region) is touched. The distances of moving paths W 1 to W 3 are different from each other. Therefore, the moving distance along which the object 60 moves to the reference portion 55 A or 55 B of the next destination differs, according to the positional relation between the operation position and the position of the object 60 . Meanwhile, the operation timing to touch the object 60 , that is, the timing at which the object 60 arrives at each of the reference portions 55 A and 55 B is constant regardless of the moving path. For this reason, the path and moving velocity of the object 60 which moves toward the one player change according to the touch operation of the other player. Since a difficulty level of the game is changed due to this, and the operation in which influence on the other player is considered is required to each player.
[0053] Incidentally, in FIG. 4 , there is displayed only one object 60 in the game region 52 . However, a plurality of objects 60 in which positions, velocities, or paths are different from each other may be displayed in the game region 52 . In such a case, control about displays or movements of the objects 60 such as the appearance positions, the moving paths, or the disappearance positions of the objects 60 is executed for each object 60 according to the examples described above.
[0054] Further, pieces of music with different difficulty levels are provided in the game machines 2 , as the music used in the music game. Furthermore, pieces of same music in which difficulty levels are different from each other are also provided. And, it is also possible to execute the play using the pieces of music with the different difficulty levels, between the one game machine 2 and the opponent game machine 2 . In the case of the play using same music having same difficulty levels, a same game screen 50 (including a case in which the upper side and the downside are reversed) is displayed at same time on the game screens 50 of the one game machine and the opponent other game machine. However, when the difficulty levels are different, number of the objects 60 to be displayed in the same time may be different. Therefore, in the case of the play using the music with different difficulty levels, the game screens 50 in which number of the objects 60 or the like are different from each other may be used at the same time.
[0055] FIG. 6 is a diagram illustrating an example of each game screen 50 displayed on each game machine 2 during the play using the same music in which the difficulty levels are different from each other. In FIG. 6 , the one game screen 50 A of the one game machine is located on the left side. In contrast, the other game screen 50 B of the other game machine of the one game machine's opponent is located on the right side. Further, FIG. 6 illustrates the one game screen 50 A and the other game screen 50 B under the play at the same time. As illustrated in FIG. 6 , in the one game screen 50 A, there is displayed one object 60 moving toward the second reference portion 55 B on the first left path W 1 from the first reference portion 55 A.
[0056] On the other hand, each reference portion 55 A or 55 B are located in the opponent game machine 2 on the position in which the upper side and the downside are reversed so that it is easy to play for the second player. Specifically, the first reference portion 55 A used by the first player is located on the upper side in the other game screen 50 B, in the opposite from the one game screen 50 A. Also, the second reference portion 55 B used by the second player is located on the downside in the other game screen 50 B. Furthermore, in addition to the object 60 located on the first left path W 1 extending from the rebounding point R 1 , other two objects 60 are displayed on the other game screen 50 B. Specifically, as compared with the one game screen 50 A, in the other game screen 50 B, there are added displays of the object 60 moving on the first right path W 3 and the object 60 moving on the straight line path W 2 . Further, the straight line path W 2 and the first right path W 3 extend from the rebounding point R 1 different from the first left path W 1 of the first reference portion 55 A.
[0057] Normally, in the case of the play using the same music having same difficulty levels, a game screen in which the upper side and the downside of the one game screen 50 A have been reversed (the first reference portion 55 A is located on the upper side, the second reference portion 55 B is located on the downside) should be displayed at the same time on the other game machine 2 . However, as described in FIG. 6 , in the case of the play using the music with the different difficulty levels, the different game screen 50 between the one game machine and the other game machine may be displayed. And, the one object 60 on the first left path W 1 is seen by the first player. In contrast, a total of three objects 60 in which two objects 60 are added to the one object 60 are seen by the second player. Therefore, the appropriate operations for the three objects 60 are required to the second player playing through the other game machine 2 .
[0058] Further, when the appropriate operations have been executed for the three objects 60 by the second player, three objects 60 corresponding to the three objects 60 and moving toward the first reference portion 55 A may be further displayed on the other game screen 50 B. However, three objects 60 corresponding to these three objects 60 are not always displayed on the one game screen 50 A. In the one game screen 50 A, for example, only one object 60 may be displayed as the object 60 corresponding to the three objects 60 , according to the difficulty level of the music used by the one game machine 2 . In other words, the play using the game screen 50 in which number of the objects 60 is different from each other may be executed, between the one game machine 2 and the other game machine 2 .
[0059] As described above, when the play between the pieces of music with different difficulty levels is executed, used number of the objects 60 is different between both game machines 2 . Therefore, it is not possible to use operation information of each player directly. In a case like this, one player's operation information is reflected on the other game screen 50 , according to a predetermined reflection condition. Further, a predetermined ratio may be used as the predetermined reflection condition. As an example of the predetermined ratio like this, there is used a ratio of number of the objects 60 displayed. Referring to the example of FIG. 6 , the predetermined ratio in this case is described below. In the example of FIG. 6 , three objects 60 are displayed on the other game screen 50 B, for one object 60 displayed on the one game screen 50 A. That is, number of the objects 60 displayed is a ratio of 1 to 3. Accordingly, in this case, the ratio of 1 to 3 is applied as the predetermined ratio. Specifically, when the second player has missed the touch operation to the objects 60 three times through the other game machine, this is reflected on the game screen 50 A as one time miss. That is, in the example of FIG. 6 , when the second player has missed the operations (when the appropriate operations have not been executed) for all of the three objects 60 displayed on the other game screen 50 B, the information of this miss operation is reflected as the operation for the one object 60 displayed on the one game screen 50 A.
[0060] On the other hand, the operation results of the game machine 2 side in which number of the objects 60 displayed is less, that is, the operation results of the one game machine side in the example of FIG. 6 are reflected directly. In other words, in the example of FIG. 6 , the miss operation for the one object 60 displayed on the one game screen 50 A is reflected directly as the miss operation for one of the three objects 60 included in the other game screen 50 B. In the way like this, one operation result is reflected to the other display. In this case, “1” or “3” constituting the ratio of 1 to 3 function as a predetermined number of the present invention. Further, the miss operation is employed as a specific kind of act of the present invention.
[0061] Incidentally, when the same music is used, common objects 60 corresponding to each other may be included. In contrast, when the different pieces of music are used, such common objects 60 may not be included. Therefore, the objects 60 to which the operation results on the other game machine are reflected are not limited to the objects 60 with the correspondence relation. Operation results on the other game machine may be reflected to the objects 60 without the correspondence relation, as far as it is reflected with the predetermined ratio. Further, the objects 60 to which the operation results are reflected is not limited to the objects 60 immediately after meeting the predetermined reflection condition. For example, the operation result (for example, the miss operation) for the object 60 meeting the predetermined reflection condition (for example, the object 60 for which the miss operation corresponding to predetermined number has been executed) may be reflected to the object 60 which is delayed in predetermined number from the object to which the operation result should be reflected. In other words, the relation between the object 60 meeting the predetermined reflection condition and the object 60 to which its result is reflected may be shifted at predetermined number.
[0062] Next, the details of the sequence data 28 will be described with reference to FIG. 7 and FIG. 8 . FIG. 7 is a diagram illustrating an example of contents of the sequence data. As illustrated in FIG. 7 , the sequence data 28 includes a condition definition portion 28 a and an operation sequence portion 28 b. In the condition definition portion 28 a, there is described information designating an execution condition of a game that differs according to the music such as information designating the tempo, a beat, a track of music, and a sound effect to be generated when the touch operation is performed on the objects 60 . Incidentally, in FIG. 7 , the condition definition portion 28 a is included only in the head portion of the sequence data 28 , but the condition definition portion 28 a may be added to an appropriate intermediate position of the operation sequence portion 28 b. Thus, processing of changing the tempo of the music, an assignment of a sound effect, or the like can be actualized.
[0063] Meanwhile, in the operation sequence portion 28 b, each timing to touch each object 60 , and information indicating each player (in other words, information indicating each reference portion at which the object 60 should arrive, among the reference portions 55 A and 55 B) are described in association with each other. Further, the operation sequence portion 28 b also includes information for indicating the appearance position of each object 60 .
[0064] As a part of details is illustrated in FIG. 7 , in this example, the operation sequence portion 28 b includes an operation timing portion 28 c, a display position indication portion 28 e, a record information portion 28 h, and an appearance position indication portion 28 g. The operation timing portion 28 c indicates timings (operation timings) to perform operations in the music. The display position indication portion 28 e indicates each player on which the objects 60 start to be displayed (in other words, any one of reference portions on which the objects 60 start to be displayed). The record information portion 28 h is for distinguishing each record. The appearance position indication portion 28 g indicates each appearance position of each object 60 . In other words, the operation sequence portion 28 b is configured as a set of a plurality of records in which these pieces of information are described so as to be associated with each other.
[0065] Each operation timing is described such that a bar number in the music, a beat number, and a value representing a time in a beat are separated by a comma. The time in a beat refers to an elapsed time from the head of one beat, and is represented by the number of units, from the head of the beat, obtained by equally dividing the length of one beat into n unit times. For example, when a time in which n is 100 , and ¼ elapses from the head of the second beat in the second beat of the first bar of music is designated as an operation timing, “01,2,025” is described.
[0066] In the display position indication portion 28 e, there are described indications for each player side on which the objects 60 should start to be displayed. Specifically, in a case indicating the first reference portion 55 A side corresponding to the first player, there is described “P1”. And, in a case indicating the second reference portion 55 B side corresponding to the second player, there is described “P2”. Each indication for each player on which each object 60 starts to be displayed corresponds to the indication for the reference portion requiring the touch operation, since the objects 60 move between the reference portions 55 A and 55 B. Specifically, when the first reference portion 55 A is indicated as the position for starting the display, this corresponds to the indication for the touch operation on the second reference portion 55 B, since the object 60 in which the display is started moves toward the second reference portion 55 B at the opposite side. Similarly, when the second reference portion 55 B is indicated as the position for starting the display, this corresponds to the indication for the touch operation on the first reference portion 55 A located at the opposite side, that is, located at the moving direction of the object 60 in which the display is started. Furthermore, the indication of the player on which the object 60 starts to be displayed corresponds to an indication of the color of the object 60 to be displayed. And, a blue object 60 is displayed when the indication of the player is “P1”. Also, a red object 60 is displayed when the indication of the player is “P2”.
[0067] In the record information portion 28 h, there are described numbers according to alignment sequence for each object 60 . Specifically, as the record information, “1” is described in the initial record. And, after this, unique numbers such as “2”, “3”, or the like are described in each record in descending order from upper side.
[0068] In the appearance position indication portion 28 g, there is described information indicating the record numbers. In other words, as the information indicating the appearance position, there are described numbers such as “1”, “2”, “3”, or the like. When “1” is described in the appearance position indication portion 28 g, as the appearance position, there is indicated the arrival position of the object indicated by the record of which “1” is described in the record information portion 28 h . Specifically, as the appearance position of the object 60 corresponding to the record of which “1” is described in the appearance position indication portion 28 g, there is indicated the position at which the object 60 corresponding to the number 1 of the record information portion 28 h has been touched appropriately, or has arrived by the miss operation. Similarly, when “2” or “3” are described in the appearance position indication portion 28 g, as the appearance positions, there is indicated the position at which the object 60 corresponding to the records of which “2” or “3” are described in the record information portion 28 h has been touched appropriately, or has arrived by the miss operation.
[0069] Furthermore, the information described in the appearance position indication portion 28 g also corresponds to an indication of the appearance timing. Specifically, the object 60 corresponding to the record of which “1” is described in the appearance position indication portion 28 g starts to be displayed at a timing at which the object 60 corresponding to the record of which “1” is described in the record information portion 28 h has been touched appropriately (or the timing in which this object 60 arrived at each end portion 52 U or 52 B). In other words, in order to make an effect of continuity, in the appearance position indication portion 28 g, there is described the indication for associating one record with next record corresponding to the next object 60 so that the next object starts to be displayed on the arrival position (or the position on which the appropriate touch operation has been executed) of the object 60 corresponding to the one record at the arrival timing (or the timing at which the appropriate touch operation has been executed). Further, information indicating fixed position is described as the initial appearance position for the appearance position corresponding to the initial record. For example, as the information indicating such an initial appearance position, an alphabet such as “S” or the like is described in the appearance position indication portion 28 g.
[0070] In the example of FIG. 7 , it is indicated that the red object 60 arriving at the second reference portion 55 B at a timing in which “010” elapses from the start point in time of the fourth beat of the first bar appears at the initial appearance position on the first reference portion 55 A. Further, by the indication of this example, the arrival position and arrival timing (or, the position on which the appropriate touch operation has been executed and the timing thereof) of this object 60 function as the appearance position and the appearance timing of the blue object 60 arriving at the second reference portion at a timing in which “016” elapses from the start point in time of the fourth beat of the first bar.
[0071] On the other hand, FIG. 8 is a diagram illustrating an example of contents of the sequence data 28 corresponding to high difficulty level. The part illustrated in FIG. 8 corresponds to the part illustrated by the sequence data 28 of FIG. 7 . In other words, in the part of FIG. 7 and the part of FIG. 8 , there is illustrated the case in which the music is same but the difficulty level is different with each other (the difficulty level of FIG. 8 is higher than that of FIG. 7 ). When the part illustrated in FIG. 7 is compared with the part illustrated in FIG. 8 , as illustrated in FIG. 8 , in the sequence data 28 of FIG. 8 , as the record information portion 28 h, there are added two records in which numbers of “25” and “26” are described. Specifically, in the sequence data 28 of FIG. 8 , there is added the indication displaying the object 60 arriving at the first reference portion 55 A at the timing in which “041” elapses from the start point in time of the second beat of the second bar. Similarly, there is also added the indication displaying the object 60 arriving at the first reference portion 55 A at the timing in which “042” elapses from the start point in time of the second beat of the second bar. In other words, the sequence data 28 of FIG. 8 includes more indications for the operation timings than that of FIG. 7 by these added records. Therefore, when the sequence data 28 of FIG. 8 is used, in comparison with the case in which the sequence data 28 of FIG. 7 is used, number of objects displayed becomes large by number of these records. In this way, the game data 22 includes not only the sequence data 28 corresponding to the pieces music with the different difficulty levels from each other but also sequence data 28 corresponding to the pieces of same music having the different difficulty levels.
[0072] Next, a configuration for actualizing the play using the pieces of music with the different difficulty levels will be described with reference to FIG. 9 . FIG. 9 is a functional block diagram of the game control unit 11 for actualizing the play using the pieces of music with the different difficulty levels. As illustrated in FIG. 9 , the game control unit 11 is provided with a storage portion 63 , a position calculation portion 66 , an image generation portion 67 , and a condition determination portion 68 . The operation information of the one game machine (own game machine) and the opponent game machine (the other game machine) is stored in the storage portion 63 . And, the condition determination portion 68 determines the paths W on which the objects 60 to be displayed on the one game screen 50 A should be arranged, based on the operation information stored in the storage portion 63 . At this time, the condition determination portion 68 also determines whether or not the predetermined reflection condition in which the operation information in one of game machines 2 should be reflected to the game screen 50 of the other game machine 2 is met. This determination result is provided to the position calculation portion 66 .
[0073] The position calculation portion 66 calculates each position (coordinate) on the game screen 50 on which each object 60 should be arranged, based on the determination of the condition determination portion 68 . The calculation result is provided to the image generation portion 67 . And, based on the calculation result of the position calculation portion 66 , the image generation portion 67 generates and outputs image data so that the game screen 50 on which the objects 60 are arranged at the calculated positions is displayed. Due to this, the game screen 50 differing from one of game machines (for example, the other game machine) is displayed on the other monitor 8 (for example, the monitor 8 of the one game machine) so that one operation information (for example, the operation information of the other game machine) is reflected to the other (for example, the one game machine) according to the predetermined reflection condition.
[0074] Next, processes executed by the game control unit 11 for actualizing the play using the pieces of music with the different difficulty levels between both game machines 2 through the network 5 will be described. The game control unit 11 , in order to actualize such a play, executes an operation detection process routine of FIG. 10 , a sequence process routine of FIG. 11 , and subroutines of FIG. 12 and FIG. 13 . Incidentally, in addition to the above processes, the game control unit 11 executes various kinds of well known processes necessary for executing the music game such as a matching process, a process for evaluating operations of the players, or the like. However, details of these processes are not described.
[0075] FIG. 10 is a diagram illustrating an example of a flowchart of the operation detection process routine executed by the game control unit 11 . The game control unit 11 executes the routine of FIG. 10 at predetermined cycle repeatedly. The routine of FIG. 10 is a process executed for obtaining contents (the operation position and the operation timing) of the touch operation by the first player and the second player.
[0076] When the routine of FIG. 10 is started, in Step 51 , the game control unit 11 first determines whether or not the touch operation has been executed by the first player after the last routine is finished, with reference to outputs of the touch panel 9 . When the touch operation has been executed, the game control unit 11 proceeds to Step S 2 . In Step 2 , the game control unit 11 acquires the position in which the touch operation is executed by the first player, and the timing at which the touch operation is executed. And, the game control unit 11 also generates the operation information including them, and causes the storage portion 63 to store this operation information. In next Step 3 , the game control unit 11 sends the operation information stored in Step 2 , to the opponent game machine 2 .
[0077] In next Step S 4 , the game control unit 11 determines whether or not the operation information has been received from the opponent game machine 2 after the finish of the last routine. When the operation information has been received, the game control unit 11 proceeds to Step S 5 . And, the game control unit 11 causes the storage portion 63 to store the received operation information with the receipt time in this Step S 5 . After the finish of the processing in Step S 5 , the game control unit 11 finishes the current process. On the other hand, when the determination result in Step S 1 is negative result, that is, when the touch operation has not been executed, the game control unit 11 skips Step S 2 and Step S 3 , and proceeds to Step S 4 . Furthermore, when the determination result in Step S 4 is negative result, that is, when the operation information has not been received, the game control unit 11 skips Step S 5 , and finishes the current routine. As the actual operation timing of each player, there is handled each of operation timings of the first player and the second player included in the operation information stored by the routine of FIG. 10 .
[0078] On the other hand, FIG. 11 is a diagram illustrating an example of a flowchart of the sequence process routine executed by the game control unit 11 . The routine of FIG. 11 is a process executed for displaying and moving the objects 60 in the game region 52 . The game control unit 11 executes the routine of FIG. 11 at predetermined cycle repeatedly. The cycle is equal to the rendering cycle of the game screen 50 , that is, the frame rate. Incidentally, the cycle in which the routine of FIG. 11 is executed is equal to the cycle in which the routine of FIG. 10 is executed, or longer than that.
[0079] When the routine of FIG. 11 is started, in step S 11 , the game control unit 11 first acquires a current time in the music. For example, clocking is started, by an internal clock of the game control unit 11 , and the current time is acquired from a value of the internal clock, based on a reproduction start point time of the music. The time on the music may be specified based on elapsed time from the reproduction start point time. Further, it may be specified based on another value which is correlated with the elapsed time. For example, the time may be specified by using number of beats from the reproduction start point time of the music, number of frames of the game screen 50 , or the like.
[0080] Next, in Step S 12 , the game control unit 11 acquires data of the operation timings which are present within a time length corresponding to a display range of the game region 52 which should be rendered at the next frame, from the sequence data 28 . And, the game control unit 11 retains it in the internal storage. As an example, the display range is set to a time range of about two bars of the music from the current time (incidentally, the time at the rendering time of the next frame) to the future. In next Step S 13 , the game control unit 11 executes a subroutine for determining the paths at which all of the objects 60 to be rendered in next frame should be arranged. The details of this subroutine will be described later.
[0081] In next Step S 14 , the game control unit 11 calculates coordinates of the objects 60 to be rendered in next frame. As an example, this calculation is made as follows. First, the game control unit 11 determines each path W to display each object 60 included in the display range, based on the processing result of Step S 13 . Next, the game control unit 11 determines the position of each object 60 from the reference portions 55 A and 55 B in the time axis direction (that is, the moving direction of the objects 60 ), according to the moving direction (the reference portions 55 A or 55 B at which the objects 60 should arrive) corresponding to each the object 60 , and a time difference between each operation timing and a current time. Through this operation, it is possible to acquire the coordinates of the objects 60 necessarily for arranging each object 60 on each path W along the time axis from each reference portion 55 A or 55 B.
[0082] In next Step S 15 , the game control unit 15 generates image data necessary for rendering the game region 52 , based on the coordinates of the objects 60 calculated in Step S 14 . Specifically, the game control unit 11 generates the image data so that each object 60 is arranged on each calculated coordinate. Images of the objects 60 or the like may be acquired from the image data 27 . In next step S 16 , the game control unit 11 outputs the image data to the display control unit 12 . As a result, the display of the game region 52 on the monitor 8 is renewed. When the processing of Step S 16 ends, the game control unit 11 finishes the current routine. By executing repeatedly the above-described processes, each object 60 appears at the predetermined position in game region 52 . Further, each object 60 proceeds on each path W according to the operation of each player, in tune with the progress of the music. And, the display of each object 60 is controlled so that each object 60 arrives at each reference portion 55 A or 55 B at the predetermined operation timing.
[0083] Next, a path determination process routine will be described, in reference to FIG. 12 and FIG. 13 . FIG. 12 and FIG. 13 are diagrams illustrating an example of a flowchart of the path determination process routine. This routine is called and executed in Step S 13 , as the subroutine of the routine of FIG. 11 . The routine of FIG. 12 and FIG. 13 is a process for determining the path at which each object 60 should be arranged according to the operation result of each player. Further, the game control unit 11 executes this routine through the condition determination portion 68 mainly.
[0084] When the routine of FIG. 12 is started, in Step S 21 , the game control unit 11 first determines whether or not there are unprocessed records. The unprocessed record means each record of the sequence data 28 acquired in Step S 12 of the routine of FIG. 11 , that is, each record in which the processed record is not set among the operation timings. In other words, the unprocessed record means the operation timing in which the path W to arrange the object 60 is not determined yet among the operation timings included in the display range. When the result of Step S 21 is negative result, that is, when the unprocessed record does not exist in the operation timings in display range, the game control unit 11 finishes the current routine. And, the game control unit 11 returns to the routine of FIG. 11 .
[0085] On the other hand, when the result of Step S 21 is of affirmative result, that is, when the unprocessed record exists, the game control unit 11 proceeds to Step S 22 . In Step S 22 , the game control unit 11 determines whether or not the unprocessed record of the processing target is of a record for the own game machine. This determination is executed, for example, based on the display position indication portion 28 e included in the sequence data 28 . Specifically, when the record of the processing target, that is, the display position indication portion 28 e associated with the operation timing of the processing target is “P1”, the game control unit 11 determines it as the record for the own game machine. In contrast, when the display position indication portion 28 e of that is “P2”, the game control unit 11 determines it as the record for the opponent game machine. When this determination result is of affirmative result, that is, when the record of the processing target is of the record for the own game machine, the game control unit 11 proceeds to Step S 23 .
[0086] In Step S 23 , the game control unit 11 determines whether or not there is the operation information including the operation timing of a record associated with the record of the processing target as the record indicating the appearance position within a predetermined range. As described above, in the sequence data 28 , there are the operation timings associated with each other through the appearance position indication portion 28 g. For example, among the records associated with these, the record indicating the appearance position is referred to as the indication record. In contrast, the record in which the appearance position is indicated is referred to as the subjected indication record. In Step S 23 , the game control unit 11 determines whether or not there is the operation information including the operation timing corresponding to the indication record of the processing target within the predetermined range. This reason is that the operation result to the object 60 corresponding to the indication record is reflected to the object 60 corresponding to the record of processing target. Further, this predetermined range is of the range of time which is set to the operation timing described in the sequence data 28 as an acceptable range in which it can be assumed that the appropriate operation has been performed. Furthermore, this predetermined range also is of the range of the distance which is set to the arrival position (the rebounding position of the moving target) of the object 60 to each reference portion 55 A (or 55 B) as an acceptable range in which it can be assumed that the object 60 is touched. When this determination result is affirmative, that is, when there is the operation information including the operation timing of the indication record within the predetermined range, the game control unit 11 proceeds to Step S 24 .
[0087] In Step S 24 , the game control unit 11 determines the path W at which the object 60 corresponding to the record of the processing target should be arranged, as the normal path. Specifically, the normal path is determined as follows, based on the operation information. The game control unit 11 first determines a positional relation between the position of the touch operation and the position of the object 60 , based on the determined operation information. Further, the game control unit 11 determines the path W based on the positional relation. This determination is executed, as described above, based on any one of four regions O, R, S, and L illustrated in FIG. 5 in which the touch operation has been performed, or which is the nearest from the position of the touch operation. The relation between each region O, R, S, or L and the path is as described above. And, as the appearance position on the normal path, there is employed the appearance position indicated by the indication record described above. In other words, the normal path is determined, based on the touch operation included in the operation information and the appearance position indicated by the indication record.
[0088] In next Step S 25 , the game control unit 11 sets the record of the processing target to the processed record, and returns to the processing of Step S 21 . Due to this, the operation result of the own game machine is reflected to the object 60 corresponding to the operation result of the other game machine.
[0089] On the other hand, when the determination result of Step S 23 is negative, that is, when there is not the operation information including the operation timing of the indication record within the predetermined range, the game control unit 11 proceeds to Step S 26 . In Step S 26 , the game control unit 11 determines the path W on which the object 60 corresponding to the record of the processing target is arranged, as the miss path. In the case in which there is not the operation information including the operation timing of the indication record within the predetermined range, this means that the appropriate operation is not performed to the object 60 corresponding to the indication record. In this case, the object 60 of the indication record corresponding to this record of the processing target arrives at any one of both end portions 52 U and 52 B. Therefore, for example, as the miss path of such a case, there is employed the path W extending toward the reference portion 55 A (or 55 B) at the opposite side in the shortest distance from the position on the end portion 52 U (or 52 B) at which the object 60 of the indication record arrives. Further, in this case, the position on the end portion 52 U (or 52 B) at which the object 60 of the indication record arrives is used as the appearance position of the object 60 corresponding to the record of the processing target. And, the game control unit 11 proceeds to Step S 25 , and executes the processing described above, after finishing the processing of Step S 30 .
[0090] Furthermore, when the determination result of Step S 22 is negative result, that is, when the record of the processing target is of the record for the opponent game machine, the game control unit 11 proceeds to Step S 27 of FIG. 13 . In Step S 27 , the game control unit 11 determines whether or not there is the operation information including the operation timing of the indication record associated with the record of the processing target within the predetermined range, using the operation information stored in the storage portion 63 . This determination is executed in the same way as Step S 23 described above. When this determination result is negative, that is, when there is not the operation information including the operation timing of the indication record within the predetermined range, the game control unit 11 proceeds to Step S 28 .
[0091] In Step S 28 , the game control unit 11 determines whether or not the predetermined reflection condition is met. As the predetermined reflection condition, for example, there is employed a condition which is met in a case in which a specific kind of operation reaches at the predetermined ratio between the own game machine and the other game machine. Further, in Step S 27 , when there is not the operation information, the control unit 11 can determine this as the miss operation (the operation in which the position or the timing of the touch operation is not appropriate). In other words, the game control unit 11 determines whether or not it is the miss operation as the specific kind of act. Therefore, in Step S 28 , as an example of the specific kind of operation, there is applied the miss operation. Further, as the predetermined ratio, for example there is applied a ratio according to the difficulty level. As the ratio like this, for example, there is used the ratio of number of the operation timings. Specifically, when number of the operation timings is the ratio of 1 to 3, this ratio is applied as the predetermined ratio. In other words, in this case, if the difficulty level of the other game machine is higher than that of the own game machine, in Step S 28 , the game control unit 11 determines that the predetermined reflection condition has been met when the miss operation has been performed three times on the other game machine. Contrariwise, if the difficulty level of the own game machine is higher than that of the other game machine, in Step S 28 , the game control unit 11 determines that the predetermined reflection condition has been met when the miss operation has been performed one time on the other game machine. Incidentally, the predetermined ratio is not limited to the embodiment in which the predetermined ratio is set according to the difficulty level. For example, as the predetermined ratio, the fixed ratio may be set in advance.
[0092] When the determination result of Step S 28 is affirmative result, that is, when the predetermined reflection condition is met, the game control unit 11 proceeds to Step S 29 . In Step S 29 , the game control unit 11 determines the path W on which the object 60 corresponding to the record of the processing target should be arranged, as the miss path. This determination is executed in same way as Step S 26 described above. The game control unit 11 returns to Step S 25 of FIG. 12 , after finishing the processing of Step S 29 . And, the game control unit 11 executes the processing described above in Step S 25 .
[0093] On the other hand, when the determination result of Step S 27 is affirmative result, or when the determination result of Step S 28 is negative result, in other words, when there is the operation information including the operation timing of the indication record within the predetermined range, or when the predetermined reflection condition is not met, the game control unit 11 proceeds to Step S 30 .
[0094] In Step S 30 , the game control unit 11 determines the path W on which the object 60 corresponding to the record of the processing target should be arranged, as the automatic path. In this case, for example, as the appearance position, there is used the rebounding point R 2 at which the object 60 corresponding to the record of the processing target arrives. Further, as the automatic path, there is used each path W extending from the rebounding point R 2 . And, any one of paths W may be determined by lottery. In other words, in this case, in Step S 30 , as the automatic path, there is used the path W which is determined by lottery from the paths W extending from the rebounding point R 2 at which the object 60 corresponding to the indication record arrives. Further, in this case, the object 60 corresponding to the indication record disappears on the second reference portion 55 B on which the rebounding point R 2 is provided. Incidentally, the automatic path may be fixed for each rebounding point R 2 in advance. Or, the automatic path may be changed in predetermined order. Furthermore, the automatic path may be determined by lottery from the paths W, according to the operation information on the other game machine, for example, based on each path W which can be determined in the case in which the operation information is used. And, as the automatic path, the high rate path may be used.
[0095] The game control unit 11 returns to Step S 25 of FIG. 12 , after finishing the processing of Step S 30 . And, the game control unit 11 executes the processing described above, in Step S 25 . Through the execution of the routine of FIG. 12 , the path W on which each object 60 corresponding to each operation timing should be arranged is determined. Further, between both game machines 2 during the play using the same music having the different difficulty levels, according to the predetermined reflection condition, the operation result of one of the game machines is reflected to the game screen of the other.
[0096] As described above, according to this embodiment, between the one game machine and the other game machine, the operation information of one of game machines is reflected to the game screen 50 of the other, using the predetermined reflection condition. Further, as an example of the predetermined reflection condition, there is used the ratio of number of the operation timings. That is, it is possible to try to adjust the difference of the difficulty level, according to number of the operation timings. Due to this, it is possible to actualize the play between both game machines 2 in which number of the operation timings to be operated is different from each other. In other words, it is possible to use the pieces of music with the different difficulty levels from each other, between the one game machine and the other game machine.
[0097] Further, it is possible to expand the target of the opponent, since it is possible to actualize the play using pieces of music with the different difficulty levels. Due to this, it is possible to increase opportunities of the play, and, for example, it is possible to actualize the play with friends having the different play levels in which the play is not made normally. Accordingly, it is possible to improve the interest of the game.
[0098] In the above-described embodiment, the control unit 10 functions as a music reproduction device. Further, the control unit 10 functions as a reference timing teaching device, a game region presenting device, a mark display control device, and a condition determination device, by executing the routine of FIG. 11 , FIG. 12 , and FIG. 13 through the game control unit 11 . Furthermore, the control unit 10 functions as an other machine information acquiring device, by executing the routine of FIG. 10 through the game control unit 11 .
[0099] The present invention is not limited to the above-described embodiment and can be implemented in appropriate embodiments. In the above-described embodiment, there is employed the miss operation as the specific kind of act. However, the specific kind of act is not limited to such an embodiment. For example, various kinds of operations indicating the paths W 1 , W 2 , and W 3 may be employed as the specific kind of act.
[0100] In addition to the object 60 , other operation indication marks may be displayed in the game. For example, when a predetermined display condition has been met (for example, a case in which a predetermined operation is performed, a case in which a predetermined score is obtained, a case in which a predetermined option is acquired, or the like meet this condition), a special object may be displayed as the one of such operation indication marks. Further, when the special object is displayed on the other game machine, a special object may be also displayed on the one game machine as operation reference mark corresponding to any one of the reference portions. And, the operation information to the special object of the other machine may be reflected directly to the special object corresponding to this which is displayed in the one machine, separately from the predetermined reflection condition. In other words, the moving path of special operation indication mark in the one game machine may be changed according to the operation information to the special object in the other game machine. Due to this, it is possible to use the special operation indication mark as a means capable of directly reflecting the one operation information to the other.
[0101] Further, in the above-described embodiment, as the difference of contents between pieces of reference timing data, there is employed number of the reference timings. However, the difference of contents between pieces of reference timing data is not limited to the embodiment like this. The differences such as a difference in which number of the reference timings is same but the moving velocity of the displayed reference indication marks corresponding to the reference timings is different from each other, a difference in which the reference timing itself is difference from each other, or the like may be employed as the difference of contents between pieces of reference timing data. And, in these cases, for example, number according to velocity ratio, or the like may be used as the predetermined number used to the predetermined reflection condition.
[0102] Further, in the above-described embodiment, between the one game machine and the other game machine, there are executed same games having the different difficulty levels. However, the game played on the game machines 2 is not limited to the game like this. The game having completely different rule or contents may be played between the one game machine and the other game machine, as long as the one play act is reflected to the progress of the other game according to the predetermined reflection condition.
[0103] In the above-described embodiment, on the game machines 2 , there is played the music game. However, the game played on the game machines 2 is not limited to the embodiment like this. For example, as the other games, a RPG (role-playing game), an action game, a sports game, a shooter game, or the like may be played on the game machine 2 . Further, in the above-described embodiment, the game machine 2 is applied to the game system in which the center server 3 exists between the game machines 2 . However, the game system to which the game machine of the present invention is applied is not limited to the embodiment like this. For example, the center server 3 may be omitted. That is, the game machine may be applied to the game system configured by two game machines connected with each other through a communication line. Furthermore, the game machine of the present invention may be actualized in appropriate embodiments such as an arcade game machine installed in commercial facility, a stationary game machine for home use, a portable game machine, or the like. | Provided is a game machine which can actualize a play between games having different difficulty levels. The game machine is applied to a game system that progresses a game between a plurality of game machines connected via a network. The game machine comprises an external storage that stores a sequence data wherein each operation timing is written so as to differ from each other. And, the game machine: teaches each operation timing, of based on sequence data that differs from sequence data used in another machine functioning as another terminal in the game system; obtains operation information for the other machine; and, based on it, determines whether or not prescribed reflection conditions have been fulfilled. Then, when the prescribed reflection conditions have been fulfilled based on its results, the game machine reflects the operation information for the other machine in a travel path for an object for teaching the operation timing for the game machine. | 89,012 |
FIELD OF THE INVENTION
This invention relates to silicone foam control compositions. More particularly, this invention relates to silicone foam control compositions comprising a silicone antifoam agent, mineral oil, a polydiorganosiloxane containing at least one polyoxyalkylene group, and a finely divided filler.
BACKGROUND OF THE INVENTION
The use of various silicone containing compositions as antifoams or defoamers is known. In this regard, it is well established that this art is highly unpredictable and slight modification can greatly alter performance of such compositions. Most of these compositions contain silicone fluid (usually dimethylpolysiloxane), often in combination with small amounts of silica filler. Additionally, these compositions may include various surfactants and dispersing agents in order to impart improved foam control or stability properties to the compositions.
Silicone compositions which are useful as foam control agents have been taught in the art. For example, Aizawa et al., in U.S. Pat. Nos. 4,639,489 and 4,749,740, the disclosures of which are hereby incorporated by reference, teach a method for producing a silicone defoamer composition wherein a complex mixture of polyorganosiloxanes, filler, a resinous siloxane and a catalyst to promote reaction of the other components are heated together at 50° C. to 300° C.
More recently, a method for preparing a composition similar to that described by Aizawa et al., cited supra, was disclosed by Miura in U.S. Pat. No. 5,283,004, the disclosure of which is hereby incorporated by reference. In this disclosure, the above mentioned complex silicone mixture additionally contains at least 0.2 weight parts of an organic compound having at least one group selected from —COR, —COOR′ or —(OR″) n —, wherein R and R′ are hydrogen or a monovalent hydrocarbon group, R″ is a divalent hydrocarbon group having 2 to 6 carbon atoms and the average value of n is greater than one. It is further disclosed that all the ingredients, including a catalyst, must be reacted at elevated temperatures to obtain the desired antifoam agent.
John et al., in European Patent Application No. 217,501, published Apr. 8, 1987, discloses a foam control composition which gives improved performance in high foaming detergent compositions which comprises (A) a liquid siloxane having a viscosity at 25° C. of at least 7×10 −3 m 2 /s and which was obtained by mixing and heating a triorganosiloxane-endblocked polydiorganosiloxane, a polydiorganosiloxane having at least one terminal silanol group and an organosiloxane resin, comprising monovalent and tetravalent siloxy units and having at least one silanol group per molecule, and (B) a finely divided filler having its surface made hydrophobic. John et al. further describes a method for making the foam control compositions and detergent compositions containing said foam control compositions.
McGee et al. in U.S. Pat. No. 5,380,464 discloses a foam control composition comprising a silicone defoamer reaction product and a silicone glycol copolymer which is particularly effective in defoaming highly acidic or highly basic aqueous systems. However, when a foam control composition comprising a silicone antifoam agent and a silicone glycol copolymer is employed, it is added in the form of a liquid or after dilution with water to a foamable liquid thus requiring higher levels of the silicone copolymer.
McGee et al. in U.S. Pat. No. 5,543,082 discloses a foam control composition prepared by mixing at room temperature a silicone defoamer reaction product, a silicone glycol copolymer, and a hydroxyl-endblocked polydiorganosiloxane polymer.
In European Patent Application No. 0638346 is disclosed a composition comprising a reaction product, a nonaqueous liquid continuous phase, and a moderately hydrophobic particulate stabilizing aid. EP'346 discloses that the reaction product is prepared by heating a mixture of a polyorganosiloxane fluid, a silicon compound, a finely divided filler, and a catalytic amount of a compound for promoting the reaction of the other components at a temperature of 50° C. to 300° C. EP'346 further discloses that these compositions can further contain at least one nonionic silicone surfactant, and a nonreinforcing inorganic filler.
In European Patent Application No. 0663225 is disclosed a foam control composition comprising a silicone antifoam agent and a crosslinked organopolysiloxane polymer having at least one polyoxyalkylene group.
Fey et al. in U.S. Pat. No. 5,908,891 discloses a dispersible silicone composition comprising (I) a silicone composition prepared by reacting a polyorganosiloxane, a silicon compound, optionally a finely divided filler, and a catalytic amount of a compound for promoting the reaction of the other components and (II) mineral oil. Fey et al. further discloses that the mineral oil is effective as a dispersing agent for the silicone composition (I).
SUMMARY OF THE INVENTION
This invention relates to silicone foam control compositions. More particularly, this invention relates to silicone foam control compositions comprising a silicone antifoam agent, mineral oil, a polydiorganosiloxane containing at least one polyoxyalkylene group, and a finely divided filler.
It is an object of the present invention to prepare silicone compositions which can be advantageously utilized to control foam in foam producing systems.
It is a further object of the present invention to provide silicone compositions wherein there is provided improvement in the control of foaming behavior.
It is a further object of the present invention to provide silicone foam control compositions which are stable and easily dispersible.
DETAILED DESCRIPTION OF THE INVENTION
The present invention relates to a silicone foam control composition comprising (I) a silicone antifoam agent prepared by reacting at a temperature of 50° C. to 300° C. a mixture comprising: (i) 100 weight parts of at least one polyorganosiloxane selected from the group consisting of (A) a polyorganosiloxane having a viscosity of about 20 to 100,000 mm 2 /s at 25° C. and being expressed by the general formula R 1 a SiO (4-a)/2 in which R 1 is a monovalent hydrocarbon or halogenated hydrocarbon group having 1 to 10 carbon atoms and a has an average value of 1.9 to 2.2, (B) a polyorganosiloxane having a viscosity of 200 to about 100 million mm 2 /s at 25° C. expressed by the general formula R 2 b (R 3 O) c SiO (4-b-c)/2 in which R 2 is a monovalent hydrocarbon or halogenated hydrocarbon group having 1 to 10 carbon atoms, R 3 is hydrogen or a monovalent hydrocarbon group having 1 to 10 carbon atoms, b has an average value of 1.9 to 2.2 and c has a sufficiently large value to give at least one —OR 3 group in each molecule, at least one such —OR 3 group being present at the end of the molecular chain, and (C) a mixture of (A) and (B); (ii) 0.5 to 20 weight parts of at least one silicon compound selected from (a) an organosilicon compound of the general formula R 4 d SiX 4-d in which R 4 is a monovalent hydrocarbon group having 1 to 5 carbon atoms, X is selected from a halogen atom or a hydrolyzable group and d has an average value of one or less, (b) a partially hydrolyzed condensate of said compound (a), (c) a siloxane resin comprising (CH 3 ) 3 SiO 1/2 units and SiO 4/2 units wherein the ratio of (CH 3 ) 3 SiO 1/2 units to SiO 4/2 units is 0.4:1 to 1.2:1, or (d) a condensate of said compound (c) with said compound (a) or (b); and (iii) a catalytic amount of a compound for promoting the reaction of components (i) and (ii); (II) at least one mineral oil; (III) at least one polydiorganosiloxane having at least one polyoxyalkylene group; and (IV) at least one finely divided filler. The silicone foam control compositions of this invention can optionally comprise a polyglycol.
The silicone foam control compositions of this invention comprise (I) a silicone antifoam agent, (II) at least one mineral oil, (III) at least one polydiorganosiloxane containing at least one polyoxyalkylene group, and (IV) at least one finely divided filler. Component (I) of the present invention can be prepared by reacting (i) a polyorganosiloxane, (ii) a silicon compound, and (iii) a catalytic amount of a compound for promoting the reaction of the other components.
Component (i) may be selected from (A) polyorganosiloxanes comprising siloxane units of the general formula R 1 a SiO (4-a)/2 and having a viscosity of 20 to 100,000 mm 2 /s (centistokes (cS)) at 25° C. The organo groups R 1 of the polyorganosiloxane (A) are the same or different monovalent hydrocarbon or halogenated hydrocarbon groups having one to ten carbon atoms. Specific examples thereof are well known in the silicone industry and include methyl, ethyl, propyl, butyl, octyl, trifluoropropyl, phenyl, 2-phenylethyl and vinyl groups. The methyl group is particularly preferred. In the above formula, a has a value of 1.9 to 2.2. It is particularly preferred that polyorganosiloxane (A) is a trimethylsilyl-terminated polydimethylsiloxane having a viscosity of about 350 to 15,000 mm 2 /s at 25° C.
Alternatively, component (i) may be selected from (B) polyorganosiloxanes comprising siloxane units of the general formula R 2 b (R 3 O) c SiO (4-b-c)/2 and having a viscosity of 200 to 100 million centistokes at 25° C. wherein R 2 is independently selected from the monovalent hydrocarbon or halogenated hydrocarbon groups designated for group R 1 , R 3 is a hydrogen atom or R 2 , and the —OR 3 group is present at least at the end of a molecular chain of the polyorganosiloxane. The value of b is from 1.9 to 2.2 and c has a value so as to provide at least one —OR 3 group per molecule. It is particularly preferred that polyorganosiloxane (B) is a hydroxyl-terminated polydimethylsiloxane having a viscosity of about 1,000 to 50,000 mm 2 /s at 25° C. Component (i) may also be (C) a mixture of (A) and (B) in any proportion.
Component (ii) is at least one silicon compound selected from (a) to (d):(a) an organosilicon compound of the general formula R 4 d SiX 4-d wherein R 4 is a monovalent hydrocarbon group having one to five carbon atoms, X is a halogen atom or a hydrolyzable group, such as —OR 5 or —OR 6 OR 7 , in which R 6 is a divalent hydrocarbon group having one to five carbon atoms and R 5 and R 7 are each a hydrogen atom or a monovalent hydrocarbon group having one to five carbon atoms, the average value of d not exceeding 1, (b) a partially hydrolyzed condensate of the compound (a), (c) a siloxane resin comprising (CH 3 ) 3 SiO 1/2 and SiO 2 units and having a (CH 3 ) 3 SiO 1/2 /SiO 2 ratio of 0.4/1 to 1.2/1, or (d) a condensate of the siloxane resin (c) with the compound (a) or (b). It is preferred that component (ii) is selected from either an alkyl polysilicate wherein the alkyl group has one to five carbon atoms, such as methyl polysilicate, ethyl polysilicate and propyl polysilicate, or the siloxane resin (c). Most preferably, component (ii) is either ethyl polysilicate or a siloxane resin copolymer comprising (CH 3 ) 3 SiO 1/2 units and SiO 2 units in a molar ratio of approximately 0.4:1 to 1.2:1.
Component (iii) is a compound used as a catalyst for promoting the reaction of the other components. Any compound which promotes condensation reactions or rearrangement/condensation reactions is suitable as component (iii). It is preferably selected from siloxane equilibration catalysts, silanol-condensing catalysts, or a combination thereof. Catalysts suitable as component (iii) are exemplified by alkali metal hydroxides such as potassium hydroxide, sodium hydroxide, or cesium hydroxide, alkali metal silanolates such as potassium silanolate, alkali metal alkoxides such as potassium isopropoxide or potassium ethoxide, quaternary ammonium hydroxides such as betahydroxyethyltrimethyl ammonium hydroxide, benzyltrimethyl ammonium hydroxide; and tetramethyl ammonium hydroxide, quaternary ammonium silanolates, quaternary phosphonium hydroxides such as tetrabutyl phosphonium hydroxide and tetraethylphosphonium hydroxide, quaternary phosphonium silanolates, metal salts of organic acids such as dibutyltin dilaurate, stannous acetate, stannous octanoate, lead napthenate, zinc octanoate, iron 2-ethylhexoate, and cobalt naphthenate, mineral acids such as sulfuric or hydrochloric acid, organic acids such as acetic acid or organosulfonic acids, and ammonium compounds such as ammonium carbonate or ammonium hydroxide. It is preferred that the catalyst is selected from potassium silanolate, potassium hydroxide, or sodium hydroxide.
The mixture can further comprise up to 30 weight parts of component (iv) a finely divided filler. The finely divided filler is exemplified by fumed, precipitated, or plasmatic TiO 2 , Al 2 O 3 , Al 2 O 3 /SiO 2 , ZrO 2 /SiO 2 , and SiO 2 . The finely divided filler can hydrophilic or hydrophobic. The filler can be hydrophobed during manufacture (i.e. in-situ) or independently. Various grades of silica having a particle size of several millimicrons to several microns and a specific surface area of about 50 to 1000 m 2 /g, preferably a surface area of 50 to 300 m 2 /g, are commercially available and suitable for use as component (iv). Preferably component (iv) is a hydrophobic silica having a surface area of about 50 to 300 m 2 /g.
The mixture can further comprise up to 20 weight parts of component (v), a polyorganosiloxane comprising siloxane units of the general formula R 8 e (R 9 O) f SiO (4-e-f)/2 and having a viscosity of 5 to 200 mm 2 /s at 25° C. wherein R 8 is a monovalent hydrocarbon or halogenated hydrocarbon group having one to ten carbon atoms and R 9 is hydrogen or a monovalent hydrocarbon group having one to ten carbon atoms. The value of e is between 1.9 and 2.2 and f has a value so as to provide two or more —OR 9 groups in each molecule. It is particularly preferred that component (v) is a hydroxyl-terminated polydimethylsiloxane having a viscosity of about 10 to 100 mm 2 /s at 25° C. It is preferred that component (v) is added when filler (iv) is a hydrophilic silica.
A mixture of components (i), (ii), and (iii), optionally containing components (iv) and/or (v), is reacted under heat to produce the silicone antifoam agent (I), the proportions of the various components being: Component (i)—100 weight parts; Component (ii) —0.5 to 20, preferably 1 to 7, weight parts; Component (iii) —A catalytic amount (usually in the range of 0.03 to 1 part by weight); Component (iv), if present, —up to 30, preferably 1 to 15, and highly preferred is 5 to 15 weight parts; Component (v), if present, —up to 20, preferably 1 to 10, weight parts.
The proportions of components (A) and (B) used depends largely on their respective viscosities. It is preferable to use a mixture of (A) and (B) which has a viscosity of 1,000 to 100,000 mm 2 /s at 25° C.
The silicone antifoam agent (I) is prepared by first mixing components (i), (ii), and (iii) and heating this blend to about 110 to 120° C. Finely divided filler (iv), if desired, is then uniformly mixed in using an appropriate dispersing device, such as a homomixer, colloid mill or triple roll mill. The resulting mixture is heated at a temperature of 50° C. to 300° C., preferably 100° C. to 300° C., and reacted for one to eight hours, although the reaction time varies depending on the temperature. If component (v) is to be employed in the composition, it is generally added after the filler (iv). It is preferable to carry out all mixing and heating operations in an inert gas atmosphere in order to avoid any danger and to remove volatile matter (unreacted matter, by-products, etc.). The mixing order of the components and the heating temperature and time as hereinabove stated are not believed critical, but can be changed as required. It is further preferred that, after reaction, the catalyst is neutralized to further stabilize silicone antifoam agent (I).
Alternatively, silicone antifoam agent (I) preferably comprises a diorganopolysiloxane, a silicon compound, and a catalyst for promoting the reaction of these components, and this combination optionally containing a filler such as silica. These systems contain a mixture of a trimethylsilyl-terminated polydimethylsiloxane and a diorganopolysiloxane having silicon-bonded hydroxyl groups or silicon-bonded alkoxy groups along its main chain or at its chain ends, said alkoxy groups having from 1 to 6 carbon atoms. The silicon compound (ii) acts as a crosslinker for the diorganopolysiloxane by reacting with the functionality of the latter. It is further preferred that the above diorganopolysiloxane is either a linear or a branched polymer or copolymer of siloxane units selected from dimethylsiloxane units, methylphenylsiloxane units or methyltrifluoropropylsiloxane units. Most preferably, the diorganopolysiloxane of component (A) is a polydimethylsiloxane containing Si-bonded hydroxyl or methoxy functionality. The above mentioned silicon compound (ii) is preferably a siloxane resin comprising (CH 3 ) 3 SiO/ 2 and SiO 2 units and having a molar ratio of (CH 3 ) 3 SiO 1/2 /SiO 2 between 0.4:1 and 1.2:1. The latter resin may be prepared according to methods taught in, e.g., U.S. Pat. No. 2,676,182 to Daudt et al. and typically contains from about 0.5 to about 3 weight percent of hydroxyl groups.
A highly preferred silicone antifoam agent is a homogeneous blend of a hydroxyl- terminated polydimethylsiloxane, a trimethylsilyl- terminated polydimethylsiloxane having a viscosity in the range of about 1,000 to 50,000 mm 2 /s at 25° C., an alkyl polysilicate wherein the alkyl group has one to five carbon atoms, such as methyl polysilicate, ethyl polysilicate and propyl polysilicate, and a potassium silanolate catalyst reacted at a temperature of 50 to 300° C.
The silicone antifoam agent (I) can also be a silicone antifoam agent comprising (a) silicone and (b) silica and can be prepared by admixing a silicone fluid with a hydrophobic silica. In industrial practice, the term “silicone” has become a generic term which encompasses a variety of relatively high molecular weight polymers containing siloxane units and hydrocarbon groups of various types. Preferred as component (a) are polydimethylsiloxanes having a molecular weight within the range of from about 2,000 to about 200,000. Component (b) is exemplified by silica aerogels, xerogels, or hydrophobic silicas of various types. Any of several known methods may be used for making a hydrophobic silica which can be employed herein in combination with a silicone fluid as the antifoam agent. For example, a fumed silica can be reacted with a trialkyl chlorosilane (i.e. “silanated”) to affix hydrophobic trialkylsilane groups on the surface of the silica. Silicas having organosilyl groups on the surface thereof are well known and can be prepared in many ways such as by contacting the surface of a fumed or precipitated silica or silica aerogel with reactive silanes such as chlorosilanes or alkoxysilanes or with silanols or siloxanols or by reacting the silica with silanes or siloxanes. Various grades of silica having a particle size of several millimicrons to several microns and a specific surface area of about 500 to 50 m 2 /g are commercially available and several hydrophobic silicas having different surface treatments are also commercially available.
Component (I) is present in the silicone foam control compositions of this invention in an amount from 10-80 weight parts, preferably from 30 to 60 weight parts, and most preferably from 40 to 60 weight parts, said weight parts being based on the total weight of the composition.
Component (II) is mineral oil. The term “mineral oil” as used herein refers to hydrocarbon oils derived from carbonaceous sources, such as petroleum, shale, and coal, and equivalents thereof. The mineral oil of component (II) can be any type of mineral oil, many of which are commercially available, including heavy white mineral oil which is high in paraffin content, light white mineral oil, petroleum oils such as aliphatic or wax-base oils, aromatic or asphalt-base oils, or mixed base oils, petroleum derived oils such as lubricants, engine oils, machine oils, or cutting oils, and medicinal oils such as refined paraffin oil. The above mentioned mineral oils are available commercially at a variety of viscosities from Amoco Chemical Company (Chicago, Ill.) under the tradename Amoco White Mineral Oil, from Exxon Company (Houston, Tex.) under the tradenames Bayol™, Marcol™, or Primol™, from Lyondell Petrochemical Company (Houston, Tex.) under the trade name Duoprime® Oil, and from Shell Chemical Company (Houston, Tex.) under the tradename ShellFlex® Mineral Oil. Preferably the mineral oil has a viscosity of from about 1 to about 20 millipascal-seconds at 25° C. Component (II) can also be a mixture of the above-described mineral oils.
Component (II) is present in the silicone foam control compositions of this invention in an amount from 10-80 weight parts, preferably from 30 to 60 weight parts, and most preferably from 30 to 50 weight parts, said weight parts being based on the total weight of the composition.
Component (III) is at least one polydiorganosiloxane compound having at least one polyoxyalkylene group. The polyoxyalkylene group is exemplified by polyoxyalkylene groups having the formulae
—R 10 (OCh 2 Ch 2 ) g OR 11 ,
wherein R 10 is a divalent hydrocarbon group having from 1 to 20 carbon atoms, R 11 is selected from a hydrogen atom, an alkyl group, an aryl group, or an acyl group, and g, h, and i independently have an average value from 1 to 150. As used herein to describe Component (III), the polydiorganosiloxane having at least one polyoxyalkylene group, it is understood that the various siloxane units and the oxyethylene, oxypropylene and oxybutylene units may be distributed randomly throughout their respective chains or in respective blocks of such units or in a combination of random or block distributions.
Those skilled in the art will appreciate that the term “polydiorganosiloxane having at least one polyoxyalkylene group” standing alone, encompasses a number of compounds, including those based upon cyclic and resinous siloxane compounds. While cyclic and resinous oxyalkylene-modified siloxanes can be used in the foam control compositions of this invention, they are comparatively expensive and thus, are not as cost effective as the linear polyoxyalkylene-containing polydiorganosiloxane compounds described hereinbelow.
Preferably Component (III) is a polydiorganosiloxane compound having the formula
Me 3 SiO(Me 2 SiO) x (MeQSiO) y SiMe 3 ,
wherein Q is selected from the group consisting of
wherein Me denotes methyl, x has an average value from 100 to 500, y has an average value from 1 to 50, z has a value of 2 to 10, g has an average value of 1 to 36, and h has 25 an average value of 1 to 36.
Component (III) of the silicone foam control compositions of this invention can also be a cross-linked polydiorganosiloxane polymer having at least one polyoxyalkylene group. This class of compounds has been generally described by Bahr et.al. in U.S. Pat. Nos. 4,853,474 and 5,136,068, incorporated herein by reference to teach cross-linked polydiorganosiloxane polymers suitable as (III). Compounds suitable as (III) include polydiorganosiloxane-polyoxyalkylene polymer molecules which are intentionally cross-linked through a cross-linking agent joined thereto by nonhydrolyzable bonds and being free of internal hydrolyzable bonds.
These may be obtained by a method comprising preparing a cross-linked polydiorganosiloxane polymer and combining a polyoxyalkylene group therewith or by a method comprising preparing a linear polyorganosiloxane having a polyoxyalkylene group combined therewith and cross-linking the same.
The cross-linking in this system can be attained through a variety of mechanisms. Those skilled in the art will readily recognize the systems wherein the required components are mutually compatible to carry out the method of preparing these polydiorganosiloxanes. By way of illustration, an extensive bibliography of siloxane polymer chemistry is provided in Siloxane Polymers , S. J. clarson and J. A. Semlyen eds., PTR Prentice Hall, Englewood cliffs, N.J., (1993).
Not to be construed as limiting this invention, it is preferred that the cross-linking bonds and the bonds to the polydiorganosiloxane-polyoxyalkylene molecules are not hydrolyzable, and that the cross-linking bridge contains no hydrolyzable bonds. It is recognized that similar emulsifiers wherein the polyoxyalkylene units are attached to the organopolysiloxane units via SiOC bonds are useful in applications not requiring extended stability under conditions where hydrolysis may occur. It is further recognized that such emulsifiers containing cross-links formed by SiOC bonds offer benefits of improved emulsion stability and consistency in such applications not requiring extended stability under conditions where hydrolysis may occur.
Preferably, the cross-linked polydiorganosiloxane polymer is obtained by the addition reaction between the following components: (i) an organopolysiloxane having an Si—H group at each of its terminals and a polydiorganosiloxane having at least two allyl groups in the side chains of each molecules thereof, or (ii) more preferably, an polydiorganosiloxane having at least two Si—H groups in the side chains of each molecule thereof, and a polydiorganosiloxane having each of its terminals blocked with an allyl group or a silanol group.
The preferred cross-linking radical is a vinyl-terminated polydiorganosiloxane used in combination with an Si—H containing backbone. This organosiloxane bridge should not contain any reactive sites for the polyoxyalkylene moieties. An organosiloxane bridge cooperates with the siloxane backbones which it bridges to create a siloxane network at the interface of water and the silicone antifoarn agent. This network is thought to be important in effecting the stabilizing properties and characteristics of the present invention. The siloxane bridge works with other types of antifoams. Other bridge types may be more suitable for non-silicone antifoams (e.g. an alkane bridge for mineral oil based antifoams).
The cross-linked polydiorganosiloxane polymer to be used as (III) should be one that satisfies the following conditions: (1) it has a three-dimensional crosslinked structure, (2) it has at least one polyoxyalkylene group, and (3) it has fluidity (i.e. it is “free flowing”). The term “three-dimensional cross-linked structure” used herein denotes a structure in which at least two organopolysiloxane molecules are bonded together through at least one bridge.
The exact number of polydiorganosiloxane-polyoxyalkylene polymer molecules which will be bridged together will vary within each compound. One limitation on such cross-linking is that the overall molecular weight must not become so great as to cause the material to gel. The extent of cross-linking must thus also be regulated relative to the molecular weight of each individual polymer molecule being cross-linked since the overall molecular weight must also be maintained sufficiently low to avoid gelling. In controlling the cross-linking reaction there is also the possibility that some un-cross linked material will be present.
In the present invention, it is preferred that component (III) is a compound having a viscosity of 100 to 100,000 mm 2 /s at 25° C. and having the unit formula:
wherein R 12 is a monovalent hydrocarbon group, A is a group having the formula (Ch 2 ) q —(R 14 2 SiO) r Si(Ch 2 ) s or the formula O(R 14 2 SiO) r —SiO wherein R 14 denotes a monovalent hydrocarbon group, q has a value of 2 to 10, r has a value of 1 to 5000, s has a value of 2 to 10, R 13 denotes a group having its formula selected from the group consisting of:
wherein R 15 is selected from a hydrogen atom, an alkyl group, an aryl group, or an acyl group, t has a value of 2 to 10, u has a value of from greater than zero to 150, v has a value of from greater than zero to 150, and w has a value of from greater than zero to 150, j has a value of 1 to 1000, k has a value of from greater than zero to 30, 1 has a value of 1 to 1000, m has a value of 1 to 1000, n has a value of from greater than zero to 30, p has a value of 1 to 1000. The groups R 12 and R 14 can be the same or different as desired and are preferably alkyl groups or aryl groups and it is highly preferred that they are both methyl.
In the formulae hereinabove, it is preferred that j has a value of 1 to 500 and it is highly preferred that j has a value of 1 to 250, it is preferred that k has a value of from greater than zero to 20 and it is highly preferred that k has a value of from 1 to 15, it is preferred that l has a value of 1 to 100 and it is highly preferred that I has a value of 1 to 50, it is preferred that m has a value of 1 to 500 and it is highly preferred that m has a value of 1 to 250, it is preferred that n has a value of from greater than zero to 20 and it is highly preferred that n has a value of from greater than 1 to 15, it is preferred that p has a value of 1 to 100 and it is highly preferred that p has a value of 1 to 50, it is preferred that q has a value of 2 to 6, it is preferred that r has a value of 1 to 2500 and it is highly preferred that r has a value of 20 to 1000, it is preferred that s has a value of 2 to 6, it is preferred that t has a value of 2 to 4, it is preferred that u has a value of from 1 to 100 and it is highly preferred that u has a value of 5 to 50, it is preferred that v has a value of from 1 to 100 and it is highly preferred that v has a value of 5 to 50, it is preferred that w has a value of from 1 to 100 and it is highly preferred that w has a value of 1 to 50. It is preferred that the cross-linked polydiorganosiloxane polymer of component (III) is triorganosiloxy endblocked at each terminal of the polymer, and it is highly preferred that the polymer is trimethylsiloxy endblocked at each terminal of the cross-linked polymer.
The method used to prepare the crosslinked polydiorganosiloxane polymers is disclosed in European Patent Application No. 0663225. A specific example of the method for producing the crosslinked polydiorganosiloxane polymers will now be described. Preparation of a crosslinked polydiorganosiloxane polymer was done through the following steps: (I) a charging step in which a linear polysiloxane having hydrogen atoms in its side chains, a polysiloxane having vinyl groups and a catalyst for promoting the reaction, particularly platinum catalysts such as an isopropanol solution of H 2 PtCl 6 6H 2 O with a 2% methanol solution of sodium acetate are put in a reactor, (II) an agitation/heating step in which agitation is conducted, for example, at 40° C. for 30 minutes, (III) an input step in which a polyoxyalkylene and a solvent (isopropanol) are put in the reactor, (IV) a reflux step in which the isopropanol is refluxed, for example, at 80° C. for 1.5 to 2 hours while monitoring the reaction rate of Si—H, (V) a stripping step in which the isopropanol is stripped, for example, at 130° C. under a reduced pressure of 25 mmHg, and (VI) a final step in which the reduced pressure condition of step (V) is released and the reaction mixture is cooled to 60° C. to obtain a final product.
An example of a linear polysiloxane having hydrogen atoms in its side chains suitable for step (I) is a polysiloxane having its formula selected from:
wherein Me hereinafter denotes methyl and j, k, l, m, n, and p are as defined above. An example of a polysiloxane having vinyl groups suitable for step (I) is a polysiloxane having the formula:
wherein Me denotes methyl, Vi hereinafter denotes vinyl, and r is as defined above. The reaction of these two compounds in step (II) results in a cross-linked siloxane polymer having the formula
Introduction of a polyoxyalkylene group into the obtained crosslinked organopolysiloxane polymer (steps III-VI) is accomplished by reacting the crosslinked polymer with a polyoxyalkylene compound having its formula selected from the group consisting of
wherein u, v, and w are as defined above.
Preferred as Component (III) are cross-linked polydiorganosiloxane polymers having the formula
wherein Me denotes methyl, j has a value of 1 to 250, k has a value of from 1 to 15, l has a value of 1 to 50, m has a value of 1 to 250, n has a value of from greater than 1 to 15, p has a value of 1 to 50, r has a value of 20 to 1000, u has a value of 5 to 50, v has a value of 5 to 50, and R 15 is hydrogen, methyl, or C(O)CH 3 .
Component (III) is present in the silicone foam control compositions of this invention in an amount from 1-50 weight parts, preferably from 5 to 20 weight parts, and most preferably from 10 to 20 weight parts, said weight parts being based on the total weight of the composition.
Component (IV) is at least one finely divided filler. The finely divided filler is exemplified by fumed, precipitated, or plasmatic TiO 2 , Al 2 O 3 , Al 2 O 3 /SiO 2 , ZrO 2 /SiO 2 , and SiO 2 . The finely divided filler can be hydrophilic or hydrophobic. The filler can be hydrophobed during manufacture (i.e. in-situ) or independently. Various grades of silica having a particle size of several millimicrons to several microns and a specific surface area of about 50 to 1000 m 2 /g, preferably a surface area of 50 to 300 m 2 /g, are commercially available and suitable for use as component (iv). Preferably component (IV) is a hydrophobic silica having a surface area of about 50 to 300 m 2 /g. Hydrophobic precipitated silicas are especially preferred as component (IV).
Component (IV) is present in the silicone foam control compositions of this invention in an amount from 1-20 weight parts, preferably from 1 to 10 weight parts, and most preferably from 2 to 6 weight parts, said weight parts being based on the total weight of the composition.
The silicone foam control compositions of this invention can further comprise (V) a polyglycol. The polyglycol is exemplified by polyethylene glycol, polypropylene glycol, polyethylene glycol-polypropylene glycol copolymers, condensates of polyethylene glycol with polyols, condensates of polypropylene glycol with polyols, and condensates of polyethylene glycol-polypropylene glycol copolymers with polyols.
Component (V), if used, is present in the silicone foam control compositions of this invention in an amount from 1-50 weight parts, preferably from 5 to 20 weight parts, and most preferably from 10 to 20 weight parts, said weight parts being based on the total weight of the composition.
In addition to the above-mentioned components, the silicone foam control compositions of the present invention may also contain adjuvants such as corrosion inhibitors and dyes. The compositions of the present invention may be prepared by blending components (I)-(IV), and any optional components, to form a homogenous mixture. This may be accomplished by any convenient mixing method known in the art such as a spatula, mechanical stirrers, in-line mixing systems containing baffles, blades, or any of the like mixing surfaces including powered in-line mixers or homogenizers, a drum roller, a three-roll mill, a sigma blade mixer, a bread dough mixer, and a two roll mill. The order of mixing is not considered critical.
The present invention also relates to a process for controlling foam in a foaming system wherein the above-described silicone foam control composition is added to a foaming or foam-producing system, in an amount sufficient to reduce foaming, as determined by routine experimentation. Typically, the silicone foam control compositions of the present invention are added at a concentration of about 0.001 to 0.1 weight parts based on the weight of the foaming system, however the skilled artisan will readily determine optimum concentrations after a few routine experiments. The method of addition is not critical, and the composition may be metered in or added by any of the techniques known in the art. Examples of foaming systems contemplated herein include media encountered in the production of phosphoric acid and in sulphite or sulphate process pulping operations, bauxite digestion medium in the production of aluminum, metal working fluids, paper manufacture, detergent systems, hydrocarbon based systems, etc. The compositions of the present invention can be used as any kind of foam control composition, i.e. as defoaming compositions and/or antifoaming compositions. Defoaming compositions are generally considered as foam reducers whereas antifoaming compositions are generally considered as foam preventors. The compositions of this invention find utility as foam control compositions in various media such as inks, coatings, paints, detergents, pulp and paper manufacture, textile dyes, textile scours, and hydrocarbon containing fluids.
EXAMPLES 1-7
Each of the silicone foam control compositions were prepared by mixing the ingredients in Table 1 hereinbelow. The amounts listed in the Examples below are in weight parts and the viscosity was measured at 25° C. unless otherwise indicated. The ingredients used in the Examples are defined as follows:
Silicone Antifoam Agent l was prepared according to the method disclosed in Example 1 of Aizawa et al in U.S. Pat. No. 4,639,489. The amounts of ingredients used were as follows: 59.2 weight parts of a trimethylsiloxy-terminated polydimethylsiloxane having a viscosity of 1000 mm 2 /s at 25° C., 28.2 weight parts of a hydroxy-terminated polydimethylsiloxane having a viscosity of 12,500 mm 2 /s at 25° C., 2.8 weight parts of ethyl polysilicate (“Silicate 45” from Tama Kagaku Kogyo Co., Ltd., Japan); 1.3 weight parts of a potassium silanolate catalyst, 2.8 parts of Aerosil 200 Silica (silica having a surface area of 200 m 2 /g from Degussa-Huls Corporation), and 4.8 weight parts of hydroxy-terminated polydimethylsiloxane having a viscosity of 40 mm 2 /s at 25° C. In addition to the above ingredients, this formulation also included 0.625 weight parts of water, 0.005 weight parts of Silwet® L-77 Silicone Glycol (from CKWITCO Corporation) and 0.09 weight parts of L-540 Silicone Glycol (a silicone polyether block copolymer wherein the polyether blocks consist of 50/50 mole percent of polyoxyethylene/polyoxypropylene from Union Carbide Corp., Danbury, Conn.).
Silicone Antifoam Agent 2 is a reaction product prepared according to the method of John et al. as described in EP 0217501, and was prepared by mixing together 64.3 weight parts of a trimethylsiloxy-terminated polydimethylsiloxane, 3.42 weight parts of a silicone resin, 32 weight parts of a hydroxyl-terminated polydimethylsiloxane, and 0.15 weight parts of a catalyst containing 10 wt % potassium hydroxide in isopropyl alcohol. The mixture was reacted at 80° C. with mixing for 5 hours and neutralized with 0.015 weight parts glacial acetic acid and 0.14 weight parts water.
Silicone Antifoam Agent 3 was prepared by heating a mixture of: 91 weight parts of a trimethylsiloxy-endblocked polydimethylsiloxane having a viscosity of 500 millipascal-seconds at 25° C., 3 parts of hydroxyl-terminated polydimethylsiloxane, 6 parts hydrophobic silica, and 0.025 parts ammonium carbonate.
Mineral Oil 1 is Shellflex® 6111 Mineral Oil, a light mineral oil having a viscosity of about 3 mm 2 /s at 40° C. from Shell Chemical Company, Houston, Tex.
Mineral Oil 2 is Duoprime® 55, a white mineral oil having a viscosity of about 10 millipascal-seconds at 25° C. from Lyondell Petrochemical Company, Houston, Tex.
Polydorganosiloxane 1 is a cross-linked polydiorganosiloxane polymer having at least one polyoxyalkylene group prepared by the method described in Tonge et al in European Patent Application No. 0663225, as follows:
Component (A1): was a linear polysiloxane having the formula:
Wherein Me denotes methyl, j has a value in the range of 70 to 110, and k+1 is in the range of 5 to 15.
Component (B1): was a polysiloxane having the formula
wherein Me denotes methyl, Vi denotes vinyl, and wherein the polysiloxane has a molecular weight ranging from 8000 to 25,000.
Component (C1): was a polyoxyalkylene having the formula:
having a molecular weight in the range of from 2000 to 4000 and the ratio of u:v is 1:1.
Component (D): was isopropanol (as a solvent).
Component (E): was a 2% isopropanol solution of H 2 PtCl 6 .6H 2 O.
In the Examples, A1 had values of j=108, and k+1=10, B1 had a molecular weight of approximately 11,000, and C1 had a molecular weight of approximately 3,100. The polydiorganosiloxane was prepared by adding 12.8 parts of (A1), 2.6 of (B1) into a reactor, mixing, and heating to 80° C. Next, 0.001 parts of (E) were added and the mixture was reacted for 60 minutes. 60.2 parts of (C1) and 24.4 parts of (D) were then added. The mixture was heated to 90° C. 0.001 additional parts of (E) were added. The mixture was reacted at 90° C. for 2 hours, followed by a vacuum strip to remove the isopropanol. The mixture was cooled and filtered.
Polydiorganosiloxane 2 is an oxyalkylene-containing polydimethylsiloxane having the formula
where Me denotes methyl, x=4, y=396, g=18, and h=18. The polydimethylsiloxane was diluted to a level of 47% in cyclosiloxanes.
Polydiorganosiloxane 3 is an oxyalkylene-containing polydimethylsiloxane having the formula
where Me denotes methyl, x=2, y=22, and g=12.
Silica 1 is Sipernat® D10, a hydrophobic silica from Degussa Corp. (Ridgefield Park, N.J.).
Silica 2 is Sipernat® D13, a hydrophobic silica from Degussa Corp. (Ridgefield Park, N.J.).
Polyglycol 1 is Polyglycol E-8000, a polyethylene glycol having molecular weight of about 8000 from The Dow Chemical Company (Midland, Mich.).
Continuous Phase 1 is P15-200®, an ethylene oxide/propylene oxide triol copolymer with glycerin having a number average molecular weight of 2,600 from The Dow Chemical Company (Midland, Mich.).
Surfactant 1 is a nonionic silicone surfactant of trimethylsilyl end capped polysilicate prepared according to the method described in Keil, U.S. Pat. No. 3,784,479. A mixture of 7 weight parts of a siloxane resin (which is a 70% xylene solution of a hydroxy-functional siloxane resin copolymer comprising (CH 3 ) 3 SiO 1/2 and SiO 2 units having a (CH 3 ) 3 SiO 1/2 to SiO 2 ratio of 0.75:1), 15 weight parts of a copolymer of ethylene oxide and propylene oxide having a number average molecular weight of 4000, and 38 weight parts of xylene was reacted at reflux for 8 hours with 0.2 weight parts of a stannous octoate, 0.1 weight parts of phosphoric acid was added and the product was blended with 40 weight parts of a polyethylene glycol-polypropylene glycol copolymer. The product was stripped at 5.3 kPa at 140° C. to remove xylene and filtered.
Stabilizing Aid 1 is Aerosil® 972, a fumed silica that has been treated to a moderate level with dichlorodimethylsilane, having a surface area of 110 m 2 /g, a methanol wettability of 45%, and is available from Degussa Corp. (Ridgefield Park, N.J.).
TABLE 1
Ingredients
Ex 1
Ex 2
Ex 3
Ex 4
Ex 5
Ex 6
Ex 7
Ex 8
Ex 9
Silicone Antifoam Agent 1
46
46
46
0
0
46
46
40
41.5
Silicone Antifoam Agent 2
0
0
0
46
0
0
0
0
0
Silicone Antifoam Agent 3
0
0
0
0
46
0
0
0
0
Mineral Oil 1
37
37
37
37
37
0
37
37
41.5
Mineral Oil 2
0
0
0
0
0
37
0
0
0
Polydiorganosiloxane 1
13
0
0
13
13
13
13
13
13
Polydiorganosiloxane 2
0
13
0
0
0
0
0
0
0
Polydiorganosiloxane 3
0
0
13
0
0
0
0
0
0
Silica 1
4
4
4
4
4
4
0
0
4
Silica 2
0
0
0
0
0
0
4
5
0
Polyglycol 1
0
0
0
0
0
0
0
5
0
COMPARISON EXAMPLES 1-3
Each of the comparison silicone foam control compositions were prepared by mixing the ingredients in Table 2 hereinbelow. The amounts listed in Table 2 below are in weight parts.
TABLE 2
Ingredients
C Ex 1
C Ex 2
C Ex 3
Silicone Antifoam Agent 1
46
46
46
Silicone Antifoam Agent 2
0
0
0
Silicone Antifoam Agent 3
0
0
0
Mineral Oil 1
0
0
0
Mineral Oil 2
0
0
0
Polydiorganosiloxane 1
0
50
0
Polydiorganosiloxane 2
0
0
50
Polydiorganosiloxane 3
50
0
0
Silica 1
0
0
0
Silica 2
4
4
4
COMPARISON EXAMPLES 4-8
Comparison Examples 4, 5, and 8 were prepared by mixing together the ingredients listed in Table 3 using moderate mechanical agitation. The amounts listed in Table 3 below are in weight parts. Comparison Examples 6 and 7 were prepared by mixing the amounts specified in Table 3 below for Silicone Antifoam Agent 1 with that for Silica 1 to form a premix, then blending this premix with Polydiorganosiloxane 1 in the amount specified in Table 3 below using moderate mechanical agitation.
TABLE 3
Ingredients
C Ex 4
C Ex 5
C Ex 6
C Ex 7
C Ex 8
Silicone Antifoam
50
50
46
26
30
Agent 1
Silicone Antifoam
0
0
0
0
0
Agent 2
Silicone Antifoam
0
0
0
0
0
Agent 3
Mineral Oil 1
0
0
0
0
0
Mineral Oil 2
0
0
0
0
0
Continuous
0
0
0
0
0
Phase 1
Polydiorgano-
50
0
50
70
70
siloxane 1
Polydiorgano-
0
50
0
0
0
siloxane 2
Polydiorgano-
0
0
0
0
0
siloxane 3
Silica 1
0
0
4
4
0
COMPARISON EXAMPLES 9-11
Comparison Examples 9 and 10 were prepared by mixing together the ingredients listed in Table 4 using moderate mechanical agitation. The amounts listed in Table 4 below are in weight parts. Comparison Example 11 was prepared by mixing the amounts specified in Table 4 below for Silicone Antifoam Agent 1 with that for Silica 1 to form a premix, then blending this premix with Mineral Oil 1 in the amount specified in Table 4 below using moderate mechanical agitation.
TABLE 4
Ingredients
C Ex 9
C Ex 10
C Ex 11
Silicone Antifoam Agent 1
50
50
46
Silicone Antifoam Agent 2
0
0
0
Silicone Antifoam Agent 3
0
0
0
Mineral Oil 1
50
0
50
Mineral Oil 2
0
50
0
Continuous Phase 1
0
0
0
Polydiorganosiloxane 1
0
0
0
Polydiorganosiloxane 2
0
0
0
Polydiorganosiloxane 3
0
0
0
Silica 1
0
0
4
COMPARISON EXAMPLES 12-13
Comparison Example 12 was prepared by adding 31 parts of Silicone Antifoam Agent 1 to a combination of 4 parts of Surfactant 1 in 42 parts of Continuous Phase 1 under moderate mechanical agitation. The resulting mixture was then added to a premix containing 2 parts of Stabilizing Aid 1 in 21 parts of Continuous Phase 1.
Comparison Example 13 was prepared by making a premix of 36 parts of Silicone Antifoam Agent 1 with 4 parts of Silica 2 under moderate mechanical agitation. This premix was then added to a mixture of 2.5 parts of Stabilizing Aid 1 in 57.5 parts of Continuous Phase 1 under mechanical agitation.
TABLE 5
Ingredients
C Ex 12
C Ex 13
Silicone Antifoam Agent 1
31
36
Silicone Antifoam Agent 2
0
0
Silicone Antifoam Agent 3
0
0
Mineral Oil 1
0
0
Mineral Oil 2
0
0
Continuous Phase 1
63
57.5
Polydiorganosiloxane 1
0
0
Polydiorganosiloxane 2
0
0
Polydiorganosiloxane
0
0
Surfactant 1
4
0
Stabilizing Aid 1
2
2.5
Silica 1
0
0
Silica 2
0
4
Test Protocols
Foam control composition samples prepared according to the above examples and comparative examples were added to portions of the following detergent prototype, and the resulting compositions were evaluated as to wash foam production and stability.
Detergent Prototype Formulation (Percentages given are by weight and do not add up to 100.0 due to Rounding)
29.8% Distilled Water
33.7% Witcolate LES-60C by Witco (contains an alkyl ether sulfate)
15.7% Glucopon 600 UP by Henkel (contains an alkyl polyglycoside)
8.3% Sodium Citrate
7.0% Propylene Glycol
2.6% Neodol 23.6.5 by Shell Chemical Company (a linear alcohol ethoxylate)
2.0% Ethanolamine
1.0% Emery 621 Coconut Fatty Acid (by Henkel)
Wash Foam Test
General Electric Model WWA7678MALWH washing machines were loaded in turn with twelve 106.7 cm×58.4 cm towels (86% cotton, 14% polyester) for ballast and filled with 68.1 liters water of 0 ppm hardness containing 112 g of the detergent prototype and 0.112 g of the foam control compositions (0.1 weight %) of the examples and comparative examples. The foam height was measured at various times during a 12 minute wash cycle as summarized in Table VI below. Thus, “Ht3” refers to the foam height in the washer after 3 minutes into the washer cycle, going up to “Ht12” for 12 minutes into the cycle. Foam heights are given as 99 if there was foam out of the machine. To obtain “Wash Results” ratings, foams heights after 12 minutes into the cycle were characterized as “Good” if less than 1.5 cm, “OK” if from 1.5-7 cm and “Fail” if over 7 cm.
Stability Test
Samples of foam control compositions were prepared according to the above examples and comparative examples and mixed with prototype detergent such that the foam control composition was 1% by weight of the final composition. The resulting blends were allowed to stand for one week and visually evaluated according to the following rating.
1=clear with no or very little surface scum or “collar” around the container wall.
2=slight amount of collar or surface scum/oil; can be re-dispersed into detergent.
3=fair amount of collar or surface scum/oil; more difficult to re-disperse.
4=significant collar or surface scum/oil; hard to re-disperse
5=agglomeration or coalescence of silicone visible and cannot be re-dispersed.
TABLE 6
Ht 3
Ht 6
Ht 9
Ht 12
Avg
Avg
Avg
Avg
Wash
Stability
Example
(cm)
(cm)
(cm)
(cm)
Results
Results
Ex 1
0.50
1.00
1.67
4.08
OK
2
Ex 2
−1.17
1.00
1.00
2.92
OK
1
Ex 3
0.50
0.75
1.00
0.67
Good
1
Ex 4
0.50
0.50
1.17
3.33
OK
4
Ex 5
3.25
6.17
8.17
99.00
Fail
2
Ex 6
0.00
0.50
0.50
0.92
Good
3
Ex 7
0.00
0.00
0.00
0.50
Good
2
Ex 8
0.00
0.50
0.50
1.42
Good
3
Ex 9
2.08
4.42
5.50
6.08
OK
2
Comp Ex 1
0.50
1.83
2.00
4.42
OK
5
Comp Ex 2
6.42
99
99
99
Fail
3
Comp Ex 3
0.50
1.00
1.83
3.08
OK
5
Comp Ex 4
13.00
99
99
99
Fail
1
Comp Ex 5
2.50
3.08
3.00
3.00
OK
5
Comp Ex 6
9.67
99
99
99
Fail
4
Comp Ex 7
99
99
99
99
Fail
4
Comp Ex 8
99
99
99
99
Fail
4
Comp Ex 9
99
99
99
99
Fail
2
Comp Ex 10
99
99
99
99
Fail
2
Comp Ex 11
1.58
4.67
9.42
99
Fail
3
Comp Ex 12
1.25
4.58
4.75
8.50
Fail
4
Comp Ex 13
0.50
0.50
0.50
0.50
Good
3 | This invention relates to silicone foam control compositions comprising a silicone antifoam agent, mineral oil, a polydiorganosiloxane containing at least one polyoxyalkylene group, and a finely divided filler. The foam control compositions of this invention can be advantageously utilized to control foam in foam producing systems, provide improvement in the control of foaming behavior, and are stable and easily dispersible. | 67,763 |
This invention claims the benefit of priority from U.S. Provisional patent application 60/461,336 filed Apr. 9, 2003.
FIELD OF THE INVENTION
This invention relates to high power output laser systems and more particularly to those high power laser systems and methods of producing high power lasers with diode arrays, which are compact, use fewer optical elements and have increased ease of adjustment of power delivery and laser output.
BACKGROUND AND PRIOR ART
The current art for disk laser pumping involves either complex arrays of mirrors to redirect pump light from a conventional array into the disk many times to achieve both efficient absorption and uniformity or an array of diodes placed around the rim of the disk pumping through the rim towards the center. Both suffer from complexity and the former is not as rugged as applications demand. Also, both suffer from scalability limitations for higher power.
The current art is represented by the laser technology such as Giesen's multi-pass face pumped thin disk laser (see C. Stewen, K. Contag, M. Larionov, A. Giesen, and H. Hugel, “A 1-kW CW thin disc laser”, IEEE Journal of Selected Topics in Quantum Electronics, 2000, 6(4): 650-657). Patents related to the work of Giesen and others include, U.S. Pat. No. 6,438,152 to Contag et al. disclosing a complex system with a plurality of pumping branches and U.S. Pat. No. 6,577,666 B2 to Erhard et al. with a plurality of optical refocusing legs. Vetrovec's proposal of edge pumping a disk gain medium (see J. Vetrovec, “Compact active mirror laser (CAMIL)”, SPIE, Photonics West Laser ' 2002 Conference , San Jose, Calif., Jan. 22–26, 2001) also requires complex systems with many optical components and also have pump power delivery and laser outputs which are most often highly non-uniform. U.S. Pat. Nos. 6,603,793 B2 and 6,625,193 B2 to Vetrovec provide several arrangements of gain elements, diode arrays, optical medium and optical coatings to achieve high power lasers; however, all arrangements are unlike the arrangement of elements in the present invention.
In addition to the above, annular or circular arrangements of laser diode bars mounted in a dielectric block are disclosed in U.S. Pat. No. 5,627,850 to Irwin et al. and U.S. Pat. No. 6,647,037 B2 to Irwin. U.S. Pat. No. 6,661,827 B2 to Lam et al. discloses a radial array of laser diodes mounted in a segmented conductive ring surrounding a laser rod.
None of the prior art arrangements of diode bars, gain elements, or optical elements have the configuration of an open ring as disclosed herein. Not only does the present invention have a unique configuration, the invention meets the commercial need for a laser pump that is scalable to high power laser output, uses fewer optical elements, and is easy to adjust the pump power delivery and laser output to provide improved uniformity.
SUMMARY OF THE INVENTION
It is a primary objective of the present invention to develop a laser pump that is scalable to high power laser output and uses fewer optical elements.
Another object of the present invention is to provide a more efficient disk laser pump source that is scalable to higher powers and of increased ruggedness.
A further object of the present invention is to provide a disk laser pump that is easy to manufacture and compatible with both disk laser and disk amplifier configurations.
Preferred embodiments of the invention include a new configuration of diode laser bars to face pump thin disk solid state lasers comprising an array of diode bars placed on a washer shaped substrate and a method of modifying the output of a high average power disk laser comprising the steps of: operating said disk laser with an array of diode bars placed on a washer shaped substrate which allows laser light to reach the disk-shaped gain medium through its central hole; and, cooling said diode array from its back surface whereby said combination provides a more efficient disk laser pump source which is scalable to higher powers and is of increased ruggedness.
Further objects and advantages of this invention will be apparent from the following detailed description of the presently preferred embodiments, which are illustrated schematically in the accompanying drawings.
BRIEF DESCRIPTION OF THE FIGURES
FIG. 1A shows a top view of the ring of diode bars in an array of diode bars placed on a flat washer shaped substrate.
FIG. 1B shows one group of arrayed diode bars delivering light to thin disk of a solid-state laser gain medium.
FIGS. 2A , 2 B and 2 C show the results of calculating the absorbed pump power density at the entrance surface of a Yb:YAG laser disk when it is pumped by an array such as shown in FIGS. 1A and 1B .
FIGS. 2D , 2 E and 2 F show the distribution of absorbed pump power at the back surface of a Yb:YAG laser disk when it is pumped by an array such as shown in FIGS. 1A and 1B .
FIG. 3 shows a laser diode array configured on the inside of a conical ring for face-pumping a thin disk laser.
FIG. 4 is a schematic illustration of a beam prism controlled single emitting element of a laser diode bar with cooling system.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Before explaining the disclosed embodiments of the present invention in detail, it is to be understood that the invention is not limited in its application to the details of the particular arrangements shown since the invention is capable of further embodiments. Also, the terminology used herein is for the purpose of description and not of limitation
According to this invention, the above objects are met by incorporation of a new configuration of diode laser bars to face pump thin disk solid-state lasers. In FIG. 1 there is shown an array of diode bars 10 , having a length of approximately 1 centimeter (cm), placed on a flat washer shaped substrate 12 . The washer shaped substrate 12 allows laser light to reach the disk-shaped gain medium located below the central hole 14 of the substrate while arraying the diode bars 10 in such a manner as to be contiguous with the circular geometry of the substrate disk. The diode bars 10 can be fitted with beam control prisms shown as 18 in FIG. 4 or other optical elements to allow for control of the angular spread of the emitted light and its direction of propagation away from the surface of the array. An example of a beam control prism and other optical elements to control laser emitted light are shown in U.S. Pat. No. 5,208,456, which is incorporated by reference. Optical elements useful in focusing a light beam on the desired plane may be passive or in-line optics, including, but not limited to, lenses, mirrors and prisms. The array of diode bars 10 can be cooled from the back surface of the substrate 12 with a cooling device 200 (shown in FIG. 4 ). In FIG. 1 , one group of the arrayed diode bars 10 a , spaced approximately 15 cm from the thin disk 16 , are shown delivering light to thin disk 16 of a solid-state laser gain medium. The diode bars are placed on the side of the ring facing the gain medium and the backside is cooled using various techniques known by those skilled in the art, such as, but not limited to, those described in U.S. Pat. Nos. 6,480,514, 5,105,430 and 5,105,429, which are incorporated by reference. An exemplary cooling technique can be a spray cooling system 200 . The pump power pattern 17 shows some spill over of light off the edge of the disk 16 . This can be controlled by adding slow axis angular spread control to the beam control prisms or by aiming the light in different manners. FIG. 1 shows that the diode bars 10 are stacked along radii of the washer shaped substrate 12 with their lengths perpendicular to the radii. This is one embodiment. Other embodiments would include those orienting the diode bar lengths at other angles with respect to the radii.
The choice of which diode bar 10 directs its light to which location on the surface of the disk gain medium depends on the particular application and the need for more uniformity or for more pump absorption efficiency. Again, any set of such choices is within the scope of the present invention.
FIGS. 2A , 2 B, 2 C, 2 D, 2 E, and 2 F show the results of calculating the absorbed pump power density in a Yb:YAG laser disk 16 when it is pumped by an array such as shown in FIGS. 1A and 1B . The concentration of Yb is approximately 10 (atomic weight) at. %. The size of Yb:YAG thin disk is approximately 50 millimeters (mm) in diameter and approximately 2 mm in thickness. The distance between diode lasers and Yb:YAG is approximately 150 mm, approximately 132 diode bars are used and total power is approximately 5280 watts (W). The divergence angles of the diode lasers are approximately 20 and approximately 8 degrees. The incident angle of the diode laser is approximately 14 degrees. The diode lasers can be arranged as a ring with an inner radius of approximately 40 mm and the outer radius of approximately 56 mm. The uniformity of pump light distribution due to the array is excellent.
Referring now to FIG. 2A , a three-dimensional plot 20 shows the distribution of absorbed pump power at the entrance surface of a disk pumped by diode laser light from an array of diode lasers, as shown in FIGS. 1A and 1B . FIG. 2B shows a plot 21 of the cross section of the distribution of absorbed pump power in 20 taken parallel to the x axis in 20 and through the center of the disk. FIG. 2C is a plot 22 of the cross section of the distribution of absorbed pump power in 20 is taken parallel to the y axis in 20 and through the center of the disk.
FIG. 2D is another three-dimensional plot 25 showing the distribution of absorbed pump power at the back surface of a disk pumped by diode laser light from an array of diode lasers, as shown in FIGS. 1A and 1B . FIG. 2E is a plot 26 of the cross section of the distribution of absorbed pump power in 25 taken parallel to the x axis in 25 and through the center of the disk. FIG. 2F is a plot 27 of the cross section of the distribution of absorbed pump power in 25 taken parallel to the y axis of 25 and through the center of the disk.
The efficiency of absorption is approximately 78%. By simply accepting a lower efficiency, the roll off in absorbed pump power at the rim of the disk 16 can be eliminated. As indicated above and shown in FIG. 3 , there are other means, to achieve an improvement in uniformity without giving up absorption efficiency.
FIG. 3 shows an alternative to the flat washer array, and is another embodiment of the present invention. By arraying the diode bars 30 on the inside of a conical ring 32 , some of the diode bars 30 are closer to the thin disk 34 than others. Line D is the distance between the diode bars 30 and the thin disk 34 , a distance that can be variable. The slow axis spread problem alluded to above can be compensated for, by this approach, as the near diode bars 30 a produce light 36 that spreads less and spills over the rim of the disk less when it reaches the surface of the disk 34 . This provides a wider range of choices as to which area of the disk 34 is illuminated by which diode bar 30 .
In FIG. 4 , a single laser diode bar 40 measuring approximately one centimeter (cm) in width contains nineteen emitting elements 42 . A quantum-well active layer 50 with emitting elements 42 is sandwiched between a top insulating plate 52 , a second top cathode layer 54 and a bottom anode layer 56 . A cooling system 200 , preferably, a spray cooling system, is connected to the substrate of the laser diode emitting elements 42 . The cooling system 200 (not shown in the drawings) is also attached to the back of the laser diode bars in FIGS. 1 and 3 . The beam controlled prism 18 is nearly one-quarter of the optical fiber placed on the front of the emitting area 44 of the emitting elements 42 and can be adjusted by the micro-mechanical system which can adjust the direction and the fast-axis divergence angle of the laser diode output beam 58 . The beam-controlled prism 18 is connected to the laser diode bar 40 by placing the prism on the groove 45 of the substrate of the laser diode bar 40 .
Thus, the present invention provides an efficient disk laser pump source in a novel configuration with an array of diode bars placed on a washer shaped substrate, cooled from the back surface while laser light emitted from the diode bars is focused to a disk-shaped gain medium located below the central hole of the substrate. The high power laser array system is compact, robust and easy to scale to high power laser output, uses fewer optical elements, and it is easy to adjust the pump power delivery and laser output.
The advantages of the invention are less cost, more efficient disk laser pump sources, scalability to higher powers, greatly increased ruggedness, ease of manufacture and compatibility with both disk laser and disk amplifier configurations. It is useful to pump high average power disk lasers for manufacturing, medical and military applications. Manufacturing applications include, but are not limited to, materials processing. Military uses include directed energy weapons that demand the very high beam quality that disk lasers provide.
While the invention has been described, disclosed, illustrated and shown in various terms of certain embodiments or modifications which it has presumed in practice, the scope of the invention is not intended to be, nor should it be deemed to be, limited thereby and such other modifications or embodiments as may be suggested by the teachings herein are particularly reserved especially as they fall within the breadth and scope of the claims here appended. | Systems, configurations and methods of using laser diodes in ring-shaped arrays placed a distance away from thin disk solid-state laser gain media, which provide uniformly absorbed pump power distribution with high absorption efficiency. This results in major improvements in the scalability and ruggedness of such lasers and disk laser amplifiers. Use of the diode laser pump configurations of the invention results in compact, robust and scalable lasers that produce high quality, high power outputs. | 14,009 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of U.S. Provisional Patent Application Ser. No. 60/879,415, entitled DIGITAL AUDIO SYSTEM WITH SAFETY FEATURES, filed on Jan. 9, 2007.
TECHNICAL FIELD
[0002] The present invention is directed to a system and method for providing a user with information related to sound exposure from earphones or headphones, and in particular, to a digital audio processor that displays information regarding sound exposure within a human ear canal in response to an audio input.
BACKGROUND OF THE INVENTION
[0003] According to the National Institutes of Health, approximately 28 million Americans have a hearing impairment. Hearing loss covers an age span of approximately 17 in 1,000 children under the age of 18 and approximately 314 in 1,000 adults over the age of 65. This indicates that the incidence of hearing loss increases with age. In addition, ten million Americans have suffered irreversible noise-induced hearing loss, and 30 million more are exposed to dangerous sound levels each day.
[0004] One source of these dangerous sound levels is earphones and headphones. Generally, the user of earphones or headphones has no knowledge of or reference for the actual sound level presented to their ears. Without knowledge of the actual audio levels being applied to the ear canal, the user is at risk of accruing hearing damage with long-term use. With the increased use of insert-earphones (also know as in-ear earphones, isolating earphones, or canal-phones) and portable audio players, it is becoming more commonplace and understood that unsafe audio levels are being played and hearing damage is likely to occur. The Occupational Safety and Health Administration (OSHA) and other governmental and industry organizations have published sound-pressure-level versus exposure-time guidelines which indicate safe limits of exposure to noise.
[0005] In some instances, an earphone user may understand the risk involved in listening to sound at louder levels, but currently does not have a tool available for determining the level of sound to which he or she is actually being exposed. This problem is further exacerbated by the listening experience that is provided by noise-isolating or insert-earphones. In particular, a user of these earphones no longer has the reference of the ambient environment from which to determine the relative level of reproduced audio. In addition, the audio drivers of insert-earphones provide little of the bone-conduction vibration that bigger headphones or speakers create, which may lead the user into believing that the listening level is lower than actual.
[0006] One available method for protecting hearing is a volume limiter that is available on some portable audio devices. However, the protection offered by a Volume limiter is arbitrary because it limits the volume level based solely on the output of the instrument without taking into consideration the sensitivity of the earphones and how efficiently they couple sound to a user's eardrum. Thus, this method may cause the user to over or underestimate the levels of audio to which they are subject, and may provide a false sense of security. In addition, while it is understood that exposure to high sound-pressure-levels can be harmful to one's hearing, the duration of the exposure is key to understanding the relative level of danger. However, the volume limiter solution fails to take into account this duration to the exposure of the sound, which can further offer the user a false sense of protection.
SUMMARY OF THE INVENTION
[0007] A system and method is provided for measuring and displaying audio level information to an earphone or headphone user. In an embodiment, an audio processor device measures and displays the time-weighted average levels to which the earphone or headphone user has been exposed.
[0008] In another embodiment in accordance with the present invention, an audio processor device implements a measurement of and provides an indication of the audio presentation level of an earphone into the ear canal. The indication can take the form of a graph that shows the audio level as it changes with time input or the level can be indicated numerically, preferably in known units, for example, decibels (dB), or the indication can take the form of a series of colored lights or markers that progressively indicate the relative risk level. This indication is based on a calibration to the sensitivity of the earphones being used with the audio processor device. The calibration is entered into the audio processor device via the user interface and stored in memory. In an alternative embodiment, the calibration is performed using a potentiometer or gain switch. The indication can be displayed in decibels of sound-pressure-level (dB SPL) optionally with a weighing function applied, such as A, B, or C weighting.
[0009] In yet another embodiment in accordance with the present invention, an audio processor device provides the measurement and indication of the time-weighed noise (audio) exposure. In this embodiment, an indicator is employed that provides the user with knowledge of the amount of exposure to sound that is being or has been presented to the user's ears. This indication can give an overall exposure indication or can provide warnings to the user when a particular threshold of exposure has been exceeded.
[0010] In a further embodiment in accordance with the present invention, an audio processor device uses the measured sound-pressure level or the time-weighted exposure to limit the output of the audio stream. This function can be performed by a compression circuit to limit the dynamic-range or sound-pressure-levels, a limiter circuit that prevents the sound-pressure-level from exceeding a preset limit, or as an adaptive function that reduces the output when preset limits of exposure have been met.
[0011] In a further embodiment in accordance with the present invention, an integral microphone is provided with the audio processor that allows the introduction of ambient sound into the audio output. The output of the microphone can be either mixed with a separate audio program, or listened to independently. This audio signal allows the user to audibly interact with the environment while using sound-isolating earphones.
[0012] In still yet another embodiment in accordance with the present invention, the integral microphone is used to calibrate the sensitivity and/or frequency response of a user's earphones. An audio signal is supplied to the earphones and the response of the earphone measured through a known acoustical coupling volume or known acoustical coupling impedance by the integral microphone. The response as measured is then stored and can be used to provide the calibration for the sensitivity of the earphones. An audio signal such as a chirp or frequency sweep can be used as the source to the earphones in order to measure the transfer function of the earphones. The stored measurement can be used to implement a custom frequency equalization based on the actual frequency response of the earphone and a user-defined frequency response objective. One objective of the earphone calibration can be to normalize the earphone response to that of the frequency response at the tympanic membrane of an average human when exposed to a uniform diffuse sound field. In order to suitably represent the complex frequency dependent impedances of a nominal human ear canal, additional acoustic treatments, for example tuned acoustic dampers, can be used in the acoustical coupling volume. Compensations can also be implemented in the calibration software to assist in properly evaluating the response in view of the nominal human ear canal response.
[0013] In yet another embodiment in accordance with the present invention, the audio processor device uses stored calibration profiles for commonly known earphones. The sensitivity or frequency response of one or more earphones can be stored in the memory of the audio processor as supplied by the manufacturer or can be downloaded into the audio processor device through a computer connection, such as by means of a Universal Serial Bus (USB) connection or wireless USB connection. The earphone user can select the appropriate earphone profile from a selection through the user interface on the digital audio processor device or from a separate computer. The stored earphone can be used to set earphone frequency or amplitude characteristics that are appropriate for the user's earphones and the user's preferences.
[0014] In a further embodiment in accordance with the present invention, calibrated electronic equalization functions are provided with the audio processor device that allow the user to adjust the spectral aspects of sound reproduction using conventional bass and treble controls as well as a graphic equalizer, in a package no larger than 3.25 cubic inches.
[0015] Other embodiments, systems, methods, features, and advantages of the present invention will be, or will become, apparent to one having ordinary skill in the art upon examination of the following drawings and detailed description. It is intended that all such additional systems, methods, features, and advantages included within this description be within the scope of the present invention, and can be protected by the accompanying claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0016] The invention may be better understood with reference to the following drawings. The components in the drawings are not necessarily to scale, emphasis instead being placed upon illustrating the principles of the invention. In the drawings, like reference numbers designate corresponding parts throughout.
[0017] FIG. 1 is a simplified functional block diagram of an audio processor device in accordance with the present invention;
[0018] FIG. 2 is a simplified functional block diagram of the audio processor device of FIG. 1 connected to an audio source and earphones;
[0019] FIG. 3 is a plan view of an embodiment of an audio processor device incorporating the functionality of FIG. 1 ;
[0020] FIG. 4 is an elevation view of the bottom of the audio processor device of FIG. 3 ;
[0021] FIG. 5 is a partial cross sectional view of an earphone calibration system in accordance with the present invention wherein an earphone is mounted to the audio processor device of FIG. 3 ;
[0022] FIGS. 6-12 depict various menu screens that can be presented on the display of the digital audio processor device of FIG. 3 ;
[0023] FIG. 13 is a chart depicting the recommended maximum exposure time to various sound levels; and,
[0024] FIGS. 14 and 15 are block diagrams depicting a method wherein the sensitivity of earphones can be subjectively determined.
DETAILED DESCRIPTION
[0025] The following descriptions of detailed embodiments are for exemplifying the principles and advantages of the inventions claimed herein. They are not to be taken in any way as limitations on the scope of the inventions.
[0026] Turning to FIG. 1 , a general functional block diagram is provided of an embodiment of a digital audio processor device 101 in accordance with the present invention. It should be appreciated that the functional blocks of FIG. 1 can be realized by any number of hardware and/or software components configured to perform the specified functions described herein. For example, the present invention can employ various integrated circuit components, e.g., memory elements, processing elements, logic elements, look-up tables, and the like, which can carry out a variety of functions under the control of one or more microprocessors or other control devices. Moreover, it should be appreciated that the interconnecting lines in FIG. 1 can be realized by any number of electrically conductive or other communication signal paths such as, but not limited to, electrically conductive wire(s), electrically conductive trace(s), wireless communication (including but not limited to BLUETOOTH), serial bus, parallel bus, or any combination thereof.
[0027] In FIG. 1 , an audio input jack 12 is provided having a left input 100 and a right input 102 for receiving analog electrical input audio signals into the device 101 . The inputs are electrically connected in a conventional manner to conventional analog-to-digital converters 115 having a digital electrical output 126 representative of the analog electrical inputs 112 , 113 . In an embodiment, dual 24-bit stereo multi-bit sigma-delta codecs are used having part number TLV320AIC23B.
[0028] Receiving the digital electrical signals 126 from the analog-to-digital converters 115 is a 48-bit digital audio processor 140 (e.g., part number TAS3103) having a processed output 142 . Digital-to-analog converters 154 receive the processed signals 142 and produce analog electrical outputs 152 , 156 responsive to the input 142 . The analog outputs 152 , 156 are amplified by output amplifiers 170 wherein the amplified output is provided as electrical output audio signals to an output jack 14 having a left output 104 and a right output 106 .
[0029] A conventional microcontroller 128 (e.g., part number MSP430F133) is electrically connected to the left input 100 of the input jack 12 , the analog-to-digital converters 115 , the output amplifiers 170 , and the digital audio processor 140 . Accordingly, the microcontroller 128 provides for monitoring the electrical input audio signals received at jack 12 and controlling the electrical output audio signals provided at jack 14 wherein the output audio signals are responsive, at least in part, to the input audio signals. Stated another way, the input audio signals have an effect on the audio output signals produced by the device 101 .
[0030] The microcontroller 128 is also electrically coupled to a display 162 that, as explained in more detail further herein, displays the status of the device and audio level generated by headphones electrically connected to the output of the device. The microcontroller 128 determines the audio level based, in part, on the electrical signals received at the input jack 12 of the device and commands entered by a user via the user interface controls 114 .
[0031] In addition to the user interface controls 114 , a programming connector 130 and a USB connector 132 are electrically coupled to the microcontroller 128 . The programming connector 130 provides for ease in coupling the microcontroller to a conventional device (not shown) for programming the microcontroller before final assembly of the device. Further, the USB connector 132 can be coupled to a Universal Serial Bus (not shown) wherein power from the bus can be used to charge the battery 139 contained within the device 101 and, in an embodiment, the device can communicate over the Universal Serial Bus. Alternatively, power to the connector 132 can be supplied from a conventional Universal Serial Bus charging unit (not shown). In an embodiment, but not necessarily, the battery 139 can be a conventional lithium-polymer rechargeable battery.
[0032] A microphone 110 is also provided for monitoring of environmental sounds with the device. The microphone 110 is electrically connected to an analog-to-digital converter 111 wherein analog signals from the microphone are converted into digital signals 119 that are received by the digital audio processor 140 to generate processed output signals 142 . As indicated previously, the digital-to-analog converters 154 receive the processed signals 142 and produce analog electrical outputs 152 , 156 responsive to the processed signals 142 . The analog outputs 152 , 156 are amplified by output amplifiers 170 wherein the amplified output is provided as electrical output audio signals to an output jack 14 having a left output 104 and a right output 106 .
[0033] When the microphone 110 input is selected by a user via the user interface controls 114 , the microcontroller 128 determines the input audio level based, in part, on the electrical signals produced by the microphone 110 in response to external or environmental audio signals received by the microphone. The microcontroller 128 controls the display for depicting the audio level generated by headphones electrically connected to the output of the device 101 wherein the audio level is based on commands entered by the user via the user interface controls 114 and the ambient audio level received by the microphone 110 .
[0034] Also provided in the device 101 of FIG. 1 are a battery management and voltage regulator 150 , a power module interface 114 , and a power module 168 for controlling power distribution within the device 101 . In addition, within the functional blocks shown in FIG. 1 , the device provides a three-band equalizer, overload detection, sound level meter, and hearing safety monitor as described in detail further herein.
[0035] Turning to FIG. 2 , a simplified functional block diagram is provided of the device of FIG. 1 connected to an audio source 212 and earphones 216 . As in FIG. 1 , it should be appreciated that the interconnecting lines in FIG. 2 can be realized by any number of electrically conductive or other communication signal paths such as, but not limited to, electrically conductive wires.
[0036] Moreover, the audio source 212 can be any conventional device having an audio output. For instance, but not necessarily, the audio source 212 can be a portable media player such as the iPod manufactured by Apple Inc. of Cupertino, Calif., which can play MP3, AAC/M4A, Protected AAC, AIFF, WAV, Audible audiobook files.
[0037] Preferably, but not necessarily, the audio output of the audio source 212 is a conventional earphone jack 218 wherein one end of an interconnect cable 214 is plugged into the earphone jack of the audio source and the other end of the cable is plugged into the input jack 12 of the audio processor 101 .
[0038] The earphones 216 can be conventional in design. For instance, but not necessary, the earphones can be manufactured by one or more companies such as Etymotic Research under the model designation ER-4S, ER-4P, and ER-6i having a sensitivity of 108 dB/V, 120 dB/V, and 125 dB/V at 1 kHz, respectively. Further, but not necessary, the earphones can be manufactured by Shure under the model designation E2C, E3C, E4C, E5C, and E500 having a sensitivity of 123 dB/V, 129 dB/V, 124 dB/V, 132 dB/V at 1 kHz, respectively. Moreover, but not necessarily, the earphones can also be manufactured by Ultimate Ears under the model designation Super.fi3 studio, Super.fi5 Pro, and Super.fi5 EB having a sensitivity of 134 dB/V, 136 dB/V, and 136 dB/V at 1 kHz, respectively.
[0039] Turning to FIG. 3 , a plan view is provided of an embodiment of a digital audio processor device 301 incorporating the functionality of FIG. 1 . The device 301 includes an outer housing 320 constructed of a generally rigid plastic, metal, or metal alloy. The housing 320 also includes a select switch 315 and two buttons 312 , 314 as part of the user interface controls 114 of FIG. 1 . In an embodiment, button 312 can be used to turn off and on device 301 , enable the audio input 12 , and also select audio functions of the device as described in detail further herein. Further, button 314 can be used to turn on and off device 301 , enable the internal microphone 110 ( FIG. 1 ), and also select audio functions of the device as described in detail further herein. Either or both the audio input 12 and microphone 110 can be selected at any time. However, if neither input is selected, then the device 301 will turn off.
[0040] In an embodiment, buttons 312 and 314 are constructed of a generally clear rigid plastic wherein light emitting diodes are mounted in proximity behind the buttons. Preferably, but not necessarily, a blue light emitting diode 306 is mounted in proximity behind button 312 and a red light emitting diode 308 is mounted in proximity behind button 314 .
[0041] Switch 315 is a conventional switch for allowing the user to make selections as explained in detail further herein. In an embodiment, the switch 315 can be depressed in the direction of arrow 300 and rolled in the direction of arrows 302 and 304 .
[0042] Visible through the housing 320 of the device 301 is the display 162 comprising a conventional liquid crystal display. In an embodiment, the housing 320 includes a generally clear rigid plastic window 330 mounted over the display 162 to protect it.
[0043] Located towards the bottom 342 of the housing 320 and extending through the housing are a plurality of slits 316 . Mounted behind the slits 316 is a convention microphone 110 ( FIG. 1 ). Preferably, but not necessarily, the slits 316 are located in a circular indentation 346 formed in the housing 320 .
[0044] Also mounted about the indentation 346 in the housing 320 is a charge indicator 310 comprising a light emitting diode wherein the diode is controlled by regulator 150 ( FIG. 1 ). In an embodiment, the charge indicator is a red light emitting diode that will illuminate when the charge cycle for the battery 139 begins and will extinguish when the charge cycle is complete.
[0045] Turning to FIG. 4 , an elevation view is provided of the bottom 342 of the housing 320 of the processor device 301 . Preferably, but not necessarily, the bottom 342 includes the inputs and outputs associated with the device 301 . In particular, the bottom 342 of the device 301 includes the audio signal input 12 , the audio signal output 14 , and the digital interface connection 132 . As indicated previously, the audio signal input 12 can be, for example, a stereo jack for the connection of a stereo audio signal. The audio signal output 14 can be, for example, a stereo jack for the connection of earphones. In an embodiment, the digital interface connection 132 can provide for digital communication with an audio player, computer, or other digital device. This connection can, for example, be a Universal Serial Bus (USB) connection.
[0046] Turning back to FIG. 1 , in operation a user enters into the digital audio processor device 101 a sensitivity level that represents the acoustic sensitivity of the earphones 216 ( FIG. 2 ) the user will attach to the device. This setting is entered into the user interface controls 114 which is then entered into the flash memory of the microcontroller 128 . A signal source 212 ( FIG. 2 ), or optionally a stereo signal source, such as the earphone output 218 ( FIG. 2 ) of a music player for example, is operatively connected to an audio processing device 101 . As indicated previously, the signal source applied to the audio processing device 101 can be music, speech, or any other audio source that can be applied to an earphone. The analog-to-digital converter 115 receives the analog audio signal and converts it to a digital signal, which is then sent to the digital audio processor 140 . The digital audio processor 140 queries the microcontroller 128 for the previously stored earphone sensitivity setting which is contained within the flash memory stage of the microcontroller 128 . The digital audio processor 140 calculates the level being applied by the earphones by measuring the rms level of the audio stream and adding in a correction factor based on the stored earphone sensitivity level. This measurement is done while the audio stream passes through the digital audio processor 140 uninterrupted, allowing the user to ascertain the audio level while concurrently listening to the audio source(s). The digital audio processor 140 used within the device 101 passes the measured level information to the microcontroller 128 which then drives the display 162 to provide a bar graph indication and/or numerical indication.
[0047] Referring again to FIG. 1 , as the digital audio processor 140 within the device 101 passes the audio level measurements to the microcontroller 128 , the audio level is sampled and averaged resulting in a time-weighted measurement. The result of this time-weighted measurement can be stored in the flash memory on the microcontroller 128 as it is calculated for later summation and/or provided to the user via the display 162 . When the time-weighted measurement exceeds a particular threshold, a warning or automatic gain reduction can be triggered by the microcontroller 128 .
[0048] As indicated previously, a typical use of the device as shown in FIG. 1 includes applying an input from an audio source to the input channels 100 and 102 , and attaching an earphone to the output channels 104 and 106 . The analog audio signal stream from the external audio source is digitized by the A/D converter 115 . The resulting digital stream is sent to the digital audio processor 140 where it is measured and selected processing functions are applied to the digital signal. For example, the signal can be filtered according to an equalization setting selected by the user, or a microphone input can be digitally added to the audio stream. Signal limiting, signal compression, frequency equalization, and digital delays and crossfeeds are also functions that can be processed by this stage, for example. Audio level information is passed from the digital audio processor 140 to the microcontroller 128 . The signal is then fed from the digital audio processor 140 to the digital-to-analog converter 154 . The digital-to-analog converter 154 transforms the digital audio stream into an analog audio signal to be fed to the output amplifier 170 . The output amplifier 170 provides any amplification required and drives the output 104 and 106 .
[0049] Continuing with FIG. 1 , in an embodiment, the audio input to the device 101 is preset to provide a gain of +6 dB that may be adjusted. Further, the microphone output can be processed through an A-weighting filter. When the microphone 110 is on and the audio channel 12 is off, the display 162 will show the sound level in the environment as measured by the microphone. The levels can be shown in dBA SPL (A-weighted sound pressure level in dB)
[0050] Turning to FIG. 3 , as previously indicated the device 301 includes the housing 320 , the display 162 , and the user controls 312 , 314 , and 315 . The user controls 312 and 314 are switches, in the form of buttons, which allow the user to selectively engage or disengage the audio and microphone inputs. Integrated within the user controls 312 and 314 are indicators 306 and 308 which visibly display the status of the controls. Indicators 306 and 308 can be, for example, light-emitting-diodes (LEDs) which can be seen through a transparent portion of the controls 312 and 314 . Another aspect of the present invention is the microphone 110 ( FIG. 1 ), which is contained within the housing 320 . Control 315 allows the user to navigate the user interface which is selectively shown on the display 162 . The user can actuate the control 315 in the down direction 304 to navigate in one direction through the user interface, in the up direction 302 to navigate in the other direction, or the user can press the control 315 inwards 300 towards the housing 320 in order to make a selection in the user interface. Accordingly, display 162 shows various menu selections and visual indicators, depending on the functions selected by the user and the status of the user controls 312 , 314 , and 315 .
[0051] In an embodiment, as shown in FIG. 3 , the main screen 612 presented on the display 162 depicts a battery condition indicator 614 , the audio level indicator 616 in dB SPL and a graphical display 618 of the audio level. The battery condition indicator 614 depicts the approximate amount of life in the battery 139 ( FIG. 1 ) wherein the unfilled area 620 of the indicator enlarges as the battery charge depletes.
[0052] The audio level indicator 616 indicates, with a number, the approximate audio level being reproduced by the earphones 216 . The number indicates the level of the audio from the audio input 12 and the microphone 110 , depending on which source(s) is active.
[0053] The graphical display 618 can be a bar graph that moves from left to right, indicating the listening level in dB SPL in 3 dB steps. In an embodiment, if the bar graph reaches the far right a “+” sign appears indicating that the output is at or near clipping.
[0054] As indicated previously, there are several user-adjustable settings in the device 301 . These can be accessed by pressing the menu select switch 315 directly inwards (i.e., in the direction of arrow 300 ). Once the menu is accessed, the user can scroll through the selections by rolling upward 302 or downward 304 on the select switch 315 . On the menu screens the setting can be changed using the audio button 312 and microphone button 314 on the front of the device. When the user is finished making changes to a setting, rolling upward or downward on the select switch 315 moves to the next setting. The settings are saved in the memory of the microcontroller 128 ( FIG. 1 ). The user can exit the settings menu by waiting a short time (e.g., three seconds) for the menu to automatically time out or by pushing in on the select switch 315 .
[0055] As indicated previously, the device 301 includes a three-band parametric equalizer that can be used to provide a customized frequency response. The adjustable bands include a low-frequency (bass), mid-frequency, and high-frequency (treble) setting. These filters can be adjusted as to frequency and level for each band.
[0056] Turning to FIG. 6 , the low gain setting in menu 640 allows the user to adjust the gain of the low frequency band of the equalizer. In an embodiment, it is adjustable from +9 to −9 dB in 1 dB steps. The low frequency setting in menu 642 allows the user to adjust the corner point of the low frequency filter. In an embodiment, the frequency options are 110 Hz, 220 Hz, and 345 Hz.
[0057] Turning to FIG. 7 , the mid gain setting in menu 740 allows the user to adjust the gain of the mid frequency band of the equalizer. In an embodiment, it is adjustable from +6 to −6 db in 3 dB steps. The mid frequency setting in menu 742 allows the user to adjust the mid point of the mid-frequency filter. In an embodiment, the frequency options are 2.0 kHz, 2.5 kHz, and 3.0 kHz.
[0058] Turning to FIG. 8 , the high gain feature in menu 840 allows the user to adjust the gain of the high frequency band of the equalizer. In an embodiment, it is adjustable from +9 to −9 dB in 1 dB steps. The high frequency setting in menu 842 allows the user to adjust the corner point of the high-frequency filter. In an embodiment, the frequency options are 2.8 kHz, 5.5 kHz, and 8.3 kHz.
[0059] Turning to FIG. 9 , the earphone sensitivity setting in menu 940 indicates the value that corresponds to the type of earphone the user is using with the device 301 . Desirably, the setting is adjusted by the user to match the sensitivity of the user's earphones.
[0060] Turning to FIG. 10 , the 3DX soundfield expansion mode provides an enhanced listening environment, simulating the environment of listening to music through a pair of stereo speakers. When in a typical listening environment, in front of a pair of stereo speakers, both ears will hear the sound from both speakers. However, with earphones a person loses this ability and only the signal coming from each earphone is heard in each corresponding ear. As such, earphones cause the normal “crossfeed” to be lost. The 3DX feature attempts to recreate the experience of listening to sounds as if the user is in front of a pair of speakers. This feature and its implementation are well known to those having skill in the art. Through menu 1040 , the user can enable and disable the feature.
[0061] Turning to FIG. 11 , a menu 1140 is provided wherein the voltage gain of the audio channel can be adjusted by the user from −20 dB to +20 dB. In an embodiment, the default setting is +6 dB.
[0062] Turning to FIG. 12 , a display setting menu is provided wherein the setting can be toggled by a user between selecting either level 1240 or time 1242 . When “level” is selected, the display 162 will show the sound level in the user's ear. When “time” is selected, the display 162 will shown an estimate of the length of time the user could listen at a sound level before risking hearing damage due to the intensity of the sound. In an embodiment, the time is indicated in minutes that it is relatively safe to listen at the given sound level for a 24 hour period based on the National Institute for Occupational Safety and Health (NIOSH) workplace limits.
[0063] Turning to FIG. 13 , a chart adapted from NIOSH 98-126, incorporated herein by reference, is depicted wherein the time indicated by the device 301 that it is safe to listen at a given sound level is derived therefrom. Accordingly, the device 301 provides the user with information to make safe choices about the level and the amount of time at which to listen to a given sound level. Preferably, once the user has set his or her earphone sensitivity in the device 301 , both the levels and time shown on the display are based on the levels being produced in the ears of the user. However, it is recognized that typically only an estimate can be provided of the sound level since earphones are manufactured within various tolerances levels determined by the manufacturer.
[0064] Turning to FIG. 5 , a partial cross sectional view of an earphone calibration system in accordance with the present invention is provided wherein an earphone is mounted to the device of FIG. 3 . The calibration system 501 includes a generally cylindrical earphone coupler 504 having a known inner volume 514 and known acoustic properties. The earphone coupler 504 which for example, can be removable or can be an integral part of the housing 320 of the digital audio processor 301 , is attached to the processor 301 via an annular sealing portion 512 which can or can not be compliant. This sealing member 512 can be made, for example, to snap into the recess 346 in the housing 320 of the digital audio processor 301 . With this system 501 , an earphone 216 can be actively calibrated using the integrated microphone 110 in the digital audio processor 301 . The earphone 216 with its compliant eartip 516 to be calibrated is proximately sealed into the open end 502 of the earphone coupler 504 . A wide-band audio chirp, frequency sweep, tone, or other known audio signal can be applied to the earphone 216 , via device output 14 ( FIG. 1 ), and the resultant audio output of the earphone measured by the microphone 110 . The digital audio processor device 301 receives the signal from the microphone 110 and can store the response in memory or use the response to calibrate the output 14 of the device 301 . As will be appreciated by those having ordinary skill in the art, this calibration system can also use an external microphone connected to the digital audio processor 301 via an external connection such as, but not limited to, an input for the external microphone.
[0065] In an alternative embodiment, headphone sensitivity can be determined using both the headphone and the sound level received by microphone 110 . In particular, in this embodiment, the user inserts an earphone into only one ear canal while the other ear canal remains unobstructed. Next, the audio processor 301 generates a sound level in the ear canal of the user, via the inserted earphone, wherein the sound level is based upon the electrical signals 124 ( FIG. 1 ) generated by the microphone 110 . As such, the user adjusts the volume control of the microphone until the perceived sound level in both ears match. Accordingly, as will be appreciated by those having ordinary skill in the art, the sensitivity of the earphone can be determined based on the electrical signals 124 generated by the microphone and the signal strength required to make the earphone sound level match the environmental sound level perceived by the user.
[0066] Turning to FIGS. 14 and 15 , a block diagrams are provided depicting the method wherein the sensitivity of earphones can be subjectively determined by a user. In block 1412 of FIG. 14 , the device 101 ( FIG. 1 ) is set in a calibration mode where P m represents an arbitrary sound pressure level to which the integral microphone and a user's uncovered ear are exposed. In block 1414 , P e represents the reproduced sound pressure level at the user's other ear due to the combined effects of sound pressure level P m , the microphone sensitivity M s (in volts/sound pressure level), a reference gain setting Gm, an adjustable gain setting G s , the output amplifier gain G a , and the sensitivity of the user's earphones S e (in sound pressure level/volts). In block 1416 , if the user adjusts the calibration gain control G s such that equal sound pressure levels are perceived in each ear, P e is then equal to P m . Under these conditions, the sensitivity of the earphones are a function of the microphone sensitivity and the identified gain settings. In block 1418 , by noting these values the sound level or exposure time display can be calibrated to read the correct sound pressure level or safe exposure time for a given voltage applied to the user's earphones. Accordingly, in block 1420 , once calibrated using this procedure, the sound pressure level or safe listening time associated with an audio source 212 ( FIG. 2 ), microphone 110 ( FIG. 1 ), or any combination of the two can be displayed on display 162 ( FIG. 1 ).
[0067] Turning back to FIG. 2 , in an embodiment, the audio signal source 212 and the audio processing device 101 can be attached to each other using conventional hook and loop fasteners such as, but not limited to, VELCRO. Alternatively, the functionality of the audio signal source 212 and the audio processing device 101 can be combined into a single device 220 .
[0068] It should be emphasized that the above-described embodiments of the present invention, particularly, any “preferred” embodiments, are possible examples of implementations merely set forth for a clear understanding of the principles for the invention. Many variations and modifications may be made to the above-described embodiment(s) of the invention without substantially departing from the spirit and principles of the invention. All such modifications are intended to be included herein within the scope of this disclosure and the present invention, and protected by the following claims. | An audio processor device and method is disclosed which measures and provides information relating to the audio level being applied to the ear of a user. The processor device uses a preset or calibrated sensitivity of the applied earphones in combination with an analysis of the audio stream to provide sound-pressure-level or time-weighted exposure information to the user or limit the output when preset levels have been achieved. Also disclosed is the use of microphones, internal or external, to combine an additional audio stream, typically the ambient environment, into the main audio channel. | 40,117 |
This application is a continuation of prior application Ser. No. 09/491,175 filed Jan. 25, 2000, and claims the benefit of priority under 35 U.S.C. §119(e) from U.S. Provisional Application No. 60/117,097, filed Jan. 25, 1999 and Provisional Application No. 60/161,565 filed Oct. 26, 1999.
BACKGROUND OF THE INVENTION
Oximetry is the measurement of the oxygen level status of blood. Early detection of low blood oxygen level is critical in the medical field, for example in critical care and surgical applications, because an insufficient supply of oxygen can result in brain damage and death in a matter -of minutes. Pulse oximetry is a widely accepted noninvasive procedure for measuring the oxygen saturation level of arterial blood, an indicator of oxygen supply. A pulse oximetry system consists of a sensor applied to a patient, a pulse oximeter, and a patient cable connecting the sensor and the pulse oximeter.
The pulse oximeter may be a standalone device or may be incorporated as a module or built-in portion of a multiparameter patient monitoring system, which also provides measurements such as blood pressure, respiratory rate and EKG. A pulse oximeter typically provides a numerical readout of the patient's oxygen saturation, a numerical readout of pulse rate, and an audible indicator or “beep” that occurs in response to each pulse. In addition, the pulse oximeter may display the patient's plethysmograph, which provides a visual display of the patient's pulse contour and pulse rate.
SUMMARY OF THE INVENTION
FIG. 1 illustrates a prior art pulse oximeter 100 and associated sensor 110 . Conventionally, a pulse oximetry sensor 110 has LED emitters 112 , typically one at a red wavelength and one at an infrared wavelength, and a photodiode detector 114 . The sensor 110 is typically attached to an adult patient's finger or an infant patient's foot. For a finger, the sensor 110 is configured so that the emitters 112 project light through the fingernail and through the blood vessels and capillaries underneath. The LED emitters 112 are activated by drive signals 122 from the pulse oximeter 100 . The detector 114 is positioned at the fingertip opposite the fingernail so as to detect the LED emitted light as it emerges from the finger tissues. The photodiode generated signal 124 is relayed by a cable to the pulse oximeter 100 .
The pulse oximeter 100 determines oxygen saturation (SpO 2 ) by computing the differential absorption by arterial blood of the two wavelengths emitted by the sensor 110 . The pulse oximeter 100 contains a sensor interface 120 , an SpO 2 processor 130 , an instrument manager 140 , a display 150 , an audible indicator (tone generator) 160 and a keypad 170 . The sensor interface 120 provides LED drive current 122 which alternately activates the sensor red and IR LED emitters 112 . The sensor interface 120 also has input circuitry for amplification and filtering of the signal 124 generated by the photodiode detector 114 , which corresponds to the red and infrared light energy attenuated from transmission through the patient tissue site. The SpO 2 processor 130 calculates a ratio of detected red and infrared intensities, and an arterial oxygen saturation value is empirically determined based on that ratio. The instrument manager 140 provides hardware and software interfaces for managing the display 150 , audible indicator 160 and keypad 170 . The display 150 shows the computed oxygen status, as described above. The audible indicator 160 provides the pulse beep as well as alarms indicating desaturation events. The keypad 170 provides a user interface for such things as alarm thresholds, alarm enablement, and display options.
Computation of SpO 2 relies on the differential light absorption of oxygenated hemoglobin, HbO 2 , and deoxygenated hemoglobin, Hb, to determine their respective concentrations in the arterial blood. Specifically, pulse oximetry measurements are made at red and IR wavelengths chosen such that deoxygenated hemoglobin absorbs more red light than oxygenated hemoglobin, and, conversely, oxygenated hemoglobin absorbs more infrared light than deoxygenated hemoglobin, for example 660 nm (red) and 905 nm (IR).
To distinguish between tissue absorption at the two wavelengths, the red and IR emitters 112 are provided drive current 122 so that only one is emitting light at a given time. For example, the emitters 112 may be cycled on and off alternately, in sequence, with each only active for a quarter cycle and with a quarter cycle separating the active times. This allows for separation of red and infrared signals and removal of ambient light levels by downstream signal processing. Because only a single detector 114 is used, it responds to both the red and infrared emitted light and generates a time-division-multiplexed (“modulated”) output signal 124 . This modulated signal 124 is coupled to the input of the sensor interface 120 .
In addition to the differential absorption of hemoglobin derivatives, pulse oximetry relies on the pulsatile nature of arterial blood to differentiate hemoglobin absorption from absorption of other constituents in the surrounding tissues. Light absorption between systole and diastole varies due to the blood volume change from the inflow and outflow of arterial blood at a peripheral tissue site. This tissue site might also comprise skin, muscle, bone, venous blood, fat, pigment, etc., each of which absorbs light. It is assumed that the background absorption due to these surrounding tissues is invariant and can be ignored. Thus, blood oxygen saturation measurements are based upon a ratio of the time-varying or AC portion of the detected red and infrared signals with respect to the time-invariant or DC portion:
RD/IR =(Red Ac /Red DC )/( IR AC /IR DC )
The desired SpO 2 measurement is then computed from this ratio. The relationship between RD/IR and SpO 2 is most accurately determined by statistical regression of experimental measurements obtained from human volunteers and calibrated measurements of oxygen saturation. In a pulse oximeter device, this empirical relationship can be stored as a “calibration curve” in a read-only memory (ROM) look-up table so that SpO 2 can be directly read-out of the memory in response to input RD/IR measurements.
Pulse oximetry is the standard-of-care in various hospital and emergency treatment environments. Demand has lead to pulse oximeters and sensors produced by a variety of manufacturers. Unfortunately, there is no standard for either performance by, or compatibility between, pulse oximeters or sensors. As a result, sensors made by one manufacturer are unlikely to work with pulse oximeters made by another manufacturer. Further, while conventional pulse oximeters and sensors are incapable of taking measurements on patients with poor peripheral circulation and are partially or fully disabled by motion artifact, advanced pulse oximeters and sensors manufactured by the assignee of the present invention are functional under these conditions. This presents a dilemma to hospitals and other caregivers wishing to upgrade their patient oxygenation monitoring capabilities. They are faced with either replacing all of their conventional pulse oximeters, including multiparameter patient monitoring systems, or working with potentially incompatible sensors and inferior pulse oximeters manufactured by various vendors for the pulse oximetry equipment in use oat the installation.
Hospitals and other caregivers are also plagued by the difficulty of monitoring patients as they are transported from one setting to another. For example, a patient transported by ambulance to a hospital emergency room will likely be unmonitored during the transition from ambulance to the ER and require the removal and replacement of incompatible sensors in the ER. A similar problem is faced within a hospital as a patient is moved between surgery, ICU and recovery settings. Incompatibility and transport problems are exacerbated by the prevalence of expensive and non-portable multiparameter patient monitoring systems having pulse oximetry modules as one measurement parameter.
The Universal/Upgrading Pulse Oximeter (UPO) according to the present invention is focused on solving these performance, incompatibility and transport problems. The UPO provides a transportable pulse oximeter that can stay with and continuously monitor the patient as they are transported from setting to setting. Further, the UPO provides a synthesized output that drives the sensor input of other pulse oximeters. This allows the UPO to function as a universal interface that matches incompatible sensors with other pulse oximeter instruments. Further, the UPO acts as an upgrade to existing pulse oximeters that are adversely affected by low tissue perfusion and motion artifact. Likewise, the UPO can drive a SpO 2 sensor input of multiparameter patient monitoring systems, allowing the UPO to integrate into the associated multiparameter displays, patient record keeping systems and alarm management functions.
One aspect of the present invention is a measurement apparatus comprising a sensor, a first pulse oximeter and a waveform generator. The sensor has at least one emitter and an associated detector configured to attach to a tissue site. The detector provides an intensity signal responsive to the oxygen content of arterial blood at the tissue site. The first pulse oximeter is in communication with the detector and computes an oxygen saturation measurement based on the intensity signal. The waveform generator is in communication with the first pulse oximeter and provides a waveform based on the oxygen saturation measurement. A second pulse oximeter is in communication with the waveform generator and displays an oxygen saturation value based on the waveform. The waveform is synthesized so that the oxygen saturation value is generally equivalent to the oxygen saturation measurement.
In another aspect of the present invention, a measurement apparatus comprises a first sensor port connectable to a sensor, an upgrade port, a signal processor and a waveform generator. The upgrade port is connectable to a second sensor port of a physiological monitoring apparatus. The signal processor is configured to compute a physiological measurement based on a signal input to the first sensor port. The waveform generator produces a waveform based on the physiological measurement, and the waveform is available at the upgrade port. The waveform is adjustable so that the physiological monitoring apparatus displays a value generally equivalent to the physiological measurement when the upgrade port is attached to the second sensor port.
Yet another aspect of the present invention is a measurement method comprising the steps of sensing an intensity signal responsive to the oxygen content of arterial blood at a tissue site and computing an oxygen saturation measurement based on the intensity signal. Other steps are generating a waveform based on the oxygen saturation measurement and providing the waveform to the sensor inputs of a pulse oximeter so that the pulse oximeter displays an oxygen saturation value generally equivalent to the oxygen saturation measurement.
An additional aspect of the present invention is a measurement method comprising the steps of sensing a physiological signal, computing a physiological measurement based upon the signal, and synthesizing a waveform as a function of the physiological measurement. A further step is outputting the waveform to a sensor input of a physiological monitoring apparatus. The synthesizing step is performed so that the measurement apparatus displays a value corresponding to the physiological measurement.
A further aspect of the present invention is a measurement apparatus comprising a first pulse oximeter for making an oxygen saturation measurement and a pulse rate measurement based upon an intensity signal derived from a tissue site. Also included is a waveform generation means for creating a signal based upon the oxygen saturation measurement and the pulse rate measurement. In addition, there is a communication means for transmitting the signal to a second pulse oximeter.
Another aspect of the present invention is a measurement apparatus comprising a portable portion having a sensor port, a processor, a display, and a docking connector. The sensor port is configured to receive an intensity signal responsive to the oxygen content of arterial blood at a tissue site. The processor is programmed to compute an oxygen saturation value based upon the intensity signal and to output the value to the display. A docking station has a portable connector and is configured to accommodate the portable so that the docking connector mates with the portable connector. This provides electrical connectivity between the docking station and the portable. The portable has an undocked position separate from the docking station in which the portable functions as a handheld pulse oximeter. The portable also has a docked position at least partially retained within the docking station in which the combination of the portable and the docking station has at least one additional function compared with the portable in the undocked position.
A further aspect of the present invention is a measurement apparatus configured to function in both a first spatial orientation and a second spatial orientation. The apparatus comprises a sensor port configured to receive a signal responsive to a physiological state. The apparatus also has a tilt sensor providing an output responsive to gravity. In addition, there is a processor in communication with the sensor port and the tilt sensor output. The processor is programmed to compute a physiological measurement value based upon the signal and to determine whether the measurement apparatus is in the first orientation or the second orientation based upon the tilt sensor output. A display has a first mode and a second mode and is driven by the processor. The display shows the measurement value in the first mode when the apparatus is in the first orientation and shows the measurement value in the second mode when the apparatus is in the second orientation.
Another aspect of the present invention is a measurement method comprising the steps of sensing a signal responsive to a physiological state and computing physiological measurement based on the signal. Additional steps are determining the spatial orientation of a tilt sensor and displaying the physiological measurement in a mode that is based upon the determining step.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a block diagram of a prior art pulse oximeter,
FIG. 2 is a diagram illustrating a patient monitoring system incorporating a universal/upgrading pulse oximeter (UPO) according to the present invention;
FIG. 3 is top level block diagram of a UPO embodiment;
FIG. 4 is a detailed block diagram of the waveform generator portion of the UPO embodiment shown in FIG. 3;
FIG. 5 is an illustration of a handheld embodiment of the UPO;
FIG. 6 is a top level block diagram of another UPO embodiment incorporating a portable pulse oximeter and a docking station;
FIG. 7 is a detailed block diagram of the portable pulse oximeter portion of FIG. 6;
FIG. 8A is an illustration of the portable pulse oximeter user interface, including a keyboard and display;
FIGS. 8B-C are illustrations of the portable pulse oximeter display showing portrait and landscape modes, respectively;
FIG. 9 is a detailed block diagram of the docking station portion of FIG. 6;
FIG. 10 is a schematic of the interface cable portion of FIG. 6;
FIG. 11A is a front view of an embodiment of a portable pulse oximeter,
FIG. 11B is a back view of a portable pulse oximeter;
FIG. 12A is a front view of an embodiment of a docking station;
FIG. 12B is a back view of a docking station;
FIG. 13 is a front view of a portable docked to a docking station; and
FIG. 14 is a block-diagram of one embodiment of a local area network interface for a docking station.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 2 depicts the use of a Universal/Upgrading Pulse Oximeter (“UPO”) 210 to perform patient monitoring. A pulse oximetry sensor 110 is attached to a patient (not illustrated) and provides the UPO 210 with a modulated red and IR photo-plethysmograph signal through a patient cable 220 . The UPO 210 computes the patient's oxygen saturation and pulse rate from the sensor signal and, optionally, displays the patient's oxygen status. The UPO 210 may incorporate an internal power source 212 , such as common alkaline batteries or a rechargeable power source. The UPO 210 may also utilize an external power source 214 , such as standard 110V AC coupled with an external step-down transformer and an internal or external AC-to-DC converter.
In addition to providing pulse oximetry measurements, the UPO 210 also separately generates a signal, which is received by a pulse oximeter 268 external to the UPO 210 . This signal is synthesized from the saturation calculated by the UPO 210 such that the external pulse oximeter 268 calculates the equivalent saturation and pulse rate as computed by the UPO 210 . The external pulse oximeter 268 receiving the UPO signal may be a multiparameter patient monitoring system (MPMS) 260 incorporating a pulse oximeter module 268 , a standalone pulse oximeter instrument, or any other host instrument capable of measuring SpO 2 . The MPMS 260 depicted in FIG. 2 has a rack 262 containing a number of modules for monitoring such patient parameters as blood pressure, EKG, respiratory gas, and SpO 2 . The measurements made by these various modules are shown on a multiparameter display 264 , which is typically a video (CRT) device. The UPO 210 is connected to an existing MPMS 260 with a cable 230 , advantageously integrating the UPO oxygen status measurements with other MPMS measurements. This allows the UPO calculations to be shown on a unified display of important patient parameters, networked with other patient data, archived within electronic patient records and incorporated into alarm management, which are all MPMS functions convenient to the caregiver.
FIG. 3 depicts the major functions of the UPO 210 , including an internal pulse oximeter 310 , a waveform generator 320 , a power supply 330 and an optional display 340 . Attached to the UPO 210 is a sensor 110 and an external pulse oximeter 260 . The internal pulse oximeter 310 provides the sensor 110 with a drive signal 312 that alternately activates the sensor's red and IR LEDs, as is well-known in the art. A corresponding detector signal 314 is received by the internal pulse oximeter 310 . The internal pulse oximeter 310 computes oxygen saturation, pulse rate, and, in some embodiments, other physiological parameters such as pulse occurrence, plethysmograph features and measurement confidence. These parameters 318 are output to the waveform generator 320 . A portion of these parameters may also be used to generate display drive signals 316 so that patient status may be read from, for example, an LED or LCD display module 340 on the UPO.
The internal pulse oximeter 310 may be a conventional pulse oximeter or, for upgrading an external pulse oximeter 260 , it may be an advanced pulse oximeter capable of low perfusion and motion artifact performance not found in conventional pulse oximeters. An advanced pulse oximeter for use as an internal pulse oximeter 310 is described in U.S. Pat. No. 5,632,272 assigned to the assignee of the present invention and incorporated herein by reference. An advanced pulse oximetry sensor for use as the sensor 110 attached to the internal pulse oximeter 310 is described in U.S. Pat. No. 5,638,818 assigned to the assignee of the present invention and incorporated herein by reference. Further, a line of advanced Masimo SET® pulse oximeter OEM boards and sensors are available from the assignee-of the present invention.
The waveform generator 320 synthesizes a waveform, such as a triangular waveform having a sawtooth or symmetric triangle shape, that is output as a modulated signal 324 in response to an input drive signal 322 . The drive input 322 and modulation output 324 of the waveform generator 320 are connected to the sensor port 262 of the external pulse oximeter 260 . The synthesized waveform is generated in a manner such that the external pulse oximeter 260 computes and displays a saturation and a pulse rate value that is equivalent to that measured by the internal pulse oximeter 310 and sensor 110 . In the present embodiment, the waveforms for pulse oximetry are chosen to indicate to the external pulse oximeter 260 a perfusion level of 5%. The external pulse oximeter 260 , therefore, always receives a strong signal. In an alternative embodiment, the perfusion level of the waveforms synthesized for the external pulse oximeter can be set to indicate a perfusion level at or close to the perfusion level of the patient being monitored by the internal pulse oximeter 310 . As an alternative to the generated wavefor, a digital data output 326 , is connected to the data port 264 of the external pulse oximeter 260 . In this manner, saturation and pulse rate measurements and also samples of the unmodulated, synthesized waveform can be communicated directly to the external pulse oximeter 260 for display, bypassing the external pulse oximeter's signal processing functions. The measured plethysmograph waveform samples output from the internal pulse oximeter 310 also may be communicated through the digital data output 326 to the external pulse oximeter 260 .
It will be understood from the above discussion that the synthesized waveform is not physiological data from the patient being monitored by the internal pulse oximeter 310 , but is a waveform synthesized from predetermined stored waveform data to cause the external pulse oximeter 260 to calculate oxygen saturation and pulse rate equivalent to or generally equivalent (within clinical significance) to that calculated by the internal pulse oximeter 310 . The actual physiological waveform from the patient received by the detector is not provided to the external pulse oximeter 260 in the present embodiment. Indeed, the waveform provided to the external pulse oximeter will usually not resemble the plethysmographic waveform of physiological data from the patient being monitored by the internal pulse oximeter 260 .
The cable 230 (FIG. 2) attached between the waveform generator 320 and external pulse oximeter 260 provides a monitor ID 328 to the UPO, allowing identification of predetermined external pulse oximeter calibration curves. For example, this cable may incorporate an encoding device, such as a resistor, or a memory device, such as a PROM 1010 (FIG. 10) that is read by the waveform generator 320 . The encoding device provides a value that uniquely identifies a particular type of external pulse oximeter 260 having known calibration curve, LED drive and modulation signal characteristics. Although the calibration curves of the external pulse oximeter 260 are taken into account, the wavelengths of the actual sensor 110 , advantageously, are not required to correspond to the particular calibration curve indicated by the monitor ID 328 or otherwise assumed for the external pulse oximeter 260 . That is, the wavelength of the sensor 110 attached to the internal pulse oximeter 310 is not relevant or known to the external pulse oximeter 260 .
FIG. 4 illustrates one embodiment of the waveform generator portion 320 of the UPO 210 (FIG. 3 ). Although this embodiment is illustrated and described as hardware, one of ordinary skill will recognize that the functions of the waveform generator may be implemented in software or firmware or a combination of hardware, software and firmware. The waveform generator 320 performs waveform synthesis with a waveform look-up table (“LUT”) 410 , a waveform shaper 420 and a waveform splitter 430 . The waveform LUT 410 is advantageously a memory device, such as a ROM (read only memory) that contains samples of one or more waveform portions or segments containing a single waveform. These stored waveform segments may be as simple as a single period of a triangular waveform, having a sawtooth or symmetric triangle shape, or more complicated, such as a simulated plethysmographic pulse having various physiological features, for example rise time, fall time and dicrotic notch.
The waveform shaper 420 creates a continuous pulsed waveform from the waveform segments provided by the waveform LUT 410 . The waveform shaper 420 has a shape parameter input 422 and an event indicator input 424 that are buffered 470 from the parameters 318 output from the internal pulse oximeter 310 (FIG. 3 ). The shape parameter input 422 determines a particular waveform segment in the waveform LUT 410 . The chosen waveform segment is specified by the first address transmitted to the waveform LUT 410 on the address lines 426 . The selected waveform segment is sent to the waveform shaper 420 as a series of samples on the waveform data lines 412 .
The event indicator input 424 specifies the occurrence of pulses in the plethysmograph waveform processed by the internal pulse oximeter 310 (FIG. 3 ). For example, the event indicator may be a delta time from the occurrence of a previously detected falling pulse edge or this indicator could be a real time or near real time indicator of the pulse occurrence. The waveform shaper 420 accesses the waveform LUT 410 in a manner to create a corresponding delta time between pulses in the synthesized waveform output 428 . In one embodiment, the waveform shaper is clocked at a predetermined sample rate. From a known number of samples per stored waveform segment and the input delta time from the event indicator, the waveform shaper 420 determines the number of sequential addresses to skip between samples and accesses the waveform LUT 410 accordingly. This effectively “stretches” or “shrinks” the retrieved waveform segment so as to fit in the time between two consecutive pulses detected by the UPO.
The waveform splitter 430 creates a first waveform 432 corresponding to a first waveform (such a red wavelength) expected by the external pulse oximeter 260 (FIG. 3) and a second waveform (such as infrared) 434 expected by the external pulse oximeter 260 . The relative amplitudes of the first waveform 432 and second waveform 434 are adjusted to correspond to the ratio output 444 from a calibration curve LUT 440 . Thus, for every value of measured oxygen saturation at the sat input 442 , the calibration curve LUT 440 provides a corresponding ratio output 444 that results in the first waveform 432 and the second waveform 434 having an amplitude ratio that will be computed by the external pulse oximeter 260 (FIG. 3) as equivalent to the oxygen saturation measured by the internal pulse oximeter 310 (FIG. 3 ).
As described above, one particularly advantageous aspect of the UPO is that the operating wavelengths of the sensor 110 (FIG. 3) are not relevant to the operating wavelengths required by the external pulse oximeter 260 (FIG. 3 ), i.e. the operating wavelengths that correspond to the calibration curve or curves utilized by the external pulse oximeter. The calibration curve LUT 440 simply permits generation of a synthesized waveform as expected by the external oximeter 260 (FIG. 3) based on the calibration curve used by the external pulse oximeter 260 (FIG. 3 ). The calibration curve LUT 440 contains data about the known calibration curve of the external pulse oximeter 260 (FIG. 3 ), as specified by the monitor ID input 328 . In other words, the waveform actually synthesized is not a patient plethysmographic waveform. It is merely a stored waveform that will cause the external pulse oximeter to calculate the proper oxygen saturation valve and pulse rate values. Although this does not provide a patient plethysmograph on the external pulse oximeter for the clinician, the calculated values, which is what is actually sought, will be accurate.
A modulator 450 responds to an LED drive input 322 to generate a modulated waveform output 324 derived from the first waveform 432 and second waveform 434 . Also, a data communication interface 460 transmits as a digital data output 326 the data obtained from the sat 442 , pulse rate 462 and synthesized waveform 428 inputs.
FIG. 5 depicts a handheld UPO 500 embodiment. The handheld UPO 500 has keypad inputs 510 , an LCD display 520 , an external power supply input 530 , an output port 540 for connection to an external pulse oximeter and a sensor input 550 at the top edge (not visible). The display 520 shows the measured oxygen saturation 522 , the measured pulse rate 524 , a pulsating bar 526 synchronized with pulse rate or pulse events, and a confidence bar 528 indicating confidence in the measured values of saturation and pulse rate. Also shown are low battery 572 and alarm enabled 574 status indicators.
The handheld embodiment described in connection with FIG. 5 may also advantageously function in conjunction with a docking station that mechanically accepts, and electrically connects to, the handheld unit. The docking station may be co-located with a patient monitoring system and connected to a corresponding SpO 2 module sensor port, external power supply, printer and telemetry device, to name a few options. In this configuration, the handheld UPO may be removed from a first docking station at one location to accompany and continuously monitor a patient during transport to a second location. The handheld UPO can then be conveniently placed into a second docking station upon arrival at the second location, where the UPO measurements are displayed on the patient monitoring system at that location.
FIG. 6 shows a block diagram of a UPO embodiment, where the functions of the UPO 210 are split between a portable pulse oximeter 610 and a docking station 660 . The portable pulse oximeter 610 (“portable”) is a battery operated, fully functional, stand-alone pulse oximeter instrument. The portable 610 connects to a sensor 110 (FIG. 2) through a UPO patient cable 220 (FIG. 2) attached to a patient cable connector 618 . The portable 610 provides the sensor 110 with a drive signal 612 that alternately activates the sensor's red and IR LEDs, as is well-known in the art. The portable also receives a corresponding detector signal 614 from the sensor. The portable can also input a sensor ID on the drive signal line 612 , as described in U.S. Pat. No. 5,758,644 entitled Manual and Automatic Probe Calibration, assigned to the assignee of the present invention and incorporated herein by reference.
The portable 610 can be installed into the docking station 660 to expand its functionality. When installed, the portable 610 can receive power 662 from the docking station 660 if the docking station 660 is connected to external power 668 . Alternately, with no external power 668 to the docking, station 660 , the portable 610 can supply power 662 to the docking station 660 . The portable 610 communicates to the docking station with a bi-directional serial data line 664 . In particular, the portable 610 provides the docking station with SpO 2 , pulse rate and related parameters computed from the sensor detector signal 614 . When the portable 610 is installed, the docking station 660 may drive a host instrument 260 (FIG. 2) external to the portable 610 . Alternatively, the portable 610 and docking station 660 combination may function as a standalone pulse oximeter instrument, as described below with respect to FIG. 13 .
In one embodiment, the docking station 660 does not perform any action when the portable 610 is not docked. The user interface for the docking station 660 , i.e. keypad and display, is on the portable 610 . An indicator LED on the docking station 660 is lit when the portable is docked. The docking station 660 generates a detector signal output 674 to the host instrument 260 (FIG. 2) in response to LED drive signals 672 from the host instrument and SpO 2 values and related parameters received from the portable 610 . The docking station 660 also provides a serial data output 682 , a nurse call 684 and an analog output 688 .
An interface cable 690 connects the docking station 660 to the host instrument patient cable 230 (FIG. 2 ). The LED drive signals 672 and detector signal output 674 are communicated between the docking station 660 and the host instrument 260 (FIG. 2) via the interface cable 690 . The interface cable 690 provides a sync data output 692 to the docking station 660 , communicating sensor, host instrument (e.g. monitor ID 328 , FIG. 3) and calibration curve data. Advantageously, this data allows the docking station 660 to appear to a particular host instrument as a particular sensor providing patient measurements.
FIG. 7 provides further detail of the portable 610 . The portable components include a pulse oximeter processor 710 , a management processor 720 , a power supply 730 , a display 740 and a keypad 750 . The pulse oximeter processor 710 functions as an internal pulse oximeter, interfacing the portable to a sensor 110 (FIG. 2) and deriving SpO 2 , pulse rate, a plethysmograph and a pulse indicator. An advanced pulse oximeter for use as the pulse oximeter processor 710 is described in U.S. Pat. No. 5,632,272, referenced above. An advanced pulse oximetry sensor for use as the sensor 110 (FIG. 2) attached to the pulse oximeter processor 710 is described in U.S. Pat. No. 5,638,818, also referenced above. Further, a line of advanced Masimo SET® pulse oximeter OEM boards and sensors are available from the assignee of the present invention. In one embodiment, the pulse oximeter processor 710 is the Masimo SEr® MS-3L board or a low power MS-5 board.
The management processor 720 controls the various functions of the portable 610 , including asynchronous serial data communications 724 with the pulse oximeter processor 710 and synchronous serial communications 762 with the docking station 660 (FIG. 6 ). The physical and electrical connection to the docking station 660 (FIG. 6) is via a docking station connector 763 and the docking station interface 760 , respectively. The processor 720 utilizes a real-time clock 702 to keep the current date and time, which includes time and date information that is stored along with SpO 2 parameters to create trend data. The processor of the portable 610 and the docking station 660 (FIG. 6) can be from the same family to share common routines and minimize code development time.
The processor 720 also controls the user interface 800 (FIG. 8A) by transferring data 742 to the display 740 , including display updates and visual alarms, and by interpreting keystroke data 752 from the keypad 750 . The processor 720 generates various alarm signals, when required, via an enable signal 728 , which controls a speaker driver 770 . The speaker driver 770 actuates a speaker 772 , which provides audible indications such as, for example, alarms and pulse beeps. The processor 720 also monitors system status, which includes battery status 736 , indicating battery levels, and docked status 764 , indicating whether the portable 610 is connected to the docking station 660 (FIG. 6 ). When the portable 610 is docked and is on, the processor 720 also decides when to turn on or off docking station power 732 .
Advantageously, the caregiver can set (i.e. configure or program) the behavior of the portable display 740 and alarms when the docked portable 610 senses that an interface cable 690 has connected the docking station 660 to an external pulse oximeter, such as a multiparameter patient monitoring system. In one user setting, for example, the portable display 740 stops showing the SpO 2 811 (FIG. 8) and pulse rate 813 (FIG. 8) values when connected to an external pulse oximeter to avoid confusing the caregiver, who can read equivalent values on the patient monitoring system. The display 740 , however, continues to show the plethysmograph 815 (FIG. 8) and visual pulse indicator 817 (FIG. 8) waveforms. For one such user setting, the portable alarms remain active.
Another task of the processor 720 includes maintenance of a watchdog function. The watchdog 780 monitors processor status on the watchdog data input 782 and asserts the UP reset output 784 if a fault is detected. This resets the management processor 720 , and the fault is indicated with audible and visual alarms.
The portable 610 gets its power from batteries in the power supply 730 or from power 766 supplied from the docking station 660 (FIG. 6) via the docking station interface 760 . A power manager 790 monitors the on/off switch on the keypad 750 and turns-on the portable power accordingly. The power manager 790 turns off the portable on command by the processor 720 . DC/DC converters within the power supply 730 generate the required voltages 738 for operation of the portable 610 and docking station power 732 . The portable batteries can be either alkaline rechargeable batteries or another renewable power source. The batteries of the power supply 730 supply docking station power 732 when the docking station 660 (FIG. 6) is without external power. A battery charger within the docking station power supply provides charging current 768 to rechargeable batteries within the power supply 730 . The docking station power supply 990 (FIG. 9) monitors temperature 734 from a thermistor in the rechargeable battery pack, providing an indication of battery charge status.
A non-volatile memory 706 is connected to the management processor 720 via a high-speed bus 722 . In the present embodiment, the memory 706 is an erasable and field re-programmable device used to store boot data, manufacturing serial numbers, diagnostic failure history, adult SpO 2 and pulse rate alarm limits, neonate SpO 2 and pulse rate alarm limits, SpO 2 and pulse rate trend data, and program data. Other types of non-volatile memory are well known. The SpO 2 and pulse rate alarm limits, as well as SpO 2 related algorithm parameters, may be automatically selected based on the type of sensor 110 (FIG. 2 ), adult or neonate, connected to the portable 610 .
The LCD display 740 employs LEDs for a backlight to increase its contrast ratio and viewing distance when in a dark environment. The intensity of the backlight is determined by the power source for the portable 610 . When the portable 610 is powered by either a battery pack within its power supply 730 or a battery pack in the docking station power supply 990 (FIG. 9 ), the backlight intensity is at a minimum level. When the portable 610 is powered by external power 668 (FIG. 6 ), the backlight is at a higher intensity to increase viewing distance and angle. In one embodiment, button on the portable permits overriding these intensity settings, and provides. adjustment of the intensity. The backlight is controlled in two ways. Whenever any key is pressed, the backlight is illuminated for a fixed number of seconds and then turns off, except when the portable is docked and derives power from an external source. In that case, the backlight is normally on unless deactivated with a key on the portable 610 .
FIG. 8A illustrates the portable user interface 800 , which includes a display 740 and a keypad 750 . In one embodiment, the display 740 is a dot matrix LCD device having 160 pixels by 480 pixels. The display 740 can be shown in portrait mode, illustrated in FIG. 8B, or in landscape mode, illustrated in FIG. 8C. A tilt sensor 950 (FIG. 9) in the docking station 660 (FIG. 6) or a display mode key on the portable 610 (FIG. 6) determines portrait or landscape mode. The tilt sensor 950 (FIG. 9) can be a gravity-activated switch or other device responsive to orientation and can be alternatively located in the portable 610 (FIG. 6 ). In a particular embodiment, the tilt sensor 950 (FIG. 9) is a non-mercury tilt switch, part number CW 1300-1, available from Comus International, Nutley, N.J. (www.comus-intl.com). The tilt sensor 950 (FIG. 9) could also be a mercury tilt switch.
Examples of how the display area can be used to display SpO 2 811 , pulse rate 813 , a plethysmographic waveform 815 , a visual pulse indicator 817 and soft key icons 820 in portrait and landscape mode are shown in FIGS. 8B and 8C, respectively. The software program of the management processor 720 (FIG. 7) can be easily changed to modify the category, layout and size of the display information shown in FIGS. 8B-C. Other advantageous information for display is SpO 2 limits, alarm, alarm disabled, exception messages and battery status.
The keypad 750 includes soft keys 870 and fixed keys 880 . The fixed keys 880 each have a fixed function. The'soft keys 870 each have a function that is programmable and indicated by one of the soft key icons 820 located next to the soft keys 870 . That is, a particular one of the soft key icons 820 is in proximity to a particular one of the soft keys 870 and has a text or a shape that suggests the function of that particular one of the soft keys 870 . In one embodiment, the button portion of each key of the keypad 750 is constructed of florescent material so that the keys 870 , 880 are readily visible in the dark.
In one embodiment, the keypad 750 has one row of four soft keys 870 and one row of three fixed keys 880 . Other configurations are, of course, available, and specific arrangement is not significant. The functions of the three fixed keys 880 are power, alarm silence and light/contrast. The power function is an on/off toggle button. The alarm silence function and the light/contrast function have dual purposes depending on the duration of the key press. A momentary press of the key corresponding to the alarm silence function will disable the audible alarm for a fixed period of time. To disable the audible alarm indefinitely, the key corresponding to the alarm silence function is held down for a specified length of time. If the key corresponding to the alarm silence function is pressed while the audible alarm has been silenced, the audible alarm is reactivated. If the key corresponding to the light/contrast function is pressed momentarily, it is an on/off toggle button for the backlight. If the key corresponding to the light/contrast function is held down, the display contrast cycles through its possible values.
In this embodiment, the default functions of the four soft keys 870 are pulse beep up volume, pulse beep down volume, menu select, and display mode. These functions are indicated on the display by the up arrow, down arrow, “menu” and curved arrow soft key icons 820 , respectively. The up volume and down volume functions increase or decrease the audible sound or “beep” associated with each detected pulse. The display mode function rotates the display 740 through all four orthogonal orientations, including portrait mode (FIG. 8B) and landscape mode (FIG. 8 C), with each press of the corresponding key. The menu select function allows the functionality of the soft keys 870 to change from the default functions described above. Examples of additional soft key functions that can be selected using this menu feature are set SpO 2 high/low limit, set pulse rate high/low limit, set alarm volume levels, set display to show trend data, print trend data, erase trend data, set averaging time, set sensitivity mode, perform synchronization, perform rechargeable battery maintenance (deep discharge/recharge to remove battery memory), and display product version number.
FIG. 9 provides further details of the docking station 660 , which includes a docking station processor 910 , a non-volatile memory 920 , a waveform generator 930 , a PROM interface 940 , a tilt sensor 950 , a portable interface 970 and associated connector 972 , status indicators 982 , a serial data port 682 , a nurse call output 684 , an analog output 688 and a power supply 990 . In one embodiment, the docking station 660 is intended to be associated with a fixed (non-transportable) host instrument, such as a multiparameter patient monitoring instrument in a hospital emergency room. In a transportable embodiment, the docking station 660 is movable, and includes a battery pack within the power supply 990 .
The docking station processor 910 orchestrates the activity on the docking station 660 . The processor 910 provides the waveform generator 930 with parameters 932 as discussed above for FIGS. 3 and 4. The processor 910 also provides asynchronous serial data 912 for communications with external devices and synchronous serial data 971 for communications with the portable 610 (FIG. 6) in addition, the processor 910 determines system status including sync status 942 , tilt status 952 and power status 992 . The portable management processor 720 (FIG. 7) performs the watchdog function for the docking station processor 910 . The docking station processor 910 sends watchdog messages to the portable processor 720 (FIG. 7) as part of the synchronous serial data 972 to ensure the correct operation of the docking station processor 910 .
The docking station processor 910 accesses non-volatile memory 920 over a high-speed bus 922 . The non-volatile memory 920 is re-programmable and contains program data for the processor 910 including instrument communication protocols, synchronization information, a boot image, manufacturing history and diagnostic failure history.
The waveform generator 930 generates a synthesized waveform that a conventional pulse oximeter can process to calculate SpO 2 and pulse rate values or exception messages, as described above with respect to FIG. 4 . However, in the present embodiment, as explained above, the waveform generator output does not reflect a physiological waveform. It is merely a waveform constructed to cause the external pulse oximeter to calculate the correct saturation and pulse rate. In an alternative embodiment, physiological data could be provided to the external pulse oximeter, but the external pulse oximeter would generally not be able to calculate the proper saturation values, and the upgrading feature would be lost. The waveform generator 930 is enabled if an interface cable 690 (FIG. 6 ), described below with respect to FIG. 10, with valid synchronization information is connected. Otherwise, the power to the waveform generator 930 is disabled.
The status indicators 982 are a set of LEDs on the front of the docking station 660 used to indicate various conditions including external power (AC), portable docked, portable battery charging, docking station battery charging and alarm. The serial data port 682 is used to interface with either a computer, a serial port of conventional pulse oximeters or serial printers via a standard RS-232 DB-9 connector 962 . This port 682 can output trend memory, SpO 2 and pulse rate and support the system protocols of various manufacturers. The analog output 688 is used to interface with analog input chart recorders via a connector 964 and can output “real-time” or trend SpO 2 and pulse rate data. The nurse call output 684 from a connector 964 is activated when alarm limits are exceeded for a predetermined number of consecutive seconds. In another embodiment, data, including alarms, could be routed to any number of communications ports, and even over the Internet, to permit remote use of the upgrading pulse oximeter.
The PROM interface 940 accesses synchronization data 692 from the PROM 1010 (FIG. 10) in the interface cable 690 (FIGS. 6, 10 ) and provides synchronization status 942 to the docking station processor 910 . The portable interface 970 provides the interconnection to the portable 610 (FIG. 6) through the docking station interface 760 (FIG. 7 ).
As shown in FIG. 9, external power 668 is provided to the docking station 660 through a standard AC connector 968 and on/off switch 969 . When the docking station 660 has external power 668 , the power supply 990 charges the battery in the portable power supply 730 (FIG. 7) and the battery, if any, in the docking station power supply 990 . When the portable 610 (FIG. 6) is either removed or turned off, the docking station power 973 is removed and the docking station 660 is turned off, except for the battery charger portion of the power supply 990 . The docking station power 973 and, hence, the docking station 660 turn on whenever a docked portable 610 (FIG. 6) is turned on. The portable 610 (FIG. 6) supplies power for an embodiment of the docking station 660 without a battery when external power 668 is removed or fails.
FIG. 10 provides further detail regarding the interface cable 690 used to connect between the docking station 660 (FIG. 6) and the patient cable 230 (FIG. 2) of a host instrument 260 (FIG. 2 ). The interface cable 690 is configured to interface to a specific host instrument and to appear to the host instrument as a specific sensor. A PROM 1010 built into the interface cable 690 contains information identifying a sensor type, a specific host instrument, and the calibration curve of the specific host instrument. The PROM information can be read by the docking station 660 (FIG. 6) as synchronization data 692 . Advantageously, the synchronization data 692 allows the docking station 660 (FIG. 6) to generate a waveform to the host instrument that causes the host instrument-to display SpO 2 values equivalent to those calculated by the portable 610 (FIG. 6 ). The interface cable 690 includes an LED drive path 672 . In the embodiment shown in FIG. 10, the LED drive path 672 is configured for common anode LEDs and includes IR cathode, red cathode and common anode signals. The interface cable 690 also includes a detector drive path 674 , including detector anode and detector cathode signals.
A menu option on the portable 610 (FIG. 6) also allows synchronization information to be calculated in the field. With manual synchronization, the docking station 660 (FIG. 6) generates a waveform to the host instrument 260 (FIG. 2) and displays an expected SpO 2 value. The user enters the SpO 2 value displayed on the host instrument using the portable keypad 750 (FIG. 7 ). These steps are repeated until a predetermined number of data points are entered and the SpO 2 values displayed by the portable and the host instrument are consistent.
FIGS. 11A-B depict an embodiment of the portable 610 , as described above with respect to FIG. 6 . FIGS. 12A-B depict an embodiment of the docking station 660 , as described above with respect to FIG. 6 . FIG. 13 depicts an embodiment of the UPO 210 where the portable 610 is docked with the docking station 660 , also as described above with respect to FIG. 6 .
FIG. 11A depicts the portable front panel 1110 . The portable 610 has a patient cable connector 618 , as described above with respect to FIG. 6 . Advantageously, the connector 618 is rotatably mounted so as to minimize stress on an attached patient cable (not shown). In one embodiment, the connector 618 can freely swivel between a plane parallel to the front panel 1110 and a plane parallel to the side panel 1130 . In another embodiment, the connector 618 can swivel between, and be releasably retained in, three locked positions. A first locked position is as shown, where the connector is in a plane parallel to the front panel 1110 . A second locked position is where the connector 618 is in a plane parallel to the side panel 1130 . The connector 618 also has an intermediate locked position 45° between the first and the second locked positions. The connector 618 is placed in the first-locked position for attachment to the docking station 660 .
Shown in FIG. 11A, the portable front panel 1110 also has a speaker 772 , as described with respect to FIG. 7 . Further, the front panel 1110 has a row of soft keys 870 and fixed keys 880 , as described above with respect to FIG. 8 . In addition, the front panel 1110 has a finger actuated latch 1120 that locks onto a corresponding catch 1244 (FIG. 12A) in the docking station 660 , allowing the portable 610 to be releasably retained by the docking station 660 . An OEM label can be affixed to a recessed area 1112 on the front panel 1110 .
FIG. 11B depicts the portable back panel 1140 . The back panel 1140 has a socket 763 , a pole clamp mating surface 1160 , and a battery pack compartment 1170 . The socket 763 is configured to mate with a corresponding docking station plug 972 (FIG. 12 A). The socket 763 and plug 972 (FIG. 12A) provide the electrical connection interface between the portable 610 and the docking station 660 (FIG. 12 A). The socket 763 houses multiple spring contacts that compress against plated edge-connector portions of the docking station plug 972 (FIG. 12 A). A conventional pole clamp (not shown) may be removably attached to the mating surface 1160 . This conveniently allows the portable 610 to be held to various patient-side or bedside mounts for hands-free pulse oximetry monitoring. The portable power supply 730 (FIG. 7) is contained within the battery pack compartment 1170 . The compartment 1170 has a removable cover 1172 for protection, insertion and removal of the portable battery pack. Product labels, such as a serial number identifying a particular portable, can be affixed with the back panel indent 1142 .
FIG. 12A depicts the front side 1210 of the docking station 660 . The front side 1210 has a docking compartment 1220 , a pole clamp recess 1230 , pivots 1242 , a catch 1244 , a plug connector 972 and LED status indicators 982 . The docking compartment 1220 accepts and retains the portable 610 (FIGS. 11 A-B), as shown in FIG. 13 . When the portable 610 (FIGS. 11A-B) is docked in the compartment 1220 , the pole clamp recess 1230 accommodates a pole clamp (not shown) attached to the portable's pole clamp mating surface 1160 (FIG. 11 B), assuming the pole clamp is in its closed position. The portable 610 (FIGS. 11A-B) is retained in the compartment 1220 by pivots 1242 that fit into corresponding holes in the portable's side face 1130 and a catch 1244 that engages the portable's latch 1120 (FIG. 11 A). Thus, the portable 610 (FIGS. 11A-B) is docked by first attaching it at one end to the pivots 1242 , then rotating it about the pivots 1242 into the compartment 1220 , where it is latched in place on the catch 1244 . The portable 610 (FIGS. 11A-B) is undocked in reverse order, by first pressing the latch 1120 (FIG. 11 A), which releases the portable from the catch 1244 , rotating the portable 610 (FIGS. 11A-B) about the pivots 1242 out of the compartment 1220 and then removing it from the pivots 1242 . As the portable is rotated into the compartment, the docking station plug 972 inserts into the portable socket 763 (FIG. 11 B), providing the electrical interface between the portable 610 and the docking station 660 . The status indicators 982 are as described above with respect to FIG. 9 .
FIG. 12B depicts the back side 1260 of the docking station 660 . The back side 1260 has a serial (RS-232 or USB) connector 962 , an analog output and nurse call connector 964 , an upgrade port connector 966 , an AC power plug 968 , an on/off switch 969 and a ground lug 1162 . A handle 1180 is provided atone end and fan vents 1170 are provided at the opposite end. A pair of feet 1190 are visible near the back side 1260 . A corresponding pair of feet (not visible) are located near the front side 1210 (FIG. 12 A). The feet near the front side 1210 extend so as to tilt the front side 1210 (FIG. 12A) upward, making the display 740 (FIG. 13) of a docked portable 610 (FIG. 13) easier to read.
FIG. 13 illustrates both the portable 610 and the docking station 660 . The portable 610 and docking station 660 constitute three distinct pulse oximetry instruments. First, the portable 610 by itself, as depicted in FIGS. 11A-B, is a handheld pulse oximeter applicable to various patient monitoring tasks requiring battery power or significant mobility, such as ambulance and ER situations. Second, the portable 610 docked in the docking station 660 , as depicted in FIG. 13, is a standalone pulse oximeter applicable to a wide-range of typical patient monitoring situations from hospital room to the operating room. Third, the portable 610 docked and the upgrade port 966 (FIG. 12B) connected with an interface cable to the sensor port of a conventional pulse oximeter module 268 (FIG. 2) within a multiparameter patient monitoring instrument 260 (FIG. 2) or other conventional pulse oximeter, is a universal/upgrading pulse oximeter (UPO) instrument 210 , as described herein. Thus, the portable 610 and docking station 660 configuration of the UPO 210 advantageously provides a three-in-one pulse oximetry instrument functionality.
Another embodiment of the docking station 660 incorporates an input port that connects to a blood pressure sensor and an output port that connects to the blood pressure sensor port of a multiparameter patient monitoring system (MPMS). The docking station 660 incorporates a signal processor that computes a blood pressure measurement based upon an input from the blood pressure sensor. The docking station 660 also incorporates a waveform generator connected to the output port that produces a synthesized waveform based upon the computed measurement. The waveform generator output is adjustable so that the blood pressure value displayed on the MPMS is equivalent to the computed blood pressure measurement. Further, when the portable 610 is docked in the docking station 660 and the blood pressure sensor is connected to the input port, the portable displays a blood pressure value according to the computed blood pressure measurement. Thus, in this embodiment, the docking station 660 provides universal/upgrading capability for both blood pressure and SpO 2 .
Likewise, the docking station 660 can function as an universal/upgrading instrument for other vital sign measurements, such as respiratory rate, EKG or EEG. For this embodiment, the docking station 660 incorporates related sensor connectors and associated sensor signal processors and upgrade connectors to an MPMS or standalone instrument. In this manner, a variety of vital sign measurements can be incorporated into the docking station 660 , either individually or in combination, with or without SpO 2 as a measurement parameter, and with or without the portable 610 . In yet another embodiment, the docking station 660 can be configured as a simple SpO 2 upgrade box, incorporating a SpO 2 processor and patient cable connector for a SpO 2 sensor that functions with or without the portable 610 .
Unlike a conventional standalone pulse oximeter, the standalone configuration shown in FIG. 13 has a rotatable display 740 that allows the instrument to be operated in either a vertical or horizontal orientation. A tilt sensor 950 (FIG. 9) indicates when the bottom face 1310 is placed along a horizontal surface or is otherwise horizontally-oriented. In this horizontal orientation, the display 740 appears in landscape mode (FIG. 8 C). The tilt sensor 950 (FIG. 9) also indicates when the side face 1320 is placed along a horizontal surface or is otherwise horizontally oriented. In this vertical orientation, the display 740 appears in portrait mode (FIG. 8 B). A soft key 870 on the portable 610 can override the tilt sensor, allowing the display to be presented at any 90° orientation, i.e. portrait, landscape, “upside-down” portrait or “upside-down” landscape orientations. The handheld configuration (FIG. 11 A), can also present the display 740 at any 90° orientation using a soft key 870 . In the particular embodiment described above, however, the portable 610 does not have a tilt sensor and, hence, relies on a soft key 870 to change the orientation of the display when not docked.
FIG. 14 illustrates the docking station 660 incorporated within a local area network (LAN). The LAN shown is Ethernet-based 1460 , using a central LAN server 1420 .to interconnect various LAN clients 1430 and other system resources such as printers and storage (not shown). An Ethernet controller module 1410 is incorporated with the docking station 660 . The controller module 1410 can be incorporated within the docking station 660 housing or constructed as an external unit. In this manner, the UPO, according to the present invention, can communicate with other devices on the LAN or over the Internet 1490 .
The Ethernet controller module 1410 can be embedded with web server firmware, such as the Hewlett-Packard (HP) BFOOT-10501. The module 1410 has both a 10 Base-T Ethernet interface for connection to the Ethernet 1460 and a serial interface, such as RS-232 or USB, for connection to the docking station 660 . The module firmware incorporates HTTP and TCP/IP protocols for standard communications over the World Wide Web. The firmware also incorporates a micro web server that allows custom web pages to be served to remote clients over the Internet, for example. Custom C++ programming allows expanded capabilities such as data reduction, event detection and dynamic web page configuration.
As shown in FIG. 14, there are many applications for the docking station 660 to Ethernet interface. Multiple UPOs can be connected to a hospital's LAN, and a computer on the LAN could be utilized to upload pulse rate and saturation data from the various UPOs, displaying the results. Thus, this Ethernet interface could be used to implement a central pulse oximetry monitoring station within a hospital. Further, multiple UPOs from anywhere in the world can be monitored from a central location via the Internet. Each UPO is addressable as an individual web site and downloads web pages viewable on a standard browser, the web pages displaying oxygen saturation, pulse rate and related physiological measurements from the UPO. This feature allows a caregiver to monitor a patient regardless of where the patient or caregiver is located. For example a caregiver located at home in one city or at a particular hospital could download measurements from a patient located at home in a different city or at the same or a different hospital. Other applications include troubleshooting newly installed UPOs or uploading software patches or upgrades to UPOs via the Internet. In addition alarms could be forwarded to the URL of the clinician monitoring the patient.
The UPO may have other configurations besides the handheld unit described in connection with FIG. 5 or the portable 610 and docking station 660 combination described in connection with FIGS. 11-13. The UPO may be a module, with or without a display, that can be removably fastened to a patient via an arm strap, necklace or similar means. In a smaller embodiment, this UPO module may be integrated into a cable or connector used for attaching a sensor to a pulse oximeter. The UPO may also be a circuit card or module that can externally or internally plug into or mate with a standalone pulse oximeter or multiparameter patient monitoring system. Alternatively, the UPO may be configured as a simple standalone upgrade instrument.
Further, although a universal/upgrading apparatus and method have been mainly described in terms of a pulse oximetry measurement embodiment, the present invention is equally applicable to other physiological measurement parameters such as blood pressure, respiration rate, EEG and ECG, to name a few. In addition, a universal/upgrading instrument having a single physiological measurement parameter or a multiple measurement parameter capability and configured as a handheld, standalone, portable, docking station, module, plug-in, circuit card, to name a few, is also within the scope of the present invention.
The UPO has been disclosed in detail in connection with various embodiments of the present invention. These embodiments are disclosed by way of examples only and are not to limit the scope of the present invention, which is defined by the claims that follow. One of ordinary skill in the art will appreciate many variations and modifications within the scope of this invention. | A Universal/Upgrading Pulse Oximeter (UPO) comprises a portable unit and a docking station together providing three-instruments-in-one functionality for measuring oxygen saturation and related physiological parameters. The portable unit functions as a handheld pulse oximeter. The combination of the docked portable and the docking station functions as a standalone, high-performance pulse oximeter. The portable-docking station combination is also connectable to, and universally compatible with, pulse oximeters from various manufacturers through use of a waveform generator. The UPO provides a universal sensor to pulse oximeter interface and a pulse oximetry measurement capability that upgrades the performance of conventional instruments by increasing low perfusion performance and motion artifact immunity, for example. Universal compatibility combined with portability allows the UPO to be transported along with patients transferred between an ambulance and a hospital ER, or between various hospital sites, providing continuous patient monitoring in addition to plug-compatibility and functional upgrading for multiparameter patient monitoring systems.
The image on the portable display is rotatable, either manually when undocked or as a function of orientation. In one embodiment, the docking station has a web server and network interface that allows UPO data to be downloaded and viewed as web pages over a local area network or the Internet. | 66,136 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a divisional of U.S. application Ser. No. 13/053,352, filed Mar. 22, 2011, now allowed, which is a divisional of U.S. application Ser. No. 10/887,898, filed Jul. 12, 2004, now U.S. Pat. No. 7,916,167, which claims the benefit of a foreign priority application filed in Japan as Serial No. 2003-275185 on Jul. 16, 2003, all of which are incorporated by reference.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates to a display device having an image pickup function which can display an image and shoot an image of an object at the same time. More particularly, the invention relates to a two-way communication system which can shoot an image of a user as an object while displaying an image of the other party.
[0004] 2. Description of the Related Art
[0005] In recent years, with the advance in speed of telecommunication networks, what is called a two-way communication system such as a videophone system and a video conference has been developed, in which two parties can communicate while viewing an image of each other.
[0006] According to the two-way communication system, it is possible to shoot an image of an object (user, for example) and to display an image of the other party at the same time.
[0007] For example, an image-pickup display device having a special screen which turns to be transparent or opaque according to an incident angle of light, and an image pickup device and a projector display device each disposed in the rear of the screen is disclosed (see Patent Document 1 for example). According to such an image pickup display device, two parties can catch each other's eyes when their images are projected by the projector display device which is disposed in the opaque direction of the screen.
[0008] However, according to the Patent Document 1, it requires a special screen as well as an image pickup device and a projector display device, leading to a large and heavyweight device.
[0009] Therefore, such a device cannot be applied to a portable electronic device.
[0010] In addition, an image pickup display device having multiple small semi-transmitting mirrors each slanted slightly is disclosed (see Patent Document 2 for example). Alternatively, an image pickup display device having multiple total reflection mirrors each slanted slightly in a spaced relationship so as to serve as semi-transmitting mirrors are disclosed (see Patent Document 3 for example). Such image pickup display devices are downsized by slantingly disposing semi-transmitting mirrors.
[0011] However, according to the image pickup display device in each of the above Patent Documents, semi-transmitting mirrors are disposed over an entire display screen (display plane) of the display device, and users look at the display screen (display plane) through the semi-transmitting mirrors. Therefore, quality of the display screen (display plane) which is viewed by a user is inevitably degraded.
[0012] [Patent Document 1] Japanese Patent Laid-Open No. Hei 6-030406
[0013] [Patent Document 2] Japanese Patent Laid-Open No. Hei 5-145912
[0014] [Patent Document 3] Japanese Patent Laid-Open No. Hei 5-292493
SUMMARY OF THE INVENTION
[0015] In view of the foregoing problems, the invention provides a compact and lightweight display device having an image pickup function and a two-way communication system which can shoot an image of an object (user, for example) and display an image at the same time without degrading image quality by disposing a semi-transmitting mirror or the like which blocks an image on the display screen (display plane).
[0016] In addition, the invention provides a compact and lightweight display device having an image pickup function and a two-way communication system which can display an image and shoot an image of a user as an object while securing an eye focus of the user who is viewing the displayed image.
[0017] The invention provides a display device having an image pickup function including a display panel capable of transmitting visible light at least and arranging display elements which can be controlled by voltage or current, and an image pickup device disposed around the display panel (upper side or lower side, or the like). The image pickup device according to the invention is input with data of an image of a user (hereinafter referred to as image data) or the like by a reflector, or equipped with a fiberscope bundling optical fibers.
[0018] It is also possible to input image data condensed by an optical system such as a lens to the image pick up device through reflection by a reflector. Alternatively, image data reflected by a reflector can be input to the image pickup device after being condensed by an optical system or the like. By disposing the reflector or the lens in this manner, the position of the image pickup device and in particular, a direction of the lens of the image pickup device can be controlled.
[0019] According to the invention, the image pickup device can be disposed around the display panel by using a reflector as well as an optical system typified by a lens. Therefore, further downsizing of the device can be achieved as compared to the structure in which the image pickup device is disposed in the rear (on the back) of the display panel.
[0020] As a reflector, a structure of forming a highly reflective film over a part of a substrate formed with depressions and projections in the display panel can be used. By forming such a reflector over the substrate of the display panel, the device can be further downsized. Note that the reflector may be a small mirror or a semi-transmitting mirror, and they may be single or multiple.
[0021] The lens may have a function to condense image data. For example, a microlens can be used. In addition, a light emitting element or a liquid crystal element can be used as a display element.
[0022] The display panel is constructed so as to display various images including a still image or a moving image by controlling the luminance of each pixel so that a user can view the images.
[0023] As an embodiment of the display panel, there is the one having light emitting elements whose emission such as luminance or lighting period can be controlled by voltage or current. It is more preferable that the pixel is formed by using a light-emitting element which includes a pair of light-transmitting electrodes and a light-emitting material sandwiched between them. The light emitting material is preferably the one which generates electroluminescence which allows other relevant materials to be sandwiched between the pair of the electrodes additionally.
[0024] The light emitted from the pixel includes light within the visible light spectrum. The display panel may be formed either by arranging pixels of the same emission color, or by arranging pixels of the specified emission color in the specified area, what is called an area color display panel. Further, it may be formed by arranging pixels of a plurality of different emission colors so as to perform a multi-color display as well. Alternatively, it may be formed by arranging pixels of white emission. It is also possible to form the display panel so that a user can recognize the emission of the pixels through a colored layer (color filter or a color conversion layer).
[0025] It is preferable that a laminate of the pair of the electrodes and the light-emitting material sandwiched between them as the components constituting the light-emitting element are formed by using light-transmitting materials or formed to be thin enough to maintain light transmissivity. A display panel which is fabricated by using a pair of light-transmitting electrodes in this manner and emits light from light emitting elements to the both screen sides is hereinafter referred to as a dual emission display panel.
[0026] For example, as a material to form the pair of the electrodes, a light-transmitting conductive film material including indium oxide, zinc oxide or tin oxide (ITO, ITSO, IZO or ZnO), aluminium including alkali metal or alkaline earth metal, silver, other metal materials or a metal material including alkali metal or alkaline earth metal is used. The pair of the electrodes are formed by using the above material. In the case of using a non light-transmitting material for the pair of the electrodes, they are preferably formed to be thin enough to transmit visible light (100 nm or less, or more preferably, 20 to 50 nm).
[0027] According to the invention, by forming one of the pair of electrodes constituting the light-emitting element by using a light-transmitting conductive film material and the other electrode by using the aforementioned metal material so as to control the film thickness of each electrode, the ratio of light emitted from each electrode to outside can be controlled to be different. That is, the electrode formed by using the light-transmitting conductive film material can emit light at a higher luminance than the other electrode formed by using the metal material.
[0028] According to another embodiment of the display panel, a display panel having liquid crystal elements (liquid crystal panel) whose molecular arrangement can be controlled by voltage can be provided, in which image display is controlled by light from a light source.
[0029] In addition, when using liquid crystal elements and using a non-light transmitting electrode, the display panel can have light transmissivity by forming an opening thereon.
[0030] According to the invention, the display device having an image pickup function can be fabricated in thinner size and lighter weight by forming light emitting elements or liquid crystal elements in the pixels over a flat substrate.
[0031] The image pickup device can shoot an image of an object through the display panel. That is, the image pickup device is disposed so as to shoot an image of the object by receiving the light that has passed through the display panel or through both the display panel and the substrate mounting the display panel.
[0032] The image pickup device has a solid-state image pickup element. Specifically, it is desirable that the image pickup device has a camera (image pickup device) including a light-receiving portion formed by using an optical sensor of a CCD (Charge Coupled Device) type or a CMOS (Complementary MOS) type.
[0033] By using the display device having an image pickup function of the invention, the two-way communication system can be provided that two parties can communicate with each other through wire transmission or radio transmission while viewing an image of each other on the display screen (display plane). In addition, according to the two-way communication system of the invention, at least one party is required to have the display device having an image pickup function which can shoot an image of himself as an object while displaying an image of the other party on the display panel. Similarly, in light of the other party, he can view an image of his interlocutor (user) on the display panel while shooting an image of himself.
[0034] In addition, the display panel can display an image of the other party, an image of the user himself, text, figures, and graphic symbols. Furthermore, in two-way communication system by two people or more, an image of the user can be displayed on the display panel in addition to the image of the other side.
[0035] According to the invention, by forming a light-transmitting display panel, light from pixels is emitted not only to one screen side which is viewed by a user but also to the opposite screen side. In that case, it is concerned that unnecessary light for an object might be input to the image pickup device. Then, it is more preferable that the image pickup device is provided with a correction device in which a deviation in color or luminance of an image is corrected corresponding to the light transmissivity of the display panel, and a correction device in which the glare caused by light reflecting on the display panel is eliminated from an image.
[0036] According to the invention, by implementing a quite lightweight and thin display panel and an image pickup device, a compact and lightweight display device having an image pickup function can be provided. In particular, since the image pickup device can be disposed around the display panel by using a reflector as well as an optical system typified by a lens, further downsizing of the device can be achieved as compared to the structure in which the image pickup device is disposed in the rear of the display panel.
[0037] According to the structure of the invention, it is possible to shoot an image of an object (user, for example) and to display an image of the other party to be viewed by the user on a display screen (display plane) at the same time without disposing anything which interrupts the user's view between the display panel and the user. In addition, as an image displayed on the display panel, multi-window display for each image of the user and the other party can be performed.
[0038] Furthermore, it is also possible for a user to shoot an image of himself while seeing the displayed image of himself on the display panel. At this time, a high-quality image can be shot while securing an eye focus of the user even if he is viewing his own image.
[0039] In addition, when shooting an image of the other party and displaying the image on the display panel of the other party, each of the shooter and the other party can view the same image while shooting. At this time, the normal display is performed on the display panel of the shooter side while the inversion display is performed on the display panel of the other party. That is, the image is displayed in a mirror projection manner on the display panel of the other party.
[0040] According to the invention, a display device having an image pickup function and a two-way communication system is provided, in which image shooting and image display can be performed at the same time while securing an eye focus of the user who is viewing the displayed image. In particular, when two parties use the similar display devices having an image pickup function of the invention, they can communicate while catching each other's eyes.
[0041] The two-way communication system of the invention includes a display panel which can shoot an image as described above, in which it is possible to display an image of the user on the display panel in addition to an image of the other party while shooting an image of the user as an object.
BRIEF DESCRIPTION OF THE DRAWINGS
[0042] FIGS. 1A and 1B each illustrates a portable phone of the invention.
[0043] FIGS. 1C and 1D each illustrates an enlarged view of the portable phone of the invention.
[0044] FIG. 2A illustrates a videophone system of the invention.
[0045] FIGS. 2B and 2C each illustrates an enlarged view of the videophone system of the invention.
[0046] FIGS. 3A and 3B each illustrates a videophone system of the invention.
[0047] FIGS. 4A to 4E each illustrates a cross-sectional diagram of a dual emission display panel.
[0048] FIGS. 5A and 5B each illustrates a cross-sectional diagram of a dual emission display panel.
[0049] FIGS. 6A illustrates image corrections of the invention.
[0050] FIG. 6B illustrates a flow chart for image corrections of the invention.
[0051] FIG. 7 illustrates a graph of a simulation result.
[0052] FIG. 8A illustrates a portable phone of the invention.
[0053] FIG. 8B illustrates a configuration diagram of a controller.
[0054] FIGS. 9A and 9B each illustrates a view of an electronic apparatus of the invention.
[0055] FIG. 10 illustrates a diagram of a portable phone of the invention.
[0056] FIG. 11A illustrates a cross-sectional diagram of a liquid crystal panel of the invention.
[0057] FIGS. 11B and 11C each illustrates a top plan view of the liquid crystal panel of the invention.
[0058] FIG. 12 illustrates a cross-sectional diagram of a liquid crystal display panel of the invention.
DETAILED DESCRIPTION OF THE INVENTION
[0059] Embodiment modes of the invention are described below with reference to the accompanying drawings. Note that like components are denoted by identical numerals as of the first embodiment and will be explained in no more details
[0060] [Embodiment Mode 1]
[0061] Described in this embodiment mode is a portable phone having a dual emission display panel as an example of a display device having an image pickup function. Note that dual emission display panel herein defined is a display panel including a pair of light-transmitting electrodes, in which light from light emitting elements are emitted to both screen sides. It may simply be referred to as a dual emission panel.
[0062] FIG. 1A illustrates an overall view of a portable phone. FIG. 1B illustrates a cross-sectional view of a dual emission panel corresponding to a display panel. FIGS. 1C and 1D each illustrates an enlarged view of a display panel.
[0063] The portable phone shown in FIG. 1A includes a dual emission display panel 100 and a first housing 101 surrounding and sandwiching an edge of the dual emission panel 100 . The first housing 101 includes an audio output portion 102 , an antenna 104 or the like. A second housing 105 including an audio input portion 106 , an operating key 107 or the like is connected to the first housing 101 with a hinge 108 . An image pickup device 110 corresponding to an image pickup device is disposed at the bottom of the dual emission panel 100 .
[0064] As shown in FIG. 1B , the dual emission panel 100 includes first and second substrates 111 and 112 each having light transmissivity and an area having an EL layer (EL layer area) 113 sandwiched between them. Therefore, light is emitted in both directions of the substrates (as shown by arrows).
[0065] The first housing 101 can be formed thin since the dual emission panel 100 is quite thin. Therefore, in this embodiment mode, the image pickup device 110 is disposed not in the first housing 101 , but in the hinge 108 in a rotatable manner. At this time, a lens included in the image pickup device 110 is disposed so as to face either side of the dual emission panel 100 , the user side or the opposite side of the user. That is, the rotation angle of the image pickup device may be 180 to 250 degrees.
[0066] When carrying out two-way communication, the image pickup device 110 may be set so as to face the dual emission panel 100 . At this time, the lens of the image pickup device 110 cannot be recognized by a user. In addition, when shooting an image of the user as an object, the lens of the image pickup device 110 may be set to face the user side while it may be set to face the opposite side when shooting an image of people or things in the opposed side of the user.
[0067] Note that the image pickup device 110 may be set to face either the user side or the opposite side thereof even in carrying out two-way communication. In particular, when two-way communication is carried out with the image pickup device 110 facing the opposite side, a two-way communication can be carried out including a third party, in addition to the user and the other party, who is communicating directly with the user while viewing an image displayed on the dual emission panel. That means, by implementing the dual emission panel, two-way communication can be carried out including the third person while being recognized by the other two parties.
[0068] When the image pickup device 110 cannot be disposed in the first housing 101 owing to the thinner shape of the dual emission panel 100 , image data can be received by disposing the image pickup device 110 in the hinge 108 or in the second housing 105 as shown in this embodiment mode.
[0069] According to this embodiment mode, a thinner portable phone can be fabricated by disposing the image pickup device 110 not in the rear of the display panel 100 , but around the dual emission panel 100 , for example, at the bottom of the dual emission panel 100 as shown in FIG. 1B . Specifically, the first housing 101 can be formed thin by using the dual emission panel 100 and disposing the image pickup device 110 in the hinge 108 or the second housing 105 . Image data from outside is input to the image pickup device 110 after being reflected by a reflector or the like.
[0070] Note that the dual emission panel 100 may be either an active matrix type or a passive matrix type. In the case of the passive matrix display panel, higher light transmissivity can be obtained as compared to the active matrix display panel.
[0071] FIGS. 1C and 1D each illustrates an enlarged view of a dual emission panel with one mode of a specific reflector. Each of them shows a structure of the second substrate 112 formed with depressions and projections, on part of which a reflector is formed. Note that a region of the substrate for forming depressions and projections may correspond to a pixel portion at least.
[0072] Specific shapes of depressions and projections of the substrate are described now with reference to FIG. 1C . In the cross-sectional diagram, a length of an area having depressions and projections is denoted by L while a width thereof is denoted by D. Only one side of the substrate is formed with depressions and projections while the other side thereof has a flat surface. Specifically, the opposite side of the EL layer of the substrate has depressions and projections while the side having the EL layer has a flat surface. This second substrate 112 is attached to the first substrate 111 as a sealing substrate. In addition, each of the depressions and projections alternately includes a surface a which is parallel to the flat surface and a surface b which makes an angle of 135 degrees with the surface a. The width D of the depressions and projections is smaller by degrees in a farther place from the image pickup device 110 , and the surfaces a and b are formed in stages. A reflector is formed over the surface b. This reflector may be formed of a metal film by vapor deposition or sputtering.
[0073] According to such a substrate having depressions and projections, image data is input to the image pickup device 110 , and the image displayed on the dual emission panel 100 can be recognized from either side of the first substrate 111 or the second substrate 112 . At this time, image data reflected by the reflector is input to the image pickup device 110 through the second substrate 112 . Specifically, the image data is input to the image pickup device 110 by the reflector formed on the surface b of the substrate having depressions and projections, and the image displayed on the dual emission panel 100 can be recognized from the second substrate 112 side as well through the light-transmitting surface a.
[0074] Note that although FIG. 1C shows an example in which image data is input to the image pickup 110 after being reflected by the reflector at an angle of approximately 90 degrees assuming that the surface a makes an angle of 135 degrees with the surface b, the invention is not limited to this. That is, an angle made by the surfaces a and b, an angle at which an object is reflected or the like can be set by taking account of the position of the image pickup device 110 , the state of an object, intensity of external light, material of the substrate or the like.
[0075] FIG. 1D illustrates depressions and projections having a different structure from that in FIG. 1C . In the cross-sectional diagram, a length of an area having depressions and projections is denoted by L while a width thereof is denoted by d. Only one side of the substrate is formed with depressions and projections while the other side thereof has a flat surface. Specifically, the opposite side of the EL layer of the substrate has depressions and projections while the side having the EL layer has a flat surface. This second substrate 112 is attached to the first substrate 111 as a sealing substrate. In addition, each of the depressions and projections alternately includes a surface c which is parallel to the flat surface, a surface d which makes an angle of 135 degrees with the surface c and a surface e which makes a right angle with the surface c. The width D of the area having depressions and projections is larger by degrees in a farther place from the image pickup device 110 . A reflector is formed over the surface d. This reflector may be formed of a metal film by vapor deposition or sputtering.
[0076] According to such a substrate having depressions and projections, image data is input to the image pickup device 110 , and the image displayed on the dual emission panel 100 can be recognized from either side of the first substrate 111 or the second substrate 112 . At this time, image data reflected by the reflector is input to the image pickup device 110 through something outside the second substrate 112 , for example through air. Specifically, the image data is input to the image pickup device 110 by the reflector formed on the surface d of the substrate having depressions and projections, and the image displayed on the dual emission panel 100 can be recognized from the second substrate 112 as well through the light-transmitting surface c.
[0077] Note that although FIG. 1D shows an example in which image data is input to the image pickup 110 after being reflected by the reflector at an angle of approximately 90 degrees assuming that the surface c makes an angle of 135 degrees with the surface d, the invention is not limited to this. That is, an angle made by the surfaces c and d, an angle at which an object is reflected or the like can be set by taking account of the position of the image pickup device 110 , the state of an object, intensity of external light, material of the substrate or the like.
[0078] Although the above description is the case of processing the second substrate 112 , the first substrate 111 may be processed alternatively. When using a dual emission panel in particular, a first image data from the first substrate 111 side and a second image data from the second substrate 112 side can be each input to the lens of the image pickup device 110 by processing both of the first and second substrates 111 and 112 as shown in FIG. 10 so that each reflector on the first substrate 111 and the second substrate 112 is disposed alternately. As a reflector for this case, a half mirror coated with multiple dielectric thin film layers is preferably used. As a result, only a part of the first and second image data passes through the reflector whereas the rest is input to the image pickup device 110 after being reflected.
[0079] In addition, in FIG. 10 , the second image data reflected on the first substrate 111 and the first image data reflected on the second substrate 112 are input to the image pickup device 110 through the substrate respectively. In this case, the shapes and positions between the first substrate 111 or the second substrate 112 and the image pickup device 110 may be designed by taking account of a refraction factor between air and the substrate.
[0080] Note that the dual emission panel includes an EL layer sandwiched between first and second electrodes (corresponding to a cathode and anode of a light emitting element) each having light transmissivity. Therefore, light is emitted to both screen sides of the panel. Thus, circular polarizing plates may be disposed appropriately so as to prevent diffusion of external light due to a highly reflective wiring such as a signal line or a scan line.
[0081] In addition, when performing a black display on the dual emission panel, a polarizing plate or a circular polarizing plate may be disposed outside of the first substrate 111 and the second substrate 112 (opposite side of an EL layer) as needed although a case where the display screen (display plane) is relatively dark as compared to the external light can be disregarded. For example, a pair of polarizing plates may be disposed in crossed nicols, or a circular polarizing plate including a ¼ lambda plate and a polarizing plate may be disposed in crossed nicols to enhance contrast.
[0082] Alternatively, a polarizing plate or a circular polarizing plate may be disposed inside the first substrate 111 and the second substrate 112 (the EL layer side). In this case, an opening is formed in the polarizing plate or the circular polarizing plate at the corresponding position to the reflector in order to obtain reflection by the reflector.
[0083] The pair of the polarizing plates may be disposed with their optical axes (absorption axes and transmission axes thereof) moved in some measure to come off crossed nicols so as to enhance contrast while securing enough light transmissivity.
[0084] Furthermore, it is also possible to apply an anti-glare treatment for reducing the glare (caused by light reflecting on the panel) by forming minute concavity and convexity on the surface of the panel to diffuse the reflected light or an anti-reflective coating using an anti-reflection film. In addition, a hard-coat treatment may be also applied against external shocks and scratches.
[0085] The dual emission panel according to this embodiment mode integrates a pixel portion having an EL layer, a signal line driver circuit portion and a scan line driver circuit portion as driver circuit portions. Note that the pixel portion and the driver circuit portions are not necessarily integrated. The signal line driver circuit portion and the scan line driver circuit portion may be formed by IC chips and connected to the pixel portion by bump bonding as well. In particular, the signal line driver circuit portion may be formed by an IC chip, and connected to a wiring through an ACF (Anisotropic Conductive Film) or an FPC (Flexible Printed Circuit) board, or by using COF (Chip On Film) or TAB (Tape Automated Bonding).
[0086] The signal line driver circuit portion and the scan line driver circuit portion are connected to external circuits through a connection terminal such as an ACF (Anisotropic Conductive Film) or an FPC (Flexible Printed Circuit) board, and signals are input therethrough. The external circuits include a power source circuit, a controller, an interface (I/F) portion or the like.
[0087] By implementing the quite lightweight and thin display panel and the image pickup device as described above, a small and compact portable phone having a shooting function can be provided. In addition, since there is no need to dispose anything which interrupts the user's view between the dual emission panel and the user, it is possible to shoot an image of a user as an object and to display an image to be viewed by the user on a display screen (display plane) at the same time.
[0088] As a reflector in this embodiment mode, multiple small mirrors may be disposed as well.
[0089] The portable phone in this embodiment mode can be applied to a two-way communication system which is used for two-way communication. When carrying out two-way communication, image display and image shooting can be performed at the same time while securing an eye focus of the user who is viewing the displayed image.
[0090] Note that the image pickup device 110 may be set to face either the user side or the opposite side thereof even in carrying out two-way communication. For example, when two-way communication is carried out with the image pickup device 110 facing the opposite side, two-way communication can be carried out including a third party, in addition to the user and the other party, who is directly communicating with the user while recognizing an image displayed on the dual emission panel. That means, by implementing the dual emission panel, two-way communication can be carried out including the third person while being recognized by other two parties.
[0091] Besides the two-way communication, a user can shoot an image of himself while seeing the displayed image of himself on the display panel. At this time, a high-quality image can be shot while securing an eye focus of the user even if he is viewing his own image.
[0092] [Embodiment Mode 2]
[0093] Described in this embodiment mode is a portable phone having a dual emission display panel as an example of a display device having an image pickup function, which has a different structure from that in Embodiment Mode 1.
[0094] As shown in FIG. 8A , the first housing 101 in this embodiment mode includes a fiberscope 115 for image data input. That is, a lens (objective lens) of the fiberscope 115 is disposed in the rear (on the back) of the dual emission panel 100 in the first housing 101 . The fiberscope 115 is led out to the second housing 105 through the hinge 108 so as to be connected to the image pickup device 110 . Note that the image pickup device 110 may be disposed in the first housing 101 as well. That is, a fiberscope for transmitting an image to the image pickup device 110 through a lens may be used as shown in FIG. 8A . In addition, the diameter, the number of lenses, or the position of the fiberscope 115 may be set appropriately.
[0095] The second housing 105 includes a wiring board such as a printed wiring board 150 mounted with the image pickup device 110 , a controller 151 , a power supply circuit 152 , an I/F (interface) 154 or the like. Various signals and power supply voltages supplied to the I/F 154 are supplied to the controller 151 and the power supply circuit 152 .
[0096] FIG. 8B illustrates a configuration of the controller 151 . The controller 151 includes an A/D converter 155 , a PLL (Phase Locked Loop) 156 , a control signal generating circuit 157 , an SRAM1 (Static Random Access Memory) 158 and an SRAM2 159 , a control signal generating circuit 160 for the image pickup device 110 and an image processing circuit 153 . Although SRAMs are used in this embodiment mode, SDRAMs (Synchronous DRAMs) and DRAMs (Dynamic Random Access Memories) can be used instead if high-speed data writing or reading can be performed.
[0097] Video signals supplied through the I/F (interface) 154 are serial-to-parallel converted in the A/D converter 155 , and input to the control signal generating circuit 157 as video signals corresponding to each color of RGB. Based on the various signals supplied through the I/F 154 , Hsync signals, Vsync signals, clock signals (CLK) and alternating voltages (AC Cont) are generated in the AID converter 155 , and then input to the control signal generating circuit 157 .
[0098] The PLL 156 has a function to adjust the frequency of various signals supplied through the interface 154 to match the operating frequency of the control signal generating circuit 157 in phase. Although the operating frequency of the control signal generating circuit 157 is not necessarily equal to the frequency of various signals supplied through the interface 154 , they are adjusted in the PLL 156 so as to be synchronized with each other.
[0099] The video signals input to the control signal generating circuit 157 are once written into the SRAM 1 158 and the SRAM 2 159 and stored therein. The control signal generating circuit 157 reads out video signals bit by bit which correspond to all the pixels among the signals for all bits stored in the SRAM1 158 and the SRAM2, and then supplies them to a signal line driver circuit of the dual emission panel 100 .
[0100] In addition, the control signal generating circuit 157 supplies data for each bit regarding an emission period of a light emitting element to a scan line driver circuit of the dual emission panel 100 .
[0101] Image data from the fiberscope 115 is input to the image pickup device 110 , and then processed in the image processing circuit 153 . The signals processed in the image processing circuit 153 are input to the interface 154 , and then input to the image pickup device 110 through the control signal generating circuit 160 for the image pickup device 110 .
[0102] The power supply circuit 152 also supplies a predetermined power supply voltage to the signal line driver circuit, the scan line driver circuit and the pixel portion of the dual emission panel 100 .
[0103] According to this embodiment mode, the image pickup device can be disposed around the display panel (upper side, lower side or the like). Therefore, downsizing of the device can be achieved.
[0104] The portable phone in this embodiment mode can be applied to a two-way communication system. When carrying out two-way communication, image display and image shooting can be performed at the same time while securing an eye focus of a user who is viewing the displayed image.
[0105] Note that the image pickup device 110 may be set to face either the user side or the opposite side thereof even in carrying out two-way communication. For example, when two-way communication is carried out with the image pickup device 110 facing the opposite side, two-way communication can be carried out including a third party, in addition to the user and the other party, who is directly communicating with the user while recognizing an image displayed on the dual emission panel. That means, by implementing the dual emission panel, two-way communication can be carried out including the third person while being recognized by two other parties.
[0106] Besides the two-way communication, a user can shoot an image of himself while seeing the displayed image of himself on the display panel. At this time, a high-quality image can be shot while securing an eye focus of the user even if he is viewing his own image.
[0107] [Embodiment Mode 3]
[0108] Described in this embodiment mode is a videophone system having a dual emission display panel as an example of a display device having an image-pickup function.
[0109] FIG. 2A illustrates an overall view of a videophone system which includes a display panel 207 having a first substrate 200 , a second substrate 201 and an EL layer area 202 sandwiched between them, and an image pickup device 203 disposed at the bottom of the display panel 207 .
[0110] When a user 205 faces the display panel 207 which displays an image of the other party 206 , they can communicate while catching each other's eyes.
[0111] In the image pickup device 203 , a microlens for condensing image data which is reflected by a reflector is disposed in conformity with the size of the display panel 207 as a lens of the image pickup device.
[0112] FIGS. 2B and 2C each illustrates an enlarged view of the display panel 207 . Each figure shows a structure of the second substrate formed with depressions and projections as in FIGS. 1C and 1D , on part of which a reflector is formed. Through the reflector, image data of the user 205 is input to the image pickup device.
[0113] As a reflector, multiple small mirrors or half mirrors may be disposed.
[0114] Since the image pickup device is not required to be disposed in the rear of the display panel 207 in the videophone system as described above, further downsizing can be achieved.
[0115] FIG. 3A illustrates a videophone system having a different structure from that in FIG. 2A , in which a lens 208 and a reflector 209 are disposed in the rear of the second substrate 201 . For example, a microlens may be used as the lens 208 while a mirror may be used as the reflector 209 .
[0116] Referring to a cross-sectional diagram of the videophone system shown in FIG. 3B , the lens 208 condenses image data of a user and input it to the reflector 209 . The image data is then input to an image pickup device 210 from the reflector 209 .
[0117] At this time, the shooting range can be widened as compared to the sizes of the lens 208 and the reflector 209 by adjusting a focus of the lens 208 . Therefore, a size of the videophone system such as a depth in particular is not increased even when the lens 208 having a relatively small size compared to the display panel and the reflector 209 having about the same size as the lens 208 are disposed in the rear of the display panel.
[0118] By using an optical system for condensing image data of an object in this manner, downsizing of a videophone system is achieved.
[0119] By implementing the quite lightweight and thin display panel and the image pickup device as described above, a compact and lightweight portable videophone can be provided. In addition, since there is no need to dispose anything which interrupts the user's view between the dual emission panel and the user, it is possible to shoot an image of an object (user, for example) and to display an image to be viewed by the user on a display screen (display plane) at the same time.
[0120] The videophone in this embodiment mode can be applied to a two-way communication system which is used for two-way communication. When carrying out two-way communication, image display and image shooting can be performed at the same time while securing an eye focus of a user who is viewing the displayed image.
[0121] [Embodiment Mode 4]
[0122] Described in this embodiment mode is a method for fabricating a display device having an image pickup function, and in particular, a method for fabricating a substrate having depressions and projections.
[0123] As shown in FIG. 4A , a metal mold 300 having depressions and projections is formed first. For example, when forming the substrate having depressions and projections as shown in FIG. 1C , an angle of the projection is formed to have 135 degrees. An angle made by the projection with a surface having no depressions nor projections is denoted by atan (d/L). Alternatively, a metal mold having depressions and projections as shown in FIG. 1D may be prepared as well. An organic material may be poured into the metal mold 300 to form the second substrate having depressions and projections. In addition, the second substrate having depressions and projections may be formed by whittling away a substrate using the metal mold 300 .
[0124] In this manner, a second substrate 301 having depressions and projections as shown in FIG. 4B is formed. As the second substrate 301 , a glass substrate made of barium borosilicate glass or alumino borosilicate glass, a quartz substrate, an SUS substrate or the like may be used. Alternatively, a synthetic resin substrate having flexibility such as a plastic substrate typified by PET (Polyethylene Terephthalate), PES (Polyether Sulfone) or PEN (Polyethylene Naphthalate) and an acrylic substrate can be used as long as it can withstand the processing temperatures during the manufacturing steps although it generally has a lower heat resistance temperature as compared to other substrates. Note that in the case using a substrate formed of an organic material such as synthetic resin, the second substrate may be formed by pouring the material into the metal mold 300 . Meanwhile in the case of using a glass substrate, a quartz substrate, an SUS substrate or the like, the second substrate may be formed by whittling the substrate away using the metal mold 300 .
[0125] Subsequently, a mirror surface processing is applied by forming a metal film on the depressions and projections only in one direction as shown in FIG. 4C . Specifically, the metal film is formed by applying vapor deposition or sputtering in one direction. At this time, an electric field may be applied in order to control the deposition direction of the metal film.
[0126] Then, a second substrate 301 is cut off as shown in FIG. 4D with respect to the surface having no depressions nor projections at an angle of atan (d/L).
[0127] The second substrate 301 formed like the above manner is used as a sealing substrate. That is, as shown in an enlarged cross-sectional diagram of a pixel in FIG. 4E , the second substrate 301 having depressions and projections is attached onto the pixel portion 306 by a sealant. The pixel portion 306 includes a switching transistor 304 and a driving transistor 305 formed on the first substrate 303 , a first electrode 307 of a light emitting element connected to a first electrode of the driving transistor 305 , an EL layer 308 formed over the first electrode 307 , a second electrode 309 of the light emitting element formed over the EL layer 308 and a protective film 310 formed over the second electrode 309 .
[0128] The image data is input to the image-pickup device 311 after being reflected by a reflector 302 disposed on the second substrate. Note that since image data is input from a light emitting area as well, image corrections as described in Embodiment Mode 6 are preferably performed. In addition, the size of the depressions and projections of the second substrate in actuality is quite large relatively to the size of one pixel.
[0129] Described now is the EL layer 308 . In the EL layer 308 , an HIL (Hole Injection Layer), an HTL (Hole Transporting Layer), an EML (EMmitting Layer), an ETL (Electron Transporting layer) and an EIL (Electron Injection Layer) are laminated in this order from the anode side. Typically, CuPc is used for the HIL, a-NPD is used for the HTL, BCP is used for the ETL and BCP: Li is used for the EIL.
[0130] In addition, in the case of performing a full color display, materials each emitting red (R), green (G) or blue (B) light may be selectively deposited as the EL layer 308 by vapor deposition using a deposition mask or by ink-jet printing. Specifically, CuPc or PEDOT is used for the HIL, a-NPD is used for the HTL, BCP or Alq 3 is used for the ETL and BCP: Li or CaF 2 is used for the EIL. As for the EML, for example, Alq 3 doped with dopant corresponding to each emission color of RGB (DCM and the like for R, and DMQD and the like for G) may be used. Note that the invention is not limited to the laminate structure of the aforementioned EL layer 308 .
[0131] The specific laminate structure of the EL layer 308 is described now. In the case of forming the EL layer 308 for red emission for example, CuPc having a thickness of 30 nm and a-NPD having a thickness of 60 nm are sequentially deposited. Then, by using the same mask, Alq 3 having a thickness of 40 nm which is doped with DCM 2 and rubrene as a red EML, BCP having a thickness of 40 nm as an ETL and BCP having a thickness of 1 nm which is doped with Li as an EIL are sequentially deposited. In the case of forming the EL layer 308 for green emission for example, CuPc having a thickness of 30 nm and a-NPD having a thickness of 60 nm are sequentially deposited. Then, by using the same mask, Alq 3 having a thickness of 40 nm which is doped with coumarin 545T as a green EML, BCP having a thickness of 40 nm as an ETL and BCP having a thickness of 1 nm which is doped with Li as an EIL are sequentially deposited. In the case of forming the EL layer 308 for blue emission for example, CuPc having a thickness of 30 nm and a-NPD having a thickness of 60 nm are sequentially deposited. Then, by using the same mask, bis[2-(2-hydroxyphenyl)-benzoxazolato]zinc: Zn(PBO) 2 having a thickness of 10 nm as a blue EML, BCP having a thickness of 40 nm as an ETL, and BCP having a thickness of 1 nm which is doped with Li as an EIL are sequentially deposited.
[0132] As described above, CuPc and a-NPD can be used in common to form the EL layer for each color over the entire pixel portion. In addition, the same mask can be used for each color EML for each color in such a manner that a mask is moved after forming the red EML to form the green EML, and then, it is moved again to form the blue EML. The laminate order of the EL layer for each color may be set appropriately.
[0133] In addition, in the case of white light emission, a full color display may be performed by additionally providing color filters, or color filters and color conversion layers. The color filters and the color conversion layers are formed on the second substrate, and the first substrate and second substrate may be attached to each other.
[0134] The first electrode 307 and the second electrode 309 may be formed by using light-transmitting materials. Therefore, light from the light emitting element is emitted in the both directions of the first substrate 303 and the second substrate 301 . That is, the light emitted from the light emitting element can be recognized from either side of the first substrate 303 or the second substrate 301 . In other words, the light emitted from the light emitting element can be recognized even in an area having no reflector of the second substrate 301 , namely in the light-transmitting area. In addition, an image of an object disposed on the first substrate 303 side is input to the image pickup device 311 after being reflected on the reflector of the second substrate 301 .
[0135] Materials for forming the first electrode 307 and the second electrode 309 of the light emitting element may be selected by taking account of its work function. In this embodiment mode, the first electrode 307 and the second electrode 309 are assumed to be an anode and a cathode respectively.
[0136] As for the anodic material, it is preferable to use a metal having a large work function (4.0 eV or more), an alloy, an electrically conductive compound, a mixture of them or the like. Specifically, indium tin oxide (ITO), indium zinc oxide (IZO) in which 2 to 20% of zinc oxide (ZnO) is mixed with indium oxide, gold (Au), platinum (Pt), nickel (Ni), tungsten (W), chromium (Cr), molybdenum (Mo), iron (Fe), cobalt (Co), copper (Cu), palladium (Pd), nitride metal materials (MN) or the like can be used.
[0137] As for the cathodic material, it is preferable to use a metal having a small work function (3.8 eV or less), an alloy, an electrically conductive compound, a mixture of them or the like. For example, elements that belong to the first group or the second group of a periodic table, namely alkali metals such as Li and Cs, and alkaline earth metals such as Mg, Ca and Sr, alloys including these elements (Mg:Ag, Al:Li), chemical compounds including these elements (LiF, CsF, CaF2) and in addition, transition metals including rare earth metals can be used. However, since the cathode is required to have light transmissivity, it is formed extremely thin by using these metals or an alloy including these metals, and laminated with a metal such as ITO (including alloys). These anode and cathode may be formed by vapor deposition, sputtering or the like.
[0138] According to the pixel structure described above, either the first electrode 307 or the second electrode 309 can be used as an anode or a cathode. For example, it is possible that the driving transistor has an N-type polarity, the first electrode is the cathode, and the second electrode is the anode.
[0139] In addition, the protective film 310 is deposited by sputtering or CVD to block out moisture and oxygen. It is possible to fill nitrogen or place a drying agent in the space provided between the protective film 310 and the second substrate 301 at this time Furthermore, a hygroscopic organic material may be filled in the space instead.
[0140] In addition, when disposing a polarizing plate or a circular polarizing plate as shown in FIG. 5A , a first polarizing plate (first circular polarizing plate) 315 is disposed outside the first substrate 303 (opposite side of the light emitting element) while a second polarizing plate (second circular polarizing plate) 316 is disposed on the side having the light emitting element on the second substrate 301 having depressions and projections. At this time, an opening is formed on each of the first polarizing plate 315 or the second polarizing plate 316 in order to input image data to the reflector. The opening is formed in every pixel, and it is preferable that the opening is formed at least in an area facing the reflector. The number, the shape or the position of the openings may be designed appropriately.
[0141] Alternatively as shown in FIG. 5B , a planarizing film 317 may be formed by using acrylic or an organic material such as polyimide over the second substrate 301 having depressions and projections, and the second polarizing plate 316 may be disposed outside the planarizing film 317 (the opposite side of the light emitting element). In this case, each of the first polarizing plate 315 and the second poalrizing plate 316 is not required to have an opening, however, it may be formed in an area facing the reflector.
[0142] In FIGS. 5A and 5B , the first polarizing plate 315 and the second planarizing plate 316 are disposed in crossed nicols. Alternatively, in the case of using a circular polarizing plate including a ¼ lambda plate and a polarizing plate, these polarizing plates are disposed to be in crossed nicols. However, they may come off the crossed nicols within a range of 10 degrees.
[0143] By disposing the polarizing plate or the circular polarizing plate in the above manner, contrast of the display panel can be enhanced.
[0144] The display panel fabricated in this manner is quite thin and light, therefore, downsizing of the panel can be achieved.
[0145] Such a display device having an image pickup function can be implemented with other embodiment modes described above. That is, the display device having an image pickup function fabricated as in this embodiment mode can be mounted on a portable phone or a videophone system.
[0146] [Embodiment Mode 5]
[0147] Described in this embodiment mode is an example of forming a display device having an image pickup function by using a display panel (liquid crystal panel) having liquid crystal elements.
[0148] As shown in FIG. 11A , a P-channel driving TFT 401 disposed over a light-transmitting substrate 400 has a crystalline semiconductor film which is applied crystallization by laser irradiation or heat treatment, or by using catalysis of metal elements such as nickel or titanium. A gate electrode and a gate line are formed over the semiconductor layer with a gate insulating layer interposed therebetween, and the semiconductor layer under the gate electrode corresponds to a channel forming region. Impurity elements such as boron are added to the semiconductor layer in a self-aligned manner by using the gate electrode as a mask, thus impurity regions of a source region and a drain region are obtained. A first insulating layer is formed so as to cover the gate electrode, and contact holes are formed in the first insulating layer on the impurity regions. The contact holes are formed with wirings which function as a source wiring and a drain wiring. Note that influences of concavity and convexity of a source wiring, a drain wiring and other wirings are reduced and a constant voltage is applied to a liquid crystal layer 404 . Therefore, a planarizing film 402 is preferably formed by using an organic material.
[0149] A pixel electrode 403 is disposed so as to be electrically connected to the drain electrode. Over the pixel electrode 403 , an orientation film (not shown) is disposed, and then processed by rubbing. In this embodiment mode, the pixel electrode 403 is formed of a light-transmitting conductive film such as ITO.
[0150] As in Embodiment Mode 4, the second substrate formed with the reflector 302 is prepared as an opposed substrate 406 of the liquid crystal panel. The opposed substrate 406 is formed with a polarizing plate (second polarizing plate) 407 , a color filter 408 and an opposed electrode 409 in this order. Over the opposed electrode 409 , an orientation film (not shown) is disposed, and then processed by rubbing.
[0151] The first substrate 400 is attached to the second substrate 406 with the liquid crystal layer 404 injected between them. The liquid crystal layer 404 is desirably injected in vacuum. Alternatively, the liquid crystal layer 404 may be dropped on the first substrate 400 , and then the second substrate 406 may be attached thereto. When using a large substrate in particular, dropping is more suitable than injection to fill the liquid crystal layer 404 . Subsequently, a polarizing plate (first polarizing plate) 410 is formed in the first substrate 400 side.
[0152] In such a liquid crystal display panel, an opening area 405 is formed so as to transmit image data. The image data is input to an image pickup device 411 after passing through the opening area 405 and being reflected by the reflector 302 . Therefore, it is preferable that the opening area is formed in every pixel in order to increase light-transmittancy. The shape or the number of the opening areas may be designed appropriately. For example, multiple small opening areas may be formed in every pixel. Furthermore, the number or the area of the opening areas can be reduced by enhancing a sensitivity of the image pickup device 411 or performing image corrections.
[0153] In the opening area 405 , an opening (also referred to as an opening area) is formed in the non-light transmitting film. Therefore, an opening portion is formed by patterning each of the opposed electrode 409 , the color filter 408 and the polarizing plates 407 and 410 . FIG. 11B illustrates a top plan view of the liquid crystal panel, in which the opposed electrode 409 and the opening area 405 are formed at an intersection of a signal line 412 and a scan line 413 . FIG. 11C includes polarizing plates 407 and 410 . An opening is formed corresponding to the opening area 405 . Note that FIG. 11A is a cross-sectional diagram of each of the top plan views in FIGS. 11B and 11C taken along a line A-A.
[0154] In addition, the opening may be formed even when the pixel electrode 403 is formed by a light-transmitting conductive film (such as ITO). A part of the liquid crystal layer 404 corresponding to the opening is a light-transmitting area since it includes no opposed electrode 409 or no pixel electrode 403 , and no voltage is applied thereto.
[0155] Furthermore, it is also possible to form a light-transmitting conductive film in the opening area 405 . At this time, the light-transmitting conductive film may be input an electronic signal which is different from the pixel electrode 403 and the opposed electrode 409 , thereby controlling molecules in the liquid crystal layer 404 in order to maintain the light-tranmissivity all the time. In addition, a lambda/2 plate may be disposed on the polarizing plate within the opening area 405 .
[0156] By forming the opening in the opening area 405 to obtain light-transmisisvity in this manner, a display device having an image pickup function can be provided by using a liquid crystal panel.
[0157] In addition, as a liqcuid crystal material, TN (Twist Nematic) liquid crystal, STN (Super Twist Nematic) liquid crystal or non-twist mode nematic liquid crystal using double refraction can be used. Alternatively, a liquid crystal material which requires no polarizing plate such as polymer dispersed liquid crystal (PDLC) or guest-host (GH) mode liquid crystal can used, in which ferroelectric liquid crystal, nematic liquid crystal, cholesteric liquid crystal or the like is dispersed in polymer.
[0158] As for the liquid crystal panel, either a light-transmitting liquid crystal panel, a reflective liquid crystal panel or a semi-light transmitting liquid crystal panel can be used. In particular, in the case of fabricating a light-transmitting liquid crystal panel, the pixel electrode 403 is formed of a light-transmitting conductive film. Therefore, the pixel electrode is not required to have an opening. Meanwhile in the case of fabricating a reflective liquid crystal panel, the pixel electrode is formed of a reflective conductive film. Therefore, the pixel electrode is required to have an opening.
[0159] FIG. 12 illustrates a liquid crystal display panel in which the position of the second polarizing plate 407 is different. Over the second substrate having depressions and projections, a planarizing film 415 is formed by using an organic light-transmitting material such as acryl or polyimide. Then, the second polarizing plate 407 is disposed over the planarizing film 415 . Note that the liquid crystal layer area 416 in FIG. 12 includes the driving TFT 401 , the planarizing film 402 , the pixel electrode 403 , the liquid crystal layer 404 , the opposed electrode 409 and the color filter 408 each formed over the first substrate 400 .
[0160] In addition, an opening area may be formed in the display panel having light emitting elements shown in Embodiment Mode 4 as well. For example, an opening may be formed in the first electrode or the second electrode of the light emitting element, or in the polarizing plate or the circular polarizing plate which is disposed appropriately.
[0161] The display panel fabricated in this manner is quite thin and light, therefore, downsizing of the panel can be achieved.
[0162] Such a display device having an image pickup function can be implemented with other embodiment modes described above. That is, the display device having an image pickup function fabricated as in this embodiment mode can be mounted on a portable phone or a videophone system.
[0163] [Embodiment Mode 6]
[0164] Described in this embodiment mode is a method for correcting an image that is shot by the image pickup device described in Embodiment Modes 1 to 5 with reference to FIGS. 6A and 6B .
[0165] FIG. 6A illustrates an image pickup device 701 , a display panel (dual emission panel for example) 705 , a user, a correction A in which a deviation in color or luminance of an image is corrected corresponding to the light transmissivity of the panel and a correction B in which the glare caused by light reflecting on the display panel is eliminated from an image.
[0166] FIG. 6B illustrates a flow chart showing a two-way communication system between two parties. Described below is the case where each of the two parties has the identical two-way communication device.
[0167] In two-way communication, two parties communicate with each other through image pickup devices 701 a and 701 b, communication circuits 702 a and 702 b, image processing circuits 706 a and 706 b, display panel external circuits 704 a and 704 b, display panels 705 a and 705 b and communication circuits 702 a and 702 b. Each of the image processing circuits 706 a and 706 b has a function to perform the correction A and a function to perform the correction B, and each of them is controlled by the display panel external circuits 704 a and 704 b.
[0168] Each of the image pickup devices 701 a and 701 b shoots an image of the two parties through the display panels 705 a and 705 b. At this time, the correction A in which a deviation in color or luminance of an image is corrected corresponding to the light transmissivity of the panel is performed. Also, the correction B in which the glare caused by light reflecting on the display panel is eliminated from an image of the two parties is performed. As a result, correction of the images of the two parties are completed. Either the correction A or the correction B can precede or they may be performed at the same time. In addition, each of the correction A and the correction B may be performed by using the same correction circuit. The circuit for performing the correction A may be disposed either between the communication circuits 702 a and 702 b and the display panel external circuit 704 or between the display panel external circuit 704 and the display panel 705 . Furthermore, in addition to the function to perform the correction B, a function for processing an image corresponding to a lens or focus may be performed, in which filtering process such as blurring and shrinking is applied to a component of the light emission from the display panels 705 a and 705 b.
[0169] Such corrected images are transmitted through the communication circuits 702 a and 702 b.
[0170] The images transmitted from the communication circuits 702 a and 702 b are input to the display panel external circuits 704 a and 704 b respectively, and then displayed on the display panels 705 a and 705 b. Specifically, video signals of corrected images a and b are input to signal lines disposed in the display panels 705 a and 705 b.
[0171] By using the corrected images a and b as described above, communication can be performed with high accuracy.
[0172] The method for correcting the images in this embodiment mode can be freely implemented with other Embodiment Modes described above. Thus, highly accurate two-way communication system can be provided.
[0173] [Embodiment Mode 7]
[0174] Examples of an electronic apparatus having the display panel mounting the substrate formed with depressions and projections or mounting a fiberscope of the invention include a digital camera, an audio device such as a car audio set, a notebook personal computer and an image reproducing device provided with a recording medium such as a home game player or the like. Specific examples of these electronic apparatuses are shown in FIGS. 9A and 9B . They show an operative example of electronic device/apparatus in FIG. 9 .
[0175] FIG. 9A illustrates a notebook personal computer which includes a main body 2201 , a housing 2202 , a display portion 2203 , a keyboard 2204 , an external connecting port 2205 , a pointing mouse 2206 , an image pickup device 2207 inside the housing 2202 or the like. The display panel of the invention mounting the substrate formed with depressions and projections or mounting a fiberscope can be used in the display portion 2203 . Thus, a two-way communication system using notebook personal computers can be provided.
[0176] FIG. 9B illustrates a mobile computer which includes a main body 2301 , a display portion 2302 , a switch 2303 , an operating switch 2304 , an infrared port 2305 , an image pickup device 2307 inside the housing 2306 or the like. The display panel of the invention mounting the substrate formed with depressions and projections or mounting a fiberscope can be used in the display portion 2302 . Thus, a two-way communication system using mobile computers can be provided.
[0177] In above described electronic apparatuses, by applying the display panel of the invention mounting the substrate formed with depressions and projections or mounting a fiberscope to the above electronic apparatuses, a two-way communication system in which two parties can communicate while catching each other's eyes can be provided.
[0178] Any one of Embodiment Modes as described above can be applied to the electronic apparatuses of this Embodiment Mode.
[0179] [Embodiment]
[0180] [Embodiment 1]
[0181] Described in this embodiment is a simulation result of a shooting range in the case of using the second substrate having depressions and projections shown in FIG. 1C .
[0182] Referring to FIG. 7 , X-axis denotes a shootable width (mm) while Y-axis denotes a distance from the shooting position, namely a distance between the display panel and an object (mm). In addition, a range in which an image can be input to the image pickup device through reflection by multiple reflectors is denoted by lines (line 1 to line 61 ).
[0183] FIG. 7 includes a shootable area A and a non-shootable area B. Each of the shootable area A and the non-shootable area B can be set by appropriately determining an angle, the shape, the number of reflectors, the position of the image pickup device, an optical system or the like.
[0184] Generally, an object to be shot is positioned to face the display portion. Ttherefore, the shootable area A desirably takes up the largest areas in front of the display surface as possible. Meanwhile, the non-shootable area B may desirably around the display panel, namely around the display portion. In addition, the non-shootable area B desirably performs an image-connecting processing and an interpolation processing by using the shootable area A.
[0185] An image passed through the shootable area A is inverted by a reflector and a range of the shootable area A varies according to the direction, resulting in variations in resolution of an image. For preventing this, filtering such as an image inverting processing is desirably performed. Furthermore, image correction for preventing a glare caused by light reflecting on the panel is desirably performed.
[0186] This application is based on Japanese Patent Application serial no. 2003-275185 filed in Japan Patent Office on 16, Jul. 2003, the contents of which are hereby incorporated by reference. Although the invention has been fully described by way of Embodiment Modes and Embodiments with reference to the accompanying drawings, it is to be understood that various changes and modifications will be apparent to those skilled in the art. Therefore, unless such changes and modifications depart from the scope of the invention hereinafter defined, they should be constructed as being included therein. | A compact and lightweight display device having an image pickup function and a two-way communication system which can shoot an image of a user as an object and display an image at the same time without degrading image quality by disposing a semi-transmitting mirror or the like which blocks an image on the display screen (display plane). The display device having the image pickup function includes a display panel capable of transmitting visible light at least and arranging display elements which can be controlled by voltage or current, and an image pickup device disposed around the display panel. The image pickup device is input with data of an image of a user or the like by a reflector, or equipped with a fiberscope bundling optical fibers. | 72,179 |
FIELD OF THE INVENTION
[0001] The present invention relates to the discovery that urea, a naturally occurring ubiquitous chemical in man has anti-inflammatory properties when applied topically to inflamed skin. Although the mechanism by which urea acts as an anti-inflammatory agent is unclear, this very beneficial property has many useful applications in treating dermatological conditions.
BACKGROUND OF THE INVENTION
[0002] Urea has been long recognized as a cosmetic ingredient in formulations acting as a humectant and moisturizer. High concentrations of urea, such as 40%, are also known to have mild, antibacterial effect. At these strengths the antibacterial effects are said to be similar to those of antibiotics, with the further advantage that all the common organisms are susceptible and the possibility of resistant strains need not be seriously considered. There have been reports of keratolytic activity attributed to urea with the ability at high concentrations to solubilize and denature protein. Dermatological compositions containing from 21 to 40 wt-% urea for treating dry scaly skin have been described in U.S. Pat. No. 5,919,470.
[0003] Concentrated solutions of urea can change the conformation of protein molecules. A striking effect is upon the water-binding capacity of the horny layer of the skin: pieces of normal horny layer, or scales from ichthyotic or psoriatic skin that have been soaked in 30% urea solution take up much more water. This is important because in maintaining the flexibility of the horny layer and the softness of the skin, the water content of the horny layer matters much more than its oil content.
[0004] Systemic drug therapy is associated with potentially harmful side effects. For example, oral anti-inflammatory drugs, for example corticosteroids, are distributed throughout the entire body. Systemic side effects such as elevated liver enzymes, gastrointestinal disorders and skin rashes are not uncommon and may require expensive intervention and laboratory tests. Accordingly, topical formulations for treating dermatological conditions of the skin in humans are increasingly recommended. Thus, topical compositions are generally preferred for dermatological applications. See, for example, “Practical Advice Offered On Rosacea”, Dermatology News, (April, 1985).
SUMMARY OF THE INVENTION
[0005] Topical urea, formulated in a pharmaceutically acceptable base has surprisingly shown improvement in dermal inflammation. Inflammation is a local response to cellular injury that is marked by capillary dilatation, leukocytic infiltration, redness, heat, and pain and that serves as a mechanism initiating the elimination of noxious agents and of damaged tissue. The mechanism by which urea acts as an anti-inflammatory agent is unclear.
[0006] The present invention relates to the discovery that urea, a naturally occurring ubiquitous chemical in man, has anti-inflammatory properties when applied topically to inflamed skin. Urea can be applied to the affected dermal site formulated as, for example, a cream, lotion, solution, gel, lacquer, ointment, foam, or any vehicle capable of applying urea directly to the affected site.
[0007] Accordingly, the present invention provides a method for treating inflammation on the skin of humans and animals in need thereof by topically administering a safe and effective anti-inflammatory amount of urea in a pharmaceutically acceptable carrier.
DETAILED DESCRIPTION OF THE INVENTION
[0008] Inflammation is a local response to cellular injury that is marked by capillary dilatation, leukocytic infiltration, redness, heat, and pain and that serves as a mechanism initiating the elimination of noxious agents and of damaged tissue. A human or animal must defend itself against multitude of different pathogens including viruses, bacteria, fungi, and protozoan and metazoan parasites as well as tumors and a number of various harmful agents which are capable to derange its homeostasis. For this, a plenty of effector mechanisms capable of defending the body against such antigens and agents have developed and these can be mediated by soluble molecules or by cells. If infection occurs as a consequence of the tissue damage, the innate and, later, the adaptive immune systems are triggered to destroy the infectious agent.
[0009] Inflammation is a complex stereotypical reaction of the body expressing the response to damage of its cells and vascularized tissues. In avascular tissues, e.g. in normal cornea, the true inflammation does not occur.
[0010] The discovery of the detailed processes of inflammation has revealed a close relationship between inflammation and the immune response.
[0011] The five basic symptoms of inflammation—redness (rubor), swelling (tumor), heat (calor), pain (dolor) and deranged function (functio laesa) have been known since the ancient Greek and Roman era. These signs are due to extravasation of plasma and infiltration of leukocytes into the site of inflammation. Early investigators considered inflammation a primary host defense system. From this point of view inflammation is the key reaction of the innate immune response but in fact, inflammation is more than this, since it can lead to death, as in anaphylactic shock, or debilitating diseases, as in arthritis and gout.
[0012] According to different criteria, inflammatory responses can be divided into several categories. The criteria include:
[0013] 1. time—hyperacute (peracute), acute, subacute, and chronic inflammation;
[0014] 2. the main inflammatory manifestation—alteration, exudation, proliferation;
[0015] 3. the degree of tissue damage—superficial, profound (bordered, not bordered);
[0016] 4. characteristic picture—nonspecific, specific;
[0017] 5. immunopathological mechanisms
[0018] allergic (reaginic) inflammation,
[0019] inflammation mediated by cytotoxic antibodies,
[0020] inflammation mediaded by immune complexes,
[0021] delayed-type hypersensitivity reactions.
[0022] Inflammation is the body's reaction to invasion by an infectious agent, antigen challenge or even just physical, chemical or traumatic damage.
[0023] The mechanism for triggering the response the body to injury is extremely sensitive. Responses are to tissue damage that might not normally be thought of as injury, for example when the skin is stroked quite firmly or if some pressure is applied to a tissue. In addition, the body has the capacity to respond to both minor injuries such as bruising, scratching, cuts, and abrasions, as well as to major injuries such as severe bums and amputation of limbs.
[0024] Depending on the severity of the tissue damage resulting from an injury, the integrity of the skin or internal surfaces may be breached and damage to the underlying connective tissue and muscle, as well as blood vessels can occur. In this situation infection can, and frequently does result because the normal barrier to the entry of harmful organisms has been broken. It is obviously most important that the body can respond to injury by healing and repairing the damaged tissue, as well as by eliminating the infectious agents that may have entered the wound and their toxins. It is also important that the appropriate response to the tissue damage and infection can be made: it is no use bringing all of the body's defenses into action to repair a minor scratch, just as one would not expect a single mechanism to be able to deal with the sudden loss of a limb or a major infection.
[0025] The inflammatory reaction is phylogenetically and ontogenetically the oldest defense mechanism. The cells of the immune system are widely distributed throughout the body, but if an infection or tissue damage occurs it is necessary to concentrate them and their products at the site of damage. Three major events occur during this response:
[0026] 1. An increased blood supply to the tissue “in danger”. It is performed by vasodilation. The inflamed tissue looks like containing greater number of vessels.
[0027] 2. Increased capillary permeability caused by retraction of the endothelial cells. This permit larger molecules than usual to escape from the capillaries, and thus allows the soluble mediators of immunity to reach the site of inflammation.
[0028] 3. Leukocytes migrate out of the capillaries into the surrounding tissues. In the earliest stages of inflammation, neutrophils are particularly prevalent, but later monocytes and lymphocytes also migrate towards the site of infection.
[0029] For the possibility of surrounding tissue damage, inflammatory responses must be well ordered and controlled. The body must be able to act quickly in some situations, for example to reduce or stop the lost of blood, whereas tissue repair and reconstruction can begin a little later. Therefore, a wide variety of interconnected cellular and humoral (soluble) mechanisms are activated when tissue damage and infection occur. On the other hand if the injury is negligible, the body must have mechanisms which are able to stop the tissue damage when the injury agent was removed.
[0030] The development of inflammatory reactions is controlled by cytokines, by products of the plasma enzyme systems (complement, the coagulation clothing, kinin and fibrinolytic pathways), by lipid mediators (prostaglandins and leukotrienes) released from different cells, and by vasoactive mediators released from mast cells, basophils and platelets. These inflammatory mediators controlling different types of inflammatory reaction differ. Fast-acting mediators, such as vasoactive amines and the products of the kinin system, modulate the immediate response. Later, newly synthesized mediators such as leukotrienes are involved in the accumulation and activation of other cells. Once leukocytes have arrived at a site of inflammation, they release mediators which control the later accumulation and activation of other cells.
[0031] However, in inflammatory reactions initiated by the immune system, the ultimate control is exerted by the antigen itself, in the same way as it controls the immune response itself. For this reason, the cellular accumulation at the site of chronic infection, or in autoimmune reactions (where the antigen cannot ultimately be eradicated), is quite different from that at sites where the antigenic stimulus is rapidly cleared.
[0032] The present invention relates to the discovery that urea, a naturally occurring ubiquitous chemical in man, has anti-inflammatory properties when applied topically to inflamed skin. Urea can be applied to the affected dermal site formulated as, for example, a cream, lotion, solution, gel, lacquer, ointment, foam or any other vehicle capable of applying urea directly to the affected site.
[0033] Such method includes administering to the affected skin of a human or animal with inflammation a safe and effective amount of urea, for example, from about 10 to 60 wt-%, preferably about 30-50 wt-%, and particularly about 40 wt-% of urea. The terms “administering” or “administration”, as needed herein, refer to any method which, in sound medical practice, delivers the urea, e.g., 40% urea, in such a manner so as to be effective in the treatment of inflamed dermatological disorders of the skin. The phase “safe and effective amount”, as used herein, means an amount of urea sufficient enough to significantly and positively modify the condition to be treated but low enough to avoid serious side effects, within the scope of sound medical advice. The safe and effective amount of the urea will vary with the particular pharmaceutically acceptable carriers utilized, and the like factors within the knowledge and expertise of the attending physician.
[0034] The method of the present invention typically involves administering the urea in an amount to cover the affected area. The specific preferred quantity of the urea depends upon the characteristics of the dermatological disorder.
[0035] The dosing of the compositions of this invention may be for acute conditions or chronic conditions. However, it has been found that urea is particularly effective when the inflammation is due to microbial infection.
[0036] For the method of the present invention, the duration of administration of the urea will vary according to the specific extent of the dermatological condition being treated and if the treatment requirements are for acute or chronic therapy.
[0037] Another embodiment of the invention is a method for using urea therapeutically as an anti-inflammatory to treat dermatological disorders of the skin in humans and animals by topically administering a safe and effective amount of urea in a pharmaceutically acceptable carrier.
[0038] In addition to containing a therapeutically effective amount of urea the composition includes dermatologically acceptable excipients as described in U.S. Pat. No. 5,919,470, which patent is incorporated herein by reference. The excipients particularly include skin protectants which include a combination of semi-solid and liquid petroleum fractions. The semi-solid skin protectant is contained in about 5.5 to about 20 wt-% and includes petrolatum or a synthetic or semi-synthetic hydrocarbon of the same nature as petrolatum. Mixtures of such ingredients can also be used. The preferred semi-solid material is petrolatum, commercially available from a wide variety of sources.
[0039] The liquid portion skin protectant is a liquid petrolatum and contained in the composition in about 10 to about 20 wt-%. This material can include any synthetic or semi-synthetic oleaginous liquid fraction. A preferred embodiment is mineral oil, which is a liquid mixture of hydrocarbons obtained from petroleum.
[0040] Another preferred ingredient encompassed in the composition of the present invention is propylene glycol which may be contained up to about 5 wt-% in the composition, preferably in the range of from about 1 to about 5 wt-%.
[0041] Typical compositions containing urea employed in the present invention are for example:
Ingredient Approximate Wt-% Urea 40 Petrolatum or a synthetic or semi-synthetic 5.5-20 hydrocarbon, or a semi-solid mixture thereof liquid petrolatum or synthetic or semi-synthetic 10-20 oleaginous liquid fraction, or a mixture thereof C16-18 aliphatic straight or branched chain fatty 0.25-2 alcohol or fatty acid, or a mixture thereof propylene glycol 1-5 glyceryl stearate 1-3 xanthan gum 0.01-0.5 water QS 100.0 Urea 30 Petrolatum or a synthetic or semi-synthetic 5.5-20 hydrocarbon, or a semi-solid mixture thereof liquid petrolatum or a synthetic or semi-synthetic 10-20 oleaginous liquid fraction, or a mixture thereof C 16-18 aliphatic straight or branched chain fatty 0.25-2 alcohol or fatty acid, or a mixture thereof propylene glycol 1-5 glyceryl stearate 1-3 xanthan gum 0.01-0.5 mixture of a carbomer and triethanolamine 0.05-30 Water QS 100.0
EXAMPLE
[0042] A typical formulation representing the particular and most preferred cream embodiment of the present invention is illustrated as follows:
Ingredient % W/W Purified water 36.149 Urea USP 40.000 Carbopol 940 0.25 Petrolatum 5.94 Mineral oil 12.06 Glyceryl stearate 1.875 Cetyl alcohol 0.626 Propylene glycol 3.00 Xanthan gum 0.050 Trolamine NF 0.150 TOTAL QS 100.00
[0043] The above ingredients were mixed together to form a cream in accordance with conventional, commercially known methods. | The method of treating inflammatory skin conditions with compositions containing urea as the sole active ingredient is described. Although the mechanism by which urea acts as an anti-inflammatory agent is unclear, this very beneficial property has many useful applications in treating inflammatory dermatological conditions. | 16,619 |
BACKGROUND OF THE INVENTION
This is a continuation-in-part of application Ser. No. 944,438 filed Sep. 14, 1992 now abandoned, which is a division of application Ser. No. 626,001 filed Dec. 12, 1990, now U.S. Pat. No. 5,147,647, which is a continuation-in-part of application Ser. No 500,093 filed Mar. 21, 1990 now abandoned, which is a continuation of application Ser. No. 330,959 filed Mar. 29, 1989 now abandoned which is a continuation of application Ser. No. 104,045 filed Oct. 1, 1987 now abandoned.
This invention is concerned with improvements in or relating to ocular insert devices.
Various diseases of the eye are commonly treated by frequent daily application of ophthalmic drugs for example in the form of eye drops or ointment. While this is suitable and convenient in some cases, it can be a serious disadvantage that the drug is not present in the eye in a continuous manner. With a view to overcoming this disadvantage it has been previously proposed, for example, in U.S. Pat. No. 3,416,530 of R.A. Ness assigned to Alza Corporation and subsequent patents of Alza Corporation to provide a flexible ocular insert device adapted for the controlled sustained release of the drug.
In for example U.S. Pat. No. 3,828,777 of R.A. Ness assigned to Alza Corporation it is stated that the ocular insert can be fabricated in any convenient shape for comfortable retention in the conjunctival sac of the eye and that the marginal outline can be ellipsoid, doughnut-shape, bean-shape, banana-shape, circular or rectangular; and in cross section it can be doubly convex, concavoconvex, or rectangular. It is suggested however that the original cross-sectional shape of the device is not of controlling importance. However, these previously proposed devices have in practice met with no more than limited success because most of the proposed shapes and sizes were not suitable for placement in the narrow upper and lower fornices. Also previous devices have tended not to remain in place in the eye and have at times caused irritation to the patient during use.
U.S. Pat. No. 4,186,184 to A. Zaffaroni discloses that the length of an insert device should be from 2 to 20 mm, its width 1 to 15 mm and its thickness 0.1 to 4 mm. A wide variety of shapes are disclosed, including ellipsoid, doughnut, bean, banana and square shapes.
U.S. Pat. No. 3,828,777 to Ness discloses an ocular device which is inserted in that portion of the eye bounded by the surfaces of the bulbar conjunctiva of the sclera of the eyeball and the palpebral conjunctiva of the lid. Such placement of the device would, however, be subject to eye movement and would not provide an anchored position such as is obtained in the present invention. Movement of the device causes pain, irritation, foreign body sensation and watering.
U.S. Pat. No. 4,343,787 to Katz discloses water soluble inserts for the eye in which broad dimensional ranges of sizes and shapes are employed. There is no description of an insert of a specific size and shape to allow it to be retained in the fornix portion of the eye.
U.S. Pat. No. 4,135,514 to Zaffaroni et al. relates to osmotic drug delivery devices which can be used for the administration of ocular drugs. A wide variety of shapes and sizes is disclosed.
EP-A-0 033 042 to Merck and Co., Inc. discloses ocular inserts which can take any of a variety of shapes, one of which may be an extruded rod. There is no description, however, of a device having dimensions which make it suitable for insertion into the fornix so as to be retained therein for 7 days or longer.
U.S. Pat. No. 4,730,013 to Bondi et al. discloses ocular inserts intended to overcome the problem of blurred vision arising from the use of particular insert materials. The maximum length of 5 mm employed by Bondi et al. is considerably smaller than the range of dimensions employed in the present invention. It is shown in the present invention that a device with a length of 5 mm falls well below the minimum length required for retention in the eye of humans for 7 days or more.
EPO 0 251 680 to IOLAB, Inc. discloses a device for controlled drug release to the eye, in which an external matrix rapidly soluble in body fluids and having bioerodible microparticles containing the drug are positioned in the upper or lower conjunctival cul-de-sac of the eye. There is no description of a device which is retained in the eye for seven days or longer, or of the specific shape and dimension of the device of the invention for placement in the upper or lower fornix.
U.S. Pat. No. 3,845,201 to Haddad et al. discloses an ocular device for insertion in the cul-de-sac of the conjunctiva. The device may be any of various shapes, preferably disc shaped.
U.S. Pat. No. 4,164,559 to Miyata et al. discloses a soluble device for drug delivery to the eye including a collagen insert having an ovoid shape. The device is described as insertable into the inferior fornix. There is no description of a device having the dimensions employed in the present invention for retention of seven days or longer.
U.S. Pat. No. 4,179,497 to Cohen et al. discloses water soluble inserts of various shapes for applying drugs to the cul-de-sac of the conjunctiva. Again there is no description of an insert having the specific dimensions of the invention
In the use of a prior art device known as Ocusert, the subject of U.S. Pat. No. 3,828,777 to Ness, the device is inserted into the conjunctival cul-de-sac. Either of two systems may be employed, with the Pilo-20 system measuring 5.7×13.4 mm on its axes and 0.3 mm in thickness and the Pilo-40 system measuring 5.5×13 mm on its axes and 0.5 mm in thickness. Various problems in retention and irritation which occurred in the use of this device are documented, for example, in the following publications: P. Sihvola et al., Practical problems in the use of Ocusert-pilocarpine delivery system, Acta Ophthalmol.(Copenh.), December 1980, 58 (6),pp 933-937; S.E. Smith et al., Comparison of the pupillary, refractive and hypotensive effects of Ocusert-40 and pilocarpine eyedrops in the treatment of chronic simple glaucoma, Br. J. Ophthalmol., April 1979, 63(4) pp 228-232; and I.P. Pollack et al., The Ocusert pilocarpine system: advantages and disadvantages, South Med. J., October 1976, 69 (10), pp 1296-1298.
Other ocular inserts are described in the following literature reports: Urtti et al. (1990) Controlled drug delivery devices for experimental ocular studies with timolol.1. In vitro release studies. Int. J, Pharm., 61, 235-240; and Urtti et al (1990) Controlled drug delivery devices for experimental ocular studies with timolol.2.Ocular and systemic absorption in rabbits. Int. J. Pharm., 61, 241-249. These reports describe the use of a permeable hollow tube (silicone) for ocular delivery. The tube has a diameter of 1.94 mm which is outside the dimensions employed in the present invention. Also, the device was only observed in the eye for an 8 hour period.
SUMMARY OF THE INVENTION
It is an object of the present invention to provide an improved ocular insert device adapted for the controlled sustained release of a drug. The present invention is sometimes referred to herein as OCUFIT SR.
It has been found, in accordance with the present invention, that a flexible ocular insert device having a body of a thin elongated circular cylindrical configuration of specific dimensions and with anchoring protrusions of specific dimensions is well retained in place and tolerated by the patient over a prolonged period of use, for example, up to 7 to 14 days or longer. The device may be inserted in the upper or lower fornix of the conjunctiva between the sclera of the eyeball and the upper or lower eyelid, being held in position preferably in the extreme outer end portion of the upper or lower fornix and prevented from moving downward or upward respectively by the pressure of the lid against the eyeball. This position of the ocular insert of the present invention in the upper or lower fornix is shown in detail in the drawings as described hereinafter.
In particular, the device is advantageously inserted so as to fit within the upper or lower fornix by restriction of the cross sectional dimensions of the device to allow it to slip into this position and then with a length requirement that provides for anchoring the device across the lid. Two or more protrusion elements extend radially outwardly from the core to minimize lateral movement when the device is positioned within the fornix. By locating the device within the fornix, the device is imperceptible to the patient, through restriction of the device to a specific size range and shape, with the upper limit not being governed by the geometric space limitation of the whole eye, and by placement specifically within the fornix, not simply within the conjunctival cul-de-sac. In addition, the retention of the present insert device is independent of the movement of the eye by virtue of the fornix anatomy. In contrast, a device placed anywhere on the bulbar conjunctiva would be subject to eye movement and cause discomfort to the patient.
The insert device of the present invention must be positioned precisely and remain anchored in the upper or lower fornix, known also as the superior conjunctival fornix or the inferior conjunctival fornix, as distinct from the positioning of other kinds of devices anywhere in the conjunctival cul-de-sac. The device of the present invention must be flexible to allow it to bend along the curvature of the eye within the fornix. In particular, such flexibility must be sufficient to allow it to bend along the curvature of the eye within the upper or lower fornix upon being positioned so that the longitudinal axis of the device is generally parallel to the transverse diameter of the eyeball.
The present insert device is imperceptible by the patient when anchored properly in the fornix, whereas prior art devices are perceived as foreign bodies. Upon proper positioning in the fornix, the present insert device is independent of eye movement and does not move when the eye moves. The device of the present invention also remains out of the field of vision. In addition, it can be placed and held in position without interference during surgical procedures.
The length of the present insert device is also critical to the anchoring process in the fornix. The length of the device is related to the size of the eye, hence the optimum length for the human adult is 25 mm, for children is about 15 to 18 mm and for newborn babies is 8 mm in length.
In general, for adults, the lengths of the upper fornix and lower fornix are about 45 to 50 mm and 35 to 40 mm respectively. Thus an insert device of the present invention with a length of up to 35 mm may remain in the upper fornix and one with a length of up to 25 mm may remain in the lower fornix without causing discomfort.
The invention provides, in one of its aspects, a flexible ocular insert device adapted for the controlled sustained release of an ophthalmic drug into the eye, characterized in that the device comprises a body having a thin elongated circular cylindrical configuration with at least two radially outwardly extending protrusions, the device having a length of at least 8 mm and a diameter including the protrusions not exceeding 1.9 mm. Advantageously the dimensions of the device according to the invention are selected as: a length of 8 to 25 mm for use in the lower fornix and a length of 8 to 35 mm for use in the upper fornix; and a diameter of 0.5 to 1.9 mm.
The circular cylindrical body terminates at transverse end surfaces which may for example be planar or domed.
The material of the insert device is for example a synthetic polymer.
The present invention provides a flexible ocular insert device adapted for the controlled sustained release of an ophthalmic drug into the eye, characterized in that the device comprises a body having a circular, cylindrical configuration; the length of the device is at least 8 mm and the diameter of its body including protrusions does not exceed 1.9 mm. A plurality of protrusion elements extend radially outwardly from the body, with the protrusion elements being arranged in various patterns such as ribs or a screw configuration. The protrusions should extend radially outwardly a distance sufficient to allow the device to become anchored in the fornix tissue. Generally, the protrusions will extend outwardly a distance such that the overall diameter of the device including the protrusions is approximately 15 to 30 percent greater than the diameter of the body or core.
Examples of ophthalmic drugs include antibiotics such as tetracycline, chlortetracycline, bacitracin, neomycin, polymyxin, gramicidin, cephalexin, oxytetracycline, chloramphenicol, kanamycin, rifampicin, tobramycin, gentamicin, erythromycin and penicillin; antibacterials such as sulfonamides, sulfadiazine, sulfacetamide, sulfamethizole and sulfisoxazole, nitrofurazone and sodium propionate; antivirals including idoxuridine, trifluorothymidine, acyclovir, ganciclovir and interferon; antiallergenics such as sodium cromoglycate, antazoline, methapyriline, chlorpheniramine, cetirizine and prophenpyridadine; antiinflammatories such as hydrocortisone, hydrocortisone acetate, dexamethasone, dexamethasone 21-phosphate, fluocinolone, medrysone, prednisolone acetate, fluoromethalone, betamethasone, and triamcinolone and non-steroidal agents such as indomethacin, diclofenac, flurbiprofen, piroxicam, ibuprofen and acetyl salicylic acid; decongestants such as phenylephrine, naphazoline and tetrahydrozoline: miotics and anticholinesterase such as pilocarpine, acetylcholine chloride, physostigmine, eserine, carbachol, di-isopropyl fluorophosphate, phospholine iodine, and demecarium bromide; mydriatics such as atropine sulfate, cyclopentolate, homatropine, scopolamine, tropicamide, eucatropine, and hydroxyamphetamine; sympathomimetics such as epinephrine; immunological drugs such as vaccines and immune stimulants; hormonal agents such as estrogens, estradiol, progestational, progesterone, insulin, calcitonin, parathyroid hormone and peptide, vasopressin, hypothalamus releasing factor; beta adrenergic blockers such as timolol maleate, levobunolol HC1 and betaxolol HC1; growth factors such as epidermal growth factor and fibronectin; carbonic anhydrase inhibitors such as dichlorphenamide, acetazolamide and methazolamide and other drugs such as prostaglandins, antiprostaglandins, and prostaglandin precursors.
The drugs may be used in conjunction with a pharmaceutically acceptable carrier. Examples of pharmaceutically acceptable carriers include solids such as starch, gelatin, sugars, e.g., glucose, natural gums, e.g., acacia, sodium alginate, carboxymethyl cellulose, polymers, e.g., silicone rubber; liquids such as sterile water, saline, dextrose, dextrose in water or saline; condensation products of castor oil and ethylene oxide liquid glyceryl triester of a lower molecular weight fatty acid; lower alkanols; oils such as corn oil, peanut oil, sesame oil, and the like, with emulsifiers such as mono- or di-glyceride of a fatty acid, or a phosphatide, e.g., lecithin, and the like; glycols; polyalkylene glycols; aqueous media in the presence of a suspending agent, for example, sodium carboxy-methylcellulose, sodium alginate, poly(vinylpyrolidone), alone, or with suitable dispensing agents such as lecithin, polyoxyethylene stearate. The carrier may also contain adjuvants such as preserving, stabilizing, wetting or emulsifying agents.
The mechanism of controlled sustained drug release into the eye is for example diffusion, osmosis or bio-erosion and these mechanisms are described for example in U.S. Pat. No. 4,186,184 and in "Therapeutic Systems" by Klaus Heilmann published by Georg Thieme, Stuttgart 1978.
The period of controlled sustained release is for example up to 7 to 14 days or longer.
In one exemplary embodiment of the present invention utilizing the diffusion mechanism, the configuration of the body of the insert device is tubular with its cylindrical wall closed by transverse end walls to define a reservoir for the drug which is in liquid or gel form. At least the cylindrical wall is a membrane permeable by diffusion so that the drug is released continuously at a controlled rate through the membrane into the tear fluid.
In one exemplary embodiment of the invention utilizing the osmosis mechanism, the configuration of the body of the insert device is tubular with domed end walls, and the device comprises a transverse impermeable elastic membrane dividing the tubular interior of the device into a first compartment and a second compartment; the first compartment is bounded by a semi-permeable membrane and the impermeable elastic membrane, and the second compartment is bounded by an impermeable material and the elastic membrane. There is a drug release aperture in the impermeable end wall of the device.
The first compartment contains a solute which cannot pass through the semi-permeable membrane and the second compartment provides a reservoir for the drug which again is in liquid or gel form.
When the device is placed in the aqueous environment of the eye water diffuses into the first compartment and stretches the elastic membrane to expand the first compartment and contract the second compartment so that the drug is forced through the drug release aperture.
In one exemplary embodiment of the invention utilizing the bioerosion mechanism, the configuration of the body of the insert device is rod-like being constituted from a matrix of bioerodible material in which the drug is dispersed. Contact of the device with tear fluid results in controlled sustained release of the drug by bioerosion of the matrix. The drug may be dispersed uniformly throughout the matrix but it is believed a more controlled release is obtained if the drug is superficially concentrated in the matrix.
In another embodiment of the invention, there is employed a solid non-erodible rod with pores and dispersed drug. The release of drug can take place via diffusion through the pores. Controlled release can be further regulated by gradual dissolution of solid dispersed drug within this matrix as a result of inward diffusion of aqueous solutions.
Examples of the materials for a permeable membrane for the diffusion mechanism include but are not limited to insoluble microporous materials of polycarbonates, polyvinyl chlorides, polyamides, copolymers of polyvinyl chloride and acrylonitrile, polyethylene, polypropylene, polysulphones, polyvinylidene fluorides, polyvinyl fluorides, polychloroethers, polyformaldehydes, acrylic resins, polyurethanes, polyimides, polybenzimadozoles, polyvinyl acetates, polyethers, cellulose esters, porous rubbers, cross-linked poly (ethylene oxide), crosslinked polyvinyl pyrrolidone, cross-linked poly (vinyl alcohol) and polystyrenes.
The drug in liquid or gel form for the diffusion mechanism comprises a diffusion medium which also serves as a pharmaceutical carrier and in which the active ingredient of the drug is dissolved or suspended; the active ingredient is preferably of no more than limited solubility in the medium. Examples of diffusion media include saline, glycerin, ethylene glycol, propylene glycol, water (which may also contain emulsifying and suspending agents), mixtures of propylene glycol monostearate and oils, gum tragacanth, sodium alginate, poly(vinyl pyrrolidone), polyoxyethylene stearate, fatty acids and silicone oil.
Examples of materials for an osmotic semi-permeable membrane include but are not limited to cellulose acetate and its derivatives, partial and completely hydrolyzed ethylene-vinyl acetate copolymers, highly plasticized polyvinyl chloride, homo and copolymers of polyvinyl acetate, polyesters of acrylic acid and methacrylic acid, polyvinyl alkyl ethers, polyvinyl fluoride; silicone polycarbonates, aromatic nitrogen-containing polymeric membranes, polymeric epoxides, copolymers of an alkylene oxide and alkyl glycidyl ether, polyurethanes, polyglycolic or polyacetic acid and derivatives thereof, derivatives of polystyrene such as poly(sodium styrenesulfonate) and poly(vinyl benzyltrimethylammonium chloride), ethylene-vinyl acetate copolymers.
Examples of solutes which cannot pass through the semipermeable membrane in an osmotic mechanism include but are not limited to water-soluble inorganic and organic salts and compounds such as magnesium sulfate, magnesium chloride, sodium chloride, lithium chloride, potassium sulfate, sodium carbonate, sodium sulfate, lithium sulfate, calcium bicarbonate, sodium sulfate, calcium sulfate, potassium acid phosphate, calcium lactate, magnesium succinate, tartaric acid, acetamide, choline chloride, soluble carbohydrates such as sorbitol, mannitol, raffinose, glucose, sucrose and lactose.
Examples of bioerodible matrix materials include but are not limited to polyesters of the general formula --O--(W)--CO-- and mixtures thereof, wherein W is a lower alkylene of 1 to 7 carbons and may include a member selected from the group of alkylenes of the formula --CH 2 --, or --CH--CH 2 --, and Y has a value such that the molecular weight of the polymer is from about 4,000 to 100,000. The polymers are polymerizationcondensation products of monobasic hydroxy acid of the formula C n H 2n (OH) COOH wherein n has a value of 1 to 7, preferably 1 or 2 and the acid is especially lactic acid or glycolic acid. Also included are copolymers derived from mixtures of these acids. Bioerodible materials also include poly(orthoesters). These materials have the following general formula: ##STR1## wherein R 1 is an alkylene of 4 to 12 carbons, a cycloalkylene of 5 to 6 carbons substituted with an alkylene of 1 to 7 carbons and an alkyleneoxy of 1 to 7 carbons, and R s is a lower alkyl of 1 to 7 carbons.
Other bioerodible matrix materials which may be employed include but are not limited to the following: (1) Polyanhydrides such as poly(p-carboxyphenoxy) alkyl (e.g. p-carboxyphenoxypropane) or polymeric fatty acid dimer (e.g. poly-dodecanedioic acid) compounds and further co-polymers with sebacic acid, or phthalic acid such as disclosed in Chasin et al., Polyanhdrides for Controlled Drug Delivery, Biopharm., February 1988, 33-46; and Lee et al. (1988), The Use of Bioerodible Polymers and 5 fluorouracil in Glaucoma Filtration Surgery, Invest. Ophthalmol. Vis. Sci., 29, 1692-1697; (2) Poly (alkyl-2-cyanoacrylates) such as poly (hexyl-2-cyanoacrylate) as described by Douglas et al. (1987), Nanoparticles in Drug Delivery, CRC Crit. Rev. Therap. Drug Carr. Syst., 3, 233-261; and (3) Polyamino acids such as copolymers of leucine and methyl glutamate.
Further information on membrane and bioerodible materials is contained in U.S. Pat. Nos. 3,828,777 and 4,186,184 and also the following references: Leong and Langer (1987), Polymeric Controlled Drug Delivery, Adv. Drug Del. Rev., 1, 199-233; and Smith et al. (1990), Bioerodible Polymers for Delivery of Macromolecules, Adv. Drug Del. Rev., 4, 343-357.
Examples of materials for use as non-erodible rods include but are not limited to polymers such as hydroxyethylmethacrylate and further co-polymers with methacrylic acid, methylmethacrylate, N-vinyl 2-pyrrolidone, allyl methacrylate, ethylene glycol dimethacrylate, ethylene dimethacrylate, or 1,1,1 trimethylopropane trimethacrylate, and dimethyl diphenyl methylvinyl polysiloxane.
The above and other aspects of the present invention will become more clear from the following description, to be read with reference to the accompanying drawings of devices embodying the invention. This description is given by way of example only, and not by the way of limitation of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
In the accompanying drawings:
FIG. 1 shows a diagrammatic sectional view of a diffusional ocular insert device embodying the invention.
FIG. 2 shows a diagrammatic sectional view of an osmotic ocular insert device embodying the invention.
FIG. 3 shows an enlarged diagrammatic sectional view of a bioerodible insert device embodying the invention.
FIG. 4 shows a diagrammatic sectional view of the eye with an ocular insert device of the present invention installed in the upper and lower fornix.
FIG. 5 shows a representation of the head of a patient with the location of the installed ocular insert device shown in dashed lines.
FIG. 6 shows the position of the installed ocular insert device in a closed eye.
FIGS. 7 through 12 show diagrammatic views of further embodiments of the ocular insert device of the present invention, with various anchoring configurations.
FIGS. 13 through 16 are graphic representations showing data in regard to drug release and swelling rate in accordance with the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The ocular insert device shown in FIG. 1 comprises a circular cylindrical wall 10 of a microporous synthetic polymer membrane which is insoluble in tear fluid but is permeable by diffusion. The cylindrical wall 10 is closed by transverse planar end walls 12 which may be of the same microporous synthetic polymer membrane as the cylindrical wall 10 or alternatively may be impermeable. The overall length of the device is 8 to 25 mm or up to 35 mm for the upper fornix and its external diameter 0.5-1.9 mm.
The cylindrical wall 10 and the end walls 12 define a reservoir for a drug which diffuses through the membrane as described hereinbefore.
The ocular insert device shown in FIG. 2 comprises a circular cylindrical wall 110 closed by hemispherical domed end portions 112. The device also comprises, perpendicular to the axis of the cylindrical wall, an impermeable elastic membrane 114 dividing the interior of the device into a first compartment 116 and a second compartment 118. The cylindrical wall 110 comprises different materials as respectively do the end walls 112 so that the first compartment is bounded by a semi-permeable synthetic poller membrane 120 and the elastic membrane 114 and the second compartment is bounded by an impermeable synthetic polymeric membrane 122 and the elastic membrane 114. There is an axial drug release aperture 124 in the membrane 122 at the domed end portion 112 thereof.
The first compartment 116 contains a solute and the second compartment provides a reservoir for a drug which is forced through the aperture 124 by the stretching of the elastic membrane 114 under osmosis as described hereinbefore.
The ocular insert device shown in FIG. 3 comprises a circular cylindrical body 210 with domed end portions 212. The device is constituted from a matrix of synthetic polymeric bioerodible material in which a drug is dispersed, being concentrated superficially of the matrix for controlled release therefrom as the matrix bioerodes.
The device having the configuration as shown in FIG. 3 may also be constituted of a solid non-erodible material having pores and dispersed drug as previously discussed.
The overall length and diameter of each of the devices of FIG. 2 and FIG. 3 is the same as for the device of FIG. 1.
The ocular insert device of the present invention may be installed in the fornix by the method as follows. The applicator consists of a tube with a length of about 35 mm and a flexible container with a capacity of about 500 microliter containing a pharmaceutically acceptable viscous substance in the form of a cream:
(a) Insert the OCUFIT SR device into the tube. Squeeze the container until the viscous substance pushes the device into the mouth of the tube.
(b) Ask the patient to sit down and hold his/her chin slightly up.
(c) Ask the patient to look down continuously throughout the exercise.
(d) Separate the upper lid from the globe by about 4 to 5 mm by holding the lashes and gently pulling the lid forward and upward. Insert the tube under the eyelid for about 5 mm near the inner corner (nasal canthus) of the eye. Do not touch the inner corner of the eye and the globe.
(e) Push out the OCUFIT SR device by squeezing the container gently and continuously. In the meantime move the tube slowly from the inner corner (nasal canthus) toward the outer corner (temporal canthus), holding the tip of the tube at about 5 mm from the lid margin constantly. Stop about 5 mm from the outer corner.
N.B. By squeezing the container and moving the tube from one corner to another corner of the eye, the OCUFIT SR device should come out of the tube and sit between the lid and globe near the upper fornix.
(f) Put tip of a finger at just about the end of the tube and hold the end of the OCUFIT SR device in position. Remove the tube.
(g) With the help of the tip of a finger, gently push the OCUFIT SR device upward and toward the deep fornix. Repeat the movement twice more, once in the middle of the lid and once near the inner corner.
(h) Ask the patient to move the eye upward and downward three times. Make sure that the device is in position and is not coming out.
The device may also be installed directly by the patient using similar procedures as described above.
Upon installation, the ocular insert device of the present invention will be positioned in the upper or lower fornix in one of the positions identified as SDRD as shown in FIGS. 4 through 6 of the drawings.
By the way of comparison, ocular inserts having dimensions outside those of the present invention were constructed, with dimensions as follows:
Size: Approximately 12×5×1 mm
Shape: Oval, Lower surface with concave curvature, upper surface with convex curvature
Composition: Polypeptide matrix containing erythromycin estolate
Consistency: Semi-rigid
These inserts outside the scope of the present invention were placed in the upper fornix of the right eye of 16 patients between the ages of 6 and 8. The retention of the device in this location was followed over a period of 10 days. The right eye was examined twice a day for the presence of the insert. A new insert was replaced in the fornix if dislocation occurred. The results which were obtained showed that inserts of this type outside the scope of the present invention required frequent replacement into the eye over a ten day period. In no case were such inserts retained for more than 3 days at a time.
The foregoing comparative tests show the importance of employing an ocular insert device having the size and shape as described herein.
In further embodiments of the invention, as shown in FIGS. 7 through 12, the drug releasing device or OCUFIT SR device of the present invention may be formed with a central, longitudinally extending body or core portion, and with two or more protrusion elements extending radially outwardly from the core. The protrusion elements may be of various alternative shapes such as ribs or screw shapes so that the device may be, for example, of a ribbed design, a screw design, a bump design, a segmental design or a braided design. The protrusion elements function to anchor the device in the fornix, with the tissue of the fornix filling the spaces or interstices surrounding the device between protrusions.
At least two protrusions should be employed, with a view toward providing an overall symmetrical shape for the device. In a case where only two protrusions are employed, such protrusions should be evenly spaced relative to the length of the device so that the protrusions will be equidistant from their respective ends of the device. Where more than two protrusions are employed, it is important to provide a symmetrical arrangement with even spacing so as to achieve a uniform anchoring function along the length of the device.
As shown in FIG. 7, the device 70 with ribbed configuration has circular cylindrical walls 72 with domed end portions 74. A series of arcuate shaped ribs 76, of circular, toroidal cross section, are provided at intervals along the length of the device 70. In one embodiment, the device 70 had a core diameter "a" of 1.4 mm and with the ribs protruding outwardly from the core by a distance "b" of 0.15 mm. In this embodiment, the ribs 76 had a width "c" of 1 mm and an interval "d" between ribs 76 of 5 mm and the overall length of the device 70 was 25 mm.
In another embodiment similar to that of FIG. 7, a device 70 having a total of five ribs 76 was employed, with the space between ribs 76 being adjusted accordingly so that the ribs 76 were equally spaced apart. As few as two ribs may be employed, with one rib 76 being located adjacent each end portion of the device 70. In these embodiments as with those embodiments described hereinafter, the tissue of the fornix fills the spaces or interstices surrounding the device 70 between the protrusions, which in this case are the ribs 76.
In FIG. 8 there is shown a device 80 with screw configuration having circular cylindrical walls 82 with domed end portions 84. A series of screw-type protrusions 86 are provided at intervals along the length of the device 80. In one embodiment, the device 80 had a core diameter "a" of 1.4 mm and with the screw protrusions 86 extending outwardly from the core by a distance "b" of 0.15 mm. In this embodiment, the screw protrusions 86 had a width "c" of 1 mm and an interval "d" between protrusions 86 of 5 mm and the overall length of the device 80 was 25 mm. The angle "e" was approximately 28.9 degrees in this embodiment.
The device 90 of FIG. 9 has a plurality of raised dimples or bumps 92 having a generally hemispherical shape on the circular cylindrical walls 94 with domed end portions 96. In one embodiment, the device 90 had a core diameter "a" of 1.4 mm and with the bumps 92 extending outwardly from the core by a distance "b" of 0.15 mm. In this embodiment, the bumps 92 had a width "c" of 1 mm and an interval "d" between bumps 92 of 5 mm and the overall length of the device 90 was 25 mm. There were four longitudinally aligned rows of bumps 92 equally spaced about the circumference of the device 90 in this embodiment. The number of rows may vary from about 2 to 6.
In FIG. 10 there is shown a device 100 with a segmental configuration having a series of truncated cone-shaped segments 102 interconnected along the length of the device 100 and with dome shaped end portions 104. In one embodiment, the device 100 had a core diameter "a" of 1.4 mm and with the length "c" of each segment 102 being about 1 mm. In this embodiment, the overall base width "f" of each segment 102 was 1.7 mm and the overall length of the device 100 was 25 mm.
The device 110 of FIG. 11 also has a segmented configuration with a series of truncated cone-shaped segments 112 interconnected along the length of the device 110 and with dome-shaped end portions 114. In this embodiment, however, the device 110 is formed with mirror image segmental portions 116 and 118 so that the left one-half portion 116 of the device 110 is a mirror image of the right one-half portion 118. In one embodiment, the device 110 had a core diameter "a" of 1.4 mm and with the length "c" of each segment 112 being about 1 mm. In this embodiment, the overall base width "f" of each segment 112 was 1.7 mm and the overall length of the device 110 was 25
The device 111 of FIG. 12 has a braided design in which. a series of braided segments 113 are interconnected along the length of the device 111 and with dome shaped end portions 115. In one embodiment, the device 111 had a core diameter "a" of 1.4 mm and with the length "c" of each segment 113 being 1 mm. In this embodiment, the braided segments 113 extended outwardly from the core by a distance "b" of 0.15 mm and the overall length of the device 111 was 25 mm.
In a further embodiment of the invention, the ocular insert device of the present invention may be formed with a polygonal shape in cross section, with the polygon having, for example, five or six equal sides. Such polygonal shape may be employed as the central core with any of the configurations shown in FIGS. 7 through 12.
The drug loaded OCUFIT SR device can be formed by any of various processes such as extrusion molding, injection molding, transfer molding or compression molding.
In carrying out the extrusion molding process, polymer material is blended with drug at ratios of drug up to 40% by weight on a cooled two roll mill and then fed into a screw drive extruder. By the action of the single flight screw with diminishing pitch and a length to diameter ratio of about 12:1 to 10:1, material is continuously forced out through a coin or plate die (port) with openings conforming to the shape and dimensions of the subject device (i.e. circular). For designs involving tube configurations, a mandrel held in place by a spider flange is positioned prior to the die. The continuous noodle is pulled via conveyer belt through a heated horizontal or vertical chamber (315 to 425 degrees C.) to achieve vulcanization of the material. The final OCUFIT SR device is made by a cutting apparatus where the rods are cut to size. Additional modifications such as polishing the ends of the device can be accomplished.
In carrying out the transfer molding process, the blend of polymer material and drug is placed into a heated transfer press with an aluminum or stainless steel mold containing impressions of the proper shape and size. The material is forced into the mold..at between 200 and 4000 psi. The mold itself is kept under 10 tons of clamp pressure. The mold is kept heated and under pressure at any of the following conditions:
______________________________________4-10 minutes 135 degrees C.15 minutes 100 degrees C.30 minutes 75 degrees C.2 hours 55 degrees C.5 hours 40 degrees C.24 hours Ambient temperature (25° C.)______________________________________
The mold is cooled, separated and the formed OCUFIT SR devices .are then removed.
In one embodiment, silicone rubbers/elastomers are employed as the material from which the device is formed. The silicone rubbers/elastomers are prepared as follows:
Silicone rubber prepared using dimethylsiloxane polymer or dimethyl and methylvinyl siloxane copolymers, reinforcing silica, platinum catalyst, inhibitor and siloxane crosslinker and other vulcanizing agents such as organic peroxides is either hand mixed, mixed on a two roll mill, or injection molded together with micronized drug (predominantly 10 micron particles or less). Drug is loaded into the polymer mixture at levels up to 40 weight percent of the total weight together with any other necessary excipients or release modifiers such as glycerin or sorbitol. Entrapped air within the mixture is removed by exposure to a vacuum of about 28 inches of mercury for approximately 30 minutes. Drug is solidified within the polymer matrix by curing (vulcanizing) the mixture while being molded into the desired shape.
The device may also be formed of bioerodible polymers prepared as follows:
Solid mixtures of bioerodible polymers (Polyhydroxyacids such as polylactic acid and polyglycolic acid, and polyhydroxybutyrate; Polyesters and polyorthoesters including cyclic ortho-esters with diols or diketeneacetals or diacids with diols or polyols; Polyanhydrides made from one or more of the following: p-carboxyphenoxy propane, p-carboxyphenoxy hexane, sebacic acid, dodecanedioic acid, 1,4-phenylenedipropionic acid, isophthalic acid, polypropylene fumarate and polypropylene maleate; Polypeptides; and Polycyanoacrylates) can be admixed with up to about 60% by weight of drug. The material can be compressed in aluminum or stainless steel molds situated in a Carver hydraulic press at 12 tons of pressure for at least 15 minutes at 100 degrees C.
As a further example, the device may be formed of methacrylate hydrogels prepared as follows:
Hydrogels loaded with drug can be constructed from crosslinked methacrylate polymers which include compositions containing one or more of the following: 2-hydroxyethyl methacrylate (HEMA), ethylene glycol dimethacrylate, polymethylmethacrylate, methylmethacrylate, glycol monomethacrylate, ethylene monomethacrylates, glycol dimethacrylates, vinylpyrrolidone, methacrylic acid, divinylbenzene, and alkyldiol methacrylates, acrylamide, methylene bis acrylamide.
Various crosslinking percentages can be achieved by altering the ratios of the copolymers. For example a 40:1 weight ratio of acrylamide to methylene bis acrylamide produces a 2.5% crosslinking. A buffered solution (pH 7-9) of the copolymers is made containing the desired crosslinking ratio. The final total polymer percentage can be varied from 1 to 25%. Drug is admixed into this solution. Suitable crosslinking free radical generator and catalyst (such as ammonium persulfate and tetra methyl ethylene diamine) is added. The mixture is poured into an appropriate mold with the desired shape. Polymerization occurs within 30 minutes.
These embodiments of the invention may employ the ophthalmic drugs and pharmaceutically acceptable carriers as previously described.
The following are specific examples which were carried out in accordance with the present invention.
EXAMPLE 1
One part of silastic MDX4-4210 curing agent (Dow Corning Corp, Midland, MI) was mixed with 10 parts of MDX4-4210 Silastic base elastomer (Dow Corning Corp, Midland, MI). The material was placed under vacuum of about 28 inches of mercury for 30 minutes. Material was then transfered into a cylinder situated in a transfer press. The material was then forced into a 12 cavity aluminum mold heated to 135 degrees C. which contained impressions of the ribbed device design and forced into the mold at a transfer pressure of 400 psi for 3.5 minutes. The mold itself is kept under 10 tons of clamp pressure. The mold was cooled, separated and the formed devices were removed. The devices were cleaned by soaking in isopropyl alcohol for approximately 5 minutes and allowed to air dry.
EXAMPLE 2
One part of silastic MDX4-4210 curing agent (Dow Corning Corp, Midland, MI) was mixed with 10 parts of MDX4-4210 silastic base elastomer (Dow Corning Corp, Midland, MI). Oxytetracycline hydrochloride (Sigma Chemical Co., St. Louis) in the amount of 1% by weight of the total mixture was thoroughly blended in with care taken to minimize entrapment of air. The material was placed under vacuum of about 28 inches of mercury for 30 minutes. Material was then transfered into a cylinder situated in a transfer press. The material was then forced into a 12 cavity aluminum mold heated to 135 degrees C. which contained impressions of the ribbed device design and forced into the mold at a transfer pressure of 400 psi. The mold itself was kept under 10 tons of clamp pressure for 3.5 minutes. The mold was cooled, separated and the formed devices were removed.
EXAMPLE 3
One part of Silastic MDX4-4210 curing agent (Dow Corning Corp, Midland, MI) was mixed with 10 parts of MDX4-4210 Silastic base elastomer (Dow Corning Corp, Midland, MI). Oxytetracycline hydrochloride (Sigma Chemical Co., St. Louis) in the amount of 20% by weight of the total mixture was thoroughly blended in with care taken to minimize entrapment of air. The material was placed under vacuum of about 28 inches of mercury for 30 minutes. Material was then transfered into a cylinder situated in a transfer press. The material was then forced into a 12 cavity aluminum mold heated to 121 degrees C. which contained impressions of the ribbed device design and forced into the mold at a transfer pressure of 800 psi. The mold itself was kept under 10 tons of clamp pressure for 3.25 minutes. The mold was cooled, separated and the formed devices were removed.
EXAMPLE 4
Silastic medical grade ETR elastomer Q7-4720 (Dow Corning Corp, Midland, MI) was prepared by first individually softening Part B and Part A of the elastomer on a cooled two-roll mill. The two components were then blended together in a 1:1 ratio on the two-roll mill. Material was then transfered into a cylinder situated in a transfer press. The material was then forced into a 12 cavity aluminum mold heated to 121 degrees C. at a transfer pressure of 800 psi. The mold itself was kept under 10 tons of clamp pressure for 3.25 minutes. The mold was cooled, separated and the formed devices were removed.
EXAMPLE 5
Medical grade liquid silicone rubber Silastic Q7-4840 A/B (Dow Corning Corp, Midland, MI) was prepared by mixing equal portions of the A and B components. A vacuum of 29-29 inches of mercury was applied to the mixture for 30 minutes to deair the material. The material was compression molded in an aluminum mold in a carver press for 15 minutes at 100 degrees C. under 12 tons of pressure. The mold was cooled, separated, and the devices removed. The devices were cleaned by soaking in isopropyl alcohol for approximately 5 minutes and allowed to air dry.
EXAMPLE 6
Silastic medical grade ETR elastomer LSR 76000 (Dow Corning Corp., Midland, MI) was prepared by first individually softening Part B and Part A of the elastomer on a cooled two-roll mill. The two components were then blended together in a 1:1 ratio on the two-roll mill. Oxytetracycline hydrochloride with or without USP grade dextrose premixed in various ratios was added incrementally into the blend to assure homogeneous distribution. Material was then transferred into a cylinder situated in a transfer press. The material was then forced into a 12 cavity aluminum mold heated to 121° C. at a transfer pressure of 800 psi. The mold itself was kept under 10 tons of clamp pressure for 3.25 minutes. The mold was cooled, separated and the formed devices were removed.
EXAMPLE 7
For control devices not containing any protrusion beyond the core, simple cylindrical rods were prepared as in Example 1 except using a mold with impressions of a simple rod shape.
EXAMPLE 8
A study was carried out in which the device of the present invention was inserted into the eyes of human patients with either no disease or suffering from conjunctivitis, corneal disease, anterior uveitis, trachoma, or episcleritis. Initially, one drop of anesthetic was placed on the eye. After 2 minutes a small amount of eye ointment (such as Neosporin, Burroughs Wellcome, Research Triangle Park, NC) was applied to the lower fornix. The subject was instructed to blink several times. After two to three minutes either the ribbed device of Example 1 or non-modified rod controls of Examples 2, 5 or 7 were secured in the middle with a clean blunt forceps. With the subject looking down, the upper lid was separated from the globe using the thumb of the free hand. With the subject continuing to look down, the tip of the forceps and the device was gently pushed under the lid toward the fornix about 6-7 mm inward, making sure the device was centered in the fornix. The device was released from the forceps. With a tip of the finger the device was maneuvered into the deep fornix. The subject was instructed to move the eye up and down 3 times while holding the tip of the finger over the lid near the fornix. Results are shown below in Table 1.
TABLE 1______________________________________ Days Retained Number (percent) ofDevice Type in Fornix patients retaining device______________________________________Control devices 0-6 36 (40.5%)without ribbing(from Examples4, 5, and 7) 7-28 53 (59.5%)TOTAL 89 (100%)Ribbed devices 0-6 3 (20%)(from Example 1) 7-28 12 (80%)TOTAL 15 (100%)______________________________________
Conclusion: In these experiments ribbed OCUFIT SR devices minimized lateral movement and are better retained in the fornix (80%) than rods without ribbing (59.5%) in ocular disease patients for periods of 7-28 days.
Additional work was carried out to study the retainability of a ribbed OCUFIT SR device measuring 25 mm in length ×1.4 mm (core diameter) and 1.7 mm (protrusion diameter) for a period of up to four weeks in the normal eyes of human volunteers. These were patients whose eyes were free of active disease as compared to the study of Example 8 above in which most of the patients were suffering from eye disease at the time of the test.
The configuration of the ribbed OCUFIT SR device was as shown in FIG. 7 of the drawings but with five ribs. The material employed was a solid silastic based material MDX4-4210, a medical grade elastomer. No drug was incorporated into the OCUFIT SR device and the ends of the device were rounded.
This additional study was carried out in the eyes of human volunteers, rather than experimental animals since the size and depths of the upper or lower fornix of experimental animals are different from the human eye. In some animals, the presence and movement of nictitating membrane can dislodge the OCUFIT SR device.
The method used in this study was as follows:
The volunteer was asked to sit down, hold his/her chin slightly up and to look down continuously throughout the exercise.
The eye was anaesthetized by a drop of Benoxenate (oxybuprocaine) hydrochloride 0.4% W/V (Smith & Nephew).
The upper lid was separated from the globe by about 4 to 5 millimeters by holding lashes and gently pulling the lid backward and upward. The OCUFIT SR device held in the forceps was centrally located at a midpoint between the nasal and temporal canthus and was pushed under the upper lid inward about 6 to 7 mm. The tip of a finger was positioned in the middle of the eyelid just above the end of the forceps before the OCUFIT SR device was released and forceps removed. The device was released and the ends of the device were allowed to orient toward the respective canthus. With the tip of a finger the OCUFIT SR device was gently pushed upward and toward the deep fornix. The maneuver was repeated twice more in each corner (canthus). The volunteer was asked to move the eye downward and upward three times.
The volunteer was advised:
(a) If he/she feels that the end of the OCUFIT SR device was near the inner or outer corner (nasal or temporal canthus) of the eye or feels irritation, he/she can push the OCUFIT SR device back to the middle of the fornix by closing the eye and looking down, then, with the tip of a finger gently press the corner of the eye.
(b) Repeat maneuver explained above once in the morning after waking up and once in the evening before sleeping.
(c) Avoid rubbing the eyes.
(d) It is not possible to visualize the OCUFIT SR device in the deep fornix but he/she may be aware of sensation in a corner of the eye, relieved by prodding the upper part of the lid with a finger tip after closing the eye.
After taking a history, the eyes were examined by a slit lamp. The clinical signs of the conjunctiva, cornea and anterior urea were recorded on a specially designed proforma.
The duration of retention was planned for four weeks.
Alternatively, a mechanical insertion device may be employed for insertion of the device of the present invention.
No additional topical or systemic treatment was given to any of the volunteers. The volunteers were asked to report to the investigator if the OCUFIT SR device was rejected from the eye.
The results of the retention study are shown in Table 2.
TABLE 2__________________________________________________________________________RETENTION OF RIBBED OCUFIT SR DEVICE IN THE EYE OFVOLUNTEERSSub. Days of RetentionNo. Initial Age Sex Eye 1 5 11 24 28 32+ OCUFIT SR__________________________________________________________________________1 MMR 29 F N11 Rej. MMR** 29 F N32 Rem.2 AH 24 F N3 Rej.3 SD 63 M N64 Rem.4 MH 25 M N5 Rej.5 JH 22 M N28 Rem.6 AG 23 M N28 Rem.7 MG 24 M N24 Rej.8 SH 22 M N28 Rem.9 RMW 43 M N5 Rej.__________________________________________________________________________ N = Normal ** = Second attempt Rej. Rejected Rem. Removed
Nine volunteers with normal eyes were included. The age and gender of the volunteers are presented in Table 2.
In eight volunteers, the OCUFIT SR device was inserted once and in one volunteer (MMR) it was inserted twice.
The OCUFIT SR device was inserted in the upper fornix of the left eye in 8 volunteers and in the upper fornix of the right eye in one volunteer (RMW).
The period of retention for each volunteer is shown in Table 2. In six volunteers (67%), the OCUFIT SR device was retained for 24 days or more. Of these, five retained the device for 28 days or longer before it was removed and in one volunteer (case 7, MG) the OCUFIT SR device came out on day 24 for no apparent reason. In one volunteer (case 1, MMR) the first OCUFIT SR device came out on day 11 after vigorous physical exercise. The second OCUFIT SR device in this volunteer retained well for 32 days before it was removed. In three volunteers (cases 2,4 and 9) the OCUFIT SR device retained between 3 and 5 days respectively. In cases 2 and 4, OCUFIT SR device was rejected after rubbing of the eye and in case 9, it came out from the outer corner of the eye for no apparent reason.
In FIGS. 13 and 14, there are provided various graphs showing drug release data in accordance with the present invention. In FIG. 13 a Q7-4735 elastomer was employed and the desired or theoretical release rate for efficacy is shown as well as results obtained when the device was loaded with oxytetracycline in an amount of 10% of the weight of the unloaded device.
The data in FIG. 14 is for various amounts of loading of oxytetracycline in a device formed of the MDX4-4210 elastomer, with FIG. 14 showing results over a 24 hour period.
FIG. 15 shows a graph of drug release data in accordance with the present invention, in which dextrose is employed as a release modifier. As shown in the graph, the solids percentage is maintained at 30% and the amount of dextrose is varied between 0 and 15%, as shown in the different curves. By adding dextrose, more pores or pathways are created for drug diffusion. These drugs are employed with suitable carriers as previously discussed.
In FIG. 16 there is shown a graph of the swelling rate of a particular elastomer employed in a device of the present invention. Swelling is caused by the migration of water into the polymer, dissolving the drug and causing the polymer to swell due to an osmotic effect as water forces the polymer outwardly. Such swelling can be desirable inasmuch as a device of the present invention may lock into place as it grows in size. It has been found that the silicone materials are particularly prone to swell in this manner. As indicated by the graph, it is within the scope of the invention to select the initial dimensions of a device and, by selecting the proper combination of solid materials, e.g., oxytetracycline and dextrose, to provide for the desired final dimensions of the device after swelling.
In FIG. 16 there are shown the measurements obtained with regard to swelling of a device of the present invention which has been loaded with oxytetracycline and dextrose. At large drug loads, the device can swell so that both length and diameter are increased significantly. In view of this tendency to swell when drug has been incorporated, there are several possible approaches: (1) start with a small rod that is initially inserted; (2) adjust the ratio of drug to release modifiers which will affect the rate of water diffusion into the rod; and (3) adjust the amount of platinum catalyst to facilitate more complete cross-linking of the polymeric rod material which reduces the amount of swelling.
The data in Table 3 show physical properties, including tensile strength and % elongation for a device of the present invention prepared in various formulations with various amounts of oxytetracycline, glycerine and polyethlene glycol.
TABLE 3______________________________________PHYSICAL PROPERTIES TENSILE ELONGATIONFORMULATION (PSI) (%)______________________________________30% OTC 287.2 622.810% OTC; 5% GLY 382.5 604.630% OTC; 10% PEG 8000 183.5 534.6______________________________________
While the ocular insert of the present invention has been described herein as particularly well suited for treatment of humans, it is also within the scope of the invention to employ the present invention in the treatment of other animals such as cows and horses for diseases such as pink eye and the like.
The invention may be embodied in other specific forms without departing from the spirit or essential characteristics thereof. The present embodiments are therefore to be considered in all respects as illustrative and not restrictive, the scope of the invention being indicated by the appended claims rather than by the foregoing description, and all changes which come within the meaning and range of equivalency of the claims are therefore intended to be embraced therein. | A flexible ocular insert device adapted for the controlled sustained release of an ophthalmic drug into the eye. In one embodiment, the device includes an elongated body of a polymeric material in the form of a rod or tube containing a pharmaceutically active ingredient and with at least two anchoring protrusions extending radially outwardly from the body. The device has a length of at least 8 mm and the diameter of its body portion including the protrusions does not exceed 1.9 mm. The sustained release mechanism may, for example, be by diffusion or by osmosis or bioerosion. The insert device is advantageously inserted into the upper or lower fornix of the eye so as to be independent of movement of the eye by virtue of the fornix anatomy. The protrusions may be of various shapes such as, for example, ribs, screw threads, dimples or bumps, truncated cone-shaped segments or winding braid segments. In a further embodiment, the polymeric material for the body is selected as one which swells in a liquid environment. Thus a device of smaller initial size may be employed. The present insert device is of a size and configuration such that, upon insertion into the upper or lower fornix, the device remains out of the field of vision so as to be well retained in place and imperceptible by a patient over a prolonged period of use. The device can be retained in the upper or lower fornix for 7 to 14 days or longer. | 58,187 |
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application is a continuation of copending International Application No. PCT/DE99/03543, filed Nov. 4, 1999, which designated the United States.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates to a sensor being a semiconductor component that is suitable for measurement of material deformations, forces, torques, moments and distances.
[0004] Until now, strain gauges have been used for measuring small deformations in large-scale applications. The achievable accuracy when using such deformation gauges is about 0.5% of the total measurement range, and is thus considerably poorer than the measurement accuracy of other mechanical variables. The narrow temperature range within which strain gauges can be used, and the high power requirements for the resistance bridge that is connected are also problematic.
[0005] Semiconductor chips that have, for example, a semiconductor body composed of silicon can be deformed by the influence of pressures and tensile stresses. As a rule, operating characteristics become poorer in consequence. U.S. Pat. No. 5,337,606 describes an acceleration sensor which can be produced micro-mechanically and in which a structure in the form of a grating and composed of polysilicon is anchored such that it can move relative to the substrate. Any deflection of the grating structure is detected by a capacitive measurement by electrodes that are in the form of strips and are mounted on the substrate. Deformation of the substrate in such a component is at best suitable for making the measurement result poorer.
SUMMARY OF THE INVENTION
[0006] It is accordingly an object of the invention to provide a deformation gauge that overcomes the above-mentioned disadvantages of the prior art devices of this general type, which can be used over a wider temperature range with low power consumption, and which allows high resolution and the production of digital output signals while having good resistance to overloading.
[0007] With the foregoing and other objects in view there is provided, in accordance with the invention, a semiconductor component functioning as a sensor. The semiconductor component has a substrate, first electrodes disposed on or in the substrate, and second electrodes disposed on or in the substrate. The first electrodes and the second electrodes are disposed alternately with regard to each other. Electrode bars are disposed parallel to one another and electrically insulated from the first and second electrodes and move relative to the substrate. The first and second electrodes run in a form of strips parallel to the electrode bars. The electrode bars in each case are mounted on the substrate such that the electrode bars are electrically conductively connected at one end to others of the electrode bars. The electrode bars are disposed relative to the first and second electrodes such that, in an event of shear and strain of the substrate in a predetermined plane, a capacitance between an electrode bar and a first electrode adjacent to it, and a further capacitance between the electrode bar and a second electrode adjacent to it vary in opposite senses to one another.
[0008] The semiconductor component according to the invention is a micro-mechanical sensor which is based on the knowledge that the undesirable corruption of the measurements resulting from deformation of the semiconductor chip in conventional micro-mechanical sensors can be utilized metrologically for detection of such deformations or of the pressures and stresses on which these deformations are based. For this purpose, the deformation gauge according to the invention has bars which can move relative to the electrodes disposed firmly on or in the substrate and which are composed of an electrically conductive material, preferably of silicon or polysilicon, which is conductively doped. Deformation of the substrate can be detected by determining the differential capacitance changes of the bars with respect to the substrate electrodes disposed adjacent to them. Two mutually separate groups of electrode bars which are interleaved with one another alternately like a comb are preferably used, which bars are electrically conductively connected to one another at their ends and are anchored on the substrate. Such a configuration allows the use of a capacitive measurement bridge between four connections for electronic evaluation of the capacitance change.
[0009] In accordance with an added feature of the invention, a running bar is disposed on the substrate. The electrode bars have ends that are each attached to the running bar in such a manner that attached ends of the electrode bars are also moved in the event of shear in the substrate.
[0010] In accordance with an additional feature of the invention, a layer is disposed on the substrate. The electrode bars have ends that are each attached to the layer in such a manner that attached ends of the electrode bars are also moved in the event of shear in the substrate.
[0011] In accordance with another feature of the invention, a running bar is anchored at points to the substrate. The electrode bars have ends that are each attached to the running bar in such a manner that, in an event of strain in the substrate, attached ends of the electrode bars are held at a constant distance from the points anchoring the running bar on the substrate.
[0012] In accordance with a further feature of the invention, a layer is anchored at points to the substrate. The electrode bars have ends each attached to the layer in such a manner that, in an event of strain in the substrate, attached ends of the electrode bars are held at a constant distance from the points anchoring the layer on the substrate.
[0013] In accordance with another added feature of the invention, the electrode bars include first electrode bars and second electrode bars each mounted on the substrate such that they are electrically conductively connected to one another at one end and the first electrode bars and the second electrode bars are interleaved with one another like a comb. The first electrodes, the second electrodes, the first electrode bars and the second electrode bars have separate electrical connections.
[0014] In accordance with a concomitant feature of the invention, a capacitive measurement bridge is formed by the first electrode bars and the second electrode bars being disposed alternately.
[0015] Other features which are considered as characteristic for the invention are set forth in the appended claims.
[0016] Although the invention is illustrated and described herein as embodied in a deformation gauge, it is nevertheless not intended to be limited to the details shown, since various modifications and structural changes may be made therein without departing from the spirit of the invention and within the scope and range of equivalents of the claims.
[0017] The construction and method of operation of the invention, however, together with additional objects and advantages thereof will be best understood from the following description of specific embodiments when read in connection with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] [0018]FIGS. 1 a and 1 b are diagrammatic, plan views of exemplary embodiments of a deformation sensor according to the invention;
[0019] [0019]FIG. 2 is a cross-sectional view of the deformation sensor illustrated in FIG. 1;
[0020] [0020]FIG. 3 is a circuit diagram for a capacitive measurement bridge of the configuration shown in FIG. 1 b.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0021] In all the figures of the drawing, sub-features and integral parts that correspond to one another bear the same reference symbol in each case. Referring now to the figures of the drawing in detail and first, particularly, to FIG. 1 a thereof, there is shown a plan view of a deformation gauge formed as a semiconductor component, as can be produced by CMOS-compatible micro-mechanical techniques. An upper view of elements of existing electrodes, passivation or covers has been removed in the view in FIG. 1 a . It is thus possible to see electrodes 1 , 2 which are shown in FIG. 1 a , in the form of strips, are disposed parallel to one another, and are formed in a substrate 6 (FIG. 2) or in layers applied to the substrate 6 . The electrodes 1 , 2 may, for example, be doped regions in the semiconductor material. Structures which can be produced micro-mechanically are applied to a top face of the semiconductor, which structures contain electrode bars A which are preferably electrically conductively connected to one another at one end by a transverse-running bar 3 , and are mounted on the substrate 6 . The mounting can be provided, for example, along the entire bar 3 , for example in the region of an anchor 4 that is outlined by a dash line. Such anchoring is particularly suitable for measurement of shears in the substrate 6 . One alternative is provided, for example, by mounting within the region of anchoring 5 , likewise outlined by a dash line. Such anchoring, which allows the majority of the bar 3 to move with respect to the substrate 6 , is particularly suitable for measurement of strains or compressions in the substrate 6 . The electrode bars A shown in the drawing may all be attached to the same bar 3 at one end. The embodiment illustrated in FIG. 1 b and having two separate bars 3 , to which the electrode bars A, B are attached alternately, so that the electrode bars A, B are interleaved with one another like a comb, has metrological advantageous, which will be described further below.
[0022] [0022]FIG. 2 shows the cross section, as identified in FIG. 1 b , of the described exemplary embodiments. FIG. 2 shows that an insulation layer 7 is applied to the substrate 6 . The electrodes 1 , 2 , which are fit firmly relative to the substrate 6 , are located on the insulation layer 7 .
[0023] The electrodes 1 , 2 can instead be formed entirely or partially by doped regions formed in the substrate 6 , which are surrounded by a dielectric material or by a semiconductor material which is weakly doped or is doped in the opposite sense.
[0024] The electrode bars A, B are disposed, such that they can move with respect to the substrate 6 , in the cavities that exist between the electrodes 1 , 2 . The structure is preferably covered over at the top by a passivation layer 8 . The configuration illustrated here as an example has the advantage that the electrode bars A, B are surrounded by the electrodes 1 , 2 such that a largely linear change in the capacitances or capacitance differences with respect to respectively adjacent electrodes occurs when the electrode bars A, B are deflected relative to the substrate 6 .
[0025] The stresses that occur in a body are described by a second-stage tensor, which is referred to as the stress tensor. The tensor can be represented as a three-row square matrix, whose diagonal elements indicate the stress in each one of three mutually perpendicular directions, and whose other elements indicate the stresses in the respective planes at right angles to these directions, as shears. The stress tensor is symmetrical, owing to the elastic conditions in the body. A co-ordinate transformation can thus be used such that the stress tensor is a diagonal matrix in the new co-ordinate system. The axes that define the new co-ordinate system are the eigen vectors of the matrix, the main stress directions.
[0026] The diagonal elements are the associated eigen values, the main stresses. The shear stress and the shear distortion are at a maximum in the direction of the angle bisectors between the main stress directions.
[0027] The deformation gauge is intended to allow detection of deformation of the semiconductor body in the plane in which the electrodes 1 , 2 are disposed, that is to say in the plane of the top face of the chip. Stresses and shears that occur in a plane are thus recorded. Thus, in the deformation gauge intended for shear measurement, the electrode bars A, B are preferably aligned along an angle bisector between the two main stress directions lying in the plane. The ends of the electrode fingers are preferably mounted on the substrate by the bar 3 in the surface (which is shown as an example in FIGS. 1 a and 1 b ) of the anchor 4 , which extends over the entire bar length. The stress state acting in the substrate 6 is not transmitted to the free-standing part of the electrode bars; the actual electrode bars remain free of deformation beyond the anchorage point, while the substrate 6 and the electrodes 1 , 2 which are fit in it are deformed.
[0028] In the cross section which is shown in FIG. 2, it can be seen that, in this preferred embodiment, the electrodes 1 and 2 which are firmly attached to the substrate 6 preferably have flat extents above and below the electrode bars A, D. The flat elements are electrically conductively connected to one another, and are made mechanically robust, by supports 9 . Owing to the at least partial overlap of the surfaces of the electrodes 1 , 2 and of the electrode bars A, B, the capacitance change is essentially linear with respect to the deflection of the electrode bars A, B, and is thus approximately linear with respect to the shear deformation of the substrate 6 . In this case, it is assumed that the electrode bars A, B move relative to the substrate 6 essentially in the plane in which they are disposed. Any vertical bending of the electrode bars A, B, or other manufacturing-dependent tolerances, are in this case largely insignificant. A distance between the electrode bars A, B and the vertical supports 9 of the fixed electrodes 1 , 2 can be chosen to be sufficiently large that the conducive elements of the electrodes 1 , 2 do not make any significant contribution to the capacitance change. A resistance of the micro-mechanical structure to overloading is provided by the large lateral distance between the electrode bars A, B and the supports 9 .
[0029] In the described simple embodiment, in which all the electrode bars are attached to the same transverse-running bar 3 and are thus all electrically conductively connected to one another, the evaluation is carried out by recording the differential capacitance changes of the electrode bars A, B with respect to the respectively adjacent electrodes 1 and 2 . The electrode bars A, B thus form the center connection of a capacitance half-bridge, which is formed by two variable capacitors connected in series. The external connections are formed by the electrodes 1 and 2 . The value ΔC 1A =−ΔC 2A =n·ε 0 ·(d 1 −1 +d 2 −1 )·1 2 γ/2 is thus obtained as the capacitance change of the deformation gauge having n electrode bars of length 1 , where γ is the value of the shear deformation, d 1 and d 2 are the values of the upper and lower air gap, respectively, between the electrodes 1 , 2 , and ε 0 the electrical field constant, also referred to as the absolute dielectric constant.
[0030] The electrode bar length 1 that can be achieved depends on technological characteristics. If there is a tensile stress or compressive stress in the silicon layer in which the electrode bars A, B are structured, the electrode bars are increasingly bent toward the free ends. It may thus be better to achieve high sensitivity levels of the deformation sensor with smaller air gaps between the electrodes, rather than with longer electrode bars.
[0031] The preferred embodiment illustrated in FIG. 1 b and having two groups of electrode bars A and B which are interleaved with one another like a comb has the advantage that a full capacitive bridge for detection of the measurement signals can be provided by using the four different connections. The associated circuit is illustrated schematically in FIG. 3. It can be seen from the circuit diagram that the electrode bars A and the electrode bars B each form variable capacitance capacitors with the adjacent electrodes 1 and 2 on different sides. Very minor mistuning of such capacitive bridges can be determined highly accurately by, for example, of Σ-Δ modulators using switched-capacitor-technology. In circuits such as this, which are known per se, differential SC input integrators are followed, for example, directly by a quantizer, whose output signal is fed back. The output signal from the modulator is a high-frequency bit stream, which can be further processed digitally by an electronic logic circuit that is preferably monolithically integrated on the same chip. The bit resolution which is achievable is governed by the ratio of the Σ-Δ operating frequency to the signal frequency. A decimation filter converts the high-frequency 1-bit signal to a low-frequency multi-bit signal, and at the same time provides low-pass filtering.
[0032] Owing to the symmetry of the electrode configuration shown in FIG. 1 b , temperature fluctuations have little influence on the zero point of the measurement when the substrate 6 is not deformed. Thermal expansion can be assumed to be three-dimensionally isotropic, and thus does not produce any difference signals in the measurement bridge. The symmetry characteristics ensure very little lateral sensitivity to bending and warping of the chip. Tensile and compressive stresses along the electrode bars or the bar 3 use as the anchor, which result from production and are not caused by deformation of the substrate 6 , do not lead to any difference signals in the measurement bridge. Any asymmetry which may result from adjustment errors during the manufacturing process can be compensated for by interconnecting two electrode configurations as shown in FIGS. 1 a or 1 b , which are disposed rotated through 90° with respect to one another. The sensor then contains two configurations as shown in FIGS. 1 a and 1 b . It is also possible to fit a number of such configurations on the same substrate 6 , in order to improve the measurement accuracy further.
[0033] Effects from bending of the electrode bars and thermomechemical influences can be eliminated by suitable circuitry using a compensation capacitor. In the described preferred circuit embodiment, the compensation capacitor is connected in the feedback path of the SC input integrator and, in principle, has the same circuitry as that in FIG. 3, but in which the connections 1 and 2 , and A and B, are connected to one another. Such a compensation capacitor can be formed by a further, identical micro-mechanical component.
[0034] In the alternative configuration, the deformation gauge whose anchor 5 on the substrate 6 has a small area is particularly suitable for strain measurement. Neither forces nor torques are introduced into the free-standing electrode structure, so that there is no deformation of the free-standing electrode bars when the substrate 6 is stretched or compressed. The measurement variable is the capacitance change of the electrode bars A, B with respect to the electrodes 1 , 2 attached to the substrate 6 . The value of the capacitance change when the substrate 6 deforms in this strain gauge is not proportional to the square of the length 1 of the electrode bars A, B, but is proportional to the product of the length 1 and the length of the bar 3 .
[0035] The embodiment shown in FIG. 1 b is preferable for the strain gauge, since the embodiment shown in FIG. 1 a has comparatively high lateral sensitivity to shear distortion. In the configuration shown in FIG. 1 b , the effects of shear distortion can be eliminated better. The electronic circuit that is connected can in principle correspond to the exemplary embodiment, as a shear sensor.
[0036] If one assumes thermal expansion to be three-dimensionally isotropic, then unequal thermal coefficients of expansion in the measurement object and in the substrate 6 of the deformation sensor connected to it, together with the electrode bars A, B, lead to small difference signals in the measurement bridge, which do not occur when measuring shear. These errors in the measurement of absolute strains cannot be suppressed by the compensation capacitor. Calibration by a measurement of the temperature of the sensor, if required, overcomes this in the same way as that used conventionally with strain gauges.
[0037] The active sensor area should be placed as close as possible to the center of the chip since this is where the stress state of the measurement object is best coupled into the chip and any edge effects which occur have decayed. This results in the chip size having minimum dimensions, which can be determined from the thickness of the chip and the mechanical characteristics of the mounting material, without any further difficulties. The mounting of the deformation gauge on the measurement object is subject to stringent requirements for the mechanical characteristics of the joint. However, in this respect, the deformation gauge does not differ from conventional strain gauges, so that the procedures known from strain gauges can be transferred as appropriate to the mounting of the deformation gauge according to the invention. Since the chip itself is resistant to overloading up to the ultimate stress limit of the material of the semiconductor body, the maximum deformation is defined by plastic effects or by destruction of the connecting layer to the measurement object.
[0038] Strain gauges are generally bonded. However, owing to the greater thermal load capacity of the deformation gauge according to the invention, other connection techniques are also feasible, such as soldering, anode bonding or glass bonding. Grinding the chip down to a thickness of 100 μm to 300 μm considerably reduces the shear load in the bonding joint. Further improvements are achieved with a chip that becomes thinner towards the edge.
[0039] The deformation gauge has the further advantage that a configuration of a number of the electrode configurations as shown in FIGS. 1 a or 1 b on the same chip is feasible, even with different alignments relative to the substrate 6 , and thus different sensitivity axes. | A micromechanical sensor is described which contains electrodes that are disposed on a substrate, and electrode bars made of silicon that can move with regard to the electrodes. A deformation of the substrate is measured by determining differential changes in a capacity of the electrode bars in comparison to adjacently disposed electrodes. Two groups of electrode bars are preferably used which are interlocked with one another in an alternating comb-like manner, which, are separate from one another, and are interconnected at the ends thereof in an electrically conductive manner, and which are anchored on the substrate. | 22,931 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of U.S. provisional patent application No. 61/029,648 filed Feb. 19, 2008, the disclosure of which is incorporated herein by reference in its entirety.
FIELD OF THE INVENTION
[0002] The present invention relates generally to imagers, and more particularly, to a method and resulting device for reducing crosstalk in back illuminated imagers.
BACKGROUND OF THE INVENTION
[0003] CMOS or CCD image sensors are of interest in a wide variety of sensing and imaging applications in a wide range of fields including consumer, commercial, industrial, and space electronics. Imagers based on charge coupled devices (CCDs) are currently the most widely utilized. CCDs are employed either in front or back illuminated configurations. Front illuminated CCD imagers are more cost effective to manufacture than back illuminated CCD imagers such that front illuminated devices dominate the consumer imaging market. Front-illuminated imagers, however, have significant performance limitations such as low fill factor/low sensitivity. The problem of low fill factor/low sensitivity is typically due to shadowing caused by the presence of opaque metal bus lines, and absorption by an array circuitry structure formed on the front surface in the pixel region of a front-illuminated imager. Thus, the active region of a pixel is typically relatively small (low fill factor) in large format (high-resolution) front-illuminated imagers.
[0004] Back-illuminated semiconductor (CCD and CMOS) imaging devices are advantageous over front-illuminated imagers for high fill factor, better overall efficiency of charge carrier generation and collection, and are suitable for small pixel arrays. Fabrication of thinned back illuminated imagers has several challenges. One challenge is the loss of charge carriers near the back surface due to inherent dangling bonds present at the silicon back surface, which reduces Quantum Efficiency (QE) if the backside of the thinned imager is not pinned. Eliminating this problem requires additional treatment at the backside of the device, which adds to the complexity of the fabrication process.
[0005] A second challenge is absorption of charge carriers within the epitaxial layer, which prevents charge carriers from reaching processing components on the front side, which reduces sensitivity and efficiency of the device. In back illuminated imagers, photon radiation that enters the backside of the imagers generates charge carriers in the silicon epitaxial layer. The location of the charge generation in the epitaxial layer depends on the absorption length of the incident photon, which in turn depends on its wavelength. Photons with longer wavelengths, such as red, penetrate deeper into the epitaxial layer as compared to shorter wavelengths, such as blue. To generate maximum charge carriers from all the incident photons of different wavelengths requires an appropriate thickness for the epitaxial layer. Further, charge carriers generated near the back side of the imager should be driven to the front side as quickly as possible in order to avoid horizontal drift of carriers into adjacent pixels, which may smear an image.
[0006] Additional challenges include excessive thinning of wafers, which poses yield issues such as stress in the thinned wafer, and uniformity of thickness, etc. Fabrication cost of back illuminated imagers can be higher than for front illuminated imagers due to thinning and backside treatment.
[0007] To overcome these problems, techniques employing ultra thin silicon-on-insulator (SOI) wafers for the fabrication of back illuminated CCD/CMOS imagers have been developed, an example of which is described in U.S. Pat. No. 7,238,583 (hereinafter “the '583 Patent”), which is incorporated by reference herein in its entirety. In the '583 Patent, a thin semiconductor seed layer is supported by an ultra-thin substrate and an insulator layer made of an electrically insulating material such as silicon dioxide. An epitaxial layer may be grown substantially overlying the seed layer to an appropriate thickness to accommodate devices that are to operate at wavelengths from less than 100 nanometers (deep ultraviolet) to more than 3000 nanometers (far infrared). In order to drive charge carriers to the front side without recombination near the back side, and to prevent horizontal drift, a large electric field needs to be generated within the device. This is accomplished by doping the insulation and seed layers at an initial concentration, growing the epitaxial layer on the seed layer, and then causing the dopant to diffuse into the epitaxial layer such that the final net doping profile has its highest concentration in the insulator layer, with the net doping profile decreasing monotonically within the insulator layer and epitaxial layer.
[0008] This technique solves the aforementioned problems. However, as technology advances in the fabrication of CMOS devices, the current CMOS imaging market demands high pixel density, and hence small pixel size for imagers. The scaling of pixel size also results in a lower bias supply. This limits the drift field that can be produced in a small pixel back illuminated imager array. Charge carriers that are generated near the backside due to short wavelength photons will tend to diffuse to the adjacent pixel, if there is not enough drift field. This phenomenon, which is referred as crosstalk, can be worse for a small pixel back illuminated array. Furthermore, photons that have a non-perpendicular incident angle relative to the back-side surface may generate carriers in adjacent pixels, which is a form of optical crosstalk.
[0009] Accordingly, what would be desirable, but has not yet been provided, are a method and resulting device that reduces crosstalk in back illuminated imagers. Such a method and device would employ the doping profile technique disclosed in the '583 Patent where SOI wafers are used as a starting material.
SUMMARY OF THE INVENTION
[0010] The above-described problems are addressed and a technical solution achieved in the art by providing a method and resulting device for reducing crosstalk in a back-illuminated imager, comprising providing a substrate comprising an insulator layer and a seed layer substantially overlying the insulator layer, an interface being formed where the seed layer comes in contact with the insulator layer; forming an epitaxial layer substantially overlying the seed layer, the epitaxial layer defining plurality of pixel regions, each pixel region outlining a collection well for collecting charge carriers; and forming one of an electrical, optical, and electrical and optical barrier about the outlined collection well extending into the epitaxial layer to the interface between the seed layer and the insulator layer. The seed layer and the epitaxial layer of the device have a net dopant concentration profile which has an initial maximum value at an interface of the seed layer and the insulator layer and which decreases monotonically with increasing distance from the interface within an initial portion of the semiconductor substrate and the epitaxial layer. At least one imaging component is formed at least partially overlying and extending into the epitaxial layer. A plurality of alignment keys are formed substantially overlying the epitaxial layer.
[0011] The electrical barrier can be formed about the outlined collection well using implanted dopants; an etched trench filled with an electrically insulating material; a combination of implanted dopants and an etched trench filled with an electrically insulating material. An electrical/optical barrier can be formed by filling trenches with an electrically insulating material about outlined collection wells, opening trenches about the inner filled trenches, and filling the outer trenches with dopants.
[0012] In another embodiment, a method for reducing crosstalk in a back-illuminated imager includes the steps of providing a substrate comprising an insulator layer and a seed layer substantially overlying the insulator layer, an interface being formed where the seed layer comes in contact with the insulator layer; defining pixel regions in the seed layers each pixel region outlining a collection well for collecting charge carriers; depositing an electrically insulating layer substantially overlying the seed layer; patterning the electrically insulating layer such that it forms a ring about location of the outlined collection well; and growing an the epitaxial layer substantially about the seed layer and the ring using an epitaxial lateral overgrowth (ELO) technique. The seed layer and the epitaxial layer of the device have a net dopant concentration profile which has an initial maximum value at the interface of the seed layer and the insulator layer and which decreases monotonically with increasing distance from an interface within an initial portion of the semiconductor substrate and the epitaxial layer.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] The present invention will be more readily understood from the detailed description of an exemplary embodiment presented below considered in conjunction with the attached drawings and in which like reference numerals refer to similar elements and in which:
[0014] FIG. 1A is a perspective view of a back-illuminated imager that reduces crosstalk, constructed according to an embodiment of the present invention;
[0015] FIG. 1B is a top down view of a portion of FIG. 1 , showing electrical/optical barriers forming rings about pixel collection wells;
[0016] FIG. 2 shows a side view and top down view of the alignment keys formed in the epitaxial layer, according to an embodiment of the present invention;
[0017] FIG. 3 shows a cross-section of an imager having a plurality of isolation barriers formed therein by means of implanted dopants, according to an embodiment of the present invention;
[0018] FIG. 4 is a flow diagram of a method for forming isolation barriers made from high energy implants according to the embodiment of FIG. 3 ;
[0019] FIG. 5 shows a cross-section of an imager having a plurality of isolation barriers formed therein by means of oxide trenches, according to an embodiment of the present invention;
[0020] FIG. 6 is a flow diagram of a method for forming isolation barriers made from oxide trenches according to the embodiment of FIG. 5 ;
[0021] FIG. 7 shows a cross-section of an imager having a plurality of isolation barriers formed therein by means of both oxide trenches and high energy implants, according to an embodiment of the present invention;
[0022] FIG. 8 is a flow diagram of a method for forming isolation barriers made from oxide trenches and high energy implants according to the embodiment of FIG. 7 ;
[0023] FIG. 9 shows a cross-sections of an imager having a plurality of isolation barriers formed as rings about collection well regions from oxide “pillars”, according to an embodiment of the present invention;
[0024] FIG. 10 shows a cross section of the imager of FIG. 9 with an epitaxial layer grown substantially about the pillars using an epitaxial lateral overgrowth (ELO) technique;
[0025] FIG. 11 is a flow diagram of a method for forming isolation barriers made from oxide pillars using an ELO technique according to the embodiment of FIGS. 9 and 10 ;
[0026] FIG. 12 shows a cross-section of an imager having a plurality of trenches formed therein that are filled with both an electrical barrier of oxide and an optically opaque material”, according to an embodiment of the present invention; and
[0027] FIG. 13 is a flow diagram of a method for forming isolation barriers made from oxide and an optically opaque material according to the embodiment of FIG. 12 .
[0028] It is to be understood that the attached drawings are for purposes of illustrating the concepts of the invention and may not be to scale.
DETAILED DESCRIPTION OF THE INVENTION
[0029] Referring now to FIGS. 1A and 1B , there is shown a back-illuminated imager 10 , constructed according to an embodiment of the present invention. The imager 10 may include an initial substrate 12 , sometimes referred to in the art as a semiconductor-on-insulator (SOI) substrate, which is composed of handle wafer 14 to provide mechanical support during processing, an insulator layer 16 (buried oxide layer), and seed layer 18 . The handle wafer 14 may be a standard silicon wafer used in fabricating integrated circuits. Alternatively, the handle wafer 14 may be any sufficiently rigid substrate composed of a material which is compatible with the steps of the method disclosed herein. The handle wafer, at later processing steps, can be removed completely. Insulator layer 16 may comprise an oxide of silicon with a thickness ranging up to 1 micrometer. Among other embodiments, the thickness of insulator layer 16 may fall in a range from about 10 nm to about 5000 nm. If the handle wafer 14 is completely remove, the insulator layer 16 may also be thinned to produce an anti-reflective layer. Seed layer 18 may be comprised of crystalline silicon having a thickness from about 5 nanometers to about 100 nanometers.
[0030] SOI substrates are available commercially and are manufactured by various known methods. In one method, thermal silicon oxide is grown on silicon wafers. Two such wafers are joined with oxidized faces in contact and raised to a high temperature. In some variations, an electric potential difference is applied across the two wafers and the oxides. The effect of these treatments is to cause the oxide layers on the two wafers to flow into each other, forming a monolithic bond between the wafers. Once the bonding is complete, the silicon on one side is lapped and polished to the desired thickness of seed layer 18 , while the silicon on the opposite side of the oxide forms handle wafer 14 . The oxide forms insulator layer 16 .
[0031] Another method of fabricating an SOI substrate begins with obtaining a more standard semiconductor-on-insulator (SOI) wafer in which the seed layer 18 has a thickness in the range from about 100 nm to about 1000 nm. A thermal oxide is grown on the semiconductor substrate, using known methods. As the oxide layer grows, semiconductor material of the semiconductor substrate is consumed. Then the oxide layer is selectively etched off, leaving a thinned semiconductor substrate having a desired seed layer thickness.
[0032] SOI substrates manufactured by an alternative method, known as Smart Cut.™., are sold by Soitec, S.A.
[0033] Seed layer 18 may comprise silicon (Si), Germanium (Ge), SiGe alloy, a III-V semiconductor, a II-VI semiconductor, or any other semiconductor material suitable for the fabrication of optoelectronic devices.
[0034] An epitaxial layer 20 is formed on the seed layer 18 , using seed layer 18 as the template. Depending on the material of seed layer 18 , epitaxial layer 20 may comprise silicon (Si), Germanium (Ge), SiGe alloy, a III-V semiconductor, a II-VI semiconductor, or any other semiconductor material suitable for the fabrication of optoelectronic devices. Epitaxial layer 20 may have a thickness from about 1 micrometer to about 50 micrometers. The resistivity of the epitaxial layer 20 can be controlled by controlling the epitaxial growth process.
[0035] Referring now to FIGS. 1A and 2 , alignment keys 22 are printed on and etched into the epitaxial layer 20 . The alignment keys 22 can be used to align subsequent layers during the imager fabrication process. The use of alignment keys can result in highly accurate alignment of about 0.1 micrometer or less for subsequently deposited layers. Using photolithography, key patterns 24 are printed on a top portion 26 of the epitaxial layer 20 . A trench plasma etch process can be used to etch the underlying epitaxial layer 20 below the key patterns 24 until the etched away silicon is stopped by the underlying insulator/buried oxide layer 16 . The open trenches 28 are then filled with an electrically insulating material such as an oxide of silicon, silicon carbide, silicon nitride, or poly-silicon.
[0036] Referring again to FIGS. 1A and 1B , one or more imaging structures 30 , such as but not limited to CCD or CMOS imaging structures, may be fabricated on the epitaxial layer 20 . These imaging structures 30 may include charge-coupled device (CCD) components, CMOS imaging components, photodiodes, avalanche photodiodes, phototransistors, or other optoelectronic devices, in any combination. Also included may be other electronic components such as CMOS transistors, bipolar transistors, capacitors, or resistors (not shown). After fabrication of the one or more imaging structures 30 is completed, the handle wafer 14 is removed by etching from the back side of the back-illuminated imager 10 . The insulator layer 16 can be thinned to a desired thickness such that it acts as an anti-reflective layer to a desired incoming wavelength of light. Alternatively, the insulating layer 16 can also be removed completely, and another suitable material can be deposited on the remaining epitaxial layer 20 which can be of a desired thickness so as to act as an anti-reflective coating/layer. Optical components (not shown) can be bonded to the back side of the imager 10 using the alignment keys 22 as precision guides. The one or more optical components can comprise color filters and micro-lenses to produce wavelength dependent signals.
[0037] Before the imaging structures 30 are formed, one of electrical, optical, and electrical and optical barriers 32 are formed in the epitaxial layer 20 about the collection wells 34 of each of the pixels 36 comprising the imager 10 . Each of the collection wells 34 and barriers 32 are separated from each other by regions 37 where the transfer/readout circuit elements belonging to the imaging structures 30 are fabricated. The barriers 32 preferably extend vertically from about the top surface 35 of the epitaxial layer down to the surface 38 , 39 of one of the seed layer 18 and the insulator layer 16 , respectively. The barriers 32 may be formed by one of several techniques and of several types of materials to be described hereinbelow.
Method Embodiment-1: Use of Higher Energy Implants to Create Electrical Barriers
[0038] FIG. 3 shows a cross-section of an imager 40 having a plurality of isolation barriers formed therein by means of implanted dopants. The high-energy implants 42 are formed from available techniques in the fabrication industry. Today's high-energy (on the order of MeV) implanters are capable of implanting species in the range of 2-10 um deep into silicon. Referring now to FIGS. 1-4 , a method 50 for forming isolation barriers made from high energy implants is described as follows:
[0039] At step 52 , an SOI wafer 12 which has a thin Si seed layer 18 is provided. At step 54 , an epitaxial layer 20 with a desired thickness (2-10 um) and resistivity is grown on the seed layer 18 . At step 55 , the doping profile of the epitaxial layer 20 is engineered according to the technique described in the '583 Patent. At step 56 , alignment keys 22 are formed in the epitaxial layer 20 . Sub-steps include printing alignment keys on the epitaxial layer 20 using photolithography; trench etching the epitaxial layer 20 ; and filling the trenches with an electrically insulating material, such as an oxide (preferably of silicon). At step 58 , boundary rings are defined about the collecting wells of the pixels using photolithography and with the aid of the alignment keys formed earlier. At step 60 , using high-energy implanters, appropriate dopant species are implanted at the locations of the boundary rings around collecting wells such that the dopants reach down to the interface between the insulator layer 16 and the seed layer 18 . For a p-type substrate, the high energy implants (dopants) can be formed by ion implanting p-type impurities into a p-type epitaxial layer (and likewise n-type impurities for an n-type epitaxial layer). At step 62 , the dopants can be thermally activated. At step 64 , imaging structures 30 are formed overlying the epitaxial layer 20 . The dopants can be activated by processes such as rapid thermal annealing so that the diffusion can be minimized. The dopants, once activated, provide an electrical isolation barrier such that carriers generated inside a collecting well will not diffuse into adjacent pixels.
Method Embodiment-2: Use of Oxide Trenches to Create Electrical Barriers
[0040] FIG. 5 shows a cross-section of an imager 64 having a plurality of isolation barriers formed therein by means of oxide trenches. The oxide trenches 66 , being insulators, act as electrical barriers to generated charge carriers and confine them within pixel collecting wells. One advantage of this method is that the barrier trenches 66 can be defined along with the alignment keys, eliminating the need for another photo mask. Referring now to FIGS. 1-2 , 5 and 6 , a method 68 for forming isolation barriers made from oxide trenches is described as follows:
[0041] At step 70 , an SOI wafer 12 which has a thin Si seed layer 18 is provided. At step 72 , an epitaxial layer 20 with a desired thickness (2-10 um) and resistivity is grown on the seed layer 18 . At step 73 , the doping profile of the epitaxial layer 20 is engineered according to the technique described in the '583 Patent. At step 74 , trench outlines are formed about collection wells collecting along with alignment keys 22 on the surface of the epitaxial layer 20 using photolithography. At step 76 , the epitaxial layer 20 is trench etched down to the buried oxide (insulation) layer 16 . At step 78 , the trenches 22 , 66 are filled with an electrically insulating material such as an oxide of silicon. At step 80 , the tops of the trenches 22 , 66 are planarized. At step 82 , imaging structures 30 are formed overlying the epitaxial layer 20 .
[0042] One concern with employing the method 68 is that the trench etch step may result in unnecessary traps at the interfaces between epitaxial layer silicon and trench filled oxide. However, the number traps can be reduced by thermal annealing.
Method Embodiment-3: Use of both Higher Energy Implants and Oxide Trenches to Create Electrical Barriers:
[0043] FIG. 7 shows a cross-sectional of all imager 84 having a plurality of isolation barriers 86 formed therein by means of both oxide trenches 88 and high energy implants 90 , thereby combining methods 1 and 2 by creating oxide trenches and implanting dopants around those trenches. Referring now to FIGS. 1-2 and 7 and 8 , a method 92 for forming isolation barriers made from oxide trenches and high energy implants is described as follows:
[0044] The method 92 begins by performing steps 70 to 80 of the method 68 to create oxide trenches and alignment keys. At step 94 , regions about each of the filled trenches are opened down to the oxide layer 18 , and at step 96 , the regions are implanted with high energy dopants, the dopants being thermally activated thereupon. At step 97 , imaging structures 30 are formed overlying the epitaxial layer 20 . Since the oxide trenches are encapsulated by dopants, the electrical barrier due to the dopants can reduce the effect of traps at the interface between the high energy dopants and the epitaxial silicon.
Method Embodiment-4: Use of Oxide Isolation Regions Formed by an Epitaxial Lateral Overgrowth Technique to Create Electrical Barriers
[0045] FIGS. 9 and 10 show cross-sections of an imager 98 having a plurality of isolation barriers comprising oxide “pillars” 102 formed as rings about collection wells with an epitaxial layer 106 grown substantially about the pillars 102 using an epitaxial lateral overgrowth (ELO) technique. This technique completely eliminates traps created in a trench process. Referring now to FIGS. 1-2 and 9 - 11 , a method 108 for forming isolation barriers made from oxide pillars and using an ELO technique to grow an epitaxial layer is described as follows:
[0046] At step 110 , an SOI wafer 12 which has a thin Si seed layer 18 is provided. At step 112 , an electrically insulating layer such as a layer of an oxide of silicon (not shown) is deposited substantially overlying the seed layer 18 , the thickness of the oxide layer (about 2-10 um) being substantially similar to a final desired final epitaxial layer thickness. At step 114 , the oxide layer is patterned such that it forms rings about collecting wells (not shown), and also forms alignment keys 104 . At step 118 , the oxide rings are partially dry etched anisotropically and the remaining oxide is wet etched, the remaining oxide forming the ringed pillars 102 having a height of about 3 um. At step 120 , the epitaxial layer 106 is grown substantially about the seed Si layer 18 , the ringed pillars 102 , and the alignment keys 105 using an ELO technique, such as the ELO technique described in copending U.S. patent application Ser. No. 11/844,775 filed Aug. 24, 2007, which is incorporated herein by reference in its entirety. At step 121 , the doping profile is also engineered during the epitaxial growth process to provide forward drift field as described in the '583 patent. At step 122 , imaging structures (not shown) are formed overlying the epitaxial layer 106 .
[0047] Unlike in the previous methods, the ringed pillars 102 will be standing on the Si seed layer 18 . This leaves behind a continuous thin region of Si on the back surface of the imager 98 . Charges generated within the seed layer 18 have a probability of diffusing to the adjacent pixels. This poses a problem when charges are generated by photons having short wavelength, such as ultraviolet (UV), and deep UV radiation. Therefore, the method 108 is preferably employed for imagers that sense visible and longer wavelength light.
Method Embodiment-5: Use of Isolation Regions Formed by Optically Opaque Layers to Create Optical/Electrical Barriers
[0048] FIG. 12 shows a cross-section of an imager 124 having a plurality of trenches 126 formed therein that are filled with both an electrical barrier of oxide 128 and an optically opaque material 130 . An optical barrier has the advantage that the light incident at an oblique angle will be reflected by the optical barrier so that it is confined within a collecting well of a pixel. Referring now to FIGS. 1-2 , 12 and 13 , a method 132 for forming isolation barriers made from oxide and an optically opaque material is described as follows:
[0049] At step 134 , an SOI wafer 12 which has a thin Si seed layer 18 is provided. At step 136 , an epitaxial layer 20 with a desired thickness (2-10 um) and resistivity is grown substantially overlying the seed layer 18 . At step 137 , the doping profile of the epitaxial layer 20 is engineered according to the technique described in the '583 Patent. At step 138 , trench outlines are formed about pixel collection wells along with alignment keys 22 on the surface of the epitaxial layer 20 using photolithography. At step 140 , the epitaxial layer 20 is trench etched down to the buried oxide (BOX) layer. At step 142 , the trenches are partially filled from the top of the epitaxial layer to the top of the underlying BOX oxide layer with an electrically insulating material such as an oxide of silicon. At step 144 , the remaining portions of the trenches are filled with an optically opaque material such as refractory metal. At step 146 , the tops of the trenches are planarized. At step 148 , imaging structures (not shown) are formed overlying the epitaxial layer 20 .
[0050] Note, in some embodiments, steps 142 and 144 can be combined into one trench filling step if a material is employed that provides both an electrical barrier to charge carriers and optical barrier to electromagnetic radiation.
[0051] It is to be understood that the exemplary embodiments are merely illustrative of the invention and that many variations of the above-described embodiments may be devised by one skilled in the art without departing from the scope of the invention. It is therefore intended that all such variations be included within the scope of the following claims and their equivalents. | A method and resulting device for reducing crosstalk in a back-illuminated imager is disclosed, comprising providing a substrate comprising an insulator layer and a seed layer substantially overlying the insulator layer, an interface being formed where the seed layer comes in contact with the insulator layer; forming an epitaxial layer substantially overlying the seed layer, the epitaxial layer defining plurality of pixel regions, each pixel region outlining a collection well for collecting charge carriers; and forming one of an electrical, optical, and electrical and optical barrier about the outlined collection well extending into the epitaxial layer to the interface between the seed layer and the insulator layer. The seed layer and the epitaxial layer of the device have a net dopant concentration profile which has an initial maximum value at the interface of the seed layer and the insulator layer and which decreases monotonically with increasing distance from an interface within an initial portion of the semiconductor substrate and the epitaxial layer. | 29,450 |
BACKGROUND AND SUMMARY OF THE INVENTION
This invention relates to an improvement in apparatus for detecting the presence of oxygen in an anaerobic environment, such as an anaerobic chamber.
A typical use for an anaerobic chamber is in the culturing of strict anaerobes. Various apparatus and pieces of equipment are contained within the enclosure for use in anaerobe culture. The enclosure is typically transparent, clear vinyl plastic for example, and work gloves for use by attending personnel are mounted in the wall of the enclosure. The personnel perform various work tasks within the enclosure via use of the flexible work gloves. The atmosphere within the enclosure is controlled by certain associated equipment and supply gases. Physical access to and from the interior of the enclosure is provided by an entry lock mechanism.
The presence of oxygen, even in minute amounts, can be disruptive to the anaerobic culturing process. Accordingly, anaerobic chambers may include catalyst boxes containing catalysts which are effective to aid in removal of stray oxygen from the chamber atmosphere.
As an aid to the use of an anaerobic chamber it is desirable to have an indicator of the presence of oxygen even though provisions exist for its removal. Because minute amounts of oxygen can potentially have undesired effects on anaerobic culture, it is important to be able to detect trace amounts of oxygen in an anaerobic chamber. While there are a number of commercially available oxygen detectors many of them do not possess a sufficiently high degree of sensitivity to detect trace levels. Other types of sensors which can detect trace levels are rather expensive.
There are known methods for detection of oxygen including: electrical conductivity; electrochemical cells; heat of reaction; paramagnetic analyzers; and thermomagnetic analyzers. Briefly, the electrical conductivity method involves the use of dissolved oxygen; the electrochemical cell method involves a polargraphic oxygen electrode; the heat of reaction method involves the detection of heat which occurs when oxygen and hydrogen combine and typically involves the use of a catalyst, such as palladium, to promote that action; the paramagnetic analyzer method involves the attraction of oxygen into a magnetic field; and the thermomagnetic analyzer method involves the use of heat and the paramagnetic property of oxygen. There is also a zirconium oxide analyzer which involves the use of oxygen concentration on a hot yttria tube and a measurement of differential voltage across the tube wall with a known concentration of oxygen on the inside of the tube.
The present invention relates to a trace level oxygen sensor for anaerobic environments which utilizes the heat of reaction method for detecting oxygen. It provides a number of significant advantages over other oxygen detectors, particularly for use in anaerobic environments. Several embodiments of the generic invention are disclosed. A specific preferred embodiment of the invention comprises a unique organization and arrangement which lends itself to fabrication at a cost which is a significant savings over other types of detectors for use in detecting trace levels of oxygen in an anaerobic chamber adapted for the culture of strict anaerobes. This preferred embodiment of the invention is compact and lends itself to being disposed in any desired position in the anaerobic environment and then connected by means of electrical wires to associated electronic equipment which provides information in a useful form for indicating when oxygen is present in an amount of a trace level. This preferred embodiment of the invention comprises a unique selection, organization, and arrangement of component parts in a compact assembly which does not require any significant modification of the anaerobic chamber except to provide for the wiring connection of the device to the associated electronic equipment which is typically located exterior of the chamber.
The foregoing features, advantages, and benefits of the invention, along with additional ones, will be seen in the ensuing description and claims which should be considered in conjunction with the accompanying drawings. The drawings disclose a preferred embodiment of the invention according to the best mode contemplated at the present time in carrying out the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a typical anaerobic chamber with which the present invention is used.
FIG. 2 is a semi-schematic view partly in section of a trace oxygen detector embodying principles of the present invention.
FIG. 3 is a view of a portion of FIG. 2 taken generally in the direction of arrows 2--2.
FIG. 4 is a schematic electrical diagram illustrating further detail of a portion of FIG. 2.
FIG. 5 is a semi-schematic illustration of another embodiment of trace oxygen detector embodying principles of the present invention.
FIG. 6 is a semi-schematic view of still another embodiment of trace oxygen detector embodying principles of the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
FIG. 1 shows a representative anaerobic chamber 10 with which the present invention is used. Anaerobic chamber 10 comprises a horizontal base 12 on which is supported a transparent enclosure 14. The anaerobic atmosphere is within enclosure 14 and various apparatus and pieces of equipment are located within enclosure 14. The various apparatus and pieces of equipment may be manipulated by attending personnel via the personnel inserting their hands through cuffs 16 and into flexible gloves 18 which are mounted in the enclosure's wall. An entry lock mechanism, generally 20, is associated with enclosure 14 to provide for a physical introduction and removal of articles and gases into and out of the interior of enclosure 14. The anaerobic chamber need not be described in any further detail since such chambers are in commercial use, but so that trace oxygen can be detected, the anaerobic atmosphere is provided with a sufficient level of hydrogen.
Such uses can be adversely affected by the presence of even small trace amounts of oxygen. For example, in the culturing of strict anaerobes, trace oxygen can adversely effect the culturing process. Accordingly, in order to indicate the presence of a trace level of oxygen within the anaerobic atmosphere a trace detector 20 embodying principles of the present invention is cooperatively associated with anaerobic chamber 10. The detector comprises a sensing part 22 disposed within enclosure 14. Certain components of part 22 are electric circuit elements, and they are connected via suitable wiring, 23 generally, which extends from the enclosure to associated electronic apparatus 25 which is located externally of the enclosure.
FIGS. 2, 3, and 4 illustrate detail of detector 20. Part 22 is shown in representative detail in FIGS. 2 and 3. The illustrated embodiment is of generally circular cylindrical shape which affords certain advantages for fabrication. Principles however may be embodied in other than such a shape.
Sensing part 22 comprises a circular base 24 of the type commonly used in electrical connectors. The axis is designated 26. The base 24 has a non-metallic body 28 which is an electrical insulator. A series of metal conductor terminal pins extend through body 28 in a parallel manner parallel to the axis 26. In the illustrated base there are four such pins arranged at 90° intervals about axis 26 but only three of the pins are actually used for making electrical circuit connections in this particular embodiment. For convenience in explanation, the three pins used are identified by the reference numerals 30, 32, and 34.
Part 22 further comprises two thermistors 36, 38 which are supported by their own leads on base 24. Each thermistor 36, 38 has two leads. For thermistor 36 the leads are designated 36c and 36s and for thermistor 38, 38c and 38s. The two leads 36c, 38c are in common and connect to terminal pin 32 at the upper end face of insulator body 28 as viewed in FIG. 2. Lead 36s connects to pin terminal 30 and lead 38s to terminal pin 34. The sensing tip 36t of thermistor 36 is disposed in space. The sensing tip of thermistor 38 is disposed within a thimble shaped catalytic pellet 40. Pellet 40, has a circular cylindrical shape with a central blind hole extending axially from one end. It is within this hole that the sensing tip of thermistor 38 is disposed.
The catalytic pellet 40 is of a material which promotes an exothermic chemical reaction of oxygen with hydrogen and in the illustrated example the use of palladium is an effective catalyst for promoting the exothermic reaction of free oxygen gas with hydrogen gas to form water. Hence trace oxygen which may be present within the anaerobic chamber's interior will produce such a reaction on the palladium pellet when oxygen is present in the anaerobic environment.
The sensing tips of the two thermistors 36, 38 and the palladium pellet 40 are disposed within a sampling space 42 which is defined by part 22. This sampling space is bounded at one axial end by base 24. The side of the sampling space are bounded by a tubular sidewall structure 44. An endwall structure 46 axially bound the other end opposite base 28. Details of these further side and end wall structures will be subsequently explained. The enclosure formed by the side and end wall structures forms a sampling space which is confined both volumetrically and thermally. The nature of the confinement enables the exothermic reaction of oxygen with hydrogen on pellet 40 to be detected even for trace amounts of oxygen.
The material of base 28 is one which is a reasonably good thermal insulator, so that it possesses considerable thermal inertia. A tubular walled mass of large thermal inertia is used to form the sidewall structure 44. This structure comprises a thin walled aluminum sleeve 48 having an open end fitted onto base 24 surrounded by a much thicker brass tube 50. There is preferably a thin film 52 of suitable material between the two dissimilar metals. The aluminum sleeve includes an end wall 54 with a small central aperture 56. The aperture 56 is covered by a membrane 58 of a material which is permeable to lower molecular weight gases such as oxygen and hydrogen and permitting diffusion of the anaerobic atmosphere into the sampling space.
While the construction so far described defines a sampling space 42 which is substantially confined both volumetrically and thermally, it is desirable to have temperature of the structure bounding the sampling space regulated to a desired level. This is done by a temperature regulator system 60 which is cooperatively associated with part 22. The illustrated embodiment of system 60 comprises a thin film heater assembly 62 wrapped circumferentially around the outside of tube 50. A temperature sensor 64 is disposed against heater assembly 62 and both heater 62 and sensor 64 are held in place by a suitable wrap 66 such as thermal electrical tape. The heater 62 and sensor 64 are cooperatively associated by wires in electric circuit with an electrical power supply whereby suitable current is delivered from the supply to the heater 62 to maintain a desired regulated temperature.
In the preferred embodiment of the invention a third temperature sensor in the form of a thermistor 70 is disposed to sense the ambient temperature of the anaerobic atmosphere at a location spaced from sensing part 22. In order to avoid momentary fluctuations the sensing tip of thermistor 70 is disposed in contact with a thermal mass 72 at a suitable location within the enclosure.
Wires serve to connect these various electrical components with the associated electronic apparatus which is located externally of the enclosure.
FIG. 4 depicts a representative construction for a detector circuit 73. The circuit comprises a first differential amplifier 74 and a second differential amplifier 76. The two thermistors 36 and 38 are connected with inputs of amplifier 74 to form a bridge. So long as there is no trace oxygen above the trace threshold sensing level, there is no temperature differential sensed by the two thermistors 36, 38, and the bridge remains balanced. If the oxygen content exceeds the trace threshold level, the exothermic reaction occurring on pellet 40 will create a temperature rise whose effect is more pronounced on thermistor 38 than on thermistor 36 because of the intimate relationship of pellet 40 with the former thermistor. Accordingly the bridge will become unbalanced by an amount sufficient to cause the output of amplifier 74 to give a signal indicating the presence of oxygen above the trace threshold level. The accuracy of the detector circuit sensor is rendered essentially insensitive to changes in any ambient temperature variations within the enclosure by the connection of thermistor 60 to one input of amplifier 76 and the output of amplifier 74 to the other input of amplifier 76. Ambient temperature changes which otherwise might impair the accuracy of detection are thereby substantially eliminated from having influence on the ultlmate output signal which appears at the output of amplifier 76.
The sensing part 22 is physically compact, on the order of a one inch diameter and about a one and a half inch overall length from the membrane to the tip ends of the terminal pins. It can be located at any desired location within the anaerobic chamber and indeed it is possible that there could be several parts 22 placed at different locations in the large chamber. Thus the embodiment of FIGS. 2, 3, and 4 is a device well suited for anaerobic chambers.
Other embodiments are envisioned within generic principles of the invention and one of these is portrayed in FIG. 5. The detector 100 of FIG. 5 differs from the embodiment of FIGS. 2, 3, and 4 in that it does not utilize a continuous flow communication between interior of the sampling space and the anaerobic atmosphere with the enclosure. The embodiment of FIG. 5 comprises a sampling space 102 which is enclosed both volumetrically and thermally by an enclosure 104.
Enclosure 104 contains an intake port 106 and an exhaust port 108. The intake port 106 is selectively opened and closed by a suitable valve 110. An evacuation pump 112 is associated with exhaust port 108.
When a sample from the anaerobic atmosphere is to be obtained, valve 110 is opened and pump 112 operated. The sample is drawn into the sampling space via intake 106 and the sampling space is exhausted through exhaust port 108 by the action of pump 112. When the pump has been operated sufficiently long to draw a full sample into space 102, it is shut off and valve 110 is closed. Thus the sample is contained within the sampling space, and there is no communication to the exterior because both inlet and outlet are closed.
A sensor 114 is disposed to sense the temperature of the sample. The sensor is associated with an appropriate electronic circuit 116 including a memory 118 to enable the sensed ambient temperature to be stored.
A catalyst member 120 is introduced into the chamber after the ambient temperature has been stored. The introduction of the catalyst member, which may be a coiled palladium wire for example, will induce exothermic reaction of any trace oxygen which may be present with the existing hydrogen in the atmosphere. Consequently there will be a temperature rise which can be monitored by sensor 114, and detection of a predetermined temperature rise will be indicative of oxygen above a trace threshold level.
A second temperature measurement is therefore taken in timed delay relationship to the original ambient temperature measurement a certain time after the introduction of the palladium into the chamber. A sufficient difference will indicate oxygen above the trace threshold. The unit may also include communications means 122 associated with the electronics to communicate the consequence of the sample measurement, electronically, visibly, and/or audibly. Hence FIG. 5 shows an alarm and an optional digital display associated with the electronics with the electronics calculating the difference between the two measurements and providing a corresponding signal as that difference.
Because of the time required to introduce the sample into the chamber and take the temperature measurements, the system of FIG. 5 would represent a periodic sampling occurring at perhaps one to two minute cycles. The circuitry utilized to sense temperature could be like that of FIG. 4. The enclosure may or may not include a heater for maintaining a substantially constant temperature. In this embodiment the first temperature measurement should represent ambient temperature and therefore might inherently correct for ambient temperature without a separate third transmistor as shown in FIG. 4. If some temperature correction is needed, it may be done in the electronics itself through a suitable programming. The actual sensor 114 can be the two thermistors 36, 38 connected to amplifier 74, as described in FIGS. 2, 3 and 4. The illustrated means for introducing the catalyst is intended to be merely illustrative and it can take the form of a palladium wire which is wrapped around the plunger 126 which is inserted into and removed from the sampling space via an opening in the enclosure by any suitable form of a motive means. When the palladium is disposed exterior of the sampling chamber 102 the end 128 of plunger 126 forms a stop and plug for the plunger passage.
FIG. 6 illustrates another embodiment 200 which comprises an enclosure 202 for both volumetrically and thermally bounding the sampling space 204. In this version there is a continuous flow of anaerobic atmosphere through the sampling space along the path indicated by the arrows 206. The flow is induced by any suitable means and in order to regulate the flow to a substantially constant mass, a flow regulator 208 is included in the flow path.
The sample first flows past a sensor 210 which senses ambient temperature. The flow subsequently passes across a catalyst 212 which is illustrated in the form of a palladium wire suspended as a helical coil within the sampling space. A further sensor 214 is intimately associated with the catalyst. Trace oxygen which is present in the flow through the sampling chamber will react with hydrogen at the catalyst thereby giving rise to an exothermic reaction. At a sufficient level indicative of a trace oxygen exceeding the trace threshold, there will be sufficient difference detected by sensor 214 to cause the associated electronics to yield a signal indicative of oxygen above the threshold level. In this embodiment the sensor 210 corresponds to thermistor 70 of FIG. 4 to provide ambient temperature correction.
In order to minimize the influence of exothermic effects on sensor 210 it may be desirable to place a thermal shield 220 between them in a manner depicted in FIG. 6. Even though the flow is such that convectlve heat transfer is in the opposite direction.
FIG. 6 also shows additional communication media associated with the electronics to provide electronic, visible, audible and/or any combination thereof as indicia of the sampling results.
While a preferred embodiment of the invention has been disclosed, it will be appreciated that principles are applicable to other embodiments. | An oxygen detector for detecting the presence of trace levels of oxygen in an anaerobic environment consisting of a sample chamber wherein a sample from the anaerobic environment is exposed to a catalyst, such as palladium, which promotes the exothermic chemical reaction of oxygen with hydrogen. The presence of oxygen will cause such reaction to occur on the catalyst and the consequent generation of heat. A thermistor which is in thermal proximity to the catalyst detects this heat and provides a signal. The sampling chamber is enclosed by an enclosure which serves to volumetrically and thermally confine the sample during the measurement thereby enabling small levels of exothermic heat of reaction to be detected. Entrance to the sampling chamber is through a membrane which is permeable to lower molecular weight gases such as oxygen and hydrogen which thus enables diffusion of the anaerobic atmosphere into the chamber. | 19,674 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to the field of fan devices for augmenting air circulation through forced air air conditioning and heating systems and, more particularly, to such a device designed to fit externally over a forced air register.
2. Description of the Relevant Prior Art
Due to their inherent advantages, forced air central heating and cooling systems have become the dominating means of both residential and commercial climate control in the United States within recent years. Since such installations include a system of ducts for conducting forced air to individual rooms, such systems can be adapted to both centrally heat and cool a building. Typically, a central heating and/or cooling unit acclimatizes outside air to a comfortable temperature set by a thermostat and a central blower is used to circulate the tempered air throughout the ducts to heat or cool the rooms of the building.
Problems can arise in circulating the acclimatized air to more remote portions of the building, or to upper stories thereof. According to the laws of fluid mechanics and air flow, as the column of air to be moved lengthens, air flow measured in cubic feet per second becomes diminished. Thus, it may become necessary to provide an auxiliary air circulating fan in order to provide sufficient air flow to more remote parts of a building.
This problem is particularly acute when a forced air system is used to air condition a building having two or more stories. The air cooled by the central air conditioner is relatively heavy and hard to move. It is more difficult to overcome gravity and supply such cooled air to the upper stories of a building than it is to supply air warmed by a furnace. Hence, it is not uncommon for the second floor rooms of a house to remain uncomfortably warm during the hot summer months even though the central air conditioning unit is in use. One is forced to choose between lowering the thermostat to boost the output of the air conditioning unit, thereby cooling the lower story to an uncomfortable level and wasting energy or tolerating uncomfortably warm temperatures in the upper story rooms. In fact, it is not uncommon for the dwellers to supplement forced air central air conditioning by installing expensive individual air conditioners in second story bedrooms. Obviously, such a solution is wasteful and unsatisfactory.
It has long been known to boost air circulation from a forced air unit by installing auxiliary fans inside the ducts of the system. For example, U.S. Pat. No. 4,798,518 discloses such an auxiliary fan unit for use with the duct system of an air conditioning and ventilation system. The fan unit disclosed in the referenced patent has a freely turning radial impeller and associated drive motor. A guiding structure is provided downstream from the outlet of the impeller which directs the air flow coming radially from the impeller to an axial direction. In other words, this device redirects the air flow through an angle of approximately 90°.
Another example of an in-duct circulation booster is shown in U.S. Pat. No. 3,099,201. However, these devices and others like them suffer from obvious disadvantages. Since they must be installed in the ductwork, installation is cumbersome and difficult. Moreover, the unit must be exactly sized to fit inside the ductwork. Since these devices must be permanently installed, they cannot be moved from location to location as desired.
It is also known to provide an air circulation booster as an external unit to be fitted over the aperture of a forced air register. Examples of such devices are shown in U.S. Pat. Nos. 4,722,266 and 4,846,399. While these devices have the advantage of being portable and requiring no expensive installation, the relatively small and inefficient fans used in these devices limit their utility. The average second floor register exhibits about 0.6 inches of water back pressure. The weight of the column of air and the viscous drag of the air against the walls of the ductwork act to restrict air flow; and, if any air is to flow out of the register, it must experience a pressure differential greater than 0.6 inches of water. Hence, an external booster must be as efficient as possible to overcome this static back pressure. Furthermore, an external booster must efficiently and effectively couple to the air handling system. Also, it would be highly desirable that any external air flow booster be simple to install and remove.
SUMMARY OF THE INVENTION
The invention described and claimed herein is designed to overcome the disadvantages noted in the prior art. The device of the present invention is adapted to fit over an air register of a forced air heating and air conditioning system. It includes a housing which defines an interior, which housing has a top wall, front, rear and opposed side panels, and a continuous skirt disposed along the bottom edges of the panels. The skirt is designed to seal the interior of the housing from the ambient atmosphere of a room when the booster is placed over the register. A radial flow impeller and drive motor operatively associated therewith are mounted in the interior of the housing proximate the top wall thereof with the blades of the impeller extending downward. The impeller discharges air drawn through an intake grill out in a radial direction.
The intake grill is disposed on an air intake shroud formed on the bottom of the housing. The intake grill is dimensioned to cover at least a portion of the outlet aperture of the register. The shroud surrounds the air intake grill and isolates the air drawn through the air intake grill from the rest of the interior of the housing. An air discharge grill is formed on the front panel of the housing.
The external booster further includes a baffle disposed in the interior which is configured as a continuous, curved wall beginning at a first end of the air discharge grill and terminating at the second end thereof. The continuous curved baffle defines an open curve. The baffle extends axially beyond the blades of the impeller t terminate at the bottom of the housing. The baffle is spaced from the impeller at a distance so that air expelled radially from the impeller is redirected out the discharge grill mounted on the front panel when the device is in operation, thus greatly increasing the air flow from the forced air system.
Preferably, the front panel is inclined at an angle with respect to the rest of the housing. Because the air discharge grill is thus inclined, air discharged from the device is directed both outwardly and upwardly to bolster circulation in the room. Preferably, a variable switch in the form of a rheostat is provided so that the speed and power of the booster may be adjusted as desired.
In a preferred embodiment, the intake shroud includes a flat base which has an aperture formed therein to permit air flow therethrough, thereby creating a free edge. A tapering sleeve is formed on the free edge of the base which tapers inwardly toward the bottom of the device. A flat bottom panel is formed on the end of the tapering sleeve, and the intake grill is disposed on the bottom panel.
BRIEF DESCRIPTION OF THE DRAWINGS
The following detailed description may best be understood by reference to the following drawings in which:
FIG. 1 is a perspective view of an external booster constructed in accordance with the principles of the present invention;
FIG. 2 is a bottom plan view of the device of FIG. 1;
FIG. 3 is a bottom, interior view of the device of FIG. 1 with the intake shroud removed and the impeller depicted schematically;
FIG. 4 is a cross section view of the device of FIG. 1 taken along lines IV--IV; and
FIG. 5 is a flow rate versus pressure chart depicting the performance of the device of the present invention compared with a prior art device and illustrating the advantages thereof.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Throughout the following detailed description, like reference numerals are used to reference the same element of the present invention shown in multiple figures thereof. Referring now to the drawing and in particular to FIGS. 1 and 4, there is shown an external booster 10 for increasing the flow of air through a duct of a forced air, central heating and air conditioning system (not depicted.) The booster 10 comprises a housing 12 defining a interior 14. The housing 12 includes top, back, front, and side panels 16, 17, 18, 20, 21, respectively. Disposed along a bottom edge of the housing 12 is a skirt 22. As can be seen in FIG. 4 the skirt 22 extends below the interior 14 of the housing and serves to isolate the interior 14 from the ambient environment. An air discharge grill 36 is formed on the front panel 18 of housing 14. Front panel 18 is inclined forwardly with respect to the remainder of housing 14 as is best shown in FIG. 4.
As is best seen in FIG. 2, the bottom of the housing 14 is defined by an air intake shroud 24. Shroud 24 comprises a base 26 disposed adjacent the skirt 22 and further includes a tapering sleeve 28 formed thereon. Tapering sleeve 28 tapers inwardly toward the bottom of housing 14 and formed on the end of tapering sleeve 28 is a flat, bottom panel 30. An aperture 27 covered by an intake grill 32 which is disposed on bottom panel 30. The housing 14 and the intake grill 32 are dimensioned such that, when the device 10 is placed over the air intake aperture of a register (not shown) of the forced air system, the intake grill 32 will cover at least a portion of the register aperture and the skirt 22 will be disposed around the periphery thereof.
Referring back to FIG. 4: disposed in the interior 14 of housing 12 is a radial impeller 40 and drive motor 42 associated therewith. Motor 42 is aligned coaxially with impeller 40 and mounted proximate the top panel 16 of housing 12. The blades 44 of impeller 40, thus, extend in a downward direction. By means of radial impeller 40, air is drawn in through intake grill 32 is redirected radially and outwardly in a manner depicted by the arrows shown in FIG. 4. There are a number of different fan-motor combinations of the type described herein, which are commercially available and in view of the disclosure herein, particularly the disclosure of FIG. 5, one of skill could readily select an appropriate combination. One preferred fan-motor configuration is available from EBM Industries Inc. of Connecticut and sold under the designation R 25 133 AB 25-22. This particular fan-motor combination operates at 110 volts and is capable of establishing an air flow of 80-100 CFM against a back pressure cf 0.6 inches of water when incorporated in the booster of the present invention.
Some of the air radially redirected by impeller 40 will be redirected toward front panel 18 and out discharge grill 36. However, a large portion of the redirected air will flow toward the back and side panels 17, 20, 21. To increase the efficiency of the device, a baffle 34 is provided which is configured in the manner shown in FIG. 3. Baffle 34 takes the form of a wall which defines a continuous, open curve and starts at a first end 38 of discharge grill 36 and terminates at a second end 39 thereof. A particularly effective configuration of baffle 34 is depicted in FIG. 3. It will readily be seen that baffle 34 is spaced a distance from the ends of the blades 44 of impeller 40. This arrangement causes air redirected by impeller 40 radially toward the back and side panels 17, 20 and 21 to be deflected so that it flows out discharge grill 36. Thus, the design of the baffle 34 permits virtually all of the air redirected radially by impeller 40 to be directed out the discharge grill 36, as is shown by the arrows depicted in FIG. 3. Such an arrangement greatly increases the efficiency of the booster of the present invention.
The device of the present invention may be used in a number of different ways. For example, the device may be mounted over a floor register by simply placing the device over the register, thereby enclosing and isolating it. If the floor in which the register is located is carpeted, an effective seal from the outside atmosphere will be formed by skirt 22 with the carpet. If the device is to be placed on a bare floor, a rubber gasket (not shown) may optionally be disposed around the bottom edge of the skirt 22 to effect a seal. It is important to at least partially seal the interior 14 from the surrounding atmosphere to prevent escape of air discharged from the register before it is redirected and its velocity increased by action of the impeller and also to prevent the impeller from drawing room air in preference to air in the duct of the heating/cooling system. If the register is located on a wall, the device may be mounted thereto by means of mounting brackets (not shown.)
Typically, such a device might be used in, for example, a second floor bedroom. The device may be turned on a high setting by means of variable switch 46 (preferably a rheostat) in order to quickly increase the flow rate of, for example, cool air discharged from the register. After a short period of operation on the high setting, the switch 46 may be moved to a lower setting to save energy. The high setting will have the effect of rapidly cooling the room and the lowered setting will maintain the cool temperature. Obviously, the same system could be used to increase the flow of heated air in the winter months, if necessary.
The device of the present invention may also be used to increase the air flow through the room even when the forced air system is not in operation. For example, if the forced air heating and cooling system is located in the basement, causing a positive air flow through the ductwork of the system will cause cooler basement air to move into an upper story room. If the device of the present invention is in operation, a positive air flow will be created which, on some days, may be sufficient to cool the room without the necessity of using the central air conditioning unit. This will result in a significant savings of money and energy.
The booster of the present invention is low profile and unobtrusive in appearance. The radial impeller used to redirect the air is quiet in operation and much more efficient than the axial fans used in prior art devices. Furthermore, the device is configured to create an efficient and substantially complete seal with the underlying floor or wall. Hence, the device is much more effective than any prior art device. The results of actual efficiency test performed on the device of the present invention versus a typical prior art device are depicted graphically in FIG. 5. The flow rate in cubic feet per minute is plotted against typical values for back pressure (measured in inches of water) found in forced air systems. As can be seen, the prior art device depicted by curve A is effective only at back pressures of less than 0.1 inches of water. For example, at 0 inches of water back pressure, the prior art device succeeds in producing a flow rate of approximately 95 cubic feet per minute. However, this flow rate becomes drastically reduced as backflow, approaches 0.1 and becomes 0 well before that point. In other words, the prior art device completely ceases to be effective at backflow pressures approaching 0.1. Since typical back pressure readings for forced air systems are around 0.6 inches of water, the prior art device is totally ineffective in ordinary use.
The performance of the booster device of the present invention is depicted by curve B. Again, as one would expect, the device is most effective at 0 back pressure; the booster achieved a maximum flow rate of approximately 160 cubic feet per minute. As the back pressure is increased, the flow rate drops off. However, in contrast to the prior art device, the drop off is much less severe. For example, a typical back pressure of 0.6 inches of water, the device of the present invention maintains a flow rate of over 80 cubic feet per minute, a performance almost as good as the prior art device exhibits with no back pressure. Only when the back pressure is increased to over 1 inch of water does the booster of the present invention cease its effectiveness. However, back pressures of this order of magnitude are not normally encountered in central, forced air installations. Because of the nature of the fan employed and the particular configuration of the booster housing, the device of the present invention is effective through a typical range of back pressures, in contrast to the prior art.
The booster of the present invention has been described with reference to certain embodiments and exemplifications thereof. Doubtless, variations in design may occur to one skilled in the art without departing from the scope of the subject matter claimed herein. The true scope of the present invention is defined solely by the claims appended hereto. | An external, air circulation booster which fits over a register of a forced air central air conditioning and heating system. The booster includes a housing having front, rear, side and top panels, and an air intake shroud formed on the bottom of the housing. The air intake shroud includes an air intake grill which fits over a portion of the outlet aperture of the register. An air discharge grill is formed on the front panel of the housing. A radial impellar is mounted in the side of the housing, and air radially expelled therefrom toward the side and rear of the housing is redirected by means of a baffle out the discharge grill. | 17,204 |
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application is a divisional application of U.S. application Ser. No. 12/421,800, filed on Apr. 10, 2009, which is a divisional application of U.S. application Ser. No. 10/974,845, filed on Oct. 28, 2004, now U.S. Pat. No. 7,536,421, which claims priority to U.S. provisional patent application No. 60/515,695, filed on Oct. 31, 2003, which are incorporated herein by reference in their entirety.
FIELD OF THE INVENTION
[0002] The invention relates generally to distributed processing computer systems. More particularly, the invention relates to systems and methods for distributed application management and soft object referencing in distributed processing systems to allocate data objects to network nodes to support local processing.
BACKGROUND OF THE INVENTION
[0003] In the past, there have been three major application architectures that have been used to build and deploy software that supports end-user processes. This is in contrast to lower level software that supports hardware and software processes such as operating systems. These three architectures have closely mirrored the evolution of the hardware environment. First, in the beginning of the computer age, hardware was centralized, expensive and very tightly controlled. This was typified by the mainframe computer with optional dedicated terminals to support end users. A monolithic or host-based application architecture evolved to build software in the mainframe environment, with virtually all computer tasks managed by the central mainframe computer. This application architecture was simple to manage as it was all in one place, but had shortcomings in its ability to support complex processes and in its ability to grow and expand to support larger user populations.
[0004] Second, with the advent of the networked personal computer (PC), the ability to use a PC to render graphic images and Windows® spawned a new application architecture called client-server computing. The key feature of this architecture was the delegation of some portion of the application computer tasks to the client computer. The distribution of tasks between the client and the server was based on their technical nature, with presentation/graphic tasks sent to the client, database tasks delegated to the central server, and application logic existing in either place or on a middle tier called the application server. Client-server computing was a huge improvement over past architectures in that it supported more complex processes with more intuitive interfaces and was better able to grow to support large user populations by distributing the processing and communications activities load across many computers.
[0005] Third, with the broad adoption of the Internet, a new style of application architecture emerged called n-Tier (or sometimes “thin-client”) that was expressly designed to take advantage of browsers, Internet servers, and Internet standards. Thin-client applications are designed to be small, so that the data processing is performed predominantly on the server, rather than on the client. N-Tier application architecture refers to applications that are broken into different layers or tiers, where modifications to the application may be made by altering or replacing a particular tier, rather than by replacing the entire application. The n-Tier architecture is similar to client-server computing in that computer tasks are distributed between a central server complex of computers and a client computer (typically a PC). It is different in that much of the work that the client computer performed in the client-server model is migrated back to the server. Clients are left with only a portion of the presentation logic, which runs inside of a browser or similar presentation program. This architecture had two important improvements over client-server computing. It requires no installed software at the client layer, which cuts application management costs dramatically, and it allows ubiquitous access to applications. Users may now access their software from wherever the Internet takes them. The trade-off for these improvements is that in recentralizing the computer tasks, this architecture is much slower than a traditional client-server model, and it provides weaker security and a less intuitive user interface. The result is that n-Tier applications are sufficient for simple, non-mission critical applications, but are unworkable for many of the most important software needs in today's economy. Prior attempts to overcome these challenges have fallen short in suitably addressing both concerns simultaneously. That is, there is a lack of a suitable architecture that may centralize applications while simultaneously providing an agile response, sufficient security, and an intuitive user interface.
[0006] For example, U.S. Pat. Nos. 5,924,094 and 6,446,092 appear to disclose independent distributed database systems where all nodes are peers, and no node acts as a server for the others. The systems do not distinguish between master and slave sites since each site stores all and only the data required to work off-line with local data. All application transactions are made against the local database. Sites sharing the same data synchronize their changes periodically in the background. In these systems, there are no on-line or distributed application transactions because all application transactions are local. Users employ local databases to gain performance speed. However, the '094 and '092 patents fail to disclose means by which application programs may be distributed to client devices to enable sufficient autonomy and computing capability to complete entire business transactions while simultaneously providing a secure means with which to conduct the transactions.
[0007] Additionally, U.S. Pat. Nos. 6,049,664 and 6,272,673 appear to disclose a mechanism for creating a software application for execution on a network that has multiple tiers. The mechanism includes means for specifying application components, which allows an application component to be assigned to execute on any of the tiers of the network. The mechanism also includes means for associating the application components with a hypertext page. The components are then executed in response to requests for the hypertext page. The '664 patent and the '673 patent, however, fail to disclose means with which to suitably distribute applications based upon the boundaries of a required transaction. Instead, the '664 patent and the '673 patent perform a conventional thin client distribution assignment to a client based upon the type of task being performed.
[0008] U.S. Pat. No. 6,636,900 is another example of executing distributed objects over a network. The '900 patent develops an application using object oriented code to utilize objects that are self contained application components. Each object of the application is distributed over a network. An application process may request an application object from a local or a remote network location using the address of the object, the name of the object, and any input values. If the requested object is not on the local computer, the computer on which the requested object resides receives the name of the object, executes the object using the input values, generates an output value of the object, and sends the output value to the requesting computer. The output value is then used in the running application. Thus, the object execution is remote, and the user of the requesting computer is given no indication of this remote operation. While the '900 patent employs a distributed environment, it fails to disclose means for distributed applications that are transferred to the client devices, executed, and then removed. The apparatus and method of the '900 patent provides load balancing of the application components over the network, but fails to disclose means for receiving executable applications on remote or periodically connected devices.
[0009] None of the previous architectures adequately provide the ubiquity of n-Tier applications together with the usability and sophistication of a client-server system. What is needed is a new type of architecture that distributes centralized applications while simultaneously providing agile client-side responses, sufficient security, and an intuitive user interface.
SUMMARY OF THE INVENTION
[0010] The present invention relates to systems and methods for distributed application management and soft object referencing in distributed processing systems. The present invention provides a simple, powerful, and elegant manner in which to distribute computer resources in a networked environment using distributed application management. Distributed application management is a manner of distributing tasks between computers in a network that augments client and server technologies with core services necessary to partition data management tasks. Unlike the client-server and n-Tier architectures where tasks are dispatched to a computer based on the technical type of task (e.g., database, presentation, application logic, etc.), in the distributed application management environment of the present invention, tasks are distributed based upon the boundaries of a particular business transaction. For example, if an application must execute a series of business rules, data reads, writes, updates, and presentation rendering tasks to complete the business transaction, such as applying a check to an open accounts payable, then all of these tasks are dispatched to the computer supporting that user. That is, the PC or client device operated by the user receives all the software to execute the transaction. This distributed application management frees the central server computers from having to manage the different aspects of this business transaction until it is completed and reported back to the central servers as completed. Of course, a business transaction may be any communicative action or activity involving two parties or things that reciprocally affect or influence each other and is not limited to a commercial exchange, transfer of goods, services, or funds.
[0011] The distributed application management of the present invention can temporarily distribute the entire application necessary to complete the business transaction to the client device. This distribution scheme and architecture allows the system to use the client-side computing power to manipulate the application and data in ways that would be resource-prohibitive if a shared server resource were used to accomplish these tasks. Transaction management, caching, and manipulation of business objects may be performed independently on the client, while persistence, synchronization, and query execution may take place on the server. Tasks that should be performed on the client are performed on the client, and tasks that should be performed on the server are performed on the server. This delineation provides a tremendous improvement in the performance and flexibility of Internet and other networked applications.
[0012] For example, the present invention may employ client-side computer power to perform language translation, voice recognition, integrated telephony, or rules-based data analysis. Additionally, the native processing power of a dedicated client device may be used to present a “rich client” that supports rapid and intuitive end user interaction with the application.
[0013] There are a number of complexities in managing this intelligent client architecture application once it is distributed. The data that is moved to the client must be tracked or registered by a central server resource so that updates made by other end-users (clients) can be replicated to each client that is managing and working with this data. The ability to reconcile conflicting updates to data items by multiple client devices must be adequately supported. The ability to manage and transform data between multiple data formats (relational, XML, object-based, etc.) is necessary to allow for the long term persistence, transport, and local manipulation of data. Finally, the ability to manage data objects transported to the client must be supported.
[0014] In order to address these issues, the implementation of a model driven application generation tool is needed. Because the problems created by distributing an application are significant and require a large body of software code to solve, the application generation tool of the present invention automates the creation of much of the required application code.
[0015] The distributed application management innovation of the present invention organizes computer tasks across networked computers and intelligent devices. Additionally, the present invention demonstrates specific methods for registering distributed data, resolving conflicting data updates, transforming data formats, and automating the software development process. The unique combination of these methods and a novel approach to task distribution are used to allocate data objects to network nodes to support local processing by efficiently determining the data that are needed to support transactions and local processing and by effectively synchronizing data transfers and performing collision detection on distributed processing systems to ensure the integrity of the exchanged data.
[0016] Computing devices today may be linked through a mixture of private and public networks, including the Internet. As such, the user input, the code, and the data on which the code must operate may reside on different computer devices. In order to accomplish useful work, the user input, the code, and the data are combined on a centrally located computer device, such as a server, and the results of the work performed on this central computer device are then sent to the end-user. This centralized process, while effective for some types of work, suffers from bottlenecks on the centralized device and poor performance for complex, data intensive processes or applications.
[0017] The present invention can include an application development tool and execution environment (architecture) that supports a new class of software applications designed to nm on the Internet and other public networks, including wireless and periodically connected devices. This class of software built on the platform of the present invention is significantly different from conventional classes of software available today. Applications developed on the platform of the present invention may be more quickly and easily authored and developed, run faster, and possess a friendlier user interface than conventional applications, resulting in a significantly lower total cost of ownership.
[0018] In order to provide the lower costs and ubiquity of n-Tier applications, together with the usability and sophistication of client-server environments, the present invention employs Intelligent Client Architecture (ICA). With ICA, all applications may be built with Internet standards, deployed over commodity hardware and software, and distributed through the Internet or other similar networks. ICA combines the usability of rich-client applications with the portability, maintainability, and interoperability of thin clients. By utilizing ICA, it is now possible to migrate applications out of the high cost proprietary hardware in dedicated data centers into low cost hardware/software running in shared data centers located at strategic points on the Internet. Applications that today support factories, warehouses, sales branches, and back offices will migrate from a client-server design running on in-house hardware and in-house networks to an ICA design running on public networks and shared data centers.
[0019] The invention can utilize a distributed management scheme with soft object references to capitalize upon the inherent efficiencies in local application processing while taking benefit of the power of larger server systems. The invention can allow the client and the server to cooperatively manage data, thereby blending the robust transaction capabilities, security and throughput associated with applications behind a firewall with the ubiquity, management simplicity, and device independence of n-tier architectures. ICA shifts a substantial portion of the data and processing logic to the client tier by segmenting applications based on the business transaction to be performed, resulting in outstanding response time, reduced network traffic, and a foundation for a rich-client interface.
BRIEF DESCRIPTION OF THE DRAWINGS
[0020] The above-mentioned and other features and objects of this invention and the manner of attaining them will become more apparent, and the invention itself will be better understood by reference to the following description of embodiments of the invention taken in conjunction with the accompanying figures where:
[0021] FIG. 1 is an illustration of a distributed computer network and the data requiring collision detection and data synchronization;
[0022] FIG. 2A is a process flow diagram illustrating the basic operation of the Local Computer Device Requesting Data in the Object Retrieve process of the present invention;
[0023] FIG. 2B is a process flow diagram illustrating the basic operation of the Remote Computer Device Providing Data in the Object Retrieve process of the present invention;
[0024] FIG. 2C is a process flow diagram illustrating the basic operation of the Local Computer Device Receiving the Requested Data in the Object Retrieve process of the present invention;
[0025] FIG. 2D is a process flow diagram illustrating the basic operation of the Local Computer Device Updating the Data process of the present invention;
[0026] FIGS. 2E-2G are process flow diagrams illustrating the basic operation of the Remote Computer Device Updating the Data process of the present invention;
[0027] FIG. 2H is a process flow diagram illustrating the basic operation of the Local Computer Device Completing the Data Update process in accordance with the present invention;
[0028] FIG. 3 is a schematic representation of the functional computer system network in accordance with the present invention;
[0029] FIG. 4 is a schematic representation of the functional computer system network illustrating non-conflicting data changes in the transactional cache in accordance with the present invention;
[0030] FIG. 5 is a schematic representation of the functional computer system network illustrating near real-time updates of data changes in the transactional cache in accordance with the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0031] The invention is described in detail with particular reference to certain preferred embodiments, but within the spirit and scope of the invention, it is not limited to such embodiments. It will be apparent to those of skill in the art that various features, variations, and modifications can be included or excluded, within the limits defined by the claims and the requirements of a particular use.
[0032] The following exemplary embodiment describes the data distribution and management process of the present invention in the context of a client-server business application use case. However, it should be understood that the present invention may also be used in embedded computing, grid computing, and other data and application architectures.
[0033] The present invention extends the functionality of current client-server architectures as well as those thin-client and n-Tier distributed computer applications by distributing data objects to the proper network nodes to support local processing. Once distributed, the present invention manages the distributed data and its updates by employing collision detection and data synchronization methods to track the distributed objects and manage changes to the distributed objects throughout a network of intelligent computing devices. This has many advantages over prior assemblies such as those providing simple client-server interactions, because the data objects distributed by the present invention significantly reduce the computing overhead required at the server while providing improved security and an intuitive user interface with which to utilize new applications.
[0034] These new applications are built on a new Intelligent Client Architecture (ICA), which is a fundamentally different approach to distributing computer tasks between networked computers. Intelligent Client Architecture applications organize computer tasks around transaction boundaries and push the bulk of the computer tasks to the edge (or client) of the network. In so doing, they make better use of the hardware resources at the client and provide a commodity hardware/software implementation at all levels of the network. The system and method of the present invention utilizes a software product to build Intelligent Client applications. The software product is based on two significant design innovations that enable these improvements: soft object referencing and distributed application management.
Distributed Application Management
[0035] A powerful driver of Intelligent Computer Architecture is the migration to wireless and periodically connected devices. Because these devices are not continually connected to the Internet, they require the ability to operate in both connected and disconnected modes. The present invention naturally distributes the application and data to efficiently support and enable processes on these devices in both connected and disconnected modes within a network of computer devices. Applications using intelligent computer architecture of the present invention may be built for PCs as well as extending to cell phones, portable digital assistants (PDAs), hand-held communications devices, automobiles, and other embedded devices.
[0036] In order to accomplish useful work with these devices, the computer devices require both computer instructions (“code” and user input) and data on which those instructions operate. In a non-networked environment, when a computing device contains both the code and the data on a permanent basis, it is a relatively simple matter to complete useful work as the data and the code and the user input are all permanently stored on the same device.
[0037] When the code and the data are physically separate, data and code can be distributed to the local computer devices, but this then creates the challenge of tracking and synchronizing updates to all of this distributed data. The system and method of the present invention provides collision detection and synchronization mechanisms to effectively and efficiently track and synchronize updates, thereby allowing the distribution of data and applications that previously had to be centrally housed and managed. This, in turn, makes automated processes and applications faster, more responsive, and improves the overall user experience for those processes that involve end user input.
[0038] This data distribution process is used to distribute data objects to the network nodes where they are needed to support local processing and to manage this distributed data (and its updates) once it has been distributed. The collision detection and data synchronization mechanism defines the set of processes and methods used to track these distributed data objects and to manage changes to these distributed data objects throughout a network of intelligent computing devices (“network nodes”).
Soft Object Referencing
[0039] Unlike the distributed application processes described above, soft object referencing describes a specific process that solves a specific problem inherent in distributed processing environments, including distributed application management. In order to distribute application components to support business transactions, the software must employ a process to determine what data and software are needed to support which transaction. Without this capability, the entire application and entire database would require replication to the computer supporting the business transaction, which would be cost-prohibitive and response-time prohibitive.
[0040] The system and method of the present invention addresses this issue by creating a new data type called the “Soft Object Reference.” The term “object” is used to denote a portion of the business application that contains both data and application code, sometimes referred to as “methods.” The term “object” as used herein below is intended to conform to the common use of this term within the computer software industry in such techniques as Object Oriented Development.
[0041] This soft object reference is established at design time and provides a logical boundary within the object graph that makes up the application object model. When a business transaction is initiated, it requests a target object on which it is to operate. The underlying software of the present invention traverses the object graph (starting from the requested object) and retrieves this object and all referenced objects until it reaches a soft reference. The soft references will then be transferred to the requesting device as a pointer only, and the traversing of the object graph stops at this point.
[0042] The business transaction then operates on the local objects and the soft referenced object pointers. Soft referenced objects will appear as if they were local objects to the business transaction. If the business transaction requires the actual object rather than the soft reference, this will be resolved transparently at run time by the underlying software by transporting the actual data object to replace the soft reference object. This will transport the next segment of the object graph to the requesting device until another soft reference is reached. In this manner, segments of the application are delivered on an as-needed basis to the requesting device that is executing a business transaction. This key innovation is fundamental to providing local application execution on devices with limited resource capabilities. Because on a network of computing devices there will exist a wide range of devices with a wide range of computational, communication and storage capabilities, from a large UNIX server down to a cell phone, the application must be able to be broken into pieces small enough to execute on the requesting device and small enough to transmit quickly over the network to the requesting device. Soft Object Referencing allows the logical segmentation of an application around business events so that requesting devices on a network can quickly access and execute these application segments. The unique method for segmenting applications and then manipulating these application segments provides an extremely efficient manner with which to determine what data and software are needed to support which transaction.
[0043] As discussed above, computing devices may be linked by a variety of private and public networks. User input, code, and data on which the code must operate may reside on different computer devices. To function effectively, these resources must be combined and the results of the work must be made available to the end user. While data and code may be distributed to the local computer devices, proper tracking and synchronizing of these transfers is essential for valid results. A system that distributes resources in an ineffective manner suffers from the same types of bottlenecks and poor performance that a system that performs all processing on a remote device. A useful data distribution scheme is essential to capitalize on the distributed processes.
System Operation
[0044] FIG. 1 illustrates system 100 that requires an efficient data distribution system with adequate collision detection and data synchronization to eliminate bottlenecks and other distribution and usage inefficiencies. The various components that make up the Distributed Object System 100 are listed and defined in the attached Glossary.
[0045] FIGS. 2A through 2H illustrate the basic operation of the collision detection and data synchronization mechanism in accordance with the present invention and help show the process flow that occurs and affects functional system 300 implementing synchronized distributed data/objects of the present invention. The functional system 300 is shown graphically in FIG. 3 .
Object Retrieve: Local Computer Device (Client) Requests Data
[0046] As shown in the process flow diagrams beginning with FIG. 2A , the first step in the collision detection and data synchronization mechanism is the request for data from a local computer device to a remote computer device. This would normally take place when a computer process running on the local computer device determines that it needs data to complete a task as shown at step 201 . This necessary data may reside locally on the local computer device or remotely on another computer device. This data is requested within the bounds of what is referred to as a “transaction,” which is defined as a logically grouped set of updates or data changes that must either all complete successfully, or none complete successfully.
[0047] A process running on the local device requests data to be used in a transaction. The local computer device checks local resources for the data required at step 203 . This may include checking the local file system and the local in-memory data storage (known as a local data cache). If the required data is found locally at step 205 , it is retrieved from the local file system or the main local data cache and used to complete the transaction at step 299 .
[0048] If the needed data is not found on the local computer device, a request to a remote computer device (“server”) is formatted at step 207 and sent to the server at step 209 . In many cases, there will be one central server, which will contain a master copy of all data. Thus, if the needed data is not found on the local device, there is only one remote device that needs to be checked to locate the data. In more complex cases, the local computer device will need to check a directory of remote computer devices located on the local device to determine where the needed data is located, and then use the address provided by this directory to resolve to the proper remote computer device.
[0049] The request for data is formed using a data/object model that is duplicated between the local and remote computer devices. Thus, the syntax used to request the needed data is determined from this local model. The remote computer device uses an exact copy of this model to decode or interpret this request for data.
[0050] The request for data that is to be sent to the remote computer device is formatted for transport to the remote computer device in step 207 . In the case of a browser-based application, for example, this would involve packaging the request as HTTP or HTTPS protocol.
[0000] Remote Computer Device (Server side) Provides Data
[0051] The remote computer device receives the request for data, and it is unpacked to remove the formatting elements needed for transport at step 211 in FIG. 2B . The request for data is then interpreted by comparing the data request to the data/object model on the remote computer device at step 213 .
[0052] Once the request has been interpreted by comparison to the data/object model, the request is resolved to a set of data access instructions that operate on database management software (dBMS) at step 215 . This data base management software (dBMS) is either running on the same computer device that received the data request, a computer device that is physically nearby to the computer device that received the data request, or a remote computer device connected via a network to the computer device receiving the request for data. Various known methods of resolving the request can be used.
[0053] At step 217 , the requested data is retrieved from the database management software (dBMS). The remote computer device then registers the requesting local computer device's interest in the retrieved data or object in step 219 . This registration of interest in the data retrieved by the local computer device is updated to persistent storage and is organized and indexed by the local computer device session ID and the data identifier(s) related to the data delivered to the local computer device. This persistent storage is referred to as the “Registration Table.”
[0054] The data is then packaged for transport back to the local computer device in step 221 , and in step 223 , the data is delivered to the local computer device.
Local Computer Device Receives Requested Data
[0055] In step 225 of FIG. 2C , the data is received by the local computer device and unpacked to remove elements needed for transport. In step 227 , the delivered data is added to the local data storage resources-either an in-memory data cache or a local file system, for example. The data is then copied and delivered to the requested transaction in step 229 . In step 231 , the data is stored in a data cache used to support the transaction. The transaction data cache is separate from the main local data cache or main local data storage on the file system. At this point, the data exists on the remote computer device, the main local data cache or file system, and a transaction data cache as shown in FIG. 3 .
[0056] Referring again to FIG. 2C , in step 233 , the data is registered on the local computer device as used by the transaction.
[0057] Through the use of a conventional communication process, the remote computer device updates the main data cache to reflect changes that have been made to data by other processes or users. This communication process can be either a polling mechanism (described later under “Notification Mechanism-Pull Implementation”) initiated by the local computer device, or a “push” communication process initiated by the remote computer device. These techniques are further described at the end of the process flow description.
Local Computer Device Updates the Data
[0058] The transaction operating on the local computer device makes changes to this data in step 235 as shown in FIG. 2D . These changes are accumulated in the transaction cache shown in the functional system diagram in FIG. 4 .
[0059] As shown in FIG. 4 , the collision detection process of the present invention can differentiate between conflicting and non-conflicting changes made by multiple clients to the same data items. For example, in the system shown in FIG. 4 , Client A begins Transaction Al and receives Customer “Bob” from the Server. Client A sets Bob's age to 32. Client A then receives Bob's Account and sets Bob's Account balance to $500.00. Client A then commits Transaction AI. Client B begins Transaction BI. Client B then receives Customer “Bob” from the Server. Client B sets Bob's Status to “S.” Client B then receives Bob's Account and sets Bob's Account type to “Savings.” Client B then commits Transaction B 1 . The non-conflicting changes made by Client A and Client B are differentiated by the system and method of the present invention to avoid false detection of conflicting changes that would otherwise bottleneck the process. In this fashion, the same data item may be modified by multiple clients without a degradation in system performance.
[0060] When the transaction is completed, all changes accumulated in the transaction data cache are compared against a log of data changes to the main local data cache received since the remote data was retrieved. This process is performed in step 237 as shown in FIG. 2D . Each data change consists of a “before value,” an “after value,” and a date and time stamp for individual data items. Although there is no condition or restriction on the size (or granularity) of data changes that are tracked, the collision detection and data synchronization process of the present invention works best with the lowest functional level of granularity possible. This is typically performed at the object property or relational database column/field level.
[0061] If a change has been received by the local computer device from the remote computer device to a data item that was also changed by the transaction running on the local computer device, then a local data collision is detected in step 239 , and the transaction running on the local computer device is notified both that the conflict has occurred and also is notified of the conflicting values of the data item in step 241 . The local transaction must then handle this conflict in an application specific manner as shown in step 243 .
[0062] If no conflicts are detected on the local computer device, then the changes to the data are submitted to the proper remote computer device(s) for remote conflict checking and long-term persistence. The data changes that are sent to the remote computer device are formatted for transport to the remote computer device in step 245 and then sent in step 247 . In the case of a browser-based application, this would involve packaging the request as HTTP or HTTPS protocol.
Remote Computer Device Updates the Data
[0063] As shown in step 249 in FIG. 2E , the remote computer device receives the data changes resulting from the local conflicts resolution and unpacks them to remove the elements added to support their transport to the server. In step 251 , the remote computer device then retrieves changes made by other users or other automated processes to the data items changed by the transaction at the local computer device, that were to be delivered to the main data cache/store on the local computer device, but which have not yet been sent to the local computer device. These are “queued data changes” that are waiting for the next polling interval or push transaction to update the local computer device main data cache/store. These queued data items are then stored in step 253 for comparison purposes.
[0064] In step 255 , collision detection is performed on the data based on a comparison of the local data collision conflict resolutions and the queued data changes. If a collision is found with these queued data changes in step 256 of FIG. 2F , a data change conflict message is sent to the local computer device in step 259 . This data change conflict message is packed by the remote computer device for transport and received and unpacked by the local computer device in the same manner as other messages between computer devices. After it is received and unpacked by the local computer device in step 260 , in step 261 it is forwarded to the transaction making the local data change for resolution in an application-specific manner.
[0065] If no data collision is detected with the queued data changes in step 256 , then in step 257 , the remote computer device then checks the persistent data store to match the old value of the data change to the value stored on the persistent data store.
[0066] If the old value on the data change does not match the value on the persistent data store in step 258 , a data change conflict message is sent to the local computer device in step 259 . This message is packed by the remote computer device for transport and unpacked by the local computer device in the same manner as other messages between computer devices. It is then received by the local computer device as in step 260 and forwarded to the transaction making the local data change for resolution in an application-specific manner as in step 261 . Once the remote data collision conflict is resolved in step 262 , the local computer device, in step 263 , sends a notification message to the remote computer device indicating resolution of the remote data collision conflict. Once the conflict is resolved and the remote computer device is notified of the resolution, the persistent data store on the remote computer device is updated in step 265 .
[0067] If value of the data change and the value stored on the persistent data store matches in step 258 , then there is no data conflict, no collision is detected, and the data change is made to the persistent data store as in step 265 .
[0068] As shown in FIG. 2G , the remote computer device then checks the registration table in step 267 to determine which other local computer devices must be notified of this data change. In step 269 , the remote computer device then formats the data change messages that are to be sent from the remote computer device to all other local computer devices that have registered interest in the data item. In step 271 , these messages are packed for transportation and either sent to the affected local computer devices immediately in a push model of communication, or queued for the next polling message in a polling model of communication.
[0069] In step 271 , the local computer device originating the data change is then notified of a successful data change update in a response message to the original request for data change message.
Local Computer Device Completes the Data Update Process
[0070] In step 273 , the local computer device receives a message indicated the data change update process has completed successfully. It unpacks the message to remove the elements added to allow transport and then processes the message.
[0071] In processing the message in step 275 , the local computer device first updates the main data cache on the local computer device to reflect the new value of the data item(s). The local transaction is notified in step 277 , and if the transaction is complete in step 279 , the local transaction cache is cleaned (the data changes within it are deleted) in step 281 .
[0072] If the transaction is not complete, that is, the same object is used by another transaction on the client, the changes are stored in the main cache in step 283 to be compared upon transaction completion.
Notification Mechanism
[0073] As shown in FIG. 5 , the collision detection process of the present invention also provides near real-time notification of changes made to locally cached data. For example, in the system shown in FIG. 5 , Client A receives the Customer “Bob” object from the Server. Client B then receives Customer “Bob” from the Server. Client A changes Bob's address and commits the change, i.e. accomplishes a data commit to update the database. Client B then displays customer Bob's address. Client B is notified in near real-time of the changes made to Bob's address. The system and method of the present invention ensures that the changes made by Client A will be transparently applied to Client B′s previously cached version of the data object.
[0000] a. “Pull” Implementation: Local Computer Device Initiates Synchronization
[0074] As outlined above with regard to the method of the present invention, periodically requests are sent to the remote computer device to retrieve data changes for data stored in the local computer device main data cache (as well as data used in local computer device transactions). These “notification requests” are the primary communication mechanism used to synchronize the data on the local and remote computer devices.
[0075] These requests are initiated by the local computer device on a regular interval and, in the case of communication over the Internet between local and remote computer devices, require no special network configuration or firewall configuration to receive inbound responses to these messages. These requests serve a number of functions beyond transporting data changes to synchronize local and remote computer devices, including maintaining a “heartbeat” between the two devices used to detect failures at either the local or remote computer device. The requests can also be used to transport text messages between local computer devices that are attached to a common remote computer device. This can be very useful in understanding and resolving data conflicts that may arise.
[0076] These request messages are packed for transportation in a manner appropriate to the network and communication protocol employed.
Remote Computer Device Processes Synchronization
[0077] The remote computer device receives the update request and unpacks it to remove elements added to support transportation across the network connecting the local and remote computer devices. The remote computer device then checks a resource that maintains the queue of all data changes that are relevant to the local computer device. This resource is referred to as a “mailbox” and is a queue that contains all data changes and other information, such as text messages, that should be delivered to the local computer device. The mailbox will typically contain whatever data changes have take place successfully against pieces of data that are registered to the particular local computer device since the last notification message.
[0078] If data changes are found, they are retrieved and formatted for transport to the local computer device and then sent to that device as a response to the notification message received from the local computer device.
Local Computer Device Processes Synchronization Response
[0079] The notification message is received by the local computer device and unpacked to remove the transportation elements. If data changes have been sent along with the notification message, these data changes are applied to the corresponding data items in the main data cache.
[0080] If there are any transactions in process on the local computer device, the data changes received from the notification message are stored on the local computer device and used to compare with data changes made by the transactions in process, at such time as the transactions are completed. This process of the local computer device updating the data is described above in the Data/Object Update section.
[0000] b. “Push” Implementation
[0081] In addition to the notification mechanism utilizing a pull implementation, the method of the present invention may also be achieved using a push implementation. In this scenario, Client B is also notified in near-real-time of the changes made to Bob's address, and the changes are transparently applied to Client B's previously cached version of the data object. The remote computer device processes a data change to a data item that is registered to a number of local computer devices.
[0082] The remote computer device then constructs a data change message that is sent to the impacted local computer devices immediately, without queuing in a mailbox. The local computer device then processes the data change message in the manner described above with regard to the local computer processing the synchronization response.
Mail Box for “Pull” Implementation
[0083] There is one mailbox resident on a remote computer device for each user or for each automated process where there is no end-user. Typically, in the case of a single user computer device such as a personal computer, each local computer device will maintain one session at a time. However, the Collision Detection and Data Synchronization Mechanism of the present invention may also connect computer devices that are multi-user or multi-session devices at both the local and remote computer device nodes. In this case, each unique session on the local computer device will have a corresponding session ID to uniquely identify messages within the mailbox on the remote computer device.
[0084] The definition of what constitutes a session is application-specific. However, it is generally understood to be a grouping of transactions over a defined time period that are processed serially. Sessions can be user-based, with a session start process such as a log on, allocate resources, and the like and a session end process such as a log off, de-allocate resources, and the like, with application-specific transactions between the start and end of the session. The session also may be a batch of transactions processed in an automated process from computer device to computer device. Additionally, a session could be defined as one transaction with a unique mailbox for each session/transaction. Additional transaction scenarios may also be implemented.
[0085] Each mailbox collects all notification information related to all session opened by the local computer device with the remote computer device. The mailbox may be stored in memory (in a cache on the remote computer device). However, in order to maintain the integrity of the overall application in the event of a failure at either the local or remote computer devices, the data stored in the mailbox at any time can be recreated from the Registration Table as well as session information on the local computer device. Any session information can be stored locally to enable the local computer device to recreate the session and the state of the session. For example, the local device can store a list of all objects used during a session.
[0086] In the preferred embodiments, a data set is transferred from the remote computing device to the local computing device for transaction processing. While the preferred embodiments utilize a client-server architecture, the invention can be used in a multi-tiered configuration in which the remote computing device is a computer at a level above the local computing device. The methods and structures of the preferred embodiments can be accomplished across the various tiers of an n-tier architecture.
GLOSSARY
[0087] Business Transaction—a meaningful unit of work in accomplishing a business process.
[0088] Collision—a situation where two or more independent processes attempt to update a data item with different values without the context that the other processes are attempting to update this data item.
[0089] Collision Detection—ensure client B does not successfully commit its transaction before becoming aware that a conflicting change has been committed by client A.
[0090] Computer Device—Any device with computational capability or the ability to execute computer instructions.
[0091] Database Management System—a software product used to organize and retrieve data from a data store or data cache.
[0092] Data Cache—an in memory storage area on a Computer Device which can contain either computer instructions or data. A data cache is generally understood to be “volatile” in that it will not persist if the computer device is turned off
[0093] Data Commit—an indication that a data change is confirmed and should be made available for further processing.
[0094] Data Model/Object Model—a description of the valid data elements and the acceptable and mandatory relationships between these data elements. When referring to the structure of data in a relational data format, convention is to use the term data model. When referring to the structure of data in an object oriented format, convention is to use the term object model.
[0095] Data Store—a persistent memory storage area on a computer device which can contain either computer instructions or data. A data store is generally understood to be “non-volatile” in that the information it contains will persist when the computer device is turned off
[0096] Distributed Duplicated Data Objects (D 3 O)—by distributing a copy of objects to a client side cache, rich-clients can interact with local data and methods to provide near-instant response time. Changes to object properties are reported and reconciled to the server through standard messages. The server is unburdened from all presentation logic and all transaction management save the persistence of completed transactions.
[0097] Encapsulation (see also Transaction Isolation)—ensure data available to transaction B is isolated from the changes being made to the same data in transaction A.
[0098] Heartbeat—A periodic synchronization or interrupt signal used by software to demonstrate that it is still alive.
[0099] Local Computer Device—Any device with computational capability on which a unit of work is initiated requiring computer instructions (in the form of software code and/or end user input) and data on which the computer instructions operate.
[0100] Mail Box—a queue used to store data changes and other information to be sent from a remote computer device to a local computer device.
[0101] Network—Two or more computer devices connected with a communication medium such as the Internet or a local area network. The computer devices may be connected on either a wired infrastructure or a wireless infrastructure. The connection may be either periodic or continuous.
[0102] Network Node—a computer device connected to a network. This computer device mayor may not have user input and display capability (such as that found on a personal computer). It may have only sensors and very limited state and computational capability (such as the motion detector device on a facility alarm system.)
[0103] Notification Message—a message sent between a local computer device and a remote computer device facilitate the transport of data changes between the local and remote computer devices.
[0104] Pull Mechanism—Notification messages that are initiated by the local computer device on a periodic basis. The pull mechanism is compatible with current Internet protocols (HTTP/HTTPS).
[0105] Push Mechanism—Notification messages that are initiated by the remote computer device on an event driven basis (when a data change occurs that must be sent to a local computer device). The push mechanism is not compatible with current HTTP/HTTPS protocols that drive most Internet traffic and thus requires a special protocol.
[0106] Registration Tables—A persistent data storage area that records which local computer devices contain what elements of data that requires synchronization.
[0107] Remote Computer Device—Any device with computational capability that can be connected to the Local Computer Device through any network, public or private. The Remote Computer Device could be immediately adjacent to the Local Computer Device or thousands of miles away. The concept of local and remote are relative to a particular unit of work. Thus a particular computer device can function as both a local and remote computer device for different units of work.
[0108] Shared Data Architecture (see also Soft Object Reference)—instead of centralized data, the data is shared on demand. Data is distributed by the server based on the operational need.
[0109] Soft Object Reference—a process to determine what data and software are needed to support which transaction at which computer device.
[0110] Transaction—a logically grouped set of changes to data that must all be processed or none must be processed.
[0111] Transaction Data Set—The set of data potentially involved in a transaction
[0112] Transaction Isolation (see also Encapsulation)—ensure data available to transaction B is isolated from the changes being made to the same data in transaction A.
[0113] User—an individual person accessing a software application
[0114] While the present invention have been described in connection with a number of exemplary embodiments and implementations, the present invention is not so limited but rather covers various modifications and equivalent arrangements, which fall within the purview of the appended claims. | A collision detection and data synchronization mechanism operates to expand the speed and capability of distributed applications. The execution environment employs collision detection and data synchronization to distribute data objects to appropriate network nodes to support local processing. The collision detection and data synchronization mechanism defines the set of processes and algorithms used to track distributed data objects and to manage changes to the distributed objects throughout a network of intelligent computing devices. Data and code are distributed to local computing devices necessitating tracking and synchronizing updates. The system and method ensures that data updates received during the course of a local transaction do not unwillingly affect the results of other transactions by notifying the local computing devices of changes to the data that are subject of the transaction. These conflicts are then resolved in the applications, and notification of the resolution is sent to the remaining intelligent computing devices. | 57,236 |
BACKGROUND
The invention refers to a laser applicator with an elongate catheter comprising an inner core and a cladding surrounding the core, wherein the cladding comprises a series of openings in a decoupling portion, whose opening surface increases towards the distal end.
Such a laser applicator is described in US 2009/0275931 (Vimecon), the disclosure of which is incorporated into the present application by reference. The known laser applicator comprises an elongate flexible catheter including a light guide. The distal end section is formed into a lariat-like shape whose plane extends transversely to the main portion of the catheter. Laser radiation is input into the light guide at the proximal end. A decoupling portion exists at the distal end of the catheter, where the energy is coupled laterally out of the light guide and exits from the catheter.
In particular, the laser applicator serves for the treatment of atrial fibrillation and other types of cardiac arrhythmia. It can be used to cauterize cardiac tissue by converting light energy into thermal energy. The laser radiation exiting the light guide heats the surrounding tissue to values above 60° C., resulting in the denaturation of proteins and the formation of an electrically inactive scar. For the purpose of achieving a uniform distribution of the decoupled energy over the length of the decoupling path, the width of the circular cladding segment that causes the decoupling can be varied over the decoupling path.
DE 10 2006 039 471 B3 describes a laser applicator comprising a catheter with a light guide. In a distal end section of the catheter, the cladding of the light guide has a cutout from which light exits laterally from the light guide. While the intact cladding of the light guide effects total internal reflection so that the light energy is transported in the longitudinal direction of the light guide, the cutouts at the border of the light guide core cause refraction so that light energy is coupled out. The cutouts are discrete openings of round cross section. Their diameter increases constantly from one opening to the next in the direction of the distal end of the light guide and varies from a size of 20 μm for the first opening to a size of 100 μm for the last opening. In a certain variant, the distances between two respective neighboring openings decrease in the direction of the distal end of the light guide fiber. This is to compensate for the decrease in radiance in the light guide fiber in the direction of its distal end.
Providing the openings for the lateral decoupling of laser energy from the light guide requires high precision, wherein the enlargement of the exit surface must be made in very small increments from the distal end to the proximal end.
The present application addresses the problem of making a decoupling path in a light guide by opening the cladding of the light guide in order to achieve an energy density of the decoupled radiation that is uniform over the length of the decoupling portion.
SUMMARY
An object is to provide a laser applicator whose decoupling cross section, increasing from the proximal to the distal end, can be realized in a relatively simple manner and with high precision.
In accordance with one aspect, a laser applicator has openings that are of uniform size and that are combined into spaced groups, wherein the number of openings increases from one group to the next towards the distal end.
These openings are made uniformly. Generally, these are openings of equal diameter. Such openings can be burned into the cladding of the light guide using a laser. The openings of uniform size are formed as a linear structure, i.e. a single-row chain of openings. The uniform openings can be readily formed using a laser beam. The openings are combined into groups, wherein the overall cross section of the openings increases from one group to the next in the distal direction.
Although the openings are formed with a uniform size, the invention does not exclude that different types of openings are realized in individual portions of the row of openings. In any case, however, the openings of one group have the same diameter. Preferably, all openings of the decoupling portion have the same diameter.
The groups of openings may be spaced from each other without the efficiency of a thermal tissue treatment along a continuous line being substantially affected thereby. The thermal treatment tolerates short interruptions of the welding line. This is used to divide the row of openings into groups of openings having mutual distances of less than 500 μm. Preferably, the distances between the groups are substantially equal.
The openings within a group are arranged along a line. Preferably, the openings of all groups are arranged along a straight line.
The openings of a group should be arranged rather close to each other. Preferably, their mutual distance is smaller than the diameter of an opening.
For the purpose of a fine grading of the hole surface increasing in the proximal direction of the decoupling section, it may be provided that at least two openings of a group partly overlap each other, whereby a blended hole is formed. The degree of overlap can become smaller from one group to the next in the direction of the distal end so that the surface of the blended holes becomes larger in the distal direction. This allows for a quasi-continuous increase in the cross-sectional area, the increment being independent of the size of the holes. The blended hole is preferably provided at the distal end of the group.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention may take form in various components and arrangements of components, and in various steps and arrangements of steps. The drawings are only for purposes of illustrating the preferred embodiments and are not to be construed as limiting the invention.
In the Figures:
FIG. 1 is a schematic illustration of the general structure of the laser applicator,
FIG. 2 is a cross section along line II-II in FIG. 1 ,
FIG. 3 is a schematic illustration of the groups of openings in the cladding of the light guide from the proximal end to the distal end of the decoupling portion, and
FIG. 4 is an enlarged illustration of neighboring groups of openings.
DETAILED DESCRIPTION
The laser applicator comprises a catheter 10 in the form of an elongate strand. The catheter has one or a plurality of lumens. It is preformed in the manner illustrated in FIG. 1 and is composed of a proximal section 11 and a distal end section 12 . Whereas the proximal section 11 extends substantially linearly, the distal end section 12 is formed into a loop shaped as a circle open at one point. The plane of the loop is transverse, in particular at a right angle, with respect to the longitudinal direction of the proximal section. It is dimensioned such that it contacts the wall of a blood vessel from inside with slight pressure. The outer diameter of the loop is about 4-6 mm.
The position A indicates the transition from the proximal section 11 to the end section 12 . The position B indicates the distal end of the distal end section. The decoupling portion 13 , where laser energy is coupled laterally out from the catheter, extends from the position A to the position B.
In the decoupling portion 13 , the laser applicator has the cross section illustrated in FIG. 2 . It has an integral elongate catheter body 15 of generally circular cross section and provided with a generally V-shaped groove. The groove 16 has two outwardly diverging flanks covered with a reflective layer 17 . The groove 16 extends up to near the longitudinal center axis of the catheter body 15 .
The catheter body 15 includes a lumen 18 for a form wire 19 , as well as two longitudinal cooling channels 20 and 21 extending along the entire length of the catheter.
A light guide 25 is set into the groove 16 from outside. The same has a core 26 and a cladding 27 surrounding the core, the material of the cladding having a lower refraction index than the core. The light guide 25 is fastened in the groove 16 by means of a transparent adhesive 28 . On the outer side, the catheter is sheathed by a transparent covering hose 29 .
In the decoupling portion, the cooling channels 20 , 21 are provided with outlet bores 35 , 36 that converge towards each other and eject cooling jets outward. The outlet bores extend under an acute angle with respect to each other. They make the cooling jets impinge on the target area of the heat radiation. The outlet bores have corresponding openings in the covering hose.
The light guide 25 is first machined outside the catheter by making openings 40 in the form of small bores in the decoupling portion 13 . The holes are burnt thermally into the material of the cladding by means of a focused laser beam. The light guide thus prepared is set into the lateral groove 16 of the catheter body 15 and is then fixed by means of the adhesive 28 . Thereafter, the covering hose 29 is applied.
The openings 40 in the cladding of the light guide are directed radially outward with respect to the center axis of the catheter body 15 . The adhesive 28 includes dispersing particles. The radiation escaping from the core 26 of the light guide is scattered at the particles and is reflected by the reflective layer 17 so that the radiation is focused at the focal point 42 where it acts on the body tissue.
FIG. 3 illustrates the arrangement of the openings 40 in the longitudinal direction of the light guide 25 along the length of the decoupling portion. The position A indicates the proximal end and the position B indicates the distal end of the decoupling portion 13 . In order to achieve a distribution of the laterally escaping energy that is as uniform as possible, the decoupling cross section has to increase towards the distal end.
The openings 40 in the cladding 27 of the light guide 25 are bores of a diameter of 75 μm, thermally formed by means of a corresponding laser beam. The openings 40 are uniform in size. They all have the same diameter. All openings 40 are arranged in a linear array. They are combined into groups 45 . The number of openings in a group 45 varies. It increases from the proximal end A to the distal end B. It is obvious that the first group is formed by only one opening. Thereafter, the groups become ever larger, i.e. they include more openings. The openings in a group are generally equidistant. They are arranged such that they just do not blend. The groups 45 are spaced apart. Here, the distance is 400 μm. Thus, the distance between the groups is constant along the decoupling portion.
FIG. 4 is an enlarged illustration of a series of groups 45 a , 45 b , 45 c . Here, the last openings of the group are combined into a blended hole 46 . The blended hole is formed by the overlapping of two holes, with the degree of overlap differing for the groups 45 a and 45 b . Here as well, the distance between the groups is 400 μm. By blending two openings, the overall cross section of a group can be varied with a fine grading. Thus, the overall cross section is increased quasi continuously from group 45 a via group 45 b to group 45 c . The blended hole 46 is situated at the distal end of a respective group.
The invention allows making the openings as uniform openings, where the only varying parameter for a change in the outlet cross section is the linear position of the openings.
The invention has been described with reference to the preferred embodiments. Modifications and alterations may occur to others upon reading and understanding the preceding detailed description. It is intended that the invention be construed as including all such modifications and alterations insofar as they come within the scope of the appended claims or the equivalents thereof. | A laser applicator includes an optical fiber with a core surrounded by a cladding. The cladding contains openings ( 40 ) for coupling radiative energy outward. To accomplish an even distribution of energy, the size of the opening increases from the proximal end to the distal end. The openings ( 40 ) are combined into groups ( 45 ), with the number of openings within a group varying. The openings ( 40 ) are of a uniform size so that the area of decoupling ( 13 ) can be produced in a simple manner. | 12,224 |
RELATED APPLICATIONS
[0001] This non-provisional application claims the benefit of U.S. Provisional Patent Application No. 61/072,262 filed on Mar. 31, 2008 and the non-provisional patent application Ser. No. 12/217,415 filed on Jul. 3, 2008.
FIELD OF THE INVENTION
[0002] This invention relates to the patient care monitoring system, associated method and its constituent devices which will provide monitoring, proactive prompts for treatment, recording and reporting of all prescribed actions as well as general care actions, mistakes and corrective measures administered for each patient. The patient care monitoring system matches the identification of the patient to their corresponding prescribed daily treatments, procedures, medications and general care. The system also matches the time frame specified for each of these care actions with the corresponding patient. When a mismatch is detected, the system will sound an alarm, and/or activate a warning display, and prompt any healthcare worker within its radio frequency transmission range to correct the mistake. The system will also sound an alarm or activate a warning display when the prescribed action is not acted upon or corrected within its specified time frame.
[0003] The system will further record and report prescribed treatment, procedure and medication given to a patient throughout the day along with the time of the care action. The system identifies, records and reports which healthcare worker was administering the care action as well as any mistakes and subsequent corrective actions.
BACKGROUND OF THE INVENTION
[0004] To err is human. However, medical errors, according to many research studies, have caused on average some 195,000 deaths in the U.S. annually. These deaths are preventable. The most common type of preventable medical errors are: incorrect administering of drugs (wrong prescription, wrong dosage, given to wrong patient and at wrong time), hospital acquired infections (unclean or improperly cleaned hands of healthcare staff, improperly sterilized equipment), postoperative bloodstream infection (un-sterilized and/or improper handling of sterile equipment, unclean hands), ventilator-associated pneumonia (again, un-sterilized and/or improper handling of sterile equipment, unclean hands) and negligence in basic cares (bed sores, falls, dehydration, malnutrition, etc.). The estimated cost for these medical errors is between $8.5 to $14.5 billion dollars annually. In the current climate of ever escalating healthcare costs, to prevent and reduce medical errors have become an absolute necessity. There is also a moral responsibility to provide quality healthcare to patients.
[0005] Medicare patients (65 years and older) account for 45% of all hospital admissions (excluding obstetric patient) in the U.S. This population suffers much more severe consequences from medical errors due to declining health, decreased immunological resistance and decreased recuperative ability. Consequently, out of the average 195,000 preventable deaths due to medical errors annually, a disproportional number of patients are elderly.
[0006] The latest statistics on U.S. nursing homes stated that there are 1.6 million patients occupying 1.9 million available beds, and the average stay of patients being discharged is over 290 days. For those not being discharged the average stay of patients is over 800 days. This is a clear indication that most patients in nursing homes as well as increasingly in the hospitals are aged and invalid patients (needless to add, many have difficulty in communicating their needs to healthcare staff).
[0007] These aged and invalid patients require additional care such as feeding, changing of bed pans, washing, turning them on their sides periodically, or simply communicating with them. Although each hospital and nursing home has stringent guidelines in how to take care of this type of patient properly, the workload pressure and shortage of nursing staff frequently result in lengthy improper care and further deterioration of the patient's health status. The lack of proper care thus costs the entire healthcare system (patients, their families, taxpayers, insurance companies) much more money, suffering and, in the worst case, unnecessary deaths.
[0008] It is not unusual for a person to observe the foul odor in a hospital wing or nursing home housing mostly aged and invalid patients. Numerous complaints have come from families that the patients frequently have severe skin rashes, lesions and bed sores to the degree of rotting flesh. All these are clear signs that proper patient care are not provided by these healthcare facilities.
[0009] On the other hand, by visiting any hospital or nursing home admission office, one will be bombarded with how well they have cared for their patients as well as shown the reams of patient care guidelines that they adhere to and the records of their adherence. However, there is no unbiased monitoring system that can provide data on: how often each patient is cared for, the percentage of properly carrying out treatment, procedures and medications prescribed by physicians on time and on specification other than what is recorded by nurses or their aids.
[0010] Several U.S. Congressional hearings and subsequent laws and regulations had resulted in the establishment of Federal Minimum Standards for nursing care facilities. Furthermore, each state also sets forth their minimum standards. However, the lack of effective monitoring methods and systems in providing realistic patient care monitoring data is a huge handicap in enforcing the laws and regulations particularly on those facilities supported principally by the Medicare and Medicaid programs.
[0011] Besides medical errors and negligence in providing necessary care actions, another aspect is fraudulent billing, i.e. charges without actually delivery of medical care actions, by not only healthcare facilities, but also increasingly by home care providers. Since the federal government medical insurance (Medicare) and the states' assistances are the biggest payers, they suffer the most financial loss.
[0012] Here we put forward an invention consisting of a method, monitoring devices and a system that does not disrupt the existing work routine of a healthcare facility and does not add any additional work step to the care giver. This system also ensures proper patient care is registered and reported on a daily or periodic basis. This data certainly can be forwarded to the regulatory agencies as well as family members of the patients to ensure proper care is continuously provided to those unfortunately sick, aged and/or invalid on a daily or periodic basis instead of just the period prior to or after an inspection by regulatory agencies. Furthermore, by logging these care actions, it provides a mean to track the accuracy of billing by insurance payers and thus reducing fraud.
[0013] There are numerous prior arts as cited in the Reference Section detailing various patient care monitoring systems and methods. All of them require special adaptations in order to achieve some measure of monitoring patient care. Therefore, not only new procedures must be adopted by a healthcare facility, but also added work steps. For example, added work steps such as: scanning the patient identification band, scanning every treatment/medication identification tag, waiting for remote processors to give an O.K. before proceeding in carrying out the care action, will greatly disrupt the work flow and reduce efficiency. Many of the basic care actions, such as changing a bed pan, bathing, altering a patient's laying position, special diet, etc., are not necessarily codified in most healthcare facilities, other than written in the patient's chart. Therefore, the actions are not monitored or tracked and are ignored in all the prior arts. Furthermore, many of the care actions, prescribed and general, have a timing element associated, such as medications, physiological measurements, altering a patient's laying position. Consequently, the patient care monitoring system must be able not only to record the timing of a care action being executed, but also proactively prompt the care giver to provide the care action within a specified time frame. Again, this aspect has been missing in the prior arts.
[0014] During a standard patient admission process into a healthcare facility, he/she is assigned an identification wrist band (such as a simple printed label with information like name, age, gender to assignment to a specific department/hospital wing and a specific patient room), which will stay with the patient for his/her entire stay in the facility along with a patient chart as well as entry of informational data into the central computer of the facility. During the patient's stay in the facility, a physician or attending care giver will typically examine the patient periodically (daily in hospital) and prescribe specific care actions to the said patient. The daily prescribed care action corresponding to a specific patient is entered into the patient chart as well as into the central computer of the care facility. Furthermore, standard general care actions, such as changing the patient's laying position and bed pans periodically for invalid or aging patients, bathing patients and diet precautions, etc., are also included (automatically or manually by the care giver) into the care instruction set for each patient.
[0015] To identify each patient and the treatments, procedures, medications and care actions prescribed to each patient, many prior arts suggested various approaches other than simple printed label, such as adding bar code, magnetic strip, Infrared (IR) pattern or radio frequency identification device (RFID) to the identification wrist band and to the label attaching to each care action delivery agent, administering devices or paper work as a mean in matching the patient with the care action-prescribed to him/her. U.S. Pat. Nos. 4,857,713 (Brown) and 4,857,716 (Gombrich, et al.) use printed bar code method for patient and care action identifications. Proper patient care monitoring is accomplished by scanning the bar codes of the patient and care action label as well as having a linked processor to conduct the matching. U.S. Pat. Nos. 6,824,052, 6,830,180 and 6,910,626 (Walsh) expanded the identification method to not only printed bar code, but also magnetic strip and/or Infrared (IR) pattern. As mentioned before, these methods and systems create added work steps for typical healthcare facilities as well as new equipment, linkage and installation. Also, the chaos/confusion will occur from the inaccuracy of scanning a bar code, swiping magnetic cards through a reader or line-of-sight requirements to do IR pattern recognition (error rate between 5 to 10%). U.S. Pat. Nos. 5,071,168 and 5,381,487 (Shamos) employ personal characteristics (such as fingerprint, eyeprint, and footprint) as patient identification code. Treatment/care action will only be given based on matched patient identification code. This is an even more tedious and time consuming method of patient identification. Many inaccuracies will result from the arbitrary selection of matching confidence level.
[0016] The RFID approach requires less effort of a care giver to read the identification code of a patient or a treatment/care action label/tag, since it only demands proximity to the reader and without the stringent line-of-sight demanded by optical scanner (bar code and IR methods) or moving the identification band/tag through a contact magnetic strip reader. However, a passive RFID as presented in the U.S. Pat. Nos. 6,671,563 and 6,915,170 (Engleson, et al.) still requires a reader to be placed close to the patient's identification band and to the treatment/care action tag in order to obtain the identification codes. This approach is more suitable for identification of objects rather than persons. The added work steps (placing the reader close to the identification band/label/tag and check whether a reading is made) to accomplish this data acquisition will disrupt the heavy work load of healthcare workers and result in frequent-non-usage.
[0017] Other prior arts, such as U.S. Pat. No. 7,384,410 (Eggers, et al.), use RFID method to identify patients and care delivery devices to achieve error avoidance. However, this approach will not monitor many of the care actions that require no administering devices.
[0018] The system and method stipulated in the U.S. Pat. Nos. 5,883,576, 6,255,951 and 6,346,886 (De La Huerga) as well as U.S. Pat. Nos. 6,961,000, 7,158,030 and 7,382,255 (Chung) employs the approach of reading and sending the identification codes from the patient and the treatment/care action device along with a relational check code (in Chung's patents) to a separate and independent processor for matching to determine the action to be executed corresponds to the patient. A display and alarm will then inform the care giver whether a mismatch exists. This multiple-element system not only produces added work steps (scanning/reading of the identification devices and waiting for direction from the processor), thus discouraging usage by care givers and adoption by healthcare facilities, but will also not monitor those required care actions, such as bathing invalid patients, changing wet clothes, changing bed pan, rotating patient laying/sitting posture, etc., that do not carry identification labels/tags.
[0019] The invention presented here will employ active RFID technique (contains a power source to transmit and receive RF signals for transmitting its stored codes and for receiving external data) in the patient and treatment/care action identification. This approach will provide direct and immediate verification between the patient identification band and the treatment/care action ID tag. The healthcare worker does not take any extra step to facilitate the reading of the RFID tags, thus ensuring the usage of this invention. Active RFID also achieves the determination of a match or mismatch prior to administering care action at the point-of-care. The patient ID band will also (through communication with other sensors) determine whether other general care actions without ID tags have been executed within the prescribed time frame. Furthermore, it will interact with the care giver's identification tag/band to proactively prompt him/her to provide the required care actions as well as record all the care actions given with respect to time and correctness along with the identities of the care givers administered all the care actions.
SUMMARY OF THE INVENTION
[0020] Conforming to the standard practice of a hospital or nursing home, this invention presents a patient care monitoring system and method that employs active RFID integrated with a digital processor as a device (ID band or ID tag) to transmit the programmed identification codes for each patient, care giver and for each treatment, procedure, medication and care action. By having each identification device capable of receiving and deciphering only the signals containing its own unique identification code, the patient identification wrist band will thus determine whether the treatment/procedure/medication/care action label/tag presented to him/her at the point-of-care matches the one prescribed by his/her physician. Equally, the treatment/care action label/tag will match the received patient ID code to its assigned patient code to determine whether it is the correct patient. If there is a mismatch, then a visual or audio alarm integrated into the identification devices will be displayed and/or sounded to alert the care giver of the error. Since the standard routine in a healthcare facility is for an attending physician to examine his/her patient in the morning and entering prescribed care action for the day into the patient's chart and the facility's computer system (typically at the terminals in a nurse station), the present invention will translate the prescriptions into corresponding treatment/procedure/medication/care action codes within its central processor and transmit the daily care actions and schedule via wireless communication through a RF transceiving device within each patient's room to each corresponding patient's identification band. At the same time, the central processor will send the prescribed treatments, procedures, medications and care actions to appropriate departments of the facility to program an active RFID identification tag with the unique code corresponding to the treatment, procedure, medication or care action along with the targeted patient identification code. These ID tags will then be attached to the care delivery device and/or paper work to be presented to the patient at the point-of-care. Each patient ID band and the care action ID tag will interact with each other and cross check with each other to ensure they correspond to each other before the care action is administered. At the time of administering, both the patient ID band and the care action ID tag will record the event and time as well as the ID code of the care giver. The patient ID band can also receive input from other measuring sensors, such as posture position, wetness, body temperature, pulse/heart rate to determine whether an alert to the care giver should be generated. Also, if a prescribed or general care action at a specific time frame was not administered, then, the patient ID band will transmit an alert signal continuously to prompt any care giver to provide the care action as soon as possible. All the care actions administered or non-conformance to the prescription or general care guidelines will be recorded by the patient ID band and transfer through the same RF transceiver device to the central processor to report and alert the quality control personnel of the facility. At the same time, all the treatment/care action ID labels/tags will be returned to the corresponding departments after their usage to download the recorded data and transfer to the central processor. After downloading, the memory of each ID tag can be cleared and reprogrammed for reuse.
BRIEF DESCRIPTION OF THE DRAWINGS
[0021] FIG. 1 illustrates a wrist band configuration of a patient's identification device where [ 1 ] indicates the housing for battery pack, [ 2 ] is where the RF transceiver and digital processing, memory and timing circuitry is housed, which links to [ 3 ] the capsule for an antenna. FIG. 2 shows a version where it can be the identification device worn by the healthcare giver with [ 7 ] housing the battery pack, [ 9 ] being a combination of a watch module and the RF transceiver/processing/memory/timing circuitry, and [ 10 ] being the capsule for an antenna and visual display.
[0022] FIG. 3 demonstrates a treatment/procedure/medication/care action tag, which is attached to a medicine delivery vessel [ 13 ]. In this drawing, [ 11 ] is an encapsulation of a RF transceiver, digital processing, memory and timing circuitry along with battery pack and an antenna. This waterproof capsule is covered with a printed label stating what the care action is and the patient's name, room number along with other relevant information. The entire capsule is adhered to a disposable tape [ 12 ] which in term adheres to a care action administering device [ 13 ] (such as a medication dispensing vessel in this drawing), or to the treatment/procedure/care action paper work carried by the care giver to the point-of care. The green [ 15 ] and red [ 16 ] LED indicators on each care action tag will flash when there is a match or mismatch between the prescribed care action and the patient's identity.
[0023] FIG. 4 shows a programmer machine for programming a prescribed treatment/procedure/medication/care action identification tag. This device is linked to the central processor of the healthcare facility to download the prescribed care action into a care action identification tag. Care action in code will be programmed into the inserted tag along with the targeted patient identification code. The programmed data will also be shown on the display screen [ 17 ], and an integral printer [ 19 ] will print out the coded care action, patient name, identification characteristics and room number on a visually readable label [ 20 ] that will automatically be attached to the care action identification tag. Manual programming can be done through key pads [ 18 , 21 and 22 ].
[0024] FIG. 5 illustrates how an attending physician per hospital work routine will enter his/her prescribed treatments, procedures, medications and/or care actions as well as timing for a specific patient after a round of examination into the central processor of the healthcare facility. The prescription will then be translated into corresponding care action codes and forwarded to responsible departments to program the care action identification tags and for administering.
[0025] At the same time, the physicians' prescriptions will also be sent via a RF transceiving device in a patient room [ 27 ] to the patient identification band [ 23 ] as shown in FIG. 6 . FIG. 7 demonstrates that the patient's identification band will interact with each care action identification tag [ 26 ] being administered to assure it matches the prescription and timing. The patient identification band [ 23 ] will record all the care actions administered throughout the day, their correctness and timing. The record will be transferred from the patient band [ 23 ] to the central processor again through the [ 27 ] RF transceiving device on daily basis for the central processor to produce a patient care monitoring report as indicated in FIG. 7 .
[0026] FIG. 8 presents one type of sensor network that enables the invention to provide proactive prompts to care givers for prescribed care action or general required care action. In this illustration a thin and flexible pad [ 27 ] consists of a network of pressure transducers [ 29 ], which will be placed underneath the patient's bed sheet. The signals from various pressure transducers will indicate the body movement (or lack of) of a patient as a function of time. For an invalid patient, this pad will signal the patient identification band to prompt any care giver walking into the patient room to alter the patient's body position when required to prevent and eliminate bed sores. Equally, a wetness sensor added to the pad can prompt the care giver to change the bed pan, clothing and bed sheets for the patient.
[0027] FIG. 9 a provides a block diagram and interaction between the various components of the invention, whereas the prescribed care actions are entered into the central computer of a healthcare facility and transmitted through its intranet to the in-patient-room RF Transceiving Device. This relays to the corresponding patient's ID band and to the Care Action ID Tag Programming Device for programming into a Care Action ID along with the targeted patient ID code. FIG. 9 b illustrates the wireless interaction between the patient ID band and a care action ID tag to assure correctness prior to the administering of the care action. FIG. 9 c demonstrates that the patient ID band will proactively prompt the care giver's ID band to furnish needed care action per its sensor network inputs or query from its own stored prescribed care action program.
[0028] FIG. 10 presents a possible daily patient care quality monitoring report generated by this patient care monitoring system and method.
DETAILED DESCRIPTION OF THE INVENTION
[0029] This invention presents a practical and accurate system to monitor patient care to avoid most common medical errors in a healthcare facility while it adheres to the standard healthcare work procedures and routines in administering patient care. The transparency in conducting the monitoring without requiring care givers to perform additional work steps or disrupting the trust between patients and care givers ensures this invention to be adopted and accepted by healthcare facilities. It also differentiates itself from any prior arts.
[0030] The hardware and software detailed in claim 1 consists of the following hardware components along with imbedded operating software to enable each to function as described below:
1. The patient identification device as illustrated in FIG. 1 is in the most commonly employed configuration of a wrist band. This waterproof wrist band contains a battery pack [ 1 ] which can be charged via electrical contacts [ 4 ] or electromagnetically without electrical contacts, a central plastic housing [ 2 ] for the RF transceiving, digital processing, memory and timing circuitry and a separate plastic capsule [ 3 ] for an antenna. With the current integrated circuitries and micro-electronics, all three components can be integrated into a single small housing of 0.5 in (Width)×1.0 in (Length)×0.25 in (Height) or even smaller in size. At the admission of a patient, the admission personnel will enter the relevant patient information, such as name, gender, age, ethnicity, possible illness, physician name(s), hospital room assigned, etc. into the central processor (computer) of the healthcare facility along with generating a unique identification code for the patient. This code will stay with this patient until his/her discharge. The central processor will in turn program a wrist band (as illustrated in FIG. 4 —note: the patient identification wrist band and the prescription care action identification tag programming can be done on a same device linking to the central processor) with this assigned patient code and print the patient information on a label to insert into the transparent pocket on top of the wrist band. The admission personnel will then fasten the identification wrist band on the patient's wrist (or ankle) which will be secured for the duration of the patient's stay. The patient ID band will be continuously in receiving mode to receive RF signals. Upon receiving a RF signal tuned to its receiving frequency, such as 2.3 GHz, it will examine the signal string for its own unique identification code. If the code does not exist in the signal string, then it will ignore the signal. If the code does exist, then it will match its stored care action program codes with the care action code in the signal. If it matches, then it will broadcast an “O.K” signal along with its identification code and flash its green LED indicator [ 5 ] in FIG. 1 for a period of time. If there is no match in the care action code between its stored program and that from the received signal, then it will transmit a “Mistake” signal along with its identification code and flash its red LED indicator [ 6 ] for a period of time. The patient ID band will also transmit a specific prompt signal along with its ID code to alert care giver to correct any mistake or administer the prescribed care action before the specified time period expires. All the signals transmitted by the patient ID band will be in low power range (a few milliwatts) to achieve a short distance (3-10 ft) receiving by other identification devices within a patient room. The patient ID band will record all these interactions and time and date and transmit the record to the central processor of the healthcare facility on daily basis. 2. The care giver identification device as illustrated in FIG. 2 is in a configuration of a fashionable wrist watch. This waterproof wrist watch contains a battery pack [ 7 ], which can be charged via the contacts [ 8 ] or electromagnetically without electrical contacts, a central housing [ 9 ] for the RF transceiving, digital processing, memory and timing circuitry along with the watch mechanism and a separate plastic capsule [ 10 ] for antenna and a display module. This care giver identification wrist watch will contain a unique code assigned to each individual worker during his/her employment in the facility. This care giver ID device will transmit its identification code continuously in burst mode (such as once every second or every other second) and, in between the transmissions, it will receive any RF prompt signals from the patient ID bands and activate its display [ 10 ] to show the nature of the prompt on care action not executed or mistake on care action to be administered as well as starting its built-in vibration device to alert the care giver. 3. Identification device in the configuration of a label or tag for prescribed treatment, procedure, medication and any special care action, as shown [ 11 ] in FIG. 3 , is virtually identical to the patient identification device in terms of RF transceiving, digital processing, memory and timing circuitry except all of them along with battery pack and antenna are contained in a single sealed plastic housing of 0.5 in (Width)×1.0 in (Length)×0.25 in (Height) or even smaller in size. This type of tag will each be programmed by the programming device, shown in FIG. 4 , with the code of a particular prescribed treatment, procedure, medication or care action along with the identification code of the targeted patient. This care action tag will continuously transmit, in burst mode, a signal containing its programmed care action code and the corresponding patient ID code at a cycle of once every second or some other frequency rate. The transmission will be at a specific frequency, such as 2.3 GHz, and at a low power, typically in a few milliwatts range, to affect a short distance signal transmission (3 to 10 ft range). In between transmission, the care action tag will be in receiving mode to receive signals from the patient ID band. It will ignore any signal that does not have the correct patient ID code that it carries in corresponding to the care action code. If an “O.K.” signal is received with correct patient code, then it will flash its green LED indicator [ 15 ] to signal match has been verified. When a “Mistake” signal is received with correct patient code, then it will flash its red LED indicator [ 16 ] and/or audio warning tone to signal error. 4. A central processor can be the central computer of a healthcare facility or it can be a separate personal computer (PC), a server or a combination of multiple PC and servers, which is linked with the central computer of a healthcare facility via intranet such as a wired or wireless large area network (LAN) or wide area network (WAN). This central processor will take the prescriptions issued by attending physicians (typically each morning after their rounds of examination of patients as illustrated by FIG. 5 ) and convert them into alpha-numerical codes corresponding to the specific treatments, procedures, medications (type and dosage) and special care actions along with the identification codes of the targeted patients as well as time frame to be administered. These coded data along with prescriptions entered by the physicians will be transmitted via intranet to each responsible department and/or nursing station to program and prepare the care action tags as well as administering schedule as illustrated in FIG. 9 a. This central processor will also transmit these coded prescribed care actions and time schedule to the corresponding patient's ID band via RF transceiving device, [ 27 ] of FIG. 6 , located in each patient room as shown in interaction block diagram of FIG. 9 a. The same transceiving device [ 27 ] will also relay the daily care administering log recorded by a patient ID band back to the central processor for report presentation and data archiving. 5. A RF transceiving device, [ 27 ] of FIG. 6 , which is linked to the central processor through intranet (e.g. an Ethernet connection) and contains a RF transceiving and digital processing circuitry along with antenna to convert the data strings received from the central processor and to transmit them via RF to the patient ID bands located within the room that this device [ 27 ] is located. It will also receive the daily care administering log from the patient ID bands located within a room via RF and convert them into proper format/protocol (such as TCP/IP) for transmission via intranet to the central processor. FIG. 6 illustrates the transmission and receiving actions taking place between this device [ 27 ] and the patient's ID band [ 23 ] worn by a specific patient [ 24 ]. 6. A care action identification tag programming machine, shown in FIG. 4 , which programs the memory of a care action identification tag placed within it with a set of code corresponding to the type of care action, dosage (in term of medication), delivery mean and time frame for the administering along with the patient's identification code that this care action is prescribed to. It will concurrently print out a readable label [ 19 , 20 ] adhering to the care identification tag for ease and correct delivery to the right patient room and to the right patient. This machine will be used in each department and nurse station of the healthcare facility and is linked to the central processor through intranet for downloading the care action identification codes and corresponding patient's identification code that the department and/or nurse station will be responsible to execute. 7. When a care action delivery device/agent, [ 25 ] of FIG. 7 , or associated paper work is brought to a patient, the care action identification tag [ 26 ] attached to this delivery device/agent or paper work will transmits its stored codes and associated patient's identification code continuously. FIG. 7 shows that the care action tag [ 26 ] attached to an intravenous medication bag [ 25 ] performing this process. Upon receiving this signal string, the patient's ID band [ 23 ] will examine whether its unique identification code is within the signal string. If it is not, then the patient ID band will ignore the signal string. If it is, then the ID band will further examine whether the care action codes match those stored in its memory as part of the care action program prescribed by his/her physician for the day. If it matches, then the ID band will transmit an “O.K.” signal along with its own identification code. Otherwise, it will send a “Mistake” signal with its own identification code. For “O.K.” status, the ID band will also flash the green LED [ 5 ] of FIG. 1 , for a period of time. Red LED [ 6 ] will be flashed when “Mistake” status is determined (audio alarm can also be included in the warning) along with sending out a warning signal to trigger the vibration mode of the care giver's identification band/tag to prompt the stop of administering and examine the mistake. The care action identification tag, upon receiving either the “O.K.” or “Mistake” signal with correct corresponding patient identification code from the patient ID band, will activate the flashing of green LED [ 15 ] or red LED [ 16 ] and/or audio warning on its housing as presented in FIG. 3 . All these interactions described in this section occurring at the point-of-care are illustrated by the block diagram in FIG. 9 b and are immediate as well as transparent to the care giver except when a mistake warning or no indicator/warning (signaling the patient ID code does not match the patient ID code included in the care action tag) happens. 8. The patient ID band will also periodically examine its stored care action program vs. time to determine whether a prescribed action has been administered. If not, then the ID band will issue a prompt signal which can activate the display and vibration of a care giver's identification band/tag [ 10 ] in FIG. 2 and/or transmitted through the RF transceiving device [ 27 ] in FIG. 6 to the central processor for displaying alert status in the nursing station responsible for the patient. 9. The patient ID band will also receives signals from a patient monitoring, sensor network, such as from a pressure transducer pad (as show in FIG. 8 ), wetness sensor, pulse/oximetry sensors and/or heart rate sensors to determine whether specific general care action, such as changing the patient's laying position to prevent bed sores, or changing bed pan, changing clothing or bed sheets is required. If the need is there, then the ID band will issue prompt signals to activate the display and vibration of the identification band/tag [ 10 ] of any care giver within his/her room as well as transmit through the RF transceiving device [ 27 ] to the central processor to display an alert to the care givers in the nursing station responsible for the patient. 10. The patient ID band will also record all the care action administered and time and date as well as verify all the prompts and resulting actions in its memory. At a designated time, it will transmit this log through the RF transceiving device [ 27 ] to the central processor for it to process into a daily or periodic patient care monitoring report as demonstrated in FIG. 9 a and FIG. 10 . 11. The care action identification tag will be returned to the appropriate department after administering for battery charging, disinfecting and reuse (clear codes in its memory and reprogram with a new set of instruction codes). 12. An electromagnetic (non-electrical contact) battery charger can be placed close to the patient ID band to fully charge the band's internal battery pack. Current U.S. Class: 235/437, 472.02; 340/572.1, 573.1, 573.7, 604, 614, 669; 700/108, 109, 226; 705/2, 3, 9 Current International Class: G06F 11/30, 19/00; G06K 5/00, 7/10; G08B 21/02, 04, 20; G08B 25/10, 29/18, 31/00 Field of Search: 235/380, 470, 437, 462.01-.09, .34, .46, 472.02; 340/572.1, 573.1, 573.7, 604, 614, 669; 604/67; 700/108, 109, 226; 705/2, 3, 9, 17; 713/189; 714/752
[0000]
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3. U.S. Code of Federal Regulation 42 CFR Part 483—Federal Minimum Standards of Care
4. Medtronic Remote Monitoring System, Medtronic Inc.
5. Care Trend Monitoring System, Sensitron Inc.
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9. “The Impact of Medical errors on Ninety-Day Costs and Outcomes: An Examination of Surgical Patients” by Encinosa, W E, Hellinger F J, Health Services Research, V43(6): 2067-2085
10. “Medication Errors Cost State $17.7 Billion and Cause Harm to 150,000 Californians Annually” a report from a panel created by based on California Senate Concurrent Resolution 49, www.californiaprogressreport.com/2007/03/medication_erro.html, Posted on Mar. 7, 2007
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12. “Fraud found in Medicare billings” By Julie Appleby, USA Today, Mar. 13, 2009 | A patient care monitoring system and method employ active RFID devices integrated with digital processing, memory and timing circuitry for patient identification, care giver identification and for identification of each prescribed treatment, procedure, medication and general and/or special care action. At the point-of-care, each care action identity device will match directly with the targeted patient identity device or issue an error warning to prevent mistakes. The patient identity device will also interact with an associated sensor network to proactively prompt care givers to provide general care actions, such as altering a patient's laying position, changing bed pan/clothing/bed sheet, etc. for invalid patients. Also the patient identity tag will furnish periodic records of every care action, mistakes, remedies, care givers' identities and time and date for a central processor of a healthcare facility to monitor the quality of patient care. Such record can also be potentially accessed via the Internet by the responsible regulatory agencies, accreditation associations, insurance firms and even patients' families to ensure patient care is meeting the standards as well as medical billing accuracy. | 44,420 |
DESCRIPTION
This invention relates to field-effect transistors having a current channel consisting of high-T c superconducting material the conductivity of which can be reproducibly influenced by an electrical field, and whose structure is that of an inverted (Metal-Insulator-Superconductor) MISFET in the sense that the substrate is used as the gate electrode. The invention further relates to a method for making superconducting field-effect transistors with inverted MISFET structure.
BACKGROUND OF THE INVENTION
For several decades, the electronics industry has made enormous efforts to shrink the size of electronic components and circuits with the aim of increasing the speed of operation and of reducing the power consumption/dissipation. These efforts have led to the development of integrated circuits and multi-layer ceramic devices which, in a volume of a few cubic millimeters, contain many thousands of transistors and other circuit components. These devices have very high operating speeds owing to the shortened distances the electrons need to travel inside of them. All of the modern circuits use advanced semiconductor materials, such as silicon and gallium arsenide, for example.
The discovery by Bednorz and Mueller (Z. Phys., B64 (1986) p. 189) of a new class of superconductor materials has of course opened another avenue to even lower power consumption and caused a worldwide search for possible applications of these materials in electronic circuitry. A number of studies on the electric field-effect in copper oxide compounds have been reported (for example by U. Kabasawa et al. in Japanese Journ. of Appl. Phys. 29 L86, 1990), but so far only minor field-effects in high-T c superconductors have been found. However, EP-A-0 324 044 already describes a three-terminal field-effect device with a superconducting channel in which electric fields are used to control the transport properties of channel layers consisting of high-T c superconductor materials. While this seemed to be a promising approach, growth studies of such devices have shown that in the suggested configuration the ultrathin superconducting layers readily degrade during deposition of insulator layer and top electrode.
In accordance with the present invention, this drawback is avoided through deposition of the superconducting film after the insulating layer, and locating the gate electrode underneath the insulator and the high-T c film. Still in accordance with the present invention, a conducting substrate is used as the gate electrode, and to facilitate the growth of preferably perfect crystals, substrate and insulator are chosen from the same crystallographic family of materials, that is, the lattice constants of the materials chosen to at least approximately match. For example, electrically conducting Nb-doped SrTiO 3 is used for the substrate, and undoped SrTiO 3 is used for the insulator layer.
The use of niobium-doped strontium titanate Nb: SrTiO 3 in a high-T c superconductor structure was described by H. Hasegawa et al. in their paper "Contact between High-T c Superconductor and Semiconducting Niobium-Doped SrTiO 3 ", Japanese Journ. of Appl. Phys., Vol. 28, No. 12, December 1988, pp. L 2210-L 2212, and in their EP-A-0 371 462. These references describe a diode structure where a superconducting film is deposited onto an Nb-doped SrTiO 3 substrate. The authors of these references are only interested in measuring the rectifying properties and the resistance in forward and reverse directions. They "demonstrated that there are unknown interfacial layers between the two materials", a problem that the present invention elegantly overcomes.
This invention is based on experimental evidence for a significant electric field-effect recently discovered to exist in thin superconducting films. These experiments were performed with materials of the copper oxide class of superconductors, in particular YBa 2 Cu 3 O 7- δ. Thin films of superconducting YBa 2 Cu 3 O 7- δ are already known from EP-A-0 293 836. Epitaxial growth of YBa 2 Cu 3 O 7- δ is described in EP-A-0 329 103. For the purposes of the present invention, the value of "δ" shall be considered to be close to zero (preferred), but it can be as large as 0.5. Those skilled in the art of high-T c superconductor materials will appreciate that many other materials in that class will be equally suited for the field-effect transistor structures of the MISFET type, as herein suggested. Also, other methods for depositing films of high-T c materials and of SrTiO 3 are known in the art, such as laser evaporation, electron beam evaporation and molecular beam epitaxy.
While the acronym "MISFET" is usually employed to characterize Metal-Insulator-Semiconductor Field-Effect Transistor structures, this term will in the following description be maintained for describing an analogous structure, although the embodiments of the present invention to be described will use different materials, viz. electrically conducting Nb-doped SrTiO 3 in place of the Metal, and a superconductor instead of the Semiconductor.
MISFET-type structures have been developed in accordance with the present invention which allow the application of electric fields larger than 10 7 V/cm across insulating SrTiO 3 barriers on ultrathin epitaxially grown YBa 2 Cu 3 O 7- δ channel layers. Epitaxial growth of YBa 2 Cu 3 O 7- δ rf-magnetron sputtering is described in EP-A-0 343 649. In these structures, the normal-state resistivity and the density of free carriers in the YBa 2 Cu 3 O 7- δ films can be modified substantially with gate voltages of on the order of 50 V.
Shortly after the discovery of the high-T c superconductor materials, Bednorz et al. in their above-cited EP-A-0 324 044 predicted on theoretical grounds that high-T c superconductor materials may bear an electric field-effect which is much larger than that in low-T c superconductor materials: The length scale by which electrostatic fields are screened in conducting materials is given by the sum L D +L DZ of the Debye length L D =(ε o ε r kT/q 2 n) 1/2 and the width of eventual depletion zones L DZ =N/n. Here, γ o and ε r are the dielectric constants of the vacuum and of the conducting material, respectively, k is the Boltzmann constant, T is the absolute temperature, q is the elementary charge, n is the density of mobile carriers, and N the induced areal carrier density. Because of their high carrier density, low-T c superconductors usually screen electric fields so well that the fields only have a minor influence on materials properties. To attenuate the screening, recent experiments on the electric field-effect in low-T c superconductors have focused on compounds with exceptionally low carrier density, like doped SrTiO 3 , with niobium as the dopant, for example.
In high-T c superconductor compounds, larger field-effects are expected owing to their intrinsically low carrier concentration and because of their small coherence length. The low carrier concentration of about 3 . . . 5×10 21 /cm 3 leads to screening lengths in the range of tenths of nanometers, and the small coherence lengths allow the fabrication of ultrathin layers with respectable critical temperatures. Superconducting films as thin as 1 . . . 2 nm have already been grown; electric fields can penetrate such films to a considerable extent.
OBJECTS OF THE INVENTION
It is an object of the present invention to minimize degradation effects in superconducting field-effect transistors with an inverted MISFET structure.
It is a further object of the invention to provide superconducting field-effect transistors whose inverted MISFET structure permits the deposition of the superconducting channel layer after the deposition of the insulating barrier layer.
It is still another object of the invention to provide materials for the substrate and insulator layer which have at least approximately the same lattice constants so as to facilitate crystal perfection.
BRIEF DESCRIPTION OF THE DRAWINGS
Details of two embodiments of the transistor and of the inventive method will hereafter be explained by way of example, with reference to the attached drawings in which:
FIG. 1 is a schematic diagram of a first embodiment of a field-effect transistor in accordance with the invention;
FIG. 2 is a schematic diagram of a second embodiment of an inventive field-effect transistor;
FIG. 3 shows the I G /V G characteristics of the field-effect transistor of FIG. 1;
FIG. 4 is a diagram showing the dependence of the changes of the channel resistivity as a function of the gate voltage V G ;
FIG. 5 shows the dependence of the channel resistivity as a function of the absolute temperature.
TECHNICAL DESCRIPTION OF THE PREFERRED EMBODIMENT
To apply large electric fields on thin films of superconducting YBa 2 Cu 3 O 7 , in accordance with the invention, an inverted MISFET-structure as shown in FIG. 1 is used. In this structure, a superconducting film 1 of the thickness s is separated from a gate electrode 2 by an insulating layer 3 of the thickness t. Besides the thickness of the superconductor, the resistivity rho 1 and the breakthrough field strength E BD of the insulator are crucial parameters. The required values for E BD and for rho 1 can be simply estimated, if space charge effects are neglected: To induce a surface charge density in superconducting film 1 which corresponds to the unperturbed density n of mobile charge carriers, the capacitor consisting of gate electrode 2 and superconductor film 1 has to be biased with a voltage ##EQU1## where ε i is the dielectric constant of the insulator 3. Equation (1) implies that to modulate the carrier density in high-T C superconductors substantially, the product ε i ×E BD of the dielectric constant ε i and the breakdown field strength E BD has to be of the order of 10 8 V/cm. (For comparison, SiO 2 has an ε i ×E BD product of 4×10 7 V/cm at room temperature).
In addition, the normal-state resistivity of the insulator has to be sufficiently high to avoid leakage currents which result in an input loss V G ×I G . For a typical case of I G <I DS /100 and I DS =10 μA, and an area of the gate electrode 2 of 1 mm 2 , the resistivity must be higher than 10 14 Ωcm/ε i at operating temperature.
In view of these requirements, insulating layers with high dielectric constants are recommended. Therefore, and for its good compatibility with the growth of YBa 2 Cu 3 O 7 , SrTiO 3 is selected as barrier material for insulating layer 3. The compatibility of YBa 2 Cu 3 O 7 , with SrTiO 3 has already been pointed out in EP-A-0 299 870 and EP-A-0 301 646, and the use of a buffer layer of oriented polycrystalline SrTiO 3 has been described in EP-A-0 324 220 and EP-A-0 341 788. The method recommended for fabricating the MISFET structure of FIG. 1 with a SrTiO 3 barrier layer 3 involves the following steps:
1. A gate electrode 2 is provided in the form of a (conductive) n-type {100}-oriented Nb-doped SrTiO 3 single crystal grown by a conventional zone melting technique. The doping factor is between 10 -3 and 5% niobium, preferably at 0.05% Nb. This gate electrode 2 is used as the substrate for all further depositions.
It should be pointed out that, while a single-crystal substrate is preferred, a polycrystalline or amorphous substrate may be used as well. Also, dopants other than niobium may be used to render the SrTiO 3 conducting. One example is an oxygen deficit.
2. On top of the substrate 2, a {100}-oriented insulating layer 3 of SrTiO 3 is epitaxially grown by reactive rf-magnetron sputtering at 6,7 Pa in an O sub 2/Ar atmosphere at 650° C. (temperature of the sample holder). The thickness of this layer can be in the range of 1 to 1000 nm.
3. Without breaking vacuum, a superconducting film 1 of YBa 2 Cu 3 O 7- δ is epitaxially grown on top of the insulating SrTiO 3 layer 3 by hollow cathode magnetron sputtering, wherein the value of "δ" is preferably equal to zero, but can be as large as 0.5. The thickness of the superconductor layer can be in the range of 1 to 1000 nm.
4. Metal pads, for example gold pads 4 and 5, are then sputtered onto the YBa 2 Cu 3 O 7- δ top layer 1 to form source and drain contacts, respectively.
5. Finally, a gate contact 6 is provided by diffusing silver into the Nb-doped SrTiO 3 gate/substrate 2.
FIG. 2 shows a slightly different (but more truly MISFET) structure. The preferred way to manufacture this structure involves the following steps:
1. A {100}-oriented SrTiO 3 layer 7 is provided as an insulator which is polished down to a thickness of 20 . . . 30 μm.
2. On top of the thinned insulator 7, a YBa 2 Cu 3 O 7- δ film 8 is sputtered, wherein the value of "δ" is preferably equal to zero, but can be up to 0.5.
3. Gold pads 9 and 10 are provided on top of the superconductor layer 8 to form source and drain contacts, respectively.
4. On the back side of the thinned insulator, a conducting gate electrode 11 in the form of a metal layer, a gold layer, for example, is deposited. It bears an appropriate contact 12.
5. Optionally, gate electrode 11 may be supported on an insulating substrate 13, be it for stability, as indicated in FIG. 2.
FIG. 3 shows a typical characteristic of the gate current I G through the insulating layer 3 as a function of the applied gate voltage V G for a device in accordance with FIG. 1.
The measured characteristic is the one expected for a pin-junction, the superconductor and the substrate being the p and n electrodes, respectively. In one sample studied, the insulating barrier had a resistivity of 4×10 13 Ωcm at a forward bias of 3 V, and of 4×10 14 Ωcm at a reverse bias of 20 V. Breakdown field strengths at room temperature of 5×10 5 V/cm and of 1.5×10 7 V/cm were obtained in the forward and reverse directions, respectively. The capacitance of this sample was 2×10 -7 F/cm 2 at room temperature. This value corresponds to a relatively low ε i =8 (t=40 nm). This low dielectric constant may be caused by an insulating surface layer on the Nb- doped SrTiO 3 substrate, which was observed in agreement with a report by Hasegawa et al. in Japan. Journ. of Appl. Phys., 28 L2210 (1989). The layer has a breakdown voltage of about 2 V. Nevertheless, the ε i E BD products of the SrTiO 3 barrier layers under reverse bias were about 10 8 V/cm, which is the limit of the values required by Eq. (1).
The influence of the gate voltage V G on the channel resistance R DS of a sample that consists of 10 nm thick YBa 2 Cu 3 O 7- δ film on a 40 nm thick SrTiO 3 barrier layer is shown in FIG. 4. Obvious from the diagram is an approximately linear dependence of the measured normal-state resistivity on the gate voltage, and that the effect on resisitivity changes sign when the gate voltage is reversed. The measured polarity of the voltage induced resistance change agrees with the theoretical expection: YBa 2 Cu 3 O 7- δ is a p-type conductor, hence a positive voltage V G at the gate electrode depletes the free carrier concentration in the channel and, therefore, increases the channel resistance R DS , whereas a negative voltage V G at the gate electrode enhances the free carrier concentration in the channel and, therefore, decreases the channel resistance R DS .
The value of the measured channel resistance R DS (V G ) agrees well with the theoretical prediction: Applying 30 V to the sample that was used to generate FIG. 4 and which has a capacitance of 2×10 -7 F/cm 2 , induces a change in the electron density on the electrodes of 2×10 13 /cm 2 . On the other hand, YBa 2 Cu 3 O 7- δ has a carrier density of about 3-5×10 21 /cm 3 , and this corresponds to an areal density of mobile holes in the 10 nm thick channel layer of 3-5×10 15 /cm 2 . This means that, within experimental error, at any temperature a change of the free carrier density in the channel results in a corresponding change in R DS .
The temperature dependence of the resistivity R DS (T) of the YBa 2 Cu 3 O 7- δ is shown in FIG. 5. The sample is typical for all devices of the type shown in FIG. 1.
The temperature dependence of the voltage-induced variation of the channel resistance change Delta R DS /R DS (V G T) for this sample is depicted in FIG. 4. As shown by this figure, within experimental scatter, the fractional change of the channel resistance Delta R DS /R DS is almost constant as a function of temperature. A temperature-independent Delta R DS /R DS (V G T) ratio is observed down to T C (R DS =0). The change of the channel resistance induced by the gate voltage V G corresponds to a change of the R DS (T) characteristic at midpoint T C of 50 mK for V G =18 V.
From the measurements taken with several sample embodiments of the field-effect transistor in accordance with the invention, it has been determined that the operating gate voltage V G should be in the range between 0.1 and 50 V, the thickness s of the superconducting film should be in the range between 1 and 30 nm, and the thickness of the insulating layer should be in the range between 0.3 and 100 nm.
To make sure that the structures prepared in accordance with the present invention indeed perform as expected, i.e. that the current flow in the channel can actually be controlled by the electrical field-effect, spot-checking measurements have been made as follows:
1. Measurement of R DS (V G ) on samples that had barrier layer resistances which were lower by a factor of 500 (at 20 V) than the sample yielding the curves in FIG. 4. This measurement showed the same R DS (V G ) characteristics, demonstrating that the observed effect is not caused by the finite gate current I G .
2. To elucidate whether V G primarily affects the channel resistance R DS or whether the effect is based on a change of V DS , R DS was measured for different channel currents I DS . Even if I DS is varied by four orders of magnitude, an applied gate voltage results in a change of the channel resistance R DS R and does not induce significant voltages in the channel layer.
MISFET-type heterostructures consisting of YBa 2 Cu 3 O 7- δ /SrTiO 3 multilayers have been developed which allow the application of electric fields larger than 10 7 V/cm to superconducting films of YBa 2 Cu 3 O 7- δ. In these devices, electric field-effects generate changes in the channel resistance. The YBa 2 Cu 3 O 7- δ films have a preferred thickness on the order of 10 nm and are operated with gate voltages of about 30 Volts. The channel resistivity changes can be attributed to equally strong changes of the carrier density in the high-T c superconductor. | This field-effect transistor comprises a conductive substrate (2) serving as the gate electrode, an insulating barrier layer (3), and a superconducting channel layer (1) on top of the barrier layer (3). The superconductor layer (1) carries a pair of mutually spaced electrodes (4, 5) forming source and drain, respectively. The substrate is provided with an appropriate gate contact (6).
The substrate (2) consists of a material belonging to the same crystallographic family as the barrier layer (3). In a preferred embodiment, the substrate (2) is niobium-doped strontium titanate, the barrier layer (3) is undoped strontium titanate, and the superconductor (1) is a thin film of a material having a lattice constant at least approximately similar to the one of the materials of the substrate (2) and barrier (3) layers. A preferred material of this type is YBa 2 Cu 3 O 7- δ, where 0 ¢δ≦0.5.
While the preferred embodiment of the present invention has been herein described, numerous modifications, changes and improvements will occur to those skilled in the art without departing from the spirit and scope of the present invention. | 19,098 |
STATEMENT OF RELATED APPLICATION
[0001] This application claims the benefit of U.S. Provisional Application No. 60/669,101, filed Apr. 7, 2005, which is incorporated herein by reference in its entirety.
FIELD OF THE INVENTION
[0002] The present invention relates generally to environmental management systems such as security and automation systems, and more particularly to a controller for providing flexible and incremental expandability of environmental management systems.
BACKGROUND OF THE INVENTION
[0003] In residential and commercial environments there are many stand-alone devices and often one or more individual environmental management systems functioning independently. For instance, electronic security systems are relatively common in residential and commercial environments. Individuals and families, in particular, desire a security system that monitors a defined premises and/or environment, to prevent or deter theft, burglary and robbery. In addition, there is a desire to monitor and detect other defined conditions and, in response to a detected condition, generate a warning. These other potentially hazardous conditions or threats include, for example, fire hazards, carbon monoxide and power failure and electricity outages.
[0004] A conventional security system for use in a residence, for example, includes one or more keypads with displays and a central control panel, which in some cases is remotely located from the keypads and displays. A number of sensors for detecting various conditions are arranged in the home or premises. In legacy security systems, the sensors are most commonly connected to the control panel by wired means. The sensors may be of various types designed to detect a variety of conditions. More recently, wireless security systems have become available. The sensors are generally relatively simple devices having two operational states represented by a contact that is either in an open or closed state.
[0005] In addition to security systems, home automation systems are another type of environmental management system that are becoming more readily available in residences. Home automation systems, or home management systems as they are sometimes called, enable control of lighting, heating and air conditioning, window shades or curtains, pool heaters and filtration systems, lawn sprinklers, ornamental fountains, audio/visual equipment, and other appliances. Home automation systems range from relatively simple systems that control one or a few functions in a home to more elaborate systems that control multiple, disparate features.
[0006] In general, a home automation or control system comprises one or more controlled devices, one or more controllers, and a communication link coupling a controller to a controlled device. The controllers may be directly programmable, in which case they include some form of user interface for setting switches, event timing, and the like. Alternatively, the controllers may be indirectly or remotely programmable, in which case a separate user interface may be implemented by a personal computer or the like. Systems may be programmed using either a simple command language or using a graphical user interface that requires a computer with a monitor. These systems are often expensive and require substantial investment by the user in time and energy to install and modify programming. To enter and/or change a program, a user must consult a user's manual or call a programming specialist. Hence, in comparison to some security systems, these systems can be difficult to install and adapt to changing needs. Moreover, they are difficult to expand by adding new controlled devices or new software to add functionality.
[0007] Traditionally, the security system market has been quite distinct from the home automation market. For example, not only do most security systems fail to provide the control capabilities offered by home automation systems, their monitoring abilities are also usually quite limited, typically to sensors that are either “on” or “off.” Thus, for instance, few security systems even have the capability to monitor and report something as simple as the ambient temperature of the monitored premises. In part this market segmentation arises from the different demands placed on the two different types of systems. For instance, security systems must be highly reliable and meet stringent regulatory and other requirements, something which is generally not necessary for automation systems. Security system controllers are generally designed to interface with a very limited range of sensors while home automation controllers generally interface with a large number of different devices. Additionally, security system controllers generally offer unidirectional communication between the sensors and controller, whereas automation system controllers more commonly offer bidirectional communication with various devices.
[0008] Even within the home automation market itself, there is significant market segmentation because most of the automation control manufacturers address narrow, vertical market segments, and use proprietary interfaces to protect their market. For example, some leading control manufacturers offer systems that focus on heating, ventilation, and air conditioning (HVAC) systems control. These manufacturers have little interest in controlling lighting, entertainment systems, and the like as these markets are entirely foreign to them. Other manufacturers make, for example, home entertainment controllers that integrate various video and audio components, but the primary focus has been to offer integrated control over only their own components. As a result, consumers face an array of control systems that do not interoperate, and that have proprietary interfaces that are difficult to understand and program. That is, the use of multiple platforms generally means that the interfaces are inconsistent with each other in the manner in which controls are accessed, displayed and operate so that a consumer must learn the unique interface features of each system. Hence, as more systems are added, the complexity for the consumer increases significantly as new control interfaces must be added and learned.
[0009] Recently, some efforts have been made to provide integrated security and automation systems. In addition to the simplifications that arise from using a single platform, this combination of systems offers enhanced functionality and features that neither provide on their own. For instance, home automation systems may be integrated with a home security system so that when a fire alarm is raised, for example, internal and external lights will be turned on. An example of such a system is Home Automation Inc.'s Omni Automation and Security System, which includes a controller that can support both security and automation needs.
[0010] The consumer is thus currently faced with three primary choices when considering installation of security and/or automation systems. The consumer may purchase just a security system, just an automation system or a system such as the Omni Automation and Security System that provides both security and automation. If the consumer purchases either a dedicated security or automation system, future expansion of the system to include the other is limited, thus requiring the purchase of a separate and independent system. On the other hand, if the consumer purchases an integrated security and automation system, he or she may be purchasing a system that is more capable, and hence more expensive, than their current requirements demand.
[0011] Accordingly, it would be desirable to provide a system that is flexible, interoperable with a variety of existing or legacy systems, and which allows for incremental or modular expansion to provide additional functionality as desired.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] FIG. 1 shows an example of a residential security system.
[0013] FIG. 2 is a logical diagram of a modular controller.
[0014] FIG. 3 is a block diagram representing a hardware view of the modular controller depicted in FIG. 2 .
[0015] FIG. 4 shows the modular controller of FIGS. 2 and 3 incorporated into the security system shown in FIG. 1 .
DETAILED DESCRIPTION
[0016] In general, security and automation systems may be used to provide security and automation to a home, office, or other type of commercial or residential building. In the residential context, the systems establish a home network that controls, coordinates, facilitates, and monitors user-designated activities within the home. The systems may also provide compatibility between external and internal networks, systems, and appliances. As described in more detail below, a controller is provided that is modular in construction to allow easy expansion and customization. The modular controller can be retrofitted for use in existing structures with legacy systems to provide enhanced functionality without the need for drastic remodeling, added wiring, or complicated installation/customization, and can simplify installation, whether performed by the resident or a professional installer. Moreover, the modularity of the controller provides for easy customization for either commercial or residential use. Expansion can be accomplished by adding new plug-in components or modules to the controller. Although the following examples are primarily described with reference to home applications, the described devices and concepts also are applicable for commercial use.
[0017] For purposes of illustration the following example will assume that a security system of the type shown in FIG. 1 is already present in a residence and that the resident desires to expand the system to include automation functionality. However, the same principles apply to a situation in which a home automation system is initially present and the resident wishes to expand the system to include security functionality. In other cases the resident may simply desire to expand the capacity of the automation or security system by allowing it, for instance, to monitor, say, 40 sensors instead of merely 20 sensors. Moreover, the security system is assumed to be largely a wireless system in which RF communications is used for all or some of the devices. As shown, the security system 10 comprises a central control unit 12 , a central transceiver 14 (which in some cases may be eliminated and replaced by a receiver incorporated in the central control unit 12 ), a console display/keypad 18 , a plurality of remote sensors 20 and local sensors 22 , an external network interface 24 and an alarm 26 . The remote sensors 20 may wirelessly or hard-wired to the central transceiver 14 , which communicates with the central control unit 12 via a wireless protocol. The central control unit 12 also communicates with the console display/keypad 18 over a wireless link. The central control unit 12 is connected to the external network interface 24 (e.g., an autodialer to communicate over the public switched telephone network or a data connection to communicate over the Internet) and the alarm 26 either wirelessly or via a local bus such as local bus 30 . The central control unit 12 optionally may also be hardwired to one or more local sensors 22 .
[0018] Currently available wireless security systems use any of a variety of different communication standards. For example, such systems may use, without limitation, IEEE 802.11 (e.g., 802.11a; 802.11b; 802.11g), IEEE 802.15 (e.g., 802.15.1; 802.15.3, 802.15.4), DECT, PWT, pager, PCS, Wi-Fi, Bluetooth™, cellular, and the like. While the wireless security systems, and hence wireless controllers employed in such systems, may encompass any of these standards, one particularly advantageous network protocol that is currently growing in use is ZigBee™, which is a software layer based on the IEEE standard 802.15.4. Unlike the IEEE 802.11 and Bluetooth standards, ZigBee offers long battery life (measured in months or even years), high reliability, small size, automatic or semi-automatic installation, and low cost. With a relatively low data rate, 802.15.4 compliant devices are expected to be targeted to such cost-sensitive, low data rate markets as industrial sensors, commercial metering, consumer electronics, toys and games, and home automation and security. For these reasons ZigBee may be particularly appropriate for use in both wireless security systems and wireless home automation systems.
[0019] ZigBee-compliant products operate in unlicensed bands worldwide, including 2.4 GHz (global), 902 to 928 MHz (Americas), and 868 MHz (Europe). Raw data throughput rates of 250 Kbps can be achieved at 2.4 GHz (16 channels), 40 Kbps at 915 MHz (10 channels), and 20 Kbps at 868 MHz (1 channel). The transmission distance generally ranges from 10 to 75 m, depending on power output and environmental characteristics. Like Wi-Fi, Zigbee uses direct-sequence spread spectrum in the 2.4 GHz band, with offset-quadrature phase-shift keying modulation. Channel width is 2 MHz with a 5 MHz channel spacing. The 868 and 900 MHz bands also use direct-sequence spread spectrum but with binary-phase-shift keying modulation.
[0020] Given an installed security system such as described above in connection with FIG. 1 , home automation functionality may be provided by the addition of an adjunct, modular controller. As discussed in more detail below, the modular controller may be used not only to extend an installed security or automation system, it may also be used as the foundation of an integrated system that offers security functionality, automation functionality, or both. The functionality may all be deployed in the initial system or it may be added incrementally. That is, the modular controller can be used to overcome the problem that arises when a resident wishes to expand either a security or automation system with capabilities that were not originally provided. Moreover, the security system may even operate in conformance with one wireless standard while the automation system may operate in conformance with a different wireless standard.
[0021] FIG. 2 is a logical diagram of one embodiment of a modular controller 200 . Modular or configurable functionality is implemented at the application layer by one or more plug-in components such as plug-ins 210 1 - 210 5 . The plug-in components may be physically implemented as user insertable and removable cards (e.g., flash cards, PCMA cards), modules, and the like. The form factor of the plug-ins may conform to a well-established standard or it may be proprietary. The plug-in components may be implemented on a single integrated circuit, such as an application specific integrated circuit (ASIC). However, the components may also be readily implemented on multiple separate integrated circuits or in software operating on a general purpose processor located in the modular controller 200 . The application layer may be a native graphical user interface (GUI) 202 or web browser 204 that are configurable by each of the different plug-in components. Illustrative special purpose plug-in components include a home automation component 210 1 , a home security component 210 2 , and possibly any of a variety of other components such as an intercom component 210 3 for providing telephony-type services throughout all or part of the premises or an audio component 210 4 for playing audio files (e.g., music) throughout all or part of the premises.
[0022] The plug-in components 210 1 - 210 5 operate in conformance with an application programming interface (API) layer that provides access to services available from the operating system (OS) 250 and augments those services that the OS provides. The API layer may be implemented in a variety of different ways, such as with Universal Plug-and Play protocols and procedures 220 , flash processes 230 related to a Macromedia FLASH programming environment, and/or web server products 240 .
[0023] The API layer, via the OS layer 250 , controls the driver layer 260 . The driver layer 260 , in turn, interfaces with the various hardware components of the controller such as a microprocessor, hardware communication interfaces to sensors, actuators, and the like. Drivers may be added or removed as needed to support additional or updated functionality.
[0024] FIG. 3 is a block diagram representing a hardware view of the modular controller 200 depicted in FIG. 2 . The modular controller 200 includes an antenna port 82 , RF front-end transceiver 84 , one or more plug-in ports 60 1 , 60 2 , 60 3 , . . . 60 n , microprocessor 86 having ROM 88 and RAM 90 , programming port 92 , and local bus 94 (corresponding to local bus 30 in FIG. 1 ). Local bus 94 may also be used to communicate with any local sensors, actuators, or networked devices that may be employed. RF front-end transceiver 84 may be compliant with one or more wireless formats. In some cases the front-end transceiver 84 may be compliant with the ZigBee standard as well as with at least one other wireless standard commonly used in legacy security or automation systems (e.g., IEEE 802.11). In other cases the transceiver 84 may be able to operate in conformance with a number of different wireless standards with the use of appropriate plug-in components. If employed, local bus 94 may include, for example, one or more analog-to-digital inputs, one or more digital-to-analog outputs, one or more UART ports, one or more Serial Peripheral Interface (SPI) and/or one or more digital I/O lines (not shown). The network controller may also include RAM port 98 and ROM port 100 (or a single port for both) for, among other things, upgrading software residing in the microprocessor 86 (as opposed to upgrades performed by replacement of plug-in components, discussed below). User interface 95 (e.g., a keypad/display unit) functions at the application level of FIG. 2 and allows control of the various user-adjustable parameters of the modular controller 200 .
[0025] The modular controller 200 provides a consumer with a great degree of flexibility when initially purchasing a system. For example, if the consumer is in immediate need of a security system, the consumer can purchase the modular controller 200 with only the security plug-in 2102 (along with the associated sensors and the like). If at a later time the consumer wishes to install an automation system, the consumer can simply purchase the home automation plug-in 210 , (along with the associated monitors, actuators and the like). In this way the consumer only needs to purchase as much equipment as is necessary to serve his or her immediate needs, without limiting the future expandability of the system.
[0026] The modular controller 200 also provides the consumer with a number of different upgrade paths, depending on the equipment that is already in place. For instance, if the legacy equipment includes the modular controller itself, upgrading to provide automation features is a simple matter of purchasing additional plug-in components along with any associated peripheral equipment. On the other hand, if the legacy system is a dedicated independent security system (or automation system) of a conventional type, the modular controller 200 can be incorporated into the legacy system with the use of an additional plug-in component that is configured to allow the modular controller to interoperate with the legacy controller. In other cases the legacy equipment can be upgraded to provide more capacity so that the system can monitor more sensors (in the case of a security system) or control more devices (in the case of an automation system). An example of such an arrangement is shown in FIG. 4 , in which modular controller 200 has been incorporated into the security system shown in FIG. 1 . In FIGS. 1-4 like elements are denoted by like reference numerals. Also shown in FIG. 4 are networked devices 28 that are in communication with and under the control of the modulator controller 200 . Such networked devices include, without limitation, networked appliances such as coffee makers, ovens, lights, television and stereo units, media centers.
[0027] Referring to FIG. 4 , modular controller 200 includes a plug-in 210 5 , referred to herein as a bridge plug-in, which allows modular controller 200 to interoperate with legacy controller 12 . Bridge plug-in 2105 may provide two levels of interoperability. On the physical level, bridge plug-in 210 5 may convert between a communication format employed by the legacy security system and the native communication format employed by the modular controller 200 for the system that is to be added. For instance, the security system may use a low power, low bandwidth format such as IEEE 802.15.4 while the automation system may use another wireless local access network (WLAN) format such as IEEE 802.11, a cellular based communication format (e.g., CDMA, TDMA, GSM), and the like. In addition to physical interoperability, bridge plug-in 2105 may also provide application level interoperability so that legacy controller 12 and modular controller 200 can use and respond to information received from one another. For example, if a signal is generated by a security sensor 20 indicating that a door or window has been opened, the legacy system will use that signal to activate the alarm 26 and notify the appropriate agency or entity using external network interface 24 . Likewise, modular controller 200 may use that same signal from the security sensor to turn on lights or activate a camera or other devices under control of the modular controller 200 . Depending on the level of sophistication of the bridge plug-in 201 5 , the modular controller 200 may also be able to activate and deactivate features of the legacy security system or communicate information through the legacy security controller 12 . For instance, if in response to a security sensor 20 the modular controller 200 activates a camera, the data from that camera may be forwarded from the modular controller 200 to the legacy security controller 12 , which may in turn transmit the data using external network interface 24 to the same agency or entity that is notified when a security sensor indicates unauthorized entry.
[0028] The manufacturer of the modular controller 200 may also manufacture a variety of different bridge plug-ins for various legacy security systems to enhance its flexibility. Alternatively, or additionally, the manufacturer of the legacy security system or even a third party may provide bridge plug-in components for the modular controller 200 . In this way the flexibility and number of compatible legacy systems with which the controller operates can be increased still further.
[0029] A number of other benefits arise from the use of a modular controller as described above. For example, the manufacturer may occasionally upgrade one or more the plug-in components to provide advanced features not previously available or even contemplated. For example, if lighting were eventually to become available in which the user could control not only its intensity, but also its color, it would be desirable if in addition to simply turning the lighting on and off and adjusting the dimming level, the automation system could also control the color of the lighting. The enhanced functionality can be readily achieved by providing the user with an upgraded automation plug-in module (e.g., module 210 ,) that expands the message set defining control of lighting from one that refers only to intensity to one that specifies color and intensity.
[0030] Although various embodiments are specifically illustrated and described herein, it will be appreciated that modifications and variations are covered by the above teachings and are within the purview of the appended claims without departing from the spirit and intended scope of the invention. For example, while modular functionality has been described in terms of the provision of plug-in modules, this same functionality can be provided by software components or modules that are downloaded directly to the controller without the need to add any additional hardware components to the controller. Moreover, while the environmental management system and controller have been described in terms of a wireless system and controller, in some cases the environmental management system and controller may operate in a wired manner. | A controller is provided for an environmental management system. The system includes a transceiver for transmitting signals to and receiving signals from at least one environmental sensor or actuator over a network and a processor for interpreting received signals and generating signals to be transmitted over the wireless network based upon at least one environmental management function. A plurality of ports is also provided, each for receiving a plug-in component that provides information to implement a specific environmental management function. The system also includes a user interface operatively associated with the processor and the plurality of ports for adjusting user-controllable parameters. The user-controllable parameters are determined, at least in part, by at least one of the plug-in components when operationally inserted into one of the ports. | 25,207 |
RELATED APPLICATIONS
[0001] This application claims priority under 35 U.S.C. §119 to Japanese Patent Application No. 2013-073549 filed on Mar. 29, 2013, the entire content of which is hereby incorporated by reference.
FIELD OF THE INVENTION
[0002] The present invention relates to a cell analyzer for collecting target cells in a specimen by a filter and analyzing them. The present invention also relates to a cell collecting apparatus, and a quality control method of the cell analyzer.
BACKGROUND OF THE INVENTION
[0003] There has been proposed a cell analyzer for analyzing cells contained in a biological specimen collected from a subject. WO 2006-103920 describes a cell analyzer for measuring, with a flow cytometer, epidermal cells contained in a specimen collected from a uterine cervix of a subject, and determining the progress status of canceration based on the measurement result.
[0004] In such cell analyzer, the analysis is carried out on the individual cell, and thus the number of cells to be analyzed is desirably large in order to increase the analysis precision. US 2011-076755 A describes a cell analyzer enabled to concentrate cells in the specimen for increasing the number of cells to be analyzed while suppressing the amount of specimen. A filter is used in the cell analyzer for discriminating the cells to be measured.
[0005] Since the filter is a consumable supply, it needs to be replaced after being used for a number of times. However, if the attachment of the filter is not adequate or if the filter is damaged, the target cell cannot be appropriately discriminated. In such a case, the abnormality of the filter is to be desirably recognized by the user.
SUMMARY OF THE INVENTION
[0006] A first aspect of the present invention a cell analyzer comprising: a measuring device that includes a collecting section configured to collect target cells in a specimen with a filter, and is configured to measure the target cells collected by the collecting section; and a data processing device configured to analyze the target cells based on measurement data obtained by the measuring device, wherein the cell analyzer is operable in a first mode of measuring a clinical specimen collected from a subject and a second mode of measuring a quality control specimen containing particles having size capturable by the filter; and the data processing device is programmed to acquire an amount of particles collected by the collecting section based on measurement data of the quality control specimen obtained in the second mode, and output an alarm when the amount of particles meets a predetermined condition.
[0007] A second aspect of the present invention is a cell collecting apparatus comprising: a filter provided with pores; a specimen supplying section configured to supply a specimen to the filter; a collecting section configured to collect particles captured by the filter; a detecting section configured to detect particles collected by the collecting section; and a data processing device programmed to cause the specimen supplying section to supply a quality control specimen containing particles of size capturable by the filter, cause the collecting section to collect the particles of the quality control specimen captured by the filter, cause the detecting section to detect the collected particles, acquire an amount of particles detected by the detecting section, and output an alarm when the amount of particles meets a predetermined condition.
[0008] A third aspect of the present invention is a quality control method of a cell analyzer including a filter, a measuring section and a outputting section, the method comprising: supplying a quality control specimen containing a known amount of particles to the filter, wherein the filter is provided with pores of size capable of capturing the particles; measuring, by the measuring section, an amount of the particles captured by the filter; outputting, by the outputting section, an alarm of urging a replacement of the filter when the amount of particles captured by the filter meets a predetermined condition.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] FIG. 1 is a view showing a configuration of an outer appearance of a cell analyzer according to an embodiment;
[0010] FIG. 2 is a plan view showing an internal configuration of a measuring device according to the embodiment;
[0011] FIG. 3A is a side view showing a configuration of a flow cytometer according to the embodiment;
[0012] FIG. 3B is a plan view showing the configuration of the flow cytometer;
[0013] FIG. 4 is a view showing a configuration of a discriminating/substituting section according to the embodiment;
[0014] FIG. 5A is a side view of a motor according to the embodiment;
[0015] FIG. 5B is a plan view when a mechanism for driving a piston according to the embodiment is seen from above;
[0016] FIG. 6A is a view showing a configuration of an accommodating body according to the embodiment;
[0017] FIG. 6B is a view showing a state in which the accommodating body according to the embodiment is cut;
[0018] FIG. 6C is a side view of the accommodating body according to the embodiment;
[0019] FIG. 7A and FIG. 7B are views showing a configuration of a filter member according to the embodiment;
[0020] FIG. 7C and FIG. 7D are views showing a configuration of a stirrer according to the embodiment;
[0021] FIG. 8A is a side view showing a configuration of a piston according to the embodiment;
[0022] FIG. 8B is a perspective view showing a configuration of the piston according to the embodiment;
[0023] FIG. 9 is a cross-sectional view of when the piston, the supporting plate, the filter member, the stirrer, and the accommodating body according to the embodiment are cut along a plane passing through a center axis;
[0024] FIG. 10A to FIG. 10D are views showing the procedure of installing the filter member according to the embodiment;
[0025] FIG. 11 is a view showing a fluid processing section of a measuring device according to the embodiment;
[0026] FIG. 12A to FIG. 12I are views schematically showing the state of liquid in an accommodating unit and a space according to the embodiment;
[0027] FIG. 13 is a view showing a configuration of a measuring device according to the embodiment;
[0028] FIG. 14 is a view showing a configuration of a data processing device according to the embodiment;
[0029] FIG. 15 is a flowchart showing processes of the cell analyzer in a normal measurement mode according to the embodiment;
[0030] FIG. 16 is a flowchart showing processes of the cell analyzer in a quality control measurement mode according to the embodiment;
[0031] FIG. 17A is a view showing a result screen according to the embodiment;
[0032] FIG. 17B is a view showing an error list screen according to the embodiment;
[0033] FIG. 18 is a flowchart showing processes of the cell analyzer in the quality control measurement mode according to a first variant;
[0034] FIG. 19 is a flowchart showing processes of the cell analyzer in the quality control measurement mode according to a second variant;
[0035] FIG. 20A is a view showing a flowchart showing processes of the cell analyzer in the normal measurement mode according to a third variant;
[0036] FIG. 20B is a view showing a flowchart showing processes of the cell analyzer in the quality control measurement mode according to the third variant; and
[0037] FIG. 20C is a view showing a measurement start button according to the third variant.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0038] In the present embodiment, the present invention is applied to a cell analyzer configured to prepare a measurement specimen including cells in a clinical specimen collected from a subject (patient) and to acquire information associated with canceration of cells based on the prepared measurement specimen. A cell analyzer 1 according to the present embodiment will be hereinafter described with reference to the drawings.
[0039] FIG. 1 is a view showing a configuration of an outer appearance of the cell analyzer 1 .
[0040] The cell analyzer 1 flows a measurement specimen containing cells (hereinafter referred to as “analyzing target cell”) collected from a subject through a flow cell, and irradiates the measurement specimen flowing through the flow cell with a laser light. Forward scattered light, side scattered light, fluorescence occurred from the particles in the measurement specimen are detected and light signals thereof are analyzed, thus determining whether or not the cells contain cancer cells or cells in progress of canceration. In the following embodiment, the analyzing target cell analyzed by the cell analyzer 1 is an epidermal cell of the uterine cervix collected from the subject. The cell analyzer 1 is used for screening the uterine cervical cancer.
[0041] The cell analyzer 1 includes a measuring device 2 configured to perform measurement, and the like of the analyzing target cell, and a data processing device 3 connected to the measuring device 2 and configured to perform analysis, and the like of the measurement data. On a front surface of the measuring device 2 is installed a sample setting section 2 a for setting a plurality of specimen containers 4 (see FIG. 2 ), each of which contains a mixed solution (specimen) of a preservative solution having methanol as the main component and a cell collected from the uterine cervix of the subject. A cover 2 b is arranged on the measuring device 2 , and the user opens the cover 2 b upward to access the inside of the measuring device 2 . An opening 2 c through which a sample pipette section 11 , to be described later, is inserted and removed is arranged in the measuring device 2 . The data processing device 3 includes a display section 31 configured to display an analysis result, and the like, and an input section 32 configured to receive an instruction from the user.
[0042] FIG. 2 is a plan view showing an internal configuration of the measuring device 2 .
[0043] The sample setting section 2 a sequentially transports a rack 4 a , on which a plurality of specimen containers 4 is set, up to an aspirating position of the specimen by the sample pipette section 11 . The sample pipette section 11 includes a pipette 11 a extending in a vertical direction, and is configured to aspirate and discharge the specimen by moving the pipette 11 a in the horizontal direction and the vertical direction.
[0044] When the specimen container 4 is positioned at the aspirating position of the sample setting section 2 a , the specimen contained in the specimen container 4 is aspirated by the sample pipette section 11 , and discharged to a specimen accommodating portion 12 a of a first dispersion section 12 . The first dispersion section 12 disperses aggregating cells contained in the specimen by applying a shear force. A part of the specimen, in which the process (first dispersion process) by the first dispersion section 12 is completed, is aspirated by the sample pipette section 11 , and discharged to a specimen take-in portion 13 a of a sub-detecting section 13 . The sub-detecting section 13 includes a flow cytometer 40 , and performs the measurement of the specimen (hereinafter referred to as “pre-measurement”) before the process by the discriminating/substituting section 14 , to be described later.
[0045] FIG. 3A is a view showing a configuration of the flow cytometer 40 of the sub-detecting section 13 .
[0046] The specimen discharged to the specimen take-in portion 13 a is supplied to a flow cell 43 , and the laser light exit from the semiconductor laser 41 is collected on the specimen flowing through the flow cell 43 by a lens system 42 including a plurality of lenses. The lens system 42 is configured by a collimator lens 42 a , a cylinder lens system including plano-convex cylinder lens 42 b and biconcave cylinder lens 42 c , and a condenser lens system including condenser lens 42 d and condenser lens 42 e.
[0047] The light collecting lens 44 collects the forward scattered light generated by the cells in the specimen at a scattered light detector including a photodiode 45 . The photodiode 45 converts the received light signal to an electric signal, and outputs the forward scattered light signal (FSC). The FSC is amplified by a pre-amplifier (not shown) and output to a signal processing section 27 (see FIG. 13 ) of the measuring device 2 .
[0048] Returning back to FIG. 2 , the number of analyzing target cells contained in the specimen supplied to the sub-detecting section 13 is acquired based on the FSC acquired by the pre-measurement, and the concentration of the analyzing target cell contained in the specimen supplied to the sub-detecting section 13 is calculated based on the acquired number of analyzing target cells. The amount (volume) of specimen to be supplied to the discriminating/substituting section 14 is determined based on the calculated concentration. The specimen accommodated in the specimen accommodating portion 12 a of the first dispersion section 12 is aspirated by the volume determined as above by the sample pipette section 11 , and the aspirated specimen is discharged to an accommodating unit 210 (see FIG. 6A ) of the discriminating/substituting section 14 . A predetermined number of analyzing target cells are accommodated in the accommodating unit 210 .
[0049] The discriminating/substituting section 14 substitutes the preservative solution having methanol contained in the specimen as the main component with diluted solution. In other words, the discriminating/substituting section 14 executes the process of diluting the concentration of methanol contained in the specimen using the diluted solution so that the cell staining process in the post-step can be suitably carried out. Tris-HCl (tris buffer) is used for the diluted solution. The discriminating/substituting section 14 discriminates the analyzing target cell (epidermal cell of uterine cervix) contained in the specimen, and the other cells such as red blood cells, white blood cells, bacteria and foreign substances. The concentrated solution in which the analyzing target cell is concentrated so as to include number of cells necessary for detecting the cancer cell is thereby obtained. The detailed configuration of the discriminating/substituting section 14 will be described later.
[0050] The specimen container 5 set in a holder 18 b of a reaction section 18 is gripped by a scissor-shaped grip portion 15 a of a container transfer section 15 , and positioned at a specimen hand-over portion 11 b . Subsequently, the concentrated solution accommodated in the accommodating unit 210 of the discriminating/substituting section 14 is aspirated by the sample pipette section 11 , and discharged to the specimen container 5 positioned at the specimen hand-over portion 11 b . The container transfer section 15 transfers the specimen container 5 to a second dispersion section 16 .
[0051] The second dispersion section 16 applies an ultrasonic vibration to the specimen concentrated in the discriminating/substituting section 14 . The aggregating cells remaining after the first dispersion process are dispersed to a single cell. The specimen container 5 , in which the process (second dispersion process) by the second dispersion section 16 is completed, is set in a liquid removing section 17 by the container transfer section 15 . The liquid removing section 17 removes (drains) the liquid attached to the outer surface of the specimen container 5 . The specimen container 5 , in which the process by the liquid removing section 17 is completed, is set in the holder 18 b of the reaction section 18 by the container transfer section 15 .
[0052] The reaction section 18 warms the specimen container 5 set in the holder 18 b to a predetermined temperature (about 37 degrees), and advances the reaction between the specimen in the specimen container 5 and the reagent added by a first reagent adding section 19 and a second reagent adding section 20 . The reaction section 18 includes a circular rotation table 18 a configured to be rotatable, where a plurality of holders 18 b are arranged on an outer circumferential portion of the rotation table 18 a so that the specimen container 5 can be set therein.
[0053] The first reagent adding section 19 and the second reagent adding section 20 respectively includes a supplying portion 19 a , 20 a movable to the positions P1, P2 above the specimen container 5 set in the rotation table 18 a . The first reagent adding section 19 and the second reagent adding section 20 respectively adds a predetermined amount of reagent from the supplying portion 19 a , 20 a into the specimen container 5 when the specimen container 5 is transported to the positions P1, P2 by the rotation table 18 a.
[0054] The reagent added by the first reagent adding section 19 is RNase for performing the RNA removing process on the cell, and the reagent added by the second reagent adding section 20 is a stain solution for performing the DNA staining process on the cell. According to the RNA removing process, the RNA in the cell is decomposed, so that only the DNA of the cell nucleus can be measured. The DNA staining process is carried out by propidium iodide (PI), which is the fluorescence stain solution containing pigment. The staining is selectively performed on the nucleus in the cell by the DNA staining process. The fluorescence from the nucleus can be detected.
[0055] A specimen aspirating section 21 includes a pipette 21 a movable to a position P3 above the specimen container 5 set in the rotation table 18 a , and aspirates the specimen (measurement specimen) added with the reagent in the specimen container 5 when the specimen container 5 is transported to the position P3 by the rotation table 18 a . The specimen aspirating section 21 supplies a measurement specimen aspirated by the pipette 21 a to a main detecting section 22 through a flow path (not shown). The main detecting section 22 includes a flow cytometer 50 , and performs the measurement (hereinafter referred to as “actual measurement”) of the measurement specimen prepared in the above manner.
[0056] FIG. 3B is a view showing a configuration of the flow cytometer 50 of the main detecting section 22 .
[0057] The semiconductor laser 51 , the lens system 52 , the flow cell 53 , the light collecting lens 54 , and the photodiode 55 are similar to the configuration shown in FIG. 3A . In other words, the measurement specimen aspirated by the pipette 21 a of the specimen aspirating section 21 is supplied to the flow cell 53 , and the laser light exit from the semiconductor laser 51 is collected at the measurement specimen flowing through the flow cell 53 . The photodiode 55 converts the received light signal to an electric signal, and outputs the forward scattered light signal (FSC).
[0058] The light collecting lens 56 collects the side scattered light and the fluorescence generated by the analyzing target cell and the nucleus in such cell, and introduces the same to a dichroic mirror 57 . The dichroic mirror 57 reflects the side scattered light toward a photomultiplier 58 , and transmits the fluorescence toward a photomultiplier 59 . The side scattered light is collected at the photomultiplier 58 , and the fluorescence is collected at the photomultiplier 59 . The photomultipliers 58 , 59 convert the received light signal to an electric signal, and respectively output the side scattered light signal (SSC) and the fluorescence signal (FL). The FSC, the SSC, and the FL are amplified by a pre-amplifier (not shown), and output to a signal processing section 24 (see FIG. 13 ) of the measuring device 2 .
[0059] Returning back to FIG. 2 , the number of analyzing target cells contained in the measurement specimen supplied to the main detecting section 22 is detected similar to the case of the pre-measurement based on the FSC acquired by the actual measurement. The determination on the canceration of the analyzing target cells is carried out in the data processing device 3 based on the FSC, the SSC, and the FL acquired by the actual measurement. A container washing section 23 discharges washing liquid into the specimen container 5 set in the rotation table 18 a to wash the interior of the specimen container 5 of after the measurement specimen is supplied to the main detecting section 22 by the specimen aspirating section 21 .
[0060] FIG. 4 is a view showing a configuration of the discriminating/substituting section 14 . In FIG. 4 , the Z-axis direction is the vertical direction, and the positive direction of the Z-axis and the negative direction of the Z-axis are upward direction and downward direction, respectively.
[0061] A base 100 is a plate-shaped member parallel to the XY plane. An accommodating body 200 , supporting members 110 , 130 , 170 , and a rail 150 are installed on the base 100 . In addition, various mechanisms, and the like are installed on the base 100 , but the illustration of such mechanisms, and the like is omitted in FIG. 4 for the sake of convenience.
[0062] The supporting member 110 is a plate-shaped member parallel to the XZ plane, where a hole 111 (see FIG. 9 ) that passes through in the Y-axis direction is formed in the supporting member 110 . The upper plate 120 is installed on the upper surfaces of the accommodating body 200 and the supporting member 110 . The upper plate 120 is positioned in the measuring device 2 such that the user can access the upper plate 120 when the cover 2 b (see FIG. 1 ) of the measuring device 2 is opened upward.
[0063] The upper plate 120 is formed with holes 120 a , 120 b passing in the up and down direction. The pipette 11 a of the sample pipette section 11 performs aspiration and discharging of specimen with respect to the accommodating unit 210 of the accommodating body 200 , to be described later, through the hole 120 a . The user opens the cover 2 b provided on the measuring device 2 to install and take out the filter member F with respect to the accommodating unit 220 of the accommodating body 200 , to be described later, through the hole 120 b along the broken arrow (vertical direction).
[0064] The upper plate 120 is a member having translucency, where sensors 121 , 122 including the light emitting portion and the light receiving portion are installed on the upper plate 120 . When the filter member F is correctly installed, the light emitted from the light emitting portion of the sensor 121 is shielded by the filter member F, and the light emitted from the light emitting portion of the sensor 122 is passed through a cutout F6 (see FIGS. 7A , 7 B) of the filter member F. When the filter member F is installed with the surfaces F1, F2 (see FIGS. 7A , 7 B) of the filter member F reversed, the light emitted from the light emitting portions of the sensors 121 , 122 is shielded by the filter member F. Whether or not the filter member F is correctly set thus can be detected.
[0065] The supporting member 130 supports the motor 141 . The supporting member 151 is installed to be slidably movable in the Y-axis direction on the rail 150 . A flange part 152 and a piston 160 are installed on the supporting member 151 , and tubes T1 to T4 are connected to the piston 160 . Sensors 171 , 172 including the light emitting portion and the light receiving portion are installed on the supporting member 170 .
[0066] FIG. 5A is a side view of the motor 141 . The rotation axis of the motor 141 is parallel to the Y-axis, and coincides with the center axis A, to be described later. A magnet 142 is installed on the distal end on the negative direction side of the Y-axis of the motor 141 . When the motor 141 is driven and the magnet 142 is rotated within the XZ plane, the stirrer R, to be described later, is rotated through the wall of the accommodating body 200 .
[0067] FIG. 5B is a plan view of when the mechanism for driving the piston 160 is seen from above. In FIG. 5B , the illustration of the piston 160 is omitted for the sake of convenience. The supporting member 151 is fixed to a belt 181 . The belt 181 is supported by pulleys 182 , 183 . The pulley 182 is connected to the rotation shaft of the stepping motor installed on the lower surface side of the base 100 . When the stepping motor is driven, the supporting member 151 is slidably moved in the Y-axis direction on the rail 150 , and the piston 160 is driven in the Y-axis direction. The sensors 171 , 172 are installed at positions where a light shielding portion 152 a of a flange part 152 installed on the supporting member 151 can be detected. It can be detected that the piston 160 is positioned on the leftmost side and positioned on the rightmost side by the detection signals of the sensors 171 , 172 .
[0068] FIG. 6A is a view showing a configuration of the accommodating body 200 . FIG. 6B is a view showing a state in which the accommodating body 200 is cut along a plane including a wall portion 222 in FIG. 6A . FIG. 6C is a side view when the accommodating body 200 shown in FIG. 6B is seen in the positive direction of the Y-axis.
[0069] With reference to FIG. 6A , the accommodating units 210 , 220 are formed in the accommodating body 200 . An insertion port 211 positioned at the upper part of the accommodating unit 210 is connected to a hole 120 a of the upper plate 120 , and an insertion port 221 positioned at the upper part of the accommodating unit 220 is connected to a hole 120 b of the upper plate 120 . The accommodating unit 220 includes the wall portion 222 parallel to the XZ plane, where the wall portion 222 is formed with a recess 230 to which the stirrer R, to be described later, is accommodated. A bottom surface 223 of the accommodating unit 220 has a curved surface, and a hole H21 is formed at the lowermost position of the bottom surface 223 . The negative direction side of the Y-axis of the accommodating unit 220 is opened.
[0070] With reference to FIGS. 6B and 6C , the recess 230 includes an opening 231 that opens the recess 230 toward the negative direction of the Y-axis, an inner side surface 232 that is circular when seen in the Y-axis direction, a retaining portion 233 formed on the lower side of the inner side surface 232 , and a wall portion 234 parallel to the XZ plane. The recess 230 is spaced apart from the accommodating unit 210 in plan view, that is, in a direction (horizontal direction) within the XY plane. The center axis A shown with a dotted line in FIG. 6B is an axis that passes through the circular center of when the inner side surface 232 is seen in the Y-axis direction and that is parallel to the Y-axis direction. The retaining portion 233 is formed in the inner side surface 232 so as to be recessed in a direction of separating from the center axis A. A hole H22 is formed at the lowermost position of the retaining portion 233 . A hole H23 is formed in the wall portion 234 at a position where the center axis A intersects with the wall portion 234 .
[0071] The accommodating unit 210 has a shape in which the interior gradually narrows in the depth direction (downward direction). Holes H11 to H13 are formed at the upper part of the inner side surface of the accommodating unit 210 , and holes H14, H15 are formed at the deepest part of the accommodating unit 210 . The hole H14 is connected to the hole H22 of the retaining portion 233 through a flow path 241 , and the hole H15 is connected to the hole H16 formed in an outer surface of the accommodating body 200 through a flow path 242 . The arrangement of the accommodating unit 210 , the recess 230 , and the flow path 241 is adjusted such that the hole H14 becomes lower than the hole H22. The hole H16 is connected to a valve V25 (see FIG. 11 ), and the diameter of the flow path 242 is sufficiently small. Thus, the specimen accommodated in the accommodating unit 210 does not flow toward the lower side than the hole H15.
[0072] Pins 212 to 214 are installed in the accommodating unit 210 . The pins 212 to 214 are connected to a resistance type liquid level sensor unit 293 (see FIG. 13 ). The liquid level sensor unit 293 detects whether or not the liquid level in the accommodating unit 210 is higher than the height position of the pin 212 based on a current-flowing state of the pins 212 , 214 , and detects whether or not the liquid level in the accommodating unit 210 is higher than the height position of the upper part of the pin 213 based on the current-flowing state of the pins 213 , 214 .
[0073] FIGS. 7A and 7B are views showing a configuration of the filter member F. FIGS. 7A and 7B also show the coordinate axis of when the filter member F is appropriately set with respect to the accommodating unit 220 .
[0074] The filter member F includes surfaces F1, F2 parallel to the XZ plane, a hole F3 that passes through the filter member F in the Y-axis direction, a filter F4, a thin-film like rubber F51 installed on the surface F1, and a thin-film like rubber F52 installed on the surface F2. The surfaces F1, F2 are positioned on the positive direction side of the Y-axis and the negative direction side of the Y-axis, respectively. The hole F3 has a tubular inner side surface F31. The filter F4 is installed such that the filtering surface is parallel to the XZ plane with respect to the inner side surface F31 of the hole F3. The filter F4 is provided with a plurality of pores each having a diameter that allows cells smaller than the analyzing target cells, such as red blood cells, white blood cells, bacteria, and foreign substances to pass through, but does not allow the analyzing target cells (epidermal cells of the uterine cervix) to pass through. In the present embodiment, the diameter of the hole of the filter F4 is set to 10 μm. Furthermore, the distance between the filter F4 and the surface F1 is smaller than the distance between the filter F4 and the surface F2 in the Y-axis direction. The rubber F51 is installed at the periphery of the opening on the surface F1 side of the hole F3, and a surface F11, which is a part of the surface F1, is exposed between the opening on the surface F1 side of the hole F3 and the rubber F51. The rubber F52 is installed at the periphery of the opening on the surface F2 side of the hole F3.
[0075] FIGS. 7C and 7D are views showing a configuration of the stirrer R. FIGS. 7C and 7D also show the coordinate axis of when the stirrer R is accommodated in the recess 230 .
[0076] The stirrer R includes a body portion R1 having a tubular shape, surfaces R2, R3 parallel to the XZ plane, and a magnet R4. The surfaces R2, R3 are positioned on the negative direction side of the Y-axis and the positive direction side of the Y-axis, respectively. A tubular projection R21 that projects out in the negative direction side of the Y-axis with respect to the surface R2 is formed on the surface R2, and the diameter of the projection R21 is smaller than the diameter of the outer circumference of the surface R2. A flange part R21a is further formed on the projection R21. A groove R31 that intersects at the center of the surface R3 is formed in the surface R3. The magnet R4 is installed to pass the center of the stirrer R and pass through the stirrer R within the XZ plane. Thus, the stirrer R rotates around the Y-axis as the center when the magnet 142 shown in FIG. 5A is rotated by the motor 141 .
[0077] FIGS. 8A and 8B are a side view and a perspective view, respectively, showing the configuration of the piston 160 .
[0078] The piston 160 includes a distal end 161 having a circular column shape in the positive direction side of the Y-axis. On the positive direction side of the Y-axis of the distal end 161 is formed a recess 162 , an opening 163 that opens the recess 162 in the positive direction side of the Y-axis, and a surface 164 . Holes H31 to H34 are formed on the surface on the negative direction side of the Y-axis of the recess 162 , and the holes H31 to H34 are connected to the tubes T1 to T4 through a flow path arranged inside the piston 160 . An L-shaped pipe 165 is connected to the hole H31, and the distal end of the pipe 165 is positioned at the upper part (positive direction side of the Z-axis) in the recess 162 . The surface 164 is parallel to the XZ plane, and is formed at the periphery of the opening 163 .
[0079] FIG. 9 is a cross-sectional view of when the piston 160 , the supporting member 110 , the filter member F, the stirrer R, and the accommodating body 200 are cut along the YZ plane passing through the center axis A. In FIG. 9 , each section is illustrated in a state spaced apart in the Y-axis direction for the sake of convenience. Furthermore, d11 to d16 indicate the length in the Z-axis direction, and the values of which become large in such order. Moreover, d21 to d26 indicate the length in the Y-axis direction, and the values of which become large in such order.
[0080] In the piston 160 , the diameter of the recess 162 is d12, and the diameter of the outer circumference of the surface 164 is d15. In the supporting member 110 , the diameter of the hole 111 is d16. In the filter member F, the diameter of the hole F3 is d12, the diameter of the outer circumference of the surface F11 is d14, the interval of the surface F1 and the filter F4 is d22, the interval of the surface F2 and the filter F4 is d23, and the interval of the surfaces F1, F2 is d24. In the stirrer R, the diameter of the body portion R1 is d13, the diameter of the projection R21 is d11, the width of the body portion R1 is d25, and the width of the projection R21 including the flange part R21a is d21. In the accommodating body 200 , the diameter of the inner side surface 232 is d14, and the width of the recess 230 is d26.
[0081] The recess 162 , the outer circumference of the surface 164 , the hole 111 , the hole F3, the outer circumference of the surface F11, the body portion R1, the projection R21, and the recess 230 when seen from the Y-axis direction are circular, and the centers of the circles coincide with the center axis A.
[0082] FIGS. 10A to 10D are views showing a procedure in which the filter member F is installed in the accommodating unit 220 . FIGS. 10A to 10D are cross-sectional views similar to FIG. 9 .
[0083] FIG. 10A is a view showing a state in which the filter member F is not installed in the accommodating unit 220 . In this case, the piston 160 is positioned at the leftmost side, and the surface R3 of the stirrer R is pulled toward the right direction by the magnet 142 (see FIG. 5A ) and grounded to the wall portion 234 . When the filter member F is inserted into the accommodating unit 220 through the hole 120 b of the upper plate 120 and the insertion port 221 of the accommodating unit 220 from the state of FIG. 10A , the state shown in FIG. 10B is obtained. In this case, the filter member F is supported in the upward direction by the bottom surface 223 of the accommodating unit 220 .
[0084] When the piston 160 is positioned on the rightmost side from the state shown in FIG. 10B , the surface 164 of the piston 160 is pushed against the rubber F52 of the filter member F, and the rubber F51 of the filter member F is pushed against the wall portion 222 of the accommodating unit 220 , as shown in FIG. 10C . Thus, the recess 230 and the recess 162 are joined by way of the filter F4. In this case, the opening 231 of the recess 230 is blocked by the filter member F, so that a space S1 closed with respect to the exterior is formed. Furthermore, the opening 163 of the recess 162 is closed by the filter member F, so that a space S2 closed with respect to the exterior is formed.
[0085] The space S1 is specifically formed by the side surface on the recess 230 side of the filter F4, the inner side surface F31, the surface F11, the rubber F51, the inner side surface 232 , the retaining portion 233 , and the wall portion 234 . In this case, the space S1 is structurally connected to the exterior through the holes H22, H23. However, the hole H22 is in a substantially closed state since the specimen is retained at the deepest portion of the accommodating unit 210 positioned at the lower end of the flow path 241 beyond the hole H22 during the process of discrimination/substitution. A valve V24 (see FIG. 11 ) capable of closing the flow path is installed in the flow path beyond the hole H23, and only the diluted solution is externally flowed into the space S1 in the hole H23, so that the hole H23 is in a substantially closed state. Thus, the space S1 is a space closed with respect to the exterior.
[0086] As described above, the filter F4 has a hole having a diameter that allows cells, and the like having a smaller diameter than the analyzing target cell to pass through and that does not allow the analyzing target cell to pass through. The cells, and the like having a smaller diameter than the analyzing target cell in the space S1 thus pass through the filter F4, but the analyzing target cell in the space S1 remains in the space S1.
[0087] The space S2 is specifically formed by the side surface on the side opposite to the recess 230 of the filter F4, the inner side surface F31, the rubber F52, and the recess 162 . In this case, the space S2 is structurally connected to the exterior through the holes H31 to H34. However, the holes H31 to H34 are in a substantially closed state since a valve capable of closing the flow path is installed in the flow path beyond the holes H31 to H34. Thus, the space S2 is a space closed with respect to the exterior.
[0088] When the magnet 142 (See FIG. 5A ) is rotated in the state shown in FIG. 10C , the stirrer R is rotated along the side surface (filtering surface) on the recess 230 side of the filter F4 around the center axis A as the center. In this case, the groove R31 is formed in the plane R3 of the stirrer R, as shown in FIG. 7D . Thus, the diluted solution can smoothly flow from the hole H23 into the space S1.
[0089] Furthermore, when rotated by the magnet 142 , the stirrer R can separate away from the wall portion 234 and move toward the filter member F, as shown in FIG. 10D . However, as shown in FIG. 9 , the width d21 of the projection R21 including the flange part R21a is smaller than the interval d22 of the surface F11 and the filter F4, the diameter d11 of the projection R21 is smaller than the diameter d12 of the hole F3, and the outer circumference of the surface R2 (diameter of the body portion R1) d13 is greater than the diameter d14 of the hole F3. As shown in FIG. 10D , the projection R21 including the flange part R21a makes contact with the filter F4 when the surface R2 makes contact with the surface F11 thus preventing the filter F4 from being damaged.
[0090] FIG. 11 is a view showing the fluid processing section FL of the measuring device 2 .
[0091] The valves V11 to V15, V21 to V26 are configured to be able to switch a state of opening the flow path and a state of closing the flow path. The valves V16, V17 are configured to be able to connect either one of the flow paths connected to the left side with respect to the one flow path on the right side. The holes H31 to H34 are connected to the valve V15, the valve V17, the valve V11, and the valves V12, V14. The holes H11 to H13 are connected to the valves V21 to V23. The holes H23, H16, H21 are connected to the valves V24, V25, V26. A negative pressure source P11 is connected to the valves V12, V13, V23, V25, V26, and a positive pressure source P12 is connected to the valve V17. A regulator P13 for making the pressure constant is connected to the valves V 13 to V15.
[0092] FIGS. 12A to 12I are views schematically showing the state of the liquid in the accommodating unit 210 and the spaces S1, S2 in the discriminating/substituting process.
[0093] When the discriminating/substituting process is started, the piston 160 and the filter member F are in the state shown in FIG. 10C , and the interior of the accommodating unit 210 and the spaces S1, S2 is washed. The state of the liquid then becomes the state shown in FIG. 12A .
[0094] A preparation control section 28 starts the rotation of the stirrer R with the valves V11 to V15 and V21 to V26 closed, the flow path on the atmosphere open side of the valve V 16 closed, and the flow path on the positive pressure source P12 side of the valve V17 closed. The preparation control section 28 then fills the space S1 with the diluted solution. Specifically, the valve V24 is first opened and the diluted solution is supplied into the space S1 through the hole H23. The diluted solution then moves to the accommodating unit 210 through the flow path 241 . When a predetermined time has elapsed after the liquid level has reached the height of the pin 212 , the valve V24 is closed and the supply of the diluted solution is stopped. The liquid level is in the state shown in FIG. 12B . The valves V13, V15 are then opened, and the negative pressure is applied to the space S2 through the hole H31 by the negative pressure source P11, whereby the diluted solution in the space S1 and the accommodating unit 210 is suctioned toward the space S2 through the filter F4. The valves V13, V15 are closed after the space S2 is filled with the diluted solution. Thus, the space S2 is filled with the diluted solution, as shown in FIG. 12C .
[0095] The preparation control section 28 then aspirates the specimen from the specimen accommodating portion 12 a of the first dispersion section 12 by a volume determined based on the pre-measurement with the sample pipette section 11 . The preparation control section 28 then inserts the pipette 11 a into the accommodating unit 210 through the hole 120 b and the insertion port 211 from the upper side of the upper plate 120 , and discharges the aspirated specimen into the accommodating unit 210 . The liquid level is then in the state shown in FIG. 12D .
[0096] The preparation control section 28 then applies negative pressure to the space S2, and starts the suction of the liquid (diluted solution and specimen) in the space S1 and the accommodating unit 210 . Specifically, as the valves V13, V15 are opened and the negative pressure is applied to the space S2 by the negative pressure source P11, the liquid in the space S1 and the accommodating unit 210 is suctioned toward the space S2 through the filter F4. Subsequently, when the liquid level in the accommodating unit 210 reaches the height of the pin 213 , as shown in FIG. 12E , the preparation control section 28 closes the valves V13, V15 and stops the suction by the negative pressure after elapse of a predetermined time. The liquid level is thus in the state shown in FIG. 12F .
[0097] The preparation control section 28 then applies a counter pressure (positive pressure) to the space S2, and pushes out the cells clogged in the hole of the filter F4 and the cells attached to the surface of the filter F4 on the space S1 side toward the space S1. Specifically, the cells are pushed out into the space S1 by opening the flow path on the positive pressure source P12 side of the valve V17 and applying positive pressure to the space S2 from the positive pressure source P12. After the pushing out by the counter pressure is finished, the flow path on the positive pressure source P12 side of the valve V17 is closed.
[0098] The preparation control section 28 then supplies the diluted solution to the accommodating unit 210 . Specifically, the valve V24 is opened and the diluted solution is supplied into the space S1 through the hole H23. In this case, the diluted solution moves toward the accommodating unit 210 through the flow path 241 . When a predetermined time has elapsed after the liquid level has reached the height of the pin 212 , the valve V24 is closed and the supply of the diluted solution is stopped. The liquid level is thereby in the state shown in FIG. 12D . The processes shown in FIGS. 12D to 12F are repeated for a total of three times. Accordingly, the preservative solution having methanol contained in the specimen as the main component is substituted with the diluted solution, and the cells and foreign substances other than the analyzing target cells contained in the specimen are discriminated and transferred toward the space S2. The concentrated solution in which the analyzing target cells are concentrated is generated in the space S1.
[0099] The preparation control section 28 then opens the space S2 to atmosphere. Specifically, the flow path on the atmosphere open side of the valve V17 and the valve V16 are opened and the interior of the space S2 is made to atmospheric pressure from when the liquid level is in the state shown in FIG. 12F , so that the liquid in the space S1 moves toward the accommodating unit 210 . Subsequently, when the liquid level in the accommodating unit 210 reaches the height of the pin 213 , the preparation control section 28 closes the flow path on the atmosphere open side of the valve V17 and the valve V16, stops the opening of the space S2 to atmosphere, and stops the rotation of the stirrer R. The concentrated solution of the analyzing target cell generated in the space S1 is thereby moved from the space 51 toward the accommodating unit 210 , so that the liquid level is in the state shown in FIG. 12G . The concentrated solution of the analyzing target cell is thus retained on the lower side of the accommodating unit 210 . In this case, the concentration of the concentrated solution is the highest at the lower side of the accommodating unit 210 , and becomes lower toward the space S1 from the lower side of the accommodating unit 210 .
[0100] The preparation control section 28 then inserts the pipette 11 a to the deepest portion of the accommodating unit 210 through the hole 120 b and the insertion port 211 from the upper side of the upper plate 120 , as shown in FIG. 12H . The preparation control section 28 aspirates the concentrated solution retained at the deepest portion of the accommodating unit 210 through the pipette 11 a . The liquid level is thus in the state shown in FIG. 12I . The discriminating/substituting process is thereby terminated, and the subsequent processes are carried out based on the concentrated solution aspirated by the pipette 11 a.
[0101] FIG. 13 is a view showing a configuration of the measuring device 2 .
[0102] The measuring device 2 includes the sub-detecting section 13 and the main detecting section 22 shown in FIG. 2 , and a preparation device section 29 including each section for automatically performing the preparation with respect to the specimen described above. The measuring device 2 also includes the signal processing section 24 , a measurement control section 25 , an I/O interface 26 , the signal processing section 27 , and the preparation control section 28 .
[0103] The sub-detecting section 13 outputs the forward scattered light signal (FSC) by performing the pre-measurement. The signal processing section 27 processes the FSC output from the sub-detecting section 13 , and outputs to the preparation control section 28 . The preparation control section 28 includes a microprocessor 281 and a storage unit 282 . The microprocessor 281 is connected to the preparation device section 29 , and is connected to the data processing device 3 and the measurement control section 25 by way of the I/O interface 26 .
[0104] The preparation device section 29 includes a sensor unit 291 , a motor unit 292 , the liquid level sensor unit 293 , an air pressure source 294 , a valve drive unit 295 , and the sample pipette section 11 and the specimen aspirating section 21 shown in FIG. 2 . A mechanism unit 296 includes other mechanisms shown in FIG. 2 . Each unit of the preparation drive section 29 is controlled by the preparation control section 28 , and the signal output from each unit of the preparation device section 29 is output to the preparation control section 28 .
[0105] The sensor unit 291 includes sensors 121 , 122 , 171 , 172 shown in FIG. 4 . The motor unit 292 includes a motor 141 shown in FIG. 5A , and a stepping motor connected to the pulley 182 shown in FIG. 5B . The liquid level sensor unit 293 is connected to the pins 212 to 214 shown in FIG. 6C . The air pressure source 294 includes the negative pressure source P11, the positive pressure source P12, and a positive pressure source for flowing liquid (diluted solution, washing solution, etc.) in the fluid processing section FL. The valve drive unit 295 includes a mechanism for electromagnetically driving each valve and the regulator P13 in the fluid processing section FL shown in FIG. 11 .
[0106] The main detecting section 22 performs the actual measurement to output the forward scattered light signal (FSC), the side scattered light signal (SSC), and the fluorescence signal (FL). The signal processing section 24 processes the FSC, the SSC, and the FL output from the main detecting section 22 , and then outputs to the measurement control section 25 . The measurement control section 25 includes a microprocessor 251 and a storage unit 252 . The microprocessor 251 is connected to the data processing device 3 and the preparation control section 28 by way of the I/O interface 26 .
[0107] FIG. 14 is a view showing a configuration of the data processing device 3 .
[0108] The data processing device 3 includes a personal computer, and is configured by a main body 30 , the display section 31 , and the input section 32 . The main body 30 includes a CPU 301 , a ROM 302 , a RAM 303 , a hard disk 304 , a readout device 305 , an image output interface 306 , an input/output interface 307 , and a communication interface 308 . The CPU 301 executes the computer program stored in the ROM 302 and the computer program loaded in the ROM 303 .
[0109] The hard disk 304 is stored with an operating system, a computer program to be executed by the CPU 301 , and data used in the execution of the computer program. The hard disk 304 is also stored with a program 304 a for performing processes (see FIGS. 15 and 16 ) to be performed by the data processing device 3 . The readout device 305 is configured by a CD drive, a DVD drive, or the like, and is able to read out the computer programs and data recorded in a recording medium 305 a . If the program 304 a is recorded in the recording medium 305 a , the program 304 a read out from the recording medium 305 a by the readout device 305 is stored in the hard disk 304 .
[0110] The image output interface 306 outputs an image signal corresponding to the image data to the display section 31 , and the display section 31 displays the image based on the image signal output from the image output interface 306 . The user inputs instructions through the input section 32 , and the input/output interface 307 receives signals input through the input section 32 . The communication interface 308 is connected to the measuring device 2 , and the CPU 301 transmits and receives the instruction signal and the data with the measuring device 2 through the communication interface 308 .
[0111] In the cell analyzer 1 , a mode (hereinafter referred to as “normal measurement mode”) of when measuring the clinical measurement specimen including cells collected from the subject, and a mode (hereinafter referred to as “quality control measurement mode”) of when measuring the quality control specimen used for determining the state of the measuring device 2 are prepared. The process in the normal measurement mode and the process in the quality control measurement mode will be described in order below.
[0112] FIG. 15 is a flowchart showing the process of the cell analyzer 1 in the normal measurement mode.
[0113] In the normal measurement mode, the specimen container 4 , which contains the mixed solution (specimen) of the preservative solution having methanol as the main component and the cells collected from the subject, is set in the sample setting section 2 a (see FIG. 2 ) by the user, and the process by the cell analyzer 1 is started. When the process is started, the preparation control section 28 of the measuring device 2 performs the first dispersion process on the aggregating cells in the specimen with the first dispersion section 12 (S 101 ).
[0114] The preparation control section 28 performs the pre-measurement by the sub-detecting section 13 (S 102 ), and acquires the forward scattered light signal (FSC) for every particle contained in the specimen supplied to the sub-detecting section 13 . The preparation control section 28 acquires the number of analyzing target cells supplied to the sub-detecting section 13 based on the width and the peak value of the FSC obtained by the pre-measurement. The preparation control section 28 calculates the concentration of the specimen based on the acquired number of analyzing target cells and the volume of the specimen supplied to the sub-detecting section 13 .
[0115] The preparation control section 28 then determines the volume of the specimen to be supplied to the discriminating/substituting section 14 based on the calculated concentration and the number of analyzing target cells to be supplied to the discriminating/substituting section 14 . Specifically, the volume of the specimen to be supplied to the discriminating/substituting section 14 is determined so that more than necessary analyzing target cells are not supplied to the discriminating/substituting section 14 when the concentration of the specimen is high, and as much analyzing target cells as possible are supplied to the discriminating/substituting section 14 when the concentration of the specimen is low. The preparation control section 28 aspirates the specimen accommodated in the specimen accommodating portion 12 a of the first dispersion section 12 by the determined volume, and discharges the aspirated specimen to the accommodating unit 210 of the discriminating/substituting section 14 (S 103 ).
[0116] The preparation control section 28 then calculates the number of analyzing target cells supplied to the discriminating/substituting section 14 from the volume of the specimen supplied to the discriminating/substituting section 14 and the concentration of the specimen acquired by the pre-measurement. The preparation control section 28 transmits the data (width and peak value of the FSC of each particle) acquired by the pre-measurement, and the number of analyzing target cells supplied to the discriminating/substituting section 14 to the data processing device 3 (S 104 ). The preparation control section 28 then performs the discrimination/substituting process by the discriminating/substituting section 14 (S 105 ), as described above.
[0117] The preparation control section 28 then performs the second dispersion process on the aggregating cells in the specimen with the second dispersion section 16 (S 106 ). The preparation control section 28 then adds the reagent (RNase) to the specimen, performs the RNA removing process of the analyzing target cell in the specimen container 5 , adds the reagent (stain solution) to the specimen, and performs the DNA staining process of the analyzing target cell in the specimen container 5 (S 107 ).
[0118] The measurement control section 25 of the measuring device 2 performs the actual measurement by the main detecting section 22 (S 108 ), and acquires the forward scattered light signal (FSC), the side scattered light signal (SSC), and the fluorescence signal (FL) for every particle contained in the measurement specimen supplied to the main detecting section 22 . The measurement control section 25 acquires the number of analyzing target cells supplied to the main detecting section 22 based on the width and the peak value of the FSC obtained by the actual measurement. The measurement control section 25 transmits the data (width and peak value of the FSC, SSC, FL of each particle) acquired by the actual measurement, and the number of analyzing target cells supplied to the main detecting section 22 to the data processing device 3 (S 109 ).
[0119] When the measurement is started, the CPU 301 of the data processing device 3 waits the process until receiving the data, and the like of the pre-measurement transmitted from the measuring device 2 in S 104 (S 201 ), and proceeds the process to S 202 when receiving the data (S 201 : YES). The CPU 301 waits the process until receiving the data, and the like of the actual measurement transmitted from the measuring device 2 in S 109 (S 202 ), and proceeds the process to S 203 when receiving the data (S 202 : YES). The CPU 301 stores the received data of the pre-measurement, the number of analyzing target cells supplied to the discriminating/substituting section 14 , the data of the actual measurement, and the number of analyzing target cells supplied to the main detecting section 22 in the hard disk 304 .
[0120] The CPU 301 then performs the analyzing process based on the FSC, the SSC, and the FL obtained by the actual measurement (S 203 ). Specifically, the characteristic parameters such as the forward scattered light intensity, the fluorescence intensity, and the like are acquired, and the frequency distribution data for analyzing cells and nuclei are created based on such characteristic parameters. The CPU 301 performs the discriminating process of the particles in the measurement specimen based on the frequency distribution data, and determines whether or not the analyzing target cell is abnormal, specifically, whether or not a cancerous cell (atypical cell). Subsequently, the CPU 301 displays the analysis result on the display section 31 . The process of the cell analyzer 1 in the normal measurement mode is thereby terminated.
[0121] FIG. 16 is a flowchart showing the process of the cell analyzer 1 in the quality control measurement mode. In the process of the measuring device 2 in this case, S 111 , S 112 are added in place of S 104 , S 109 in the process of the measuring device 2 of the normal measurement mode shown in FIG. 15 . Furthermore, in the process of the data processing device 3 in this case, S 211 to S 214 are added in place of S 203 in the process of the data processing device 3 of the normal measurement mode shown in FIG. 15 .
[0122] In the quality control measurement mode, the two specimen containers 4 containing the mixed solution (specimen) of the preservative solution having methanol as the main component and the quality control specimen are set in the sample setting section 2 a (see FIG. 2 ) by the user, and the process by the cell analyzer 1 is started. The specimens in the two specimen containers 4 used in the quality control measurement mode are taken into the measuring device 2 in order and processed. The quality control specimen contains particles (hereinafter referred to as “quality control particle”) having a particle diameter of the same extent as the analyzing target cell, where the diameter of the quality control particle is set to a value greater than the diameter (10 μm) of the hole of at least the filter F4, and is 15 μm in the present embodiment.
[0123] When the process is started, the entire amount of specimen in the specimen container 4 is aspirated, and discharged to the specimen accommodating portion 12 a of the first dispersion section 12 . The preparation control section 28 of the measuring device 2 performs the first dispersion process on the quality control particle in the specimen with the first dispersion section 12 (S 101 ), similar to the normal measurement mode. A part of the specimen completed with the first dispersion process and accommodated in the specimen accommodating portion 12 a is discharged to the specimen take-in portion 13 a of the sub-detecting section 13 . Thus, the specimen having the volume v1 remains in the specimen accommodating portion 12 a.
[0124] The preparation control section 28 then performs the pre-measurement by the sub-detecting section 13 (S 102 ). The preparation control section 28 acquires the number of quality control particles supplied to the sub-detecting section 13 based on the width and the peak value of the FSC obtained by the pre-measurement. The preparation control section 28 calculates a concentration c1 of the relevant specimen based on the acquired number of quality control particles and the volume of the specimen supplied to the sub-detecting section 13 . The preparation control section 28 aspirates all the specimens having the volume v1 accommodated in the specimen accommodating portion 12 a of the first dispersion section 12 , and discharges the aspirated specimens to the accommodating unit 210 of the discriminating/substituting section 14 (S 103 ).
[0125] The preparation control section 28 calculates the number n2 of quality control particles supplied to the discriminating/substituting section 14 by performing the computation of v1×c1 based on the volume v1 of the specimen supplied to the discriminating/substituting section 14 and the concentration c1 of the specimen acquired by the pre-measurement. The preparation control section 28 then transmits the data of each particle, including width and peak value of the FSC, acquired by the pre-measurement and the number n2 of quality control particles supplied to the discriminating/substituting section 14 to the data processing device 3 (S 111 ). As described above, the preparation control section 28 performs the discriminating/substituting process by the discriminating/substituting section 14 (S 105 ). The preparation control section 28 then performs the processes of S 106 , S 107 , similar to the normal measurement mode.
[0126] Similar to the normal measurement mode, the measurement control section 25 of the measuring device 2 then performs the actual measurement by the main detecting section 22 (S 108 ), and acquires the forward scattered light signal (FSC), the side scattered light signal (SSC), and the fluorescence signal (FL) for every particle contained in the measurement specimen supplied to the main detecting section 22 . The measurement control section 25 acquires a number n3 of quality control particles supplied to the main detecting section 22 based on the width and the peak value of the FSC obtained by the actual measurement. The measurement control section 25 transmits the data of each particle, including widths and peak values of FSC, SSC and FL, acquired by the actual measurement, and the number n3 of quality control particles supplied to the main detecting section 22 to the data processing device 3 (S 112 ).
[0127] When the measurement is started, the CPU 301 of the data processing device 3 performs the processes of S 201 , S 202 , similar to the normal measurement mode. The CPU 301 stores the received data of the pre-measurement, the number n2 of quality control particles supplied to the discriminating/substituting section 14 , the data of the actual measurement, and the number n3 of quality control particles supplied to the main detecting section 22 in the hard disk 304 .
[0128] The CPU 301 displays a result screen D1 on the display section 31 based on the data, and the like received in S 201 , S 202 (S 211 ). The result screen D1 will be described later with reference to FIG. 17A . The CPU 301 then calculates a collection rate by performing the computation of n3/n2 (S 212 ), and determines whether the calculated collection rate is smaller than a predetermined threshold value R (S 213 ). The threshold value R is set to the same extent as the collection rate of when abnormality is not found in the state of the filter member F. If the collection rate is smaller than the threshold value R (S 213 : YES), the CPU 301 outputs an alarm through the display section 31 to notify the user that the collection rate is low (S 214 ). The process of the cell analyzer 1 in the quality control measurement mode is thereby terminated.
[0129] FIG. 17A is a view showing the result screen D1 showing the measurement result in the quality control measurement mode. The result screen D1 includes 30 numerical display regions D11 including rows i11 to i20 and columns j1 to j3.
[0130] The values in the display region D11 of the rows i11 to i15 indicate the width of the forward scattered light signal (FSC) in the pre-measurement, the variation coefficient of the width, the peak value, the variation coefficient of the peak value, and the number of quality control particles. The values in the display region D11 of the rows i16 to i19 indicate the width of the forward scattered light signal (FSC) in the actual measurement, the variation coefficient of the width, the peak value, and the variation coefficient of the peak value. The value in the display region D11 of the row i20 indicates the collection rate acquired in S 211 of FIG. 16 . The values in the display region D11 of the columns j1, j2 indicate the result with respect to the two specimen containers 4 used in the quality control measurement mode, that is, the results for the first time and the second time. The value in the display region D11 of the column j3 indicates the average of the two results shown in the columns j1, j2.
[0131] In the result screen D1 shown in FIG. 17A , determination is made that the measurement result of the second time (column j2) and the average (column j3) of the width (row i11) of the FSC in the pre-measurement are abnormal, and thus the corresponding display region D11 is displayed in red (broken line for the sake of convenience in FIG. 17A ). Furthermore, determination is made that the result of the second time (column j2) and the average (column j3) of the collection rate (row i20) are abnormal, and thus the corresponding display region D11 is displayed in red (broken line for the sake of convenience in FIG. 17A ). In other words, whether each of the values in the display region D11 of the columns j1 to j3 of the row i20 is smaller than the threshold value R is determined (S 213 of FIG. 16 ), and as a result, the values of the columns j2, j3 of the row i20 are smaller than the threshold value R (S 213 : YES), and thus the display region D11 of the columns j2, j3 of the row i20 is displayed in red as the output of the alarm of S 214 .
[0132] If the measurement result in the quality control measurement mode includes values determined as abnormal, the corresponding display region D11 is shown in red in the result screen D1 as shown in FIG. 17A and an error list screen D2 shown in FIG. 17B is displayed on the display section 31 .
[0133] FIG. 17B is a view showing the error list screen D2. The error list screen D2 includes a list D21 and a display region D22.
[0134] In the list D21 is displayed items determined to be abnormal in the measurement result in the quality control measurement mode. In the list D21 of FIG. 17B is displayed “quality control abnormality 1” indicating that abnormality is found in the forward scattered light signal (FSC), and “quality control abnormality 2” indicating that abnormality is found in the collection rate as shown in FIG. 17A , where the second item (quality control abnormality 2) is selected. The user can select the item by pushing the item in the list D21.
[0135] The content to be handled by the user in relation to the selected item of the list D21 is displayed in the display region D22. In the display region D22 of FIG. 17B is displayed the content to be handled by the user when abnormality is found in the collection rate since the “quality control abnormality 2” is selected in the list D21. In other words, the possibility the problems have arose in the filter F4 is displayed as an output of alarm of S 214 in the display region D22 of this case, and the necessity of replacing the filter member F is displayed. Thus, if abnormality is found in the measurement result in the quality control measurement mode, the user carries out the necessary actions e.g., replacement of the filter member F and again performs the measurement in the quality control measurement mode.
[0136] According to the present embodiment, the diameter of the quality control particle is set to a value greater than the diameter of the hole of the filter F4, and thus the quality control particles do not move from the space S1 to the space S2 shown in FIG. 10C even if the process by the discriminating/substituting section 14 is carried out if abnormality is not found in the state of the filter member F, similar to the analyzing target cell. Since the quality control particles get lost by attaching to the container, the flow path, and the like before being supplied to the main detecting section 22 after being supplied to the discriminating/substituting section 14 , the value of the number n3 of quality control particles supplied to the main detecting section 22 is normally smaller by a certain proportion than the value of the number n2 of quality control particles supplied to the discriminating/substituting section 14 . However, if abnormality of the filter member F is found, e.g., the filter member F is not correctly set or the filter F4 is damaged, the quality control particles move from the space S1 to the space S2. Thus, the collection rate calculated by the computation of n3/n2 becomes small compared to when there is no abnormality of the filter member F.
[0137] Therefore, if the threshold value R is set to be the same extent as the collection rate of when abnormality is not found in the state of the filter member F, whether abnormality is found in the state of the filter member F can be determined by determining whether the collection rate is smaller than the threshold value R in the quality control measurement mode. If the collection rate is smaller than the threshold value R, the alarm is output as shown in FIGS. 17A and 17B . Thus, the user can recognize that abnormality has occurred in the state of the filter member F.
[0138] According to the present embodiment, the pre-measurement is carried out in the sub-detecting section 13 before the specimen is supplied to the discriminating/substituting section 14 , and the number n2 of quality control particles supplied to the discriminating/substituting section 14 is acquired based on the measurement data of the specimen by the pre-measurement. Thus, even if the number of quality control particles contained in the specimen container 4 is unknown, the number n2 of quality control particles supplied to the discriminating/substituting section 14 can be acquired. Therefore, whether abnormality has occurred in the state of the filter member F4 can be determined based on the number n2 of quality control particles supplied to the discriminating/substituting section 14 and the number n3 of quality control particles supplied to the main detecting section 22 . Furthermore, since the numbers n2, n3 of quality control particles are respectively obtained by the measurement data from the sub-detecting section 13 and the main detecting section 22 , the state of the filter member F4 can be rapidly determined compared to when both numbers n2, n3 of quality control particles are obtained by the measurement data from the main detecting section 22 , for example.
[0139] According to the present embodiment, the filter F4 is arranged in the filter member F, and the filter member F is set in the accommodating unit 220 through the hole 120 b shown in FIG. 4 and the insertion port 221 shown in FIG. 6A . Thus, if abnormality is found in the filter member F, the user can rapidly and easily replace the filter member F.
[0140] <First Variant>
[0141] In the embodiment described above, the number n2 of quality control particles supplied to the discriminating/substituting section 14 is calculated by performing the computation of v1×c1 based on the volume v1 of the specimen supplied to the discriminating/substituting section 14 and the concentration c1 of the specimen acquired by the pre-measurement. In the present variant, the pre-measurement is not carried out in the quality control measurement mode. The number n4 of precision particles contained in the specimen container 4 used in the quality control measurement mode is stored in advance in the hard disk 304 of the data processing device 3 . If the number n4 is stored in the recording medium such as the barcode attached to the specimen container 4 , the n4 may be read from the recording medium of the specimen container 4 using the reading device such as the barcode reader.
[0142] FIG. 18 is a flowchart showing the process of the cell analyzer 1 in the quality control measurement mode of the present variant. In the process of the measuring device 2 in this case, S 102 and S 111 are omitted from the process of the measuring device 2 shown in FIG. 16 . In the process of the data processing device 3 , S 201 is omitted from the process of the data processing device 3 shown in FIG. 16 .
[0143] When the process is started, the entire amount of specimen in the specimen container 4 is aspirated, and discharged to the specimen accommodating portion 12 a of the first dispersion section 12 . The preparation control section 28 of the measuring device 2 performs the first dispersion process on the quality control particle in the specimen with the first dispersion section 12 (S 101 ), similar to the embodiment described above. The preparation control section 28 then aspirates all the specimens accommodated in the specimen accommodating portion 12 a , and discharges the aspirated specimens to the accommodating unit 210 of the discriminating/substituting section 14 (S 103 ). All the quality control particles contained in the specimen container 4 used in the quality control measurement mode are thus discharged to the accommodating unit 210 of the discriminating/substituting section 14 , and the number of quality control particles supplied to the discriminating/substituting section 14 becomes n4.
[0144] The preparation control section 28 then performs the processes of S 105 to S 107 , similar to the embodiment described above, and the measurement control section 25 performs the processes of S 108 , S 112 , similar to the embodiment described above.
[0145] When the measurement is started, the CPU 301 of the data processing device 3 performs the process of S 202 , similar to the embodiment described above. The CPU 301 stores the data of the actual measurement and the number n3 of quality control particles supplied to the main detecting section 22 in the hard disk 304 . The CPU 301 then displays the result screen D1 on the display section 31 based on the data, and the like received in S 202 (S 211 ). In this case, the number n4 of quality control particles stored in advance in the hard disk 304 is displayed in the display region D11 of the row i15 of the result screen D1.
[0146] The CPU 301 performs the computation of n3/n4 based on the number n4 of quality control particles stored in advance in the hard disk 304 and the number n3 of quality control particles supplied to the main detecting section 22 received in S 202 to calculate the collection rate (S 212 ). The CPU 301 then performs the processes of S 213 , S 214 , similar to the embodiment described above.
[0147] According to the present variant, the number n4 of quality control particles contained in the specimen container 4 is stored in advance in the hard disk 304 , and thus the pre-measurement does not need to be carried out. The calculation of the collection rate and the output of the alarm are thus rapidly carried out, and hence the user can rapidly recognize if abnormality has occurred in the state of the filter member F.
[0148] <Second Variant>
[0149] In the embodiment described above, the pre-measurement is carried out in the sub-detecting section 13 , but in the present variant, the sub-detecting section 13 is omitted from the measuring device 2 and the pre-measurement is carried out in the main detecting section 22 in the normal measurement mode and the quality control measurement mode. Hereinafter, only the process in the quality control measurement mode will be described.
[0150] FIG. 19 is a flowchart showing the process of the cell analyzer 1 in the quality control measurement mode of the present variant. In the process of the measuring device 2 in this case, S 121 is added in place of S 102 from the process of the measuring device 2 shown in FIG. 16 . The process of the data processing device 3 is similar to the process of the data processing device 3 shown in FIG. 16 .
[0151] When the process is started, the entire amount of specimen in the specimen container 4 is aspirated, and discharged to the specimen accommodating portion 12 a of the first dispersion section 12 . The preparation control section 28 of the measuring device 2 performs the first dispersion process on the quality control particle in the specimen with the first dispersion section 12 , similar to the normal measurement mode (S 101 ). A part of the specimen completed with the first dispersion process and accommodated in the specimen accommodating portion 12 a is supplied to the main detecting section 22 , and the pre-measurement is carried out in the main detecting section 22 (S 121 ). The specimen accommodated in the specimen accommodating portion 12 a is aspirated by the pipette 11 a and discharged to the specimen container 5 , and thereafter, transferred to the main detecting section 22 by the grip portion 15 a of the container transfer section 15 , the holder 18 b of the rotation table 18 a , and the pipette 21 a of the specimen aspirating section 21 .
[0152] The main detecting section 22 can acquire the forward scattered light signal (FSC), similar to the sub-detecting section 13 of the embodiment described above. The preparation control section 28 calculates the concentration c1 of the specimen based on the number of quality control particles acquired in the pre-measurement by the main detecting section 22 and the volume of the specimen supplied to the main detecting section 22 . Similar to the embodiment described above, the preparation control section 28 aspirates all the specimens of volume v1 accommodated in the specimen accommodating portion 12 a of the first dispersion section 12 , and discharges the aspirated specimens to the accommodating unit 210 of the discriminating/substituting section 14 (S 103 ).
[0153] The preparation control section 28 then transmits the data (width and peak value of the FSC of each particle) acquired by the pre-measurement and the number n2 (=v1×c1) of quality control particles supplied to the discriminating/substituting section 14 to the data processing device 3 (S 111 ). The preparation control section 28 performs the processes of S 105 to S 107 , similar to the embodiment described above, and the measurement control section 25 performs the processes of S 108 , S 112 , similar to the embodiment described above. The processes in the data processing device 3 are also carried out similar to the embodiment described above.
[0154] According to the present variant, the pre-measurement is carried out in the main detecting section 22 , and hence the configuration of the measuring device 2 can be simplified. In this case as well, the number n2 of quality control particles supplied to the discriminating/substituting section 14 is acquired in the pre-measurement by the main detecting section 22 , and thus whether or not abnormality has occurred in the state of the filter member F can be determined based on the collection rate calculated by the computation n3/n2, similar to the embodiment described above.
[0155] According to the present variant, the pre-measurement is carried out in the main detecting section 22 before the specimen is supplied to the discriminating/substituting section 14 , and the number n2 of quality control particles supplied to the discriminating/substituting section 14 is acquired based on the measurement data of the specimen by the pre-measurement. Thus, similar to the embodiment described above, even if the number of quality control particles contained in the specimen container 4 is unknown, the number n2 of quality control particles supplied to the discriminating/substituting section 14 can be acquired.
[0156] <Third Variant>
[0157] In the present variant, a flag indicating whether the process of the cell analyzer 1 is possible is stored in the hard disc 304 of the embodiment described above. Such flag is rewritten based on the measurement result obtained in the quality control measurement mode, and the process of the cell analyzer 1 is prohibited or permitted by the value of the flag.
[0158] FIG. 20A is a flowchart showing the process of the cell analyzer 1 in the normal measurement mode of the present variant. In the process of the measuring device 2 in this case, S 131 is added to the pre-stage of S 101 from the process of the measuring device 2 shown in FIG. 15 , and in the process of the data processing device 3 , S 221 to S 223 are added to the pre-stage of S 201 from the process of the data processing device 3 shown in FIG. 15 . The value of the flag is zero at the start.
[0159] When the process is started, the CPU 301 of the data processing device 3 determines whether or not the value of the flag stored in the hard disk 304 is zero (S 221 ). If the value of the flag is zero (S 221 : YES), the CPU 301 determines whether or not the user made the measurement start instruction through the input section 32 (S 222 ). As shown in FIG. 20C , the user pushes a measurement start button 311 displayed in the display section 31 to input the measurement start instruction. If the measurement start instruction is made (S 222 : YES), the CPU 301 transmits the measurement start instruction to the measuring device 2 (S 223 ).
[0160] When the process is started, the preparation control section 28 of the measuring device 2 determines whether or not the measurement start instruction is received from the data processing device 3 (S 131 ). If the measurement start instruction is received (S 131 : YES), the preparation control section 28 performs the processes after S 101 .
[0161] FIG. 20B is a flowchart showing the process of the cell analyzer 1 in the quality control measurement mode of the present variant. The process of the measuring device 2 in this case is similar to the process of the measuring device 2 shown in FIG. 16 , and in the process of the data processing device 3 , S 231 , S 232 are added to the post-stage of when determined as YES in S 213 , and S 233 , S 234 are added to the post-stage of when determined as NO in S 213 from the process of the data processing device 3 shown in FIG. 16 .
[0162] The CPU 301 of the data processing device 3 disables (state in which the user cannot push) the measurement start button 311 shown in FIG. 20C (S 231 ) when the collection rate is smaller than the threshold value R (S 213 : YES), that is, when abnormality is found in the state of the filter member F, and sets the value of the flag to one (S 232 ). When the collection rate is greater than or equal to the threshold value R (S 213 : NO), that is, when abnormality is not found in the state of the filter member F, the measurement start button 311 shown in FIG. 20C is enabled (state in which the user can push) (S 233 ), and the value of the flag is set to zero (S 234 ).
[0163] According to the present variant, the process of the cell analyzer 1 is prohibited immediately after the startup of the cell analyzer 1 , or when abnormality is found in the state of the filter member F in the quality control measurement mode. The process of the cell analyzer 1 is permitted when the measurement in the quality control measurement mode is carried out and abnormality is not found in the state of the filter member F. Thus, the user can be prevented from making a wrong inappropriate judgment with reference to the analysis result acquired using the filter F4 in a bad state in the normal measurement mode.
[0164] In the third variant described above, when the collection rate is smaller than the threshold value R, the setting of the data processing device 3 may be changed so that the analyzing process (S 203 ) is not carried out in the normal measurement mode instead of disabling the measurement start button 311 . In this case, when the collection rate is greater than or equal to the threshold value R, the setting of the data processing device 3 is changed so that the analyzing process is carried out in the normal measurement mode. Thus, similar to the third variant described above, the user can be prevented from making the wrong inappropriate judgment with reference to the analysis result acquired using the filter F4 in a bad state in the normal measurement mode.
[0165] In the third variant, when the collection rate is smaller than the threshold value R, the setting of the data processing device 3 may be changed so that a mask is applied on the analysis result in the normal measurement mode thereafter instead of disabling the measurement start button 311 . In this case, when the collection rate is greater than or equal to the threshold value R, the setting of the data processing device 3 is changed so that the mask is not applied on the analysis result in the normal measurement mode thereafter. Thus, similar to the third variant described above, the user can be prevented from making the wrong inappropriate judgment with reference to the analysis result acquired using the filter F4 in a bad state in the normal measurement mode.
[0166] The embodiment of the present invention has been described, but the present invention is not limited to the embodiment described above, and various changes can be made other than the above on the embodiment of the present invention.
[0167] For example, in the embodiment described above, the epidermal cells of the uterine cervix are the analyzing target, but other epidermal cells such as buccal cells, bladder, pharynx, and the like, and furthermore, the epidermal cells of organs may be the analyzing target. Furthermore, urine and blood may be the analyzing target. In other words, the present invention can be applied to an apparatus for discriminating the analyzing target cell from the biological specimen with the filter.
[0168] In the embodiment described above, the analyzing target cell is retained in the space S1 by the filter F4, and the cells and foreign substances other than the analyzing target cell contained in the specimen are transferred toward the space S2. The concentrated solution of the analyzing target cell remaining in the space S1 is used in the process of post-stage. However, this is not the sole case, and the filter F4 may be set so that the diameter of the hole becomes greater than the analyzing target cell when the analyzing target cell is a cell (e.g., red blood cells) having a small diameter, so that the foreign substances greater than the analyzing target cell are shielded by the filter F4 and only the analyzing target cell can be passed. In this case, if abnormality has occurred in the state of the filter member F, the foreign substances greater than the analyzing target cell pass through the filter F4, and the specimen supplied to the main detecting section 22 contains foreign substances greater than the analyzing target cell. Therefore, if the foreign substance greater than the analyzing target cell is detected in great amount based on the result of the actual measurement by the main detecting section 22 in the quality control measurement mode, determination can be made that abnormality has occurred in the state of the filter member F.
[0169] Furthermore, in the embodiment described above, the alarm is output through the display section 31 as shown in FIGS. 17A and 17B in S 214 , but this is not the sole case, and an alarm sound may be output from a speaker installed in the data processing device 3 . The configuration in which the data processing device 3 outputs the alarm is not the sole case, and the measuring device 2 may output the alarm using the display section, the speaker, and the like.
[0170] In the embodiment described above, the number of quality control particles supplied to the discriminating/substituting section 14 is acquired by the pre-measurement by the sub-detecting section 13 , and the number of quality control particles supplied to the main detecting section 22 is acquired by the actual measurement by the main detecting section 22 . Whether or not abnormality has occurred in the state of the filter member F is determined based on the acquired numbers of quality control particles. However, this is not the sole case, and the turbidity of the quality control specimen may be acquired as a value reflecting the amount of quality control particles in the pre-measurement and the actual measurement, and the state of the filter member F may be determine based on the turbidity of the quality control specimen supplied to the discriminating/substituting section 14 and the turbidity of the quality control specimen supplied to the main detecting section 22 .
[0171] In the embodiment and the second variant described above, a ratio (collection rate) of the number n3 of quality control particles supplied to the main detecting section 22 and the number n2 of quality control particles supplied to the discriminating/substituting section 14 is calculated, and the alarm is output when the collection rate is smaller than the threshold value R, but the present invention is not limited thereto. For example, the difference between n3 and n2 may be calculated, and the alarm may be output when the difference is greater than a predetermined threshold value.
[0172] In the first variant, the ratio (collection rate) of the number n3 of quality control particles supplied to the main detecting section 22 and the number n4 of quality control particles contained in the specimen container 4 used in the quality control measurement mode is calculated, and the alarm is output when the collection rate is smaller than the threshold value R, but the present invention is not limited thereto. For example, the difference between n3 and n4 may be calculated, and the alarm may be output when the difference is greater than a predetermined threshold value.
[0173] In the embodiment described above, the flow cytometer 40 of the sub-detecting section 13 is configured to receive only the forward scattered light signal (FSC), but may be configured to further receive the side scattered light signal (SSC) and the fluorescence signal (FL), similar to the flow cytometer 50 of the main detecting section 22 . In this case, the number of analyzing target cells is acquired based on the forward scattered light (FSC) in the sub-detecting section 13 , but the number of analyzing target cells may be acquired based on the side scattered light signal (SSC) and the fluorescence signal (FL). The number of analyzing target cells is acquired based on the forward scattered light (FSC) in the main detecting section 22 , but the number of analyzing target cells may be acquired based on the side scattered light signal (SSC) and the fluorescence signal (FL).
[0174] In the embodiment described above, the sub-detecting section 13 and the main detecting section 22 are configured by a flow cytometer, but the detecting sections may be configured by an electrical resistance type detecting section.
[0175] In the embodiment described above, the discriminating/substituting section 14 is installed in the measuring device 2 , but this is not the sole case, and may be installed in the cell collecting apparatus different from the measuring device 2 . The cell collecting apparatus in this case includes the discriminating/substituting section 14 , the specimen supplying section configured to supply the specimen to the discriminating/substituting section 14 similar to the sample pipette section 11 , the measuring section configured to optically measure the quality control specimen, and the information processing section configured to process the measurement data obtained by the measuring section. In the quality control measurement mode, the cell collecting apparatus performs the process on the quality control specimen with the discriminating/substituting section 14 and measures the quality control specimen after the processing by the discriminating/substituting section 14 with the measuring section. The information processing section determines the state of the filter member F, similar to the above embodiment, based on the measurement data obtained by the measuring section, and outputs an alarm based on the determination result. The cell collecting apparatus performs the process on the biological specimen with the discriminating/substituting section 14 in the normal measurement mode. The biological specimen after the processing by the discriminating/substituting section 14 is appropriately transferred to the measuring device 2 , and the measurement of the biological specimen is carried out by the main detecting section 22 of the measuring device 2 .
[0176] In addition, various changes can be appropriately made on the embodiment of the present invention within a scope of the technical concept described in the Claims. | Disclosed is a cell analyzer comprising: a measuring device that includes a collecting section configured to collect target cells in a specimen with a filter, and is configured to measure the target cells collected by the collecting section; and a data processing device configured to analyze the target cells based on measurement data obtained by the measuring device, wherein the cell analyzer is operable in a first mode of measuring a clinical specimen collected from a subject and a second mode of measuring a quality control specimen containing particles having size capturable by the filter; and the data processing device is programmed to acquire an amount of particles collected by the collecting section based on measurement data of the quality control specimen obtained in the second mode, and output an alarm when the amount of particles meets a predetermined condition. | 97,498 |
BACKGROUND OF THE INVENTION
A. Related Applications
1. "Address Development Technique Utilizing a Content Addressable Memory", invented by James L. Brown and Richard P. Wilder, Jr., filed on Aug. 24, 1972, having Ser. No. 283,617 and assigned to the same assignee as the instant invention.
2. "Segmented Address Development", invented by Bienvenu and filed on May 16, 1974, having Ser. No. 470,496 and assigned to the same assignee as the instant invention.
3. "Data Processing System Utilizing Data Field Descriptors for Processing Data Files", invented by Charles W. Bachman, filed on Dec. 13, 1973, having Ser. No. 424,259 and assigned to the same assignee as the instant invention.
4. "Data Processing System Incorporating a Logical Compare Instruction", invented by Charles W. Bachman, filed on Dec. 13, 1973, having Ser. No. 424,406 and assigned to the same assignee as the instant invention.
5. "Data Processing System Utilizing a Hash Instruction for Record Identification", invented by Charles W. Bachman, filed on Dec. 13, 1973, having Ser. No. 424,391 and assigned to the same assignee as the instant invention.
6. "Procedure Calls And Stack Mechanism" invented by Marc Appell et al., filed on Nov. 30, 1973 in France, having French Ser. No. 73 42705, assigned to the same assignee named herein and further filed in the U.S. on a priority convention date of Dec. 2, 1974 and having U.S. Ser. No. 529,019.
B. Field of the Invention
This invention relates generally to data processing systems and more particularly to an apparatus for transferring data from a source field to a receiving field.
C. Description of the Prior Art
Because today's digital processors are capable of operating at rates many times higher than the rates at which individual users are able to supply and accept data, the concept of time sharing a single data processor between a large number of users is finding wider and wider application. A significant problem which has long been encountered by time sharing services arises from the fact that the large number of users of the service write their own data base files and therefore specify the data in their data bases in a variety of ways. As a consequence of having a variety of different data types, data processing manufacturers have had to write complicated programs to convert and handle each of the various data types. This development is expensive since it not only includes a large amount of storage space required for instructions for each data type but also results in an extremely slow performance by the data processor.
For primitive operations such as a move operation, the concept of data independence has become significant. In description controlled files, i.e., files where the description of the contents and structure of the data is carried separately from the program, data independence requires two forms of data field representation, i.e., first the form of data field seen by the program and second the form of the data field on secondary storage. This requirement, however, makes the task of deblocking and enblocking data many times more burdensome. It has been shown that a substantial amount of data processing time is used in first decoding the type of move instruction required to deblock or enblock data and second, in the selection of the specific move instruction based on the characteristics of the sending and receiving operands.
One prior art solution to the problem of providing a move instruction to deblock and enblock different formats of data utilizes an instruction having additional bits. Some of these additional bits would indicate the data type of the source and the remainder of the bits would indicate the data type of the destination. With this knowledge, the proper subroutine to be invoked in order to transfer data from the source to a description consonant with the destination would be possible. While this solution eliminates the subroutine necessary to determine the format of data, this solution suffers from the fact that the data types must be known beforehand. Moreover, when new or different users are added to the data processing system, a regression to the former practice results since a new program and additional memory space is required.
The present invention concerns itself with a move instruction defined for all data types. Thus no matter what format a user defines his data base files, the move instruction is applicable for each situation. Moreover, by providing a move instruction defined for all data types, data independence is achieved.
In the related application to Charles W. Bachman, Ser. No. 424,259, filed on Dec. 13, 1973, incorporated fully herein, the data field descriptors describing the attributes of the various fields of a user are enumerated. By utilizing these data field descriptors, the move instruction becomes a general purpose logical instruction which operates on a plurality of various data types. It accomplishes this feature by transferring and reformatting the data at the time of execution into the format required by the destination. Thus prior to the execution time, a general procedure has been followed which requires no specialized subroutine as required by the prior art. Moreover, the specialized instructions having the additional bits are not required herein since the general purpose instruction itself executes the move operation based on the data field descriptors associated with the data fields.
This solution provides further embellishments in that alteration of the records in a field or restructuring of records in a file is easily accomplished by merely changing the data field descriptor. Since the instruction is not dependent upon the information as defined by the user, any alteration or change is resolved at execution time as was the situation for the unaltered fields. As a result, no additional or new subroutines or other solutions are required.
OBJECTS OF THE INVENTION
It is an object of this invention to provide an improved data processing system which is able to operate with a variety of data types from a plurality of users.
It is another object of this invention to eliminate the requirement of special subroutines to operate on primitive operations such as a move for each variety of data types.
It is a further object of this invention to provide a move instruction in a data processing system which significantly increases the operational performance of the overall system and eliminates the programmed requirements previously necessary.
It is yet another object of this invention to provide a data processing system which can quickly and efficiently execute a logical move instruction for all data types.
SUMMARY OF THE INVENTION
The foregoing objects are achieved according to one embodiment of the invention and according to one mode of operation thereof, by providing in a data processing system a move instruction which locates both the data of the source field and the data attributes of the source and destination operands. The latter attributes are developed by indirection of an address syllable within the move instruction which specifies data field descriptors. After the data and its attributes have been determined, the move instruction under control of a control store unit and a control store interface adapter unit provides for the transfer and reformatting of the data to meet the receiving field description. When all the data of the source field has been transposed to the receiving field, the next instruction is executed.
BRIEF DESCRIPTION OF THE DRAWINGS
The novel features which are characteristic of this invention are set forth with particularity in the appended claims. The invention itself, however, both as to its organization and operation together with further objects and advantages thereof may best be understood by reference to the following description taken in connection with the accompanying drawings in which:
FIG. 1 (which includes FIGS. 1a-1c) is a schematic diagram of various hardware structures utilized in the present invention;
FIG. 2 is a general block diagram of a data processing system embodying the present invention;
FIG. 3 (which includes FIGS. 3a-3c) is a diagram of the move instruction flow utilized in the present invention;
FIG. 4 is a schematic diagram of circuitry utilized in the data processing system of FIG. 2 and designed to carry out the move instruction shown in FIG. 3 in accordance with the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
In FIG. 1 the words which provide for the implementation of the move instruction of the present invention are illustrated. More specifically, FIG. 1a shows the first word of move instruction 100 utilized in the present invention. In FIG. 1a, the first eight bits specify and operation code, i.e., OP code that has a particular bit designation which when decoded identifies the move instruction. The next 4 bits, bits 8-11 are shown as MBZ which indicates these bits must be zero. Bits 12-31 identify the first address syllable which is a logical representation of the source field operand in memory.
For the particular type of operation utilized herein the address syllable has its first bit, i.e., bit 12 set to a binary ONE. This bit is utilized to specify the indirect addressing mode which accesses data field descriptors as shown in FIG. 1c via the mechanism cited in co-pending application to Charles W. Bachman for Data Processing System Utilizing Data Field Descriptors for Processing Data Files. The retrieval and development of the data field descriptors will not be explained herein since a comprehensive description has been made in the above application.
For the move instruction, two address syllables are required since the attributes of the source and the destination must be known. Thus the first address syllable, AS1, i.e. bits 12-31, specifies the logical operand of the source as provided by the user and brought into a memory location; and the second address syllable, AS2, i.e. bits 44-63, specifies the logical operand of the destination.
Each address syllable AS1 and AS2 for a move instruction references a data field descriptor, as shown in FIG. 1c as words 102, 104, and 106. Words 102 and 104 will eventually be stored in the general registers designated in FIG. 1b as bits 32-39. In the second word of instruction 100, bits 32-35 designate a first general register corresponding to the first address syllable; bits 36-39 designate a second general register which holds the information developed by the second address syllable. The second address syllable is shown as bits 44-63 which like address syllable AS1 develops by indirection words a data field descriptor in FIG. 1c.
A data field descriptor may include up to three words shown as words 102, 104 and 106. Word 102 is a data descriptor which has a tag field for its first two bit locations. This tag field has a code 01 which indicates that an additional word(s) is part of the descriptor. This additional word(s) is an extended data descriptor 104 which may indicate another word 106 to be subsequently explained. Word 102 also contains a segmented address indicated as STE, STN and displacement. These fields locate the operand, i.e. data field, which the extended data descriptor describes. The segmented address development is fully described in the Segmented Address Development application previously cited. Any of the indirect addressing structures may be used since word 102 is merely illustrative of one indirect addressing mechanism.
Word 104 is an extended data descriptor which contains descriptors particularized to the operand. These descriptors are decoded by the circuitry to be subsequently explained such that high overall performance for the move instruction is realized. More specifically, in word 104, bits 32-34 identify a bit string which offers the user the capability of compacting information on his files in the form of bit strings. Bit 35 must be zero. Bits 36-38 specify an array field which defines array control of the operand. By array control is meant that more than one operand is located in the data field pointed to by the address syllable. If the value of bit 36 is a binary ONE, word 106 having a length and size field is accessed in order to determine the location of the particular operand and its size in the array field.
Bit 39 of the word 104 specifies an alterability indicator. If the alterability indicator is present, i.e., if the bit is a binary ONE, the operand in the source field as described by the data field descriptors may be written into the operand pointed to by the destination.
Bits 40-63 of word 104 specify the data field descriptors identifying characteristics of the data. More specifically, bits 40-47 specify the data type. By data type is meant a description of certain features of the format of information as provided from a user. For example, a binary code of certain value could indicate alphanumeric string; unpacked decimal; packed decimal; and other various formats of information. For purposes of the move instruction, four groups will be distinguished. The first group is the alphanumeric string format whereby field-to-field transformations occur. The second group includes unpacked and packed decimals which are changed to the receiving field configuration; the third group concerns additional formats which must be translated to the receiving fields description; and the fourth group concerns those formats unavailable for translation purposes and requiring an exception condition to invoke another mechanism. Translation is provided by well known means such as programmable read only chips (PROM). Depending upon the data processor, the following data types may, at least, be classified in group three: character strings, unsigned short binary data, signed short binary data, unsigned long binary data, signed long binary data, short logical binary data, long logical binary data. Obviously, as other data formats are introduced, translation tables may be provided for them.
Bits 48-55 define the key field of the operand. The key field is a description of certain features for a particular data type, i.e., a description of the form of information which the user has provided. As a result, the key field provides a secondary imposition of requirements on the data type. For example, if pounds per square feet were to be moved from a source field to pounds in a destination field, the key would indicate that such an operation was not allowable. Thus, even if data types are compatible, some conversion may be required if unequal key fields are presented.
Bits 56-63 of word 104 are an 8 bit length description of the operand pointed to by the address syllable. The length description indicates the number of bytes in the operand. The operand's length may meet the following condition: first, for a byte string the length must be less than or equal to 256 bytes; second, for a decimal string, the length must be less than 32 digits. If the length exceeds these limits, an illegal data exception results.
FIG. 1c shows word 106 containing bits 64-79 specifying a length indication and bits 80-95 specifying a size indication. Each of these is used when the array bound index of bits 36-39 of word 104 is present. A detailed explanation of these fields is given in the Charles W. Bachman patent application previously cited as related Application No. 3. In order to simplify the description of the invention, the mechanism provided by this word 106 to obtain the data is not explained herein.
The explanation of the operation of the instruction 100 as shown in FIGS. 1a and 1b and the data field descriptors resulting from the address provided by instruction 100 as shown in FIG. 1c will be better understood when viewing the block diagram of FIG. 2 which shows a data processing hardware system which utilizes the invention.
Referring to FIG. 2, a main memory 201, is comprised of four modules of metal-oxide semiconductor (MOS) memory. The four memory modules 0-3 are interfaced to the central processor unit 200 via the main store sequencer 202. The four main memory modules 0-3 are also interfaced to the peripheral subsystem such as magnetic tape units and disk drive units (not shown) via the main store sequencer 202 and the input/output controller, IOC 220. The main store sequencer gives the capability of providing access to and control of all four memory modules. Because the memory store sequencer 202 can overlap memory cycle request, more than one memory module 0-3 may be cycling at any given time. The CPU 200 and the buffer store memory 204 and the IOC 200 can each access a double word (8 bytes) of data in each memory reference. However, in a CPU memory access, either the four high-order bytes or the four low-order bytes are selected and only four bytes of information are received in the CPU 300.
Operations of the CPU are controlled by a read only memory ROM, herein called the control store unit 210. (Control store units for implementing the invention are found in a book entitled Microprogramming: Principles and Practices, by Samir S. Husson and published in 1970 by Prentice-Hall Inc. Other typical control store units are described in U.S. Pat. to Leonard L. Kreidermacher, having U.S. Pat. No. 3,634,883 issued Jan. 11, 1972, and assigned to Honeywell Inc.). Each location in the control store memory 210 can be interpreted as controlling one CPU cycle. As each location of control store is read, its contents are decoded by a micro-op decode function. Each micro-op decode function causes a specific operation within the CPU to take place. For example, control store data bits 1, 2, and 3 (not shown) being decoded as 010 could bring high a micro-op decode function that causes an A reqister (not shown) to a B register (not shown) transfer. Because each control store memory location may contain 30 to 80 bits, many micro-op decode functions can be brought high for each control store cycle.
By grouping locations, control store sequencers are obtained that can perform a specific CPU operation or instruction. As each instruction is initiated by the CPU 200, certain bits within the op-code are used to determine the control store starting sequence. Testing of certain flops (not shown) which are set or reset by instruction decode function allows the control store memory to branch to a more specific sequence when necessary.
The control store interface adapater 209 communicates with the control store unit 210, the data management unit 206, the address control unit 207 and the arithmetic logic unit 212 for directing the operation of the control store memory. The control store interface adapter 209 includes logic for control store address modification, testing, error checking, and hardware address generation. Hardware address generation is utilized generally for developing the starting address of error sequences or for the initialization sequence.
The buffer store memory 204 is utilized to store the most frequently used or most recently used information that is being processed by the CPU 200. The buffer store memory is a relatively small, very high speed memory which contains 128 columns and 2 rows, referred to as the upper row and the lower row. It is logically divided into preset blocks which are uniquely addressable. These blocks are called pages and each page of memory contains 32 bytes of information. A particular page may be addressed by the most significant 16 bits of the main memory address, the least significant five bits being used to address a particular byte of information within the page. Pages may be transferred from main memory to buffer store memory with a column assignment maintained--i.e., a page from a column one in main memory is always transferred into column one in the buffer store memory. However, whether the information is placed on the upper or lower row of the column depends on availability. Therefore, for each column of main memory pages (for instance for a system having 256K to 2 megabytes in main memory, these would be 64 to 512 pages), there are two pages in buffer store. For example, column 37 in main store may contain any two pages of information from column 37 in main memory. The two pages of information contained in the buffer store column at any given time depend on which pages have been most recently accessed by the CPU--i.e., the two most recently accessed pages typically reside in the buffer store memory 204.
Whether a given page of information is contained in buffer store 204 can be determined only by examining the contents of the buffer store directory 205. The buffer store directory is logically divided in the same manner as buffer store, however, instead of pages of information, each column in the buffer store directory 205 contains the main memory row address of the corresponding information in the buffer store 204. For example, if column 0 of buffer store 204 contains page 20 in the lower row, the buffer store directory contains 10100 and 00000 in the lower and upper row respectively. Thus, by accessing the buffer store directory 205 with the column number and comparing the requested row number with the row number contained in the buffer directory location, the CPU can determine whether a given page is contained in buffer store.
The data management unit 206 provides the data interface between the CPU 200 and main memory 201 and/or buffer store memory 204. During a memory read operation, information may be retrieved from main memory or buffer store memory. It is the responsibility of the data management unit 206 to strobe the information into the CPU registers at the proper time. The data management unit also performs the masking during partial write operations.
The instruction fetch unit 208 which interfaces with the data management unit 206, the address control unit 207, the arithmetic and logic unit 212 and the control store unit 210 is responsible for keeping the CPU 200 supplied with instructions. The unit attempts to have the next instruction available in its registers before the completion of the present invention. To provide this capability, the instruction fetch unit 208 contains a 12-word instruction register (not shown) that normally contains more than one instruction. In addition, the instruction fetch unit, under control of the control store 210, requests instructions from main memory 201 before the instruction is actually needed, thus keeping its 12-word instruction register constantly updated. Instructions are thus prefetched by means of normally unused memory cycles. The instruction fetch unit also decodes each instruction and informs the other units of the instruction's length and format.
The address control unit 207 communicates with the instruction fetch unit 208, the buffer store directory 205, the main store sequencer 202, the arithmetic logic unit 212, the data management unit 206, and the control store unit 210 via the control store interface adapter 209. The address control unit 207 is responsible for all address development in the CPU. All operations of the address control unit, including transfers to, from and within the unit, are directed by control store micro-ops and logic in the unit. The normal cycling of the address control unit depends on the types of addresses in the instruction rather than on the type of the instruction. Depending on the address types, the address control unit may perform different operations fro each address in an instruction.
The address control unit 207 also contains an associative memory that typically stores the base address of the eight most recently used memory segments, along with their segment numbers. Each time a memory request is made, the segment number is checked against the associative memory contents to determine if the base address of the segment has already been developed and stored. If the base address is contained in the associative memory, this address is used in the absolute address development, and a considerable amount of time is saved. If the base address is not contained in the associative memory, it is developed by accessing the main memory tables. However, after the base address of the segment is developed, it is stored in the associative memory, along with the segment number, for future reference.
Interfacing with the address control unit 207, the instruction fetch unit 208 and the control store unit 310 is the arithmetic logic unit 212 which is the primary work area of the CPU 200. The arithmetic logic unit's primary function is to perform the arithmetic operations and data manipulations required of the CPU. The operation of the arithmetic logic unit is completely dependent on control store micro-ops from the control store unit 210.
Associated with the arithmetic logic unit 212 and the control store unit 210 is the local store unit 211 which may be comprised of a 256-location (32 bits per location) solid state memory and the selection and read/write logic for the memory. The local store memory 211 is used to store CPU control and maintainability information. In addition, the local store memory 211 contains working locations which are primarily used for temporary storage of operands and partial results during data manipulation.
The central processing unit 200 typically contains eight base registers located in arithmetic logic unit 212 which are used in the process of address computation to define a segment number, an offset, an a ring number. The offset is a pointer within the segment and the ring number is used in the address validity calculation to determine access rights for a particular reference to a segment.
The IOC 220 is the portion of the central processor subsystem that completes a data path from a number of peripheral subsystems to main memory. It provides the path through which peripheral commands are initiated, and it controls the resulting data transfers. The IOC can handle a maximum of 16 channel control units, and each channel control unit can accommodate one peripheral control unit. It is these peripheral control units which provide to the central processing subsystem the user's data base files.
Referring now to FIG. 3 there is shown a flow diagram of the move instruction. FIG. 3 when read in conjunction with FIGS. 2 and 4 explain the overall operation of the system. FIG. 4 is a schematic diagram which shows the transfers and manipulations of the data by the move instruction at the system level. When read in conjunction with FIG. 3 showing the flow chart, the operation and procedure incorporated in the move instruction will be understood.
Since the present invention pertains to data processing systems, the description thereof can become very complex. To prevent undue burdening of the description with matter within the knowledge of those skilled in the art, a block diagram approach has been followed, with a functional description of each block and specific identification of circuitry it represents. The individual engineer is free to select elements and components such as flip-flop circuits, shift registers, etc. from his own background as from available standard references such as "Arithmetic Operations in Digital Computers", by R. K. Richards (Van Nostrand Pulbishing Company), "Computer Design Fundamentals" by Yaohan Chu (McGraw-Hill Book Company, Inc.) and "Pulse, Digital and Switching Waveforms", by Millman and Taub (McGraw-Hill Book Company, Inc.). Moreover, the details of the mechanism responsive to the micro-operations for move instructions are not shown since they are well known to those of ordinary skill in the art.
It should be noted that FIG. 3 is a detailed flow diagram of step 432 of the Charles Bachman patent application previously cited on Page 2 as reference No. 5, and is one of the general purpose logical instructions which may be executed. As a result at this time, the instruction 100 shown in FIGS. 1a and 1b is stored in an instruction register 400 of the instruction fetch unit 208 shown in FIG. 2. The move operation code has been detected by control store interface adapter 209 which in turn enables control store unit 210 to provide for a series of tests upon the data and data field descriptors of both the source data and the destination. These tests are generated by microinstructions from the control store unit 210. The results of these tests are detected by control store interface adapter 209 which, depending on the tested results, may modify the next microinstruction such that a related microinstruction incorporated the detected condition is generated.
The interconnection of the control store unit 210 and the control store interface adapter 209 provides a micro-branch technique wherein the signals received by the control store interface adapter are translated into a direct address in the control store unit 210. The operation resulting establishes a direct path for subsequent data transfers taking into account the previously detected conditions. This sequence of events occurs for each diamond illustrated in FIG. 3 and is not hereafter described in any detail. (For a further explanation of this operation, reference to the U.S. Pat. No. 3,634,883 issued to Leonard Kreidermacher, Jan. 11, 1972, and U.S. Pat. No. 3,560,993 issued to Scott Schwartz on Feb. 2, 1971, both assigned to the same assignee as this invention, should be consulted.)
Prior to start step 300, the instruction 100 is processed so as to provide the data field descriptor and the data field. While there are many alternative methods for indirect address development (see, for example, U.s. Pat. No. 3,412,382, issued to Couleur et al on Nov. 19, 1968), a preferred method is as follows.
Each address syllable contains a predetermined bit field which identifies a base register located in arithmetic and logic unit 212. This base register contains a segment number and an offset. The segment number references a table which provides a descriptor locating the segment storing the data descriptor desired. To idenfify this data descriptor, the offset provided by the base register is added to the displacement field in the address syllable.
The data descriptor may contain up to three words as shown in FIG. 1c. This is initially determined by testing the tag field of word 102 which has now been fetched. If the tag field has a 01 encoding, it is known that there is at least one additional word, i.e., word 104. After fetching word 104, bits 36 to 38 are tested to determine if word 106 should also be fetched.
Word 102 is utilized to identify the location of the operand desired whereas words 104 and 106 identify the attributes of the operand located from word 102.
Word 102 is developed exactly as the address syllable. Thus, a base register is located, the base register having a segment number and an offset. After the segment number is referenced to a table to provide a segment descriptor locating the segment containing the operand, the offset in the base register is added to the displacement of word 102 thus identifying the exact location of the operand within the segment. All the computations described are performed in the authentic and logic unit 212 in a well known manner.
To summarize the development of the data field descriptors and the operand, the address syllable of the instruction in conjunction with a base register is used to locate the data field descriptors 102 to 106. Word 102 is then utilized in conjunction with another base register to locate the particular operand desired. Words 104 and 106 describe the attributes of the operand so located.
At start step 300 in FIG. 3, the attributes of the data field descriptors (i.e., word 104, and word 106, if necessary) have been tested with the following results. The data types are legal and have been determined to be compatible and the key fields are known to be identical. After testing, data field descriptors associated with the first and second address syllables are stored in working registers 406 in the local store unit 211.
In step 302, the AC register 408 contains word 104 associated with the source operand and the AD register 410 contains word 104 associated with the receiving operand. A selection mechanism 428 selects the length byte, i.e., bits 56-63 from both AC register and AD register and transfers them to the AA register 412 and the AB register 414 respectively. The selector mechanism 428 acts on any byte in the AC or AD registers. This can be accomplished by shifting the contents to predetermined locations or by merely selecting any bit positions contained within the register. The selector mechanism is not shown in detail since not only is it well known in the art, but also to describe it would unduly burden the description herein.
In step 304 the length attribute of the first address syllable is tested to determine whether or not it is zero. This is accomplished by subtracting via the AG register 420 a constant from the length attribute contained in register 412. The zero constant is loaded under control of control store unit 210. Since it is assumed that every field referenced has a length, if a zero is obtained from the subtraction, the actual length is 256 bytes long. Thus if a zero result is tested, the control store unit 210 loads all binary ONES into the AA register 412 in step 306.
For step 308 the same test is performed on the length attribute of the receiving operand. This length value indicates the space required to be reserved for the operand in the destination field. Step 308 corresponds to step 304 except that the constant loaded in AG register 420 is subtracted from the AB register 414 via calculator 422. At this time, the length for each of the operands involved in the move operation is known.
In step 312 a determination of the data type of the source data and the destination data is made. Depending upon the data type, branches to the different microinstructions in the control store unit 210 are made. In step 312, the ascertaining of the data types is made by transferring the bytes of each data type into the AA and AB registers, respectively, via the selector mechanism 428 operating on registers 408 and 410. The data type of the source data stored in AA register 412 is then ascertained via subtraction from a constant loaded into the AG register 420 by control store unit 210. If the testing of the result indicates that the data type is an alphanumeric string, then a branch to step 316 occurs. If the tests indicate that the data type is a packed or unpacked decimal, then a branch to step 318 occurs; and if the data type is neither an alphanumeric string nor a packed or unpacked decimal, then a branch to step 320 occurs. Each of these microbranches initiate a sequence of steps to control the transfer of data to the destination. Thus, in step 314, the testing of the data type is made. Since it has been previously ascertained that the data types are compatible, only the first data type need be ascertained to determine the branch to be taken.
For purposes of discussion, it is assumed that a packed or unpacked decimal number has been determined as the data type. Upon sensing this condition, a branch to step 318 is executed and the following steps are sequenced by microinstructions of the control store unit 210 on the packed or unpacked decimal.
In step 318, the length descriptor is restored to the AA register 412 associated with the source data, i.e., the first address syllable. Since a decimal string must be less than 32 digits, the length byte is tested to see whether this requirement is fulfilled. If upon subtraction from a constant 32 loaded in the AG register 420, a less than zero condition is realized, step 321 is executed. If the subtraction results in a positive number, then an illegal data exception in step 322 is executed. This step enables an exception routine which indicates that the data is incorrect. Since is is unusual that a number would be greater than 32 digits, step 321 follows. In step 321 the same test has occurred for the length data field descriptor associated with the destination data.
In step 324, a determination of whether the source data has a legal representation is made. Since the destination data represents the transfer of legal source data, no corresponding step for the destination data is required. For a decimal number, the determination of legality involves a testing of whether the source data representation contain binary numbers greater than 1001, i.e., the four bit binary number must not have a value greater than 1001 which corresponds to a decimal 9 and whether the sign binary number is less than 1010.
A packed decimal number is a series of contiguous bytes in main storage containing a sign and magnitude representation of a decimal interger. Each byte contains two four bit digit encodings except for the rightmost byte which contains a four bit digit encoding and a four bit sign encoding. In a packed decimal number, digit encodings of 1010 to 1111 and sign encodings of 0000 through 1001 are illegal.
An unpacked decimal number is a series of contiguous bytes in main storage containging a sign and magnitude representation of a decimal interger. Each byte contains a four bit digit encoding and a four bit zone except the rightmost byte which contains a digit and sign encoding. The zones encodings of each byte of the unpacked decimal are not tested by the control store unit 210. The representation of an unpacked decimal number is illegal if, as with a packed decimal, either a digit encoding or a sign encoding is illegal.
After step 324, control store unit 210 executes microinstructions to compare the source operand data type to the destination operand data type. As a result in step 326, a multibranch situation from the comparison results. This step is accomplished by subtracting the value of the data type associated with the source operand from the data type associated with the destination operand. The result of the subtraction is a number which enables the multibranch operation to occur. Thus, if the source data is unpacked decimal and the destination data is packed decimal, a branch to step 328 occurs. If the source data is packed decimal and the destination data is unpacked decimal, a branch to step 330 occurs. If the source data and the destination data are the same, step 332 is executed.
For step 324 and for steps 328, 330 and 332, the accessing of main memory to obtain the source operand is performed. This is accomplished as follows. The main memory location as determined from the first address syllable is developed into a data descriptor which identifies the proper memory location. That data is then fetched from memory into the DN register 402 of the data management unit 206. The data is then transferred into the working registers 406 of local control unit 211. When the successive bytes have been accessed from memory, and the length field reduced to zero, the transfer of information from main memory is halted. With the information now located in the working store registers 406, transfer under micro-operation control is then made to the AC or AD registers as is necessary. For the transfer of the data to the destination register, the physical configuration of the data processing system limits the number of bytes transferred at a given moment. For the system described in FIG. 2, this would be 2 bytes at a time.
In step 328, a translation from unpacked to packed decimal is executed. This is accomplished by taking the digit representation and eliminating the zone of the unpacked decimal byte. In the last byte of the unpacked decimal, the four bit binary digit and the four bit binary sign are interchanged thus allowing a correspondence of form to the packed decimal representation. With the source data in packed format and the destination data requiring the packed format, the execution of step 332 is a mere transferral of the information into a destination location determined by the data processor.
For step 330, conversion from a packed decimal format to an unpacked decimal format is accomplished. This results by adding a four bit zone to each decimal representation in the packed format and by exchanging in the last byte the location of the digit and sign encodings. Thus, the source data is in an unpacked format. In step 332 a transferral of the data to the destination location is accomplished with the information remaining unchanged.
The reformatting of the data from packed decimal to unpacked decimal or vice versa is accomplished by utilizing the AG register to provide the zone constant. If the packed decimal to unpacked decimal reformatting is to be executed, the calculator 422 is set to add by the control store unit 210. The digit encoding is provided in the lower four bits of the byte and the zone encoding is provided in the upper four bits of the byte. The addition operation then provides the unpacked decimal format and stores the result in local store unit 211. If the opposite situation is presented, i.e., the reformatting is from unpacked decimal to packed decimal, then a transfer of the lower four bits to working registers 406 is made with the higher four zone bits discarded. Obviously, many other variations for providing the reformatting of packed and unpacked decimals may be implemented by those of ordinary skill in the art.
Since the source data and the destination data may have different lengths, step 334 indicates which length is greater. If the source data has been transferred and there is additional space according to the destination length, then extension of the source data by the addition of zeros is made. These zeros are added to the high ordered part of the number and hence no modification of the number is made. If there remains source data to transfer, but there is no space available according to the destination length indication, then the remaining bytes are truncated, i.e., the data is not transferred. Steps 336 to 344 enable the setting of condition codes to indicate whether the digits of truncated source data is significant, i.e. whether they were non-zero. If there were non-zero digits lost which is determined by a test of the remaining digits in the source data, control store unit 210 in step 338 sets the condition code in the status register 418 to a binary TWO.
Subsequently in step 340, a test is made as to whether the truncated non-zero digits are significant to the integrity of the data. This is accomplished by means (not shown). If these digits were significant, then a decimal overflow exception would be executed such that the truncated portion of the source data would be handled.
If there were no loss of non-zero digits or if there was no truncation involved, step 344 would be executed. The control store unit 210 sets the status register 418 to a binary ZERO before ending the present instruction and initiating the next instruction.
In step 314, it was determined that the source data was a decimal. However, if the source data was an alphanumeric string, a branch to step 316 is executed.
In step 317 as shown in FIG. 3b, comparison of the data type of both the source and destination data is made. This is accomplished by subtracting the data types from each other. If the data types are unequal, a branch to step 320 is made. If the data types are equal, i.e., if the result is zero, control store unit 210 executes microinstructions shown as steps 350 to 368.
In step 350 it is known that both the source data and the destination data are alphanumeric strings. In step 350 the length byte of the data field descriptor associated with the second address syllable, i.e., L2, is subtracted from the length byte of the data field descriptor associated with the first address syllable, i.e., L1. The result determines whether a branch to step 352 or to step 354 is executed. Regardless of the result, two temporary registers in working registers 406 are utilized. A first temporary register, hereinafter referred to as N, stores the minimum length description. A second temporary storage register hereinafter referred to as Y, stores the number of zeros which are added to the destination data.
If the length of the destination data is less than or equal to the length of the source data, i.e., if a zero or negative number is sensed by control interface adapter 209, a branch to step 352 is executed. With this situation, control store unit 210 sets the N register to the length of the L2 field. Since the receiving field is not greater than the source field, no blank characters, i.e., binary zeros are added. As a result, the Y register is set to a binary zero. If a positive number is sensed by control interface adapter 209 in step 350, then a branch to step 354 is executed. In step 354 the contents of the length L1 are transferred to register N and the remainder value from calculator 422 is transferred into the Y register. Thus the Y register indicates when it is necessary to stop the blank characters from being added to the destination data.
In step 356, the temporary location of the source and destination data is specified. This is shown by the address X1 which points to the source data in main memory and the address X2 which points to the place in main memory where the data will be written, being changed to S1 and S2, respectively. S1 indicates the address of the source data in the working registers 406 and S2 indicates the address to store the transferred data in working registers 406.
In step 358, control store unit 210 enables micro-operations which transfer the contents of the S1 registers to the S2 registers, one byte at a time. The number of bytes as indicated by the value stored in the N register is then decremented by one thus indicating how many additional bytes are to be transferred. This is accomplished by subtracting one via a constant in the AG register from the N register value transferred and stored in AA register 412. Thus the N-1 value is now stored in the N register. The address of the byte to be transferred, i.e., S1, is incremented by one since the next byte of the source data must be address. The micro-operations which perform this addition step have been previously described.
In step 360, the address of the next byte to be received, S2, is incremented by one since the data is stored consecutively in the working registers 406. This is shown as the S2 address becoming the S2+1 address. Thus, the registers are now set up so that the next byte of the data may be transferred.
After the contents of one byte have been transferred and the various registers set up to indicate the next data byte to be transferred, step 362 tests whether or not the minimum length field, i.e., the minimum of either of the L1 source field or L2 destination field, has been transferred. If this has not occurred, a looping back to the actual transferral step, i.e., step 358 is executed. If the minimum length has been transferred, then the value of the Y register is tested to determine whether any blank characters should be added to the destination registers. This is shown in step 364.
If the value in the Y register is unequal to a zero, and the value of the N register is presently zero, then blank characters are added to the destination data, i.e., S2, and the value of the contents contained in the Y register are decremented by one as shown in step 366. This can be accomplished by loading a one in the AG register 420 and subtracting the contents of the Y register which is contained in the AB register 414. The results from calculator 422 of byte adder 416 are then stored back into AB register 414. Upon adding a blank byte to the destination data, the address S2 is incremented again as shown in step 360. This process continues until the value in the Y register is zero. At this time, step 368 is executed which sets a condition code in the status register 418 to a zero and initiates the next instruction.
If at step 314 the data type was neither an alphanumeric string nor a packed or unpacked decimal, a branch to step 320 FIG. 3c is executed. In step 320 it is recognized that the destination data requires a translation of the source data. For this operation, a number of translation devices have been provided on programmable read only memory chips. These translation devices 424 receive an eight bit input of the source data as stored in working area 406 and provide an eight bit output to working area 406 and eventually to the destination location. The output of the hardwired programmable read only memory chips provide the same information expressed, however, in the destination code.
If in the test provided by step 369 there is no translation device available, then step 370 is executed. Step 370 is a branch by the control store unit 210 to an unavailable translation table exception. This branch notifies a mechanism that no table has been provided and, as such, other means must be used. This other means is not disclosed herein.
Assuming that one of the translation tables 424 is provided, steps 372 through 378 are executed. In each of these steps, a temporary storage register is set up as was done in steps 350 to 360. Thus the lengths and addresses of the data are stored in temporary storage registers N1, N2, S1, S2 respectively. In step 380 a test is made of the destination length. If this is zero, i.e., if there is no further storage spaces for the source data, then a condition code in status register 418 is set to zero and the translation process is completed. Usually, however, the destination length is greater than zero, so step 384 is executed.
If the source length as tested in step 384 is equal to zero and the destination length is not equal to zero as tested in step 380, the destination data must have its remaining length filled by blank bytes. This is shown in step 394. Once a blank byte field has been added, the destination length and address are decremented and incremented, respectively, and the above steps are repeated.
If the source length is not equal to zero, and the destination length is not equal to zero, then step 386 is executed. In step 386, the prom chip 424 enables the contents of the source data to be translated. The output of the prom chip is then provided in step 388 to temporary storage register, S2, in the code specified by the destination data. These codes are well known to those of skill in the art and need not be shown herein. Steps 390, 392, 396, and 398, account for the total number and addresses of bytes to be transferred as was previously explained.
When the destination length is equal to zero, the entire operation is terminated and the next instruction is executed. This occurs whether or not the source data has been fully transferred. If this condition exists, the source data to be transferred is lost.
Although it has been shown, described and pointed out the fundamental novel features of the invention applied to the preferred embodiment, it is understood that various omissions, substitutions and changes in the form and details of the device illustrated in this operation may be made by those skilled in the art without departing from the spirit of the invention. For example, the move instruction described in the prior art may be combinable with the move instruction disclosed herein such that either the source or destination field is described in the instruction itself and the other field is described at execution time by the data field descriptor. This would provide a hybrid situation wherein one portion of the instruction is logical using a data field descriptor and the other portion is structured at compilation time.
A variation of the basic move instruction may be provided by a change in the operation code. One example of this specialized move instruction would involve changing the data field descriptor of the destination field. Thus, both the data field and the data field descriptor would be moved with the data field being essentially preserved but with the data field descriptor of the destination being reformatted since it is now the same as the source field's data field descriptor. This specialized move instruction would be useful when a new format for the data fields is desired. It provides the flexibility needed to easily alter the configurations of the data fields on a day-to-day basis. Moreover, this specialized move instruction would find applicability wherein movements of the data fields is within the data processor itself, and it is desired to keep the original form of the data.
It is the intention, therefore, to be limited only as indicated by the scope of the following claims. | Apparatus for utilizing a logical, record oriented move instruction is disclosed. By utilizing separately maintained data field descriptors which define the attributes of the data, the move instruction is able to transfer a multitude of different data types. From a source operand the logical instruction transfers data field by field to the destination. At the time of transfer, the logical move instruction reformats the data to meet the destination's description. The move instruction is applicable both to removing data from a data file and to restoring data into the data file. | 53,409 |
TECHNICAL FIELD
The present invention relates to atomic frequency standards and in particular to atomic frequency standards including a resonance cavity, storage means in the resonance cavity for the storage of atomic or molecular elements, and heating means to supply heat to the resonance cavity.
BACKGROUND OF THE INVENTION
Atomic frequency standards are devices characterised by very precise and accurate frequencies of operation, the basic resonance system of which is an atom or a molecule experiencing a transition between two well defined energy levels. The general principle of operation of frequency standards is described in the book "The Quantum Physics of Atomic Frequency Standards" by J. Vanier and C. Andion, published by Adam Hilger, Bristol and Philadelphia, 1989.
Embodiments of atomic frequency standards using a gas cell and a maser are described in Swiss Patent no. 640 370 and U.S. Pat. No. 4,316,153 respectively.
In order to illustrate the operation of a known atomic frequency standard, there will now be described an atomic frequency standard employing a gas cell having reference to FIG. 1 of the accompanying drawings.
The frequency standard shown schematically in FIG. 1 comprises essentially an atomic resonator 10, a crystal oscillator and associated frequency multiplier or synthetiser circuitry 11, and a feedback circuit 12. The atomic resonator 10 consists principally of a lamp 13, a filter cell 14, a microwave cavity 15, an absorption cell 16 and a photoelectric cell 17. A power supply 18 provides the energy necessary to drive the oscillator and associated circuitry 11, lamp 13 and control the temperature of the various components of the atomic resonator 10. A conventional heating coil 18a is supplied from and controlled by a power supply circuit 18.
Another power supply circuit 19 provides power to supply a magnetic field to the microwave cavity 15 via a coil 19a. Further, the microwave cavity 15 is surrounded by a magnetic shield 20b to block external magnetic fields from influencing the operation of the atomic resonator 10.
In the atomic frequency standard shown in FIG. 1, there is produced by optical pumping a population inversion between the hyperfine levels of the ground state of the atoms which are generally alkali metals such as potassium, sodium or rubidium. In the case of a frequency standard using rubidium, a standard optical pumping arrangement as will now be described is used.
The absorption cell 16 contains the isotope rubidium 87 the spectrum of which comprises the two hyperfine components A and B, and an appropriate buffer gas such as nitrogen. The absorption cell 16 is illuminated by the rubidium 87 lamp 13 through the filter cell 14 which contains a rubidium 85 vapour, the absorption spectrum of which contains the hyperfine components a and b. The components A and a exist practically in coincidence whilst the components B and b are completely separated. The component A of the emission spectrum of the lamp 13 is therefore essentially eliminated by the filter cell 14 so that the light which reaches the absorption cell 16 is predominantly constituted by light at the frequency of the component B. Only the atoms of the rubidium 87 of the absorption cell 16 situated in the lower hyperfine level (F=1) absorb light and are transported into higher states.
After the rubidium atoms in the absorption cell 16 have been thus excited, they relax to either the upper hyperfine level (F=2) or to the lower hyperfine level of the ground state by collisions with nitrogen molecules of the buffer gas. Since these atoms are immediately excited by the arrival of the light, the lower level (F=1) is depopulated to the benefit the upper level (F=2). Because of this asymmetry in the pumping light, there is thus brought about a population inversion of these two levels and the absorption cell 16 becomes practically transparent to residual radiation from the lamp 13.
The absorption cell 16 is arranged in the microwave cavity 15 which is excited by the circuitry 11 to a frequency close to 6835 MHz, which frequency corresponds to the separation energy of the hyperfine levels F=1, m f =0 and F=2, m f =0 which brings about the hyperfine transition accompanied by the emission of electromagnetic radiation between these two levels. As soon as the atoms which participate in the stimulated emission arrive at the lower hyperfine level (F=1), they are optically pumped and transported into the excited states.
During this process, the magnetic shield 20b reduces the ambiant external field to a low level, and a small, uniform, axial magnetic field is produced by the magnetic field coil 19a driven by the power supply circuit 19. The magnetic field thus produced in the absorption cell 16 displaces the energy values of the hyperfine levels according to the known Zeeman effect and therefore adjusts the exact frequency of the electromagnetic radiation emitted in the above described stimulated emission.
The greater the number of stimulated emissions, the greater will be quantity of light absorbed in the absorption cell 16 and the smaller will be the quantity of light arriving at the photoelectric cell 17. The current produced by the photoelectric cell 17 is therefore at a minimum when the frequency of the excitation signal of the microwave cavity 15 is at the transition frequency.
The quartz oscillator 21 of the circuitry 11 produces a signal at 5 MHz, which is modulated in a phase modulator 22 to a relatively low frequency (about 100 Hz to 1 kHz) produced by a low frequency generator 23. The modulated signal is applied to a multiplier/synthesizer 24 to obtain a signal having the stimulated emission frequency of 6835 MHz. It is this signal which is employed in order to excite the microwave cavity 15.
The signal furnished by the photoelectric cell 17 is received by an amplifier 25 of the feedback circuit 12, then applied to a phase comparator 26 which also receives a reference signal from the generator 23 of the circuitry 11 in a manner to bring about a synchronous detection enabling determination of whether the carrier frequency of the signal applied to the microwave cavity 15 is well centered on the hyperfine transition frequency (6835 MHz). Any shifting is indicated by an error signal at the output of the phase comparator 26. This signal is sent to an integrator 27, which is employed in order to control a Zener diode 28 coupled to the quartz oscillator 21 and which modifies the frequency of the latter so as to maintain the multiplied frequency of the quartz oscillator 21 centered onto the frequency of the hyperfine transition of the rubidium 87.
The stability and precision of the frequencies of operation of the atomic frequency standard of FIG. 1 depend upon the interaction of the atoms or molecules in the absorption cell 16 with the electromagnetic field in the microwave cavity 15 whilst the atoms or molecules is undergoing the above-mentioned stimulated emissions. The electromagnetic field in the microwave cavity 15 has essentially the same frequency and wave length as the atomic or molecular hyperfine transition radiation, and the physical size of the microwave cavity is related to the wave length of the radiation.
The stability and precision of the frequency of operation of the atomic resonator 10 also depend on good temperature control of the lamp 13, the absorption cell 16 and the filter cell 14. This is connected with the fact that the hyperfine transition frequency as interrogated by the multiplied frequency of the quartz oscillator 21 and detected by the light signal impinging upon the photoelectric cell 17 is influenced by the simultaneously occuring optical pumping process. The hyperfine transition frequency is slightly shifted depending on the spectrum and the intensity of the light absorbed, which is in turn a function of the temperatures of the lamp 13, filter 14 and the absorption cell 16. Furthermore, shifts in the hyperfine transition frequency due to collisions with the buffer gas are a function of the pressure and temperature of the rubidium 87 and buffer gas in the absorption cell 16.
In some prior art atomic resonators not requiring heating and/or temperature control of the atomic or molecular elements in the absorption cell, electrodes have been located circumferentially around the absorption cell within the microwave cavity in order to reduce the physical dimensions of the microwave cavity, and to intensify and orient the electromagnetic field in the region of the absorption cell within the microwave cavity. The resulting concentration of the electromagnetic field in the region of the absorption cell optimizes the filling factor and the quality factor of the microwave cavity resonator. The filling factor is the ratio of the total magnetic energy in the space occupied by the atomic or molecular elements in the absorption cell, to the total magnetic energy in the resonator; the higher the filling factor, the better the response of the atomic resonator. The quality factor is given by the ratio of the frequency of the considered resonant mode of the cavity to its resonance line-width and determined by the ratio of the energy stored to the power lost via the cavity.
The electrodes of such prior art resonators however are bonded to the absorption cell, and secured in position relative to each other by the use of a fixative such as an appropriate resin. The dielectric properties of the fixative used diminish the intensity and uniformity of the electromagnetic field in the region of the absorption cell. They are furthermore electrically and thermally insulated from the cavity walls and are designed according to design equations which rely upon this electrical and thermal separation.
Such electrodes also provide a thermal mass within the microwave cavity which makes accurate control of the temperature of the microwave cavity, and the absorption cell within, more difficult. The electrodes act to block the transfer of the heat from the walls of the microwave cavity to the interior of the cavity and to the absorption cell located thereat thereby reducing the thermal response time of the atomic resonator, and storing and subsequently radiating heat when it is desired to reduce the heating in the microwave cavity.
In prior art atomic resonators, it is further necessary to provide energy to heat not just the contents of the absorption cell where the temperature is important but also the other areas in the microwave cavity where accurate control of temperature is not required.
In addition, the fact that areas of the microwave cavity other that the absorption cell are being heated means that initially the warm-up time of the prior art atomic frequency standards is greater than desired.
SUMMARY OF THE INVENTION
The object of the present invention is to provide an atomic frequency standard which alleviates or overcomes at least some of the disadvantages present in the prior art.
With this object in mind, the present invention provides an atomic frequency standard comprising a resonance cavity within an enclosure, storage means in said resonance cavity for the storage of atomic or molecular elements, field generation means to subject said storage means to a uniform oscillating magnetic field, state selection means for placing said elements in a preselected energy state, means for stimulating transitions from said preselected energy state to another preselected energy state at a predetermined frequency, and heating means for supplying heat to said enclosures, characterized in that at least one electrode is disposed about said storage means so as to thereby enhance said oscillating magnetic field of said stimulated transitions in the region of said storage means, said at least one electrode being connected to said enclosure by one or more thermally conductive members so as to thereby supply said heat to said storage means.
The following description refers in more detail to the various features of the present invention. To facilitate an understanding of the invention, reference is made in the description to the accompanying drawings where the atomic frequency standard is illustrated in a preferred embodiment. It is to be understood however that the atomic frequency standard of the present invention is not limited to the preferred embodiment as illustrated in the drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
In the drawings:
FIG. 1, already described, shows schematically an atomic frequency standard according to the prior art;
FIG. 2 is a cross-sectional side view of an atomic resonator for use in the atomic frequency standard of the present invention; and
FIG. 3 is a cross-sectional plan view of the atomic resonator of FIG. 2.
DETAILED DESCRIPTION OF THE INVENTION
The arrangement according to the invention of the atomic frequency standard as shown in FIG. 2 comprises essentially a lamp 40, an absorption cell 41, a microwave cavity 42 having a wall 43, a photoelectric cell 44, electrodes 45a to 45d and connecting members 47a to 47d.
The lamp 40 contains principally rubidium 87, or a mixture of rubidium 87 and rubidium 85, as well as an appropriate triggering gas such as argon. It is placed within an excitation coil 49, connected to cable 50, being the inductive load of a radio frequency oscillator having a frequency between about 100 and 150 MHz. A grid 51 is arranged about the assembly in order to avoid radiation of the signal towards the absorption cell 41 and the photoelectric cell 44.
A standard heating circuit (not shown) comprising a heating resistance and a temperature sensor is employed to maintain the lamp at a constant temperature, which may be 140° C.
The absorption cell 41 is placed facing the lamp 40. In the illustrated embodiment, the absorption cell 41 contains rubidium 85 and rubidium 87 as well as an appropriate buffer gas which may be nitrogen or a mixture of nitrogen and methane. It has, for example, a diameter of 14 mm and a length of 25 mm, giving an inner volume of approximately 3 cm 3 .
The atoms of rubidium 85 situated in the portion of the absorption cell 41 closest to the lamp 40 absorb the spectral component A of the latter which brings about filtering and the atoms of rubidium 87 located in the part of the absorption cell 41 furthest from the lamp 40 absorb the spectral component B of the latter, this bringing about the optical pumping required to select the state of the rubidium 87 atoms. Alternatively, an isotopic filter may be combined with an alkali source so that a lamp is provided which supplies pre-filtered light to the absorption cell 41. Yet another alternative is to use a diode laser as the light source, thereby removing the need for any filtering.
The microwave cavity 42 is protected from exterior magnetic fields by a magnetic screen 52. The microwave cavity 42 is subjected to a uniform magnetic field created by the winding 53, and a microwave frequency field created by a microwave loop 54 energized by an external oscillator via a connector 55 and a coaxial cable 56. The loop 54 may comprise an SRD (Step Recovery Diode) which multiplies the frequency of the signal furnished by the oscillator and which thus enables the use of a relatively low frequency oscillator.
The microwave cavity 42 is provided with a heating and temperature control means in order to maintain the temperature of the absorption cell 41 at its normal operating value, which may be 85° C. in the case of a rubidium 87 gas cell. Electric current may be provided in a bifilar wound heating wire 58 applied around the wall 43 of the microwave cavity 42, in order to supply heat to the microwave cavity 42. A temperature sensor 59 provides feedback to the heating and temperature control means in order to regulate the temperature of the microwave cavity 42.
The microwave cavity 42 is excited at a resonance frequency of 6835 Mhz, corresponding to the hyperfine transition frequency of the level F=2, m f =0 to the level F=1, m f =0 for the atoms of rubidium 87 in the absorption cell 41.
The absorption of the spectral component B by the atoms of rubidium 87 in the absorption cell 42 is detected by the photoelectric cell 44. This absorption signal is employed in a well known manner to slave the frequency of the interrogation signal emitted by the loop 54 to the hyperfine transition frequency of the level F=2, m f =0 to the level F=1, m f =0 of the rubidium 87.
The electrodes 45a to 45d are located about the absorption cell 41 about the longitudinal axis 57 of the absorption cell 41, and confine the oscillating magnetic field of the microwave cavity 42 to a desirable and uniform orientation with respect to the magnetically oriented rubidium 87 atoms in the absorption cell 41, as well as enhance the intensity of the field in the region of the absorption cell 41 so that optimum coupling occurs between the field and the atoms of rubidium 87 stored in the cell 41. It is to be appreciated that the electrodes 45a to 45d are merely illustrative of the electrodes which may be used and that other orientations of the electrodes about the absorption cell than that illustrated are possible. Any number of electrodes may be used around the absorption cell 41, and each electrode so used may vary in shape, size and spacing from the other electrodes.
The connecting members 47a to 47d join the electrodes 45a to 45d to the wall 43 of the microwave cavity 42 and support the electrodes in position fixed relative to each other, overcoming the need to use resin or other fixation means, which disturbs the uniformity and intensity of the oscillating magnetic field in the region of the absorption cell 42.
The connecting members 47 and 48 are made of thermally conductive material and preferably have a contacting surface contiguous to the electrodes, which surface is substantially equal to the surface of the respective electrode, in order to efficiently transfer heat supplied by the heating coil 58 from the wall 43 of the microwave cavity 42 to the electrodes 45a to 45d.
Preferably, the connecting members 47a to 47d fill almost the entire space between the external surface of the electrodes and the internal surface of the wall 43, which further enhances the heat transfer. The absorption cell 41 may thus be directly heated by the electrodes 45a to 45d, minimizing the warm-up time of the atomic resonator, reducing the attendant frequency error and providing for more accurate control and homogeneity of the temperature of the rubidium and buffer gas in the absorption cell 41. In addition, the power necessary to heat the absorption cell 41 may be reduced as the cell 41 only need be kept at the desired temperature rather that the whole microwave cavity.
In the presence of an appropriate oscillating magnetic field in the microwave cavity 42, the electrodes constitute a kind of peripheral electric circuit allowing a current to flow circularly within the electrodes, thereby characterizing a certain inductance. A peripheral electric current also flows between the electrodes about the longitudinal axis of the coil of the cell 41, thus defining a certain capacitance due to the dielectric gaps prevailing between the extremities of the electrodes. The appropriate positioning and dimensions of those electrodes affects the values of these capacitances and inductances, and may thus determine the dominant resonance frequency of the microwave cavity 42.
Due to these capacitances, a certain electric field is caused to be present between the gaps. The values of these capacitances, and-hence the resonance frequency of the microwave cavity 42, is thus affected by the dielectric value of the material through which this electric field passes. The wall of the absorption cell 41 preferably has a dielectric constant which differs from that through which the electric field passes when the cell 41 is absent. It can therfore be seen that the relative movement of the cell 41 and the electrodes 45a-45d will vary the proportion of electric field passing through the cell 41, thus altering the capacitances created by the electrodes 45a-45d and changing the resonance frequency of the microwave cavity 42.
The atomic frequency standard shown in FIG. 2 includes means 70 for positioning the storage means 41 with respect to the electrodes 45a-45d. The positioning means 70 comprises a cap member 71 having and annular skirt 72 on the inner surface of which is a screw thread 73. The outer surface of the enclosure 43 has also has a screw thread 74 for cooperating with the screw thread 73 of the cap 71. The absorption cell 41 is secured to the inner surface 75 of the cap 71. In this way, the relative screwing or un-screwing of the cap 71 and the enclosure 42 causes the absorption cell 41 to be respectively inserted or withdrawn from a position between the electrodes 45a-45d, thereby altering the proportion of electric field passing through the absorption cell 41. Variations in the wall thickness of the absorption cell 41, the dimensions of the electrodes 45a-45d and the dimensions of other components within the frequency standard which can affect the resonance frequency of the microwave cavity 42, can be compensated for by adjusting the position of the absorption cell 41.
The absorption cell 41 may be secured to the cap 71 by any convenient means. If the cell 41 is not supported by the cap 71 however, for example if the frequency standard is maintained in an inverted position to that shown in FIG. 2, the cell 41 need not be secured to the cap 71. In addition, other arrangements may be used to that shown in FIG. 2, in order to achieve relative movement between the cell 41 and the electrodes 45a-45d within the enclosure 43. For example, the absorption cell 41 may be secured to a cap-like member which cooperates with the inner wall of the container 60 and 61. These and other mechanical equivalents will be appreciated by a man skilled in the art as forming part of the present invention.
An embodiment of the present invention has been realised using four electrodes, each having a thickness of 0.8 mm and a length, in the direction of the longitudinal axis of the coil 58, of 12 mm. The gap between each electrode was 0.6 mm. The absorption cell used had a wall thickness of between 0.2 and 0.3 mm, and was made from a material having a dielectric constant of 4.5. In this exemplary arrangement, the pulling-range of the frequency standard, or in other words the difference in the resonance frequency of the microwave cavity 42 when the absorption cell 41 is completely inserted between the electrodes 45a-45d compared to when the cell 41 is completely withdrawn, was found to be 400 MHz.
In another embodiment of the present invention, the connecting members 47a to 47d, in conjunction with the electrodes 45a to 45d, may be used to support the absorption cell 41 within the microwave cavity 42. One or more of the electrodes may be fixed to the absorption cell to enable such support. Alternatively, the physical relation of two or more electrodes, or of one or more electrodes and the wall of the microwave cavity may be used to engage the cell therebetween and support the absorption cell 41. In this manner, the absorption cell may be positioned within the microwave cavity 42 so as to maximize the oscillating magnetic field in the region of the absorption cell 41.
In the arrangement shown in FIGS. 2 and 3, the oscillating magnetic flux created by the resonating structures of the electrodes 45a-45d and the members 47a-47d, is found to be optimal in the centre of the microwave cavity 42. The absorption cell 41 may thus be located there without the introduction of further support members which would cause additional dielectric losses and magnetic field perturbations.
In order to increase the structural rigidity and ease of manufacture of the atomic frequency standard of the present invention, the support members 47a-47d may be integral with the wall 43 of the microwave cavity 42. In the same fashion, the electrodes 45a-45d may also be integral with the support members 47a-47d.
The container formed by envelope 60 and cover 61 may be advantageously placed under vacuum, thereby providing several advantages over known atomic frequency resonators. These advantages are: firstly, that the thermal flux due to convertion between the lamp 40 and the cell 41 are eliminated enabling a more precise control of temperature; secondly, placing the container under a vacuum enables the lamp 40 and the cell 41 to be placed closer together without risk promoting a reduction in volume of the atomic frequency standard; thirdly, the temperature range within which the standard may be used and the frequency stability of the atomic resonator are improved; and, fourthly, the power consumption required by the atomic frequency standard is further reduced.
Advantageously, various elements of the atomic frequency standard within the container, such as the light source 40 and the microwave resonator 43, may be connected to the container 60 and 61, as shown in FIG. 2, by low thermal conductivity spacers 80 and 81. In this manner, the frequency standard within the container may be thermally separated from the container, and not subject to the same changes in temperature variation and physical expansion resulting from ambient pressure and temperature changes outside the container.
Instead of placing the container under vacuum, the container may also be filled with a gas of low thermal conductivity, such as xenon or other appropriate heavy molecular gas. This gas may be at atmospheric pressure. Filling the chamber with xenon enables the same advantages to be obtained by placing the chamber under a vacuum. At the same time, in this case, the need to use materials having low outgas properties is avoided.
Finally, it is to be understood that various modifications and/or additions may be made to the atomic frequency standard without departing from the ambit of the present invention as defined in the claims appended hereto. In particular, it is to be appreciated that the invention is not restricted in its scope to passive atomic frequency standards such as the rubidium gas cell standard, but is applicable to all atomic frequency standards in which oscillating magnetic field enhancing electrodes may be used. | The atomic frequency standard has a heating element (58) surrounding an enclosure (43) which defines a microwave resonance cavity (42). The heating element supplies heat to an absorption cell (41) located in the cavity. The absorption cell (41) is surrounded by electrodes (45a-45d) which act to enhance and orient the oscillating magnetic field in the region of the absorption cell. Thermally conductive members (47a-47d) connect the electrodes (45a-45d) to the enclosure (43) to better control the temperature of the cell while retaining the advantages due to the presence of the electrodes (45a-45d). | 26,722 |
The U.S. Government has rights in this invention pursuant to National Institutes of Health Grant No. GM-15904 to Harvard Anesthesia Research and Teaching Center to C. Berde, and Grant No. CA 5257 to R. Langer.
This is a continuation-in-part of U.S. Ser. No. 07/943,287, filed Sep. 10, 1992 now abandoned by Charles B. Berde and Robert S. Langer.
BACKGROUND OF THE INVENTION
This invention is generally in the field of anesthesiology and, in particular, the delivery of anesthetic agents which locally block pain for periods of time of less than about two weeks.
In order to provide local or regional blockade for extended periods, clinicians currently use local anesthetics administered through a catheter or syringe to a site where the pain is to be blocked. This requires repeated administration where the pain is to be blocked over a period of greater than one day, either as a bolus or through an indwelling catheter connected to an infusion pump. These methods have the disadvantage of potentially causing irreversible damage to nerves or surrounding tissues due to fluctuations in concentration and high levels of anesthetic. In addition, anesthetic administered by these methods are generally neither confined to the target area, nor delivered in a linear, continuous manner. In all cases, analgesia rarely lasts for longer than six to twelve hours, more typically four to six hours. In the case of a pump, the infusion lines are difficult to position and secure, the patient has limited, encumbered mobility and, when the patient is a small child or mentally impaired, may accidentally disengage the pump.
Drugs are typically administered in a variety of ways, including by injection, topical administration, oral ingestion, and sustained release devices. Methods which provide for systemic, rather than localized, delivery are not an option with local anesthetics since these could interfere with the patient's ability to breathe, if administered systemically. Devices could potentially provide for a sustained, controlled, constant localized release for longer periods of time than can be achieved by injection or topical administration. These devices typically consist of a polymeric matrix or liposome from which drug is released by diffusion and/or degradation of the matrix. The release pattern is usually principally determined by the matrix material, as well as by the percent loading, method of manufacture, type of drug being administered and type of device, for example, microsphere. A major advantage of a biodegradable controlled release system over others is that it does not require the surgical removal of the drug depleted device, which is slowly degraded and absorbed by the patient's body, and ultimately cleared along with other soluble metabolic waste products.
Systemic anesthetics such as methoxyflurane, have been incorporated into liposomes and lecithin microdroplets, for example, as described by Haynes, et al., Anesthesiology 63: 490-499 (1985). To date, the liposome and lecithin preparations have not been widely applied in clinical or laboratory practice, because of their inability to provide dense blockade for a prolonged period of time (i.e., three or more days) in a safe and controlled manner. The lecithin microdroplets and liposomes degrade or are phagocytized too rapidly, in a matter of hours. Other lipid based devices, formed in combination with polymer, for release of local anesthetics are described by U.S. Pat. No. 5,188,837 to Domb.
Local anesthetics have been incorporated into biodegradable polymeric devices, for example, polylactic acid microspheres, as described by Wakiyama, et al., Chem. Pharm. Bull., 30: 3719-3727 (1982). In contrast to the lipid based materials, the poly(lactic acid) devices take over a year to degrade and cause localized inflammation. Berde, et al., Abstracts of Scientific Papers, 1990 Annual Meeting, Amer. Soc. Anesthesiologists, 73: A776 (Sep. 1990), reported the use of a device formed of a polyanhydride polymer matrix of copolymer 1,3 bis (p-carboxyphenoxy)propane and sebacic acid, in a ratio of 1:4, into which dibucaine free base was incorporated by compression molding. This drug-polymer device, however, had several drawbacks. For example, because the drug was incorporated into the polymer matrix by compression molding, the device sometimes displayed bulk erosion, causing fast initial release of drug. In addition, the device often generated an inflammatory response or a capsule of serous material or fibrin, which is particularly a problem when located adjacent to nerves.
Accordingly, it is the object of this invention to provide an improved biodegradable controlled release device which administers local anesthetic for a prolonged period of time in a substantially constant, linear fashion and which provokes minimal encapsulation and/or other immune responses.
It is a further object of the present invention to provide a method and means for modulating the rate of release of the local anesthetic from the bioerodible polymer matrix.
SUMMARY OF THE INVENTION
An improved biodegradable controlled release device for the prolonged administration of a local anesthetic agent, and a method for the manufacture thereof are disclosed. The device is formed of a biodegradable polymer degrading significantly within a month, with at least 50% of the polymer degrading into non-toxic residues which are removed by the body within a two week period. Useful polymers include polyanhydrides, polylactic acid-glycolic acid copolymers and polyorthoesters containing a catalyst. Local anesthetics are incorporated into the polymer using a method that yields a uniform dispersion, such as melt casting or spray drying, not compression molding. Local inflammatory responses against the polymeric devices are avoided through selection of the polymer, repeated recrystallization of the monomers forming the polymer and resulting polymers to remove impurities, monomer and degradation products, the method of incorporation of the anesthetic and in some embodiments, by inclusion of an antiinflammatory such as dexamethasone, either within the polymer or implanted with the polymer. The device can be formed as slabs, films, microparticles, including microspheres, or a paste.
The type of anesthetic and the quantity are selected based on the known pharmaceutical properties of these compounds. It has been discovered that bupivacaine is a better anesthetic agent for use in polymeric devices than other local anesthetics such as dibucaine. It has also been determined that salts of the anesthetic agents (e.g., hydrochlorides, bromides, acetates, citrates, sulfates, etc.) yield better results when incorporated into polymeric devices than the free base forms.
It is possible to tailor a device to deliver a specified initial dosage and subsequent maintenance dose by manipulating the percent drug incorporated, the form of local anesthetic, for example, more hydrophobic free base versus more hydrophilic hydrochloride, the method of production, and the shape of the matrix.
The polymeric devices are implanted at the site where the anesthetic is to be released. This can be at the time of surgery, prior to or at the time of injection, especially when the device is in the form of microparticles, or following removal of systemic anesthetic.
Examples demonstrate the superiority of making the polymeric device using a method resulting in uniform dispersion of anesthetic in the device and prevention of inflammation by incorporation of an antiinflammatory with the anesthetic-polymeric device. The device delivers the local anesthetic at rates above 3.5 mg/day for up to four days or more with substantially zero order kinetics, i.e., linear release. The effectiveness of these devices in vivo is also demonstrated. Using a rat sciatic nerve in vivo model, it was shown that the devices provide degrees of sensory blockade for up to five to six days and motor blockade for up to three days. The blockade appeared reversible, with complete recovery of strength and sensation.
The examples also demonstrate the effect of cis-hydroxyproline and dexamethasone on inflammation, encapsulation and duration of sensory and motor blockade following implantation of bupivacaine 20% CPP:SA (20:80) polymer matrices along the sciatic nerves of rats. Cis-hydroxyproline (CHP) did not diminish encapsulation and did not alter the duration of sensory or motor blockade. In contrast, dexamethasone (DMS) produced significant reductions in encapsulation and inflammation, and was associated with more prolonged sensory analgesia. These effects were not mediated by systemic concentrations of dexamethasone, since unilateral incorporation of DMS into PLAM did not diminish encapsulation around contralateral control implants that did not receive DMS. DMS was effective in inhibiting an anti-inflammatory response and preventing encapsulation of the polymeric device in rats at doses from 45 μg to 180 μg, administered in three pellets containing between 15 μg and 60 μg DMS/pellet. The preferred dosage is 60 μg anti-inflammatory/kg body weight, which is equivalent to a dosage range of between 20 μg/kg body weight, and 1 mg/kg body weight. These doses did not produce suppression of glucocorticoid secretion.
BRIEF DESCRIPTION OF THE DRAWINGS
FIGS. 1a and 1b are graphs of the percent cumulative release of bupivacaine HCl (FIG. 1a) and dibucaine HCl (FIG. 1b) as a function of time in days, comparing release from hot melt molded devices with release from compression molded devices formed of 1,3 bis (p-carboxyphenoxy)propane:sebacic acid (CPP:SA) (1:4).
FIG. 2 is a graph of in vitro polymeric pellet release studies, percent cumulative release over time in days of 12% bupivacaine HCl in 10 ml PBS (dark circles); 20% bupivacaine HCl in 25 ml PBS (open triangles); 20% bupivacaine 10 ml PBS (dark squares); and 20% bupivacaine in 2 ml PBS (open square).
FIGS. 3a-3f are graphs of the results of nerve block assays: FIG. 3a is a graph of the number of rats over days post-implantation showing dense, partial or no block pain relief; FIG. 3b is a graph of latency in seconds over days post-implantation for G1 devices (dark squares) and control (open squares); FIG. 3c is a graph of the number of rats showing dense, partial or no block pain relief over days post-implantation; FIG. 3d is a graph of latency in seconds over days post-implantation for G2 devices (dark circles) and control (open circles); FIG. 3e is a graph of the number of rats showing dense, partial or no block pain relief over days post-implantation; and FIG. 3f is a graph of latency in seconds over days post-implantation for G3 devices (dark circles) and control (open circles). The data represent mean ±S.E.M. *Denotes p<0.05significance(†, p=0.07).
FIG. 4 is an autoradiogram of Northern blot analyses for five different rats receiving polymeric implants. This is an image of Northern autoradiograms that were digitized with an optical scanner for display and quantification. Radiolabeled probes were used to measure mRNA levels encoding substance P (preprotachykinin) extracted from DRG tissue (L4-6) corresponding to the sciatic nerves. The mean grayscale density of autoradiogram signal bands was determined by averaging the values of image pixels corresponding to specific RNA-probe hybridizations. Preprotachykinin (PPT) mRNA levels were normalized to 28S rRNA levels as a measure of total RNA loaded. Cervical DRG tissue (C3-5) was used as an additional non-operated control. N=Non; B=Bupivacaine' L=Lumbar' C=Cervical.
FIG. 5 is a graph of latency in seconds versus hours post-implantation for groups 4 (squares), 5 (diamonds), 6 (circles) and control (triangles) rats treated with PLAMs containing anesthetic and antiinflammatory.
FIGS. 6a, b, and c are graphs of number of PLAM treated rats versus hours post-implantation who showed severe impairment (dark bars), partial impairment (stripes), and no motor block (open bars).
FIG. 7 are graphs of latency in seconds versus hours post-implantation for groups 1 (squares), 2 (diamonds), 3 (circles) and control (triangles) rats treated with PLAMs containing anesthetic and antiinflammatory.
FIGS. 8a, 8b, and 8c are graphs of number of PLAM treated rats versus hours post-implantation who showed severe impairment (dark bars), partial impairment (stripes), and no motor block (open bars).
DETAILED DESCRIPTION OF THE INVENTION
Systems for the controlled and prolonged delivery of a local anesthetic agent to a targeted area are provided. These systems can be used for the management of various forms of persistent pain, such as postoperative pain, sympathetically maintained pain, or certain forms of chronic pain such as the pain associated with many types of cancer.
Polymers
It is important that the polymer degrade in vivo over a period of less than a year, with at least 50% of the polymer degrading within six months or less. More preferably, the polymer will degrade significantly within a month, with at least 50% of the polymer degrading into non-toxic residues which are removed by the body, and 100% of the drug being released within a two week period. Polymers should-also degrade by hydrolysis by surface erosion, rather than by bulk erosion, so that release is not only sustained but also linear. Polymers which meet this criteria include some of the polyanhydrides, co-polymers of lactic acid and glycolic acid wherein the weight ratio of lactic acid to glycolic acid is no more than 4:1 (i.e., 80% or less lactic acid to 20% or more glycolic acid by weight), and polyorthoesters containing a catalyst or degradation enhancing compound, for example, containing at least 1% by weight anhydride catalyst such as maleic anhydride. Other polymers include protein polymers such as gelatin and fibrin and polysaccharides such as hyaluronic acid. Polylactic acid is not useful since it takes at least one year to degrade in vivo.
The local anesthetic is present in the polymer at a concentration effective to achieve nerve blockade at the site of administration.
The polymers should be biocompatible. Biocompatibility is enhanced by recrystallization of either the monomers forming the polymer and/or the polymer using standard techniques.
Anesthetics
The systems employ biodegradable polymer matrices which provide controlled release of local anesthetics. As used herein, the term "local anesthetic" means a drug which provides local numbness or pain relief. A number of different local anesthetics can be used, including dibucaine, bupivacaine, etidocaine, tetracaine, lidocaine, and xylocaine. The preferred anesthetic is bupivacaine or dibucaine, most preferably in the form of a salt, for example, the hydrochloride, bromide, acetate, citrate, or sulfate. Compared to the free base form of these drugs, the more hydrophilic hydrochloride salt displays longer and denser nerve block, more complete release from polymer matrices, slower clearance from the targeted nerve area, and less encapsulation. Bupivacaine is a particularly long acting and potent local anesthetic when incorporated into a PLAM. Its other advantages include sufficient sensory anesthesia without significant motor blockage, lower toxicity, and wide availability.
The devices can also be used to administer local anesthetics that produce modality-specific blockade, as reported by Schneider, et al., Anesthesiology, 74: 270-281 (1991), or that possess physical-chemical attributes that make them more useful for sustained release then for single injection blockade, as reported by Masters, et al., Soc. Neurosci. Abstr., 18: 200 (1992), the teachings of which are incorporated herein.
The anesthetic is incorporated into the polymer in a percent loading of 0.1% to 70% by weight, preferably 5% to 50% by weight. It is possible to tailor a system to deliver a specified loading and subsequent maintenance dose by manipulating the percent drug incorporated in the polymer and the shape of the matrix, in addition to the form of local anesthetic (free base versus salt) and the method of production. The amount of drug released per day increases proportionately with the percentage of drug incorporated into the matrix (for example, from 5 to 10 to 20%). In the preferred embodiment, polymer matrices with not more than about 30% drug incorporated are utilized, although it is possible to incorporate substantially more drug, depending on the drug, the method used for making and loading the device, and the polymer.
Antiinflammatories
Antiinflammatories that are useful include steroids such as dexamethasone, cortisone, prednisone, and others routinely administered orally or by injection. Useful loadings are from 1 to 30% by weight. The preferred dosage is 60 μg anti-inflammatory/kg body weight, which is equivalent to a dosage range of between 20 μg/kg body weight, and 1 mg/kg body weight.
The following examples demonstrate that polymers alone and when combined with local anesthetics generate a substantial encapsulation response within two weeks of placement in rats. The encapsulation response to polymer containing local anesthetic is worse than the polymer alone. This encapsulation is a natural response to a foreign body and occurs at varying rates with many substances commonly regarded as "biocompatible". Minimization of the encapsulation response is important for proper healing, for avoidance of unsightly scars, for optimal access of drug to its site of action, and potentially to decrease the likelihood of infection.
Encapsulation involves formation of a fibrous material around foreign bodies. It begins with attempts by granulocytes to phagocytose and incorporate the foreign material during the initial acute inflammatory response. The process of encapsulation through fibrosis is due to histiocytes and fibroblasts, which generate the layers of collagenous connective tissue surrounding the implant. Encapsulation depends upon several factors, including the chemical and physical characteristics of the implant, the mechanical action of the implant, its site in the body and the presence of microorganisms.
The examples demonstrate that dexamethasone reduces encapsulation, does not reduce the intensity of the nerve block generated by the release of anesthetic from the polymer, does not affect the recovery of sensation and strength, and works only locally due to the low doses which are effective, and therefore exerts no effect on the normal pituitary-adrenal hormone responses.
Methods of Manufacture
The polymeric devices are preferably manufactured using a method that evenly disperses the anesthetic throughout the device, such as solvent casting, spray drying or hot melt, rather than a method such as compression molding. As shown by Example 1, in contrast to compression molded tablets, which sometimes display bulk erosion and fast initial release of drug, hot melt molded tablets have denser and more homogenous matrices, causing them to release drug in a more safe and linear fashion.
The form of the polymeric matrix is also important. Devices can be shaped as slabs, beads, pellets, microparticles, including microspheres and microcapsules, or formed into a paste. Microparticles, microspheres, and microcapsules are collectively referred to herein as "microparticles". The device can be coated with another polymer or other material to alter release characteristics or enhance biocompatibility. The microparticles can be administered as a suspension or as a device within a gelatin capsule, or used to form a paste, for example.
In the preferred embodiments, the device will be in the form of microparticles. A desired release profile can be achieved by using a mixture of microparticles formed of polymers having different release rates, for example, polymers releasing in one day, three days, and one week, so that linear release is achieved even when each polymer per se does not release linearly over the same time period.
Methods of Administration
In the preferred method of administration, the devices are microparticles and are administered by injection at the site where pain relief is to be achieved. Alternatively, the device is surgically implanted at the site. The pellets may be injected through a trochar, or the pellets or slabs may be surgically placed adjacent to nerves.
Potential applications include two to five day intercostal blockade for thoracotomy, or longer term intercostal blockade for thoracic post-therapeutic neuralgia, lumbar sympathetic blockade for reflex sympathetic dystrophy, or three-day ilioinguinal/iliohypogastric blockade for hernia repair.
The present invention is further described with reference to the following non-limiting examples.
EXAMPLE 1
Preparation of Polymer Matrices for Sustained Release of Bupivacaine HCl
Monomers of CPP and SA (20:80) were converted to mixed anhydrides after a 30 minute reflux in acetic anhydride. The prepolymers were then recrystallized over several weeks in a mixed solvent of acetic anhydride and dimethylformamide, followed by polycondensation under nitrogen sweep. The resulting polymers were then ground to a fine powder and mixed with crystalline Bupivacaine HCL (20%±2% drug by dry weight). Cylindrical pellets were then produced by placing a tuberculin syringe filled with drug-polymer mixture in a dry oven at 115° C. for 15-20 min. and then injecting the molten solid into teflon tubing (3.2 mm i.d.) or by compression of the polymer powder.
Release of bupivacaine from the device was measured in phosphate buffer, pH 7.4, over a period of 10 days. The results comparing release from compression molded-tablets and hot melt-pellets are shown in FIG. 1a. Significantly more linear release was obtained with devices prepared by hot melt.
EXAMPLE 2
Preparation of Polymer Matrices for Sustained Release of Dibucaine
Polymer-drug matrices were prepared as detailed above, substituting crystalline dibucaine HCl for bupivacaine HCl. Release of dibucaine from matrices was then measured in phosphate buffer, pH 7.4, over a period of 10 days. The results comparing release from compression molded-tablets and hot melt-pellets are shown in FIG. 1b. The same release profiles were observed.
EXAMPLE 3
Prolonged Regional Nerve Blockade by Controlled Release of Local Anesthetic From a Biodegradable Polymeric Matrix
Cylindrical pellets made from polymer matrices incorporated with bupivacaine-HCl were implanted surgically along the sciatic nerves of rats in vivo. Sensory and motor blockade was produced for periods ranging from two to six days. Contralateral control legs receiving polymer implants without drug showed no block. Blockade was reversible, and animals appeared to recover sensory and motor function normally. Biochemical indices of nerve and muscle function were indistinguishable from contralateral controls. This biodegradable polymer system provides a promising new alternative for the delivery of local anesthetics to peripheral nerves to produce prolonged blockage for the management of acute and chronic pain.
Methods and Materials
PLAM Implants
Biodegradable polymeric pellets were formed from a polymer mixture, 20% poly[bis(p-carboxyphenoxy) propane anhydride] (poly CPP) and 80% sebacic acid (SA), impregnated with crystalline bupivacaine·HCl, to release this local anesthetic in a controlled manner. Polymer-local anesthetic matrix (PLAM) pellets were made by mixing 150 μm sieved crystals of bupivacaine-HCl at 12% and 20% with polymer powder. In brief, cylindrical pellets were produced by melting the mixtures in a tuberculin syringe at 115° C. in a dry oven and then injecting the molten mixture into Teflon tubing (3.2 or 4.8 mm i.d.). After cooling, the pellets were cut to specified lengths and weights. Control pellets were made in an identical manner using polymer without drug.
Three sizes of PLAM pellets, loaded to 20% by weight with bupivacaine·HCl, were used as implants-to examine dosage effects. Group 1 pellets weighed 50±3 mg and were 4.0±0.3 mm long, 3.1±0.2 mm diameter. Group 2 pellets were twice the length of Group 1 pellets, 100±5 mg, 9.8±2 mm long and 3.1±0.2 diameter. Group 3 pellets weighed 125±5 mg and were 6.0±0.1 mm long, 4.7±0.2 mm diameter. Pellets were sterilized via gamma irradiation for in vitro or in vivo use. Different batches of PLAM pellets were used and similar results were obtained.
In Vitro
Bupivacaine PLAM pellets (equal in size to Group 2 pellets) loaded with 12% or 20% bupivacaine were immersed in various volumes (2 ml, 10 ml, 25 ml) of phosphate-buffered saline (PBS) with 0.1% sodium azide (pH 7.4 at 37° C.). Buffer was collected and replaced at 0.5, 2, 8, 16, 24 hour time points, then once daily thereafter for 3 weeks and stored at -20° C. before high performance liquid chromatography (HPLC) assay. Bupivacaine standards, 0.23, 0.46, 0.77, 2.3 μg, analyzed on average after every tenth sample, produced linear response values (R 2 >0.995).
PLAM Implantation
For surgery, male rats (150-250 g Sprague-Dawley) were anesthetized with 50-75 mg/kg pentobarbital (i.p.) for Groups 1 and 2 and halothane for Group 3 (4% in oxygen for induction and 2% for maintenance). The shaved skin of the dorsal thigh was incised midway between the hip and the knee. The hamstring muscles were divided with a small hemostat, exposing the dorsal aspect of the sciatic nerve. Under direct vision, polymer pellets could be easily fitted into a large space between muscle layers surrounding the nerve. The space containing the pellets was bathed with 0.5 cc of an antibiotic solution (5000 units/ml penicillin G sodium and 5000 μg/ml streptomycin sulfate). The fascia overlaying the hamstrings were reapproximated with a single suture before closing skin with two wound clips.
For all rats, PLAM pellets were implanted surgically along the sciatic nerve in the upper thigh, with drug-containing implants on the experimental side and control (drug-free) implants on the contralateral (control) side.
Nerve Block Tests
Motor Block
The rats were behaviorally tested for sensory and motor blockage in a quiet observation room at 24°±1° C. PLAM implantation was only performed in rats showing appropriate baseline hot plate latencies after at least one week of testing. In all testing conditions, the experimenter recording the behavior was unaware of the side containing the local anesthetic. To assess motor block, a 4-point scale based on visual observation was devised: (1) normal appearance, (2) intact dorsiflexion of foot with an impaired ability to splay toes when elevated by the tail, (3) toes and foot remained plantar flexed with no splaying ability, and (4) loss of dorsiflexion, flexion of toes, and impairment-of gait. For graphing clarity, partial motor block equals a score of 2 and dense motor block is a score of either 3 or 4.
Sensory Block
Sensory blockade was measured by the time required for each rat to withdraw its hind paw from a 56° C. plate (IITC Life Science Instruments, Model 35-D, Woodland Hills, CA). The rats were held with a cloth gently wrapped above their waist to restrain the upper extremities and obstruct vision. The rats were positioned to stand with one hind paw on a hot plate and the other on a room temperature plate. With a computer data collection system (Apple IIe with a footpad switch), latency to withdraw each hind paw to the hot plate was recorded by alternating paws and allowing at least fifteen seconds of recovery between each measurement. If no withdrawal occurred from the hot plate within 15 seconds for Groups 1 and 2 or 12 sec for Group 3, the trial was terminated to prevent injury and the termination time was recorded. Testing ended after five measurements per side, the high and low points were disregarded, and the mean of the remaining three points was calculated for each side. Animals were handled in accordance with institutional, state and federal guidelines.
Necropsy
The animals were sacrificed two weeks after implantation, approximately one week after they all returned to baseline levels in motor and sensory tests. In vitro approximations predict drug depletion (<5% left) from the polymer matrix by one week, corresponding well with the observed block. Thus, the sciatic nerve was free of local anesthetic for approximately one week before postmortem analyses.
Histology
Sections of sciatic nerve approximately 2-3 cm in length, adjacent and proximal to the implants, were preserved in 10% formalin solution (24 mM sodium phosphate, pH 7). Sections were then embedded in paraffin, stained with hematoxylin and eosin, and examined by light microscopy.
Plasma Analysis
Five rats (250-275 g), anesthetized with ketamine-HCl (100 mg/ml at 1.5 ml/kg, i.p.) and xylazine (4 mg/ml at 4 mg/kg, i.p.), were implanted with a silastic catheter into the right jugular vein. Two days after the catheters were implanted, Group 1 pellets loaded with 20% bupivacaine (300 mg) were implanted next to the sciatic nerve. Blood was withdrawn (0.5 cc) before implantation and 1, 4, 24, 48, 72, and 96 hours after PLAM implantation via the indwelling central venous cannulae. Plasma was extracted with an equal volume of HPLC grade methanol (Fischer Scientific, Pittsburgh, Penn.), centrifuged (10,000×g) and the methanol phase filtered (0.2 μm nylon syringe type, Rainin, Woburn, Mass.) prior to HPLC analysis. The HPLC reliably quantified bupivacaine concentrations in the plasma methanol extraction phase down to 10 ng/ml. The bupivacaine standards used for blood plasma analyses were added to plasma aliquots prior to methanol extraction. The peak matching the standard bupivacaine peak's retention time was verified in plasma samples by doping with bupivacaine.
Biochemical Assays
Acetylcholine Receptor
The gastrocnemius muscle was excised from rats that had received group 2 implants and assayed for I 125 alpha-bungarotoxin binding as described by Martyn et al., Anesthesiology 76: 822-843, 1992; and Masters et al. Meeting for the American Society of Anesthesiologists 75: A680, 1991. Gastrocnemius muscle I 125 alpha-bungarotoxin binding was used as a measure of acetylcholine receptor number, which up-regulate (increase) in response to denervation.
Substance P and its Encoding mRNA
Ganglia were excised from cervical (C3-5) and lumbar (L4-6) regions, immediately frozen on dry ice and homogenized in a 3M lithium chloride/5M urea solution. The spun-down pellets were purified for RNA analysis by the method of Masters, et al., BioTechniques, 12: 902-911, 1992, and the supernatants were desalted on C-18 columns for peptide radioimmunoassay (RIA). In the RIA, unlabeled substance P was competed against Bolten-Hunger I 125 labeled substance P with a polyclonal antibody specific for substance P in duplicate samples, as described by Too H-P, Maggio J: Radioimmunoassay of Tachykinins, Methods in Neurosciences. Edited by Conn PM. New York, Academic Press, 1991, pp 232-247. The assay was sensitive to 5-10 femtomoles/assay tube. Protein levels eluted with substance P were analyzed with a microtiter plate bicinchoninic (BCA) protein assay (Pierce, Rockford, Ill.).
Northern blot analysis of dorsal root ganglia, able to accurately detect 20% differences in RNA levels in single dorsal root ganglia, was developed as described by Masters (1992). Purified total RNA samples were quantitated with an ethidium bromide Tris-acetate/EDTA gel and equal amounts loaded onto a formaldehyde denatured Northern gel. Relative quantities of messenger RNA encoding for the neuropeptide substance P were normalized to 28S ribosomal RNA (gamma-preprotachykinin/28S rRNA autoradiography grayscale density). Ethidium bromide photonegatives and hybridization autoradiograms were digitized with a flatbed optical scanner and the resulting image analyzed for grayscale density of the signal bands.
The Northern analysis used a full length cDNA of Υ-preprotachykinin provided by Dr. J. Krause, Washington University, St. Louis, Mo. and subcloned into a Promega (Madison, Wis.) pGEM-3Z riboprobe vector. 32 P-UTP labeled riboprobe (specific activity of approximately 10 9 cpm/μg) was made using RNA T7-polymerase (Promega Piscataway, NJ). A 30-mer oligonucleotide sequence, complementary to a region of rat 28S ribosomal RNA (5'-AAUCCUGCUC AGUACGAGAG GAACCGCAGG-3'), was for normalization of total RNA loaded into the electrophoretic gel. Twenty ng of oligonucleotide was np end-labeled with the given procedure using T4 polynucleotide kinase (GIBCO BRL; Gaithersburg, Md.) and purified on a Nick size exclusion column. The specific activity of the probe was greatly reduced (to approximately 10 5 cpm/μg) by adding 4 μg unlabeled oligonucleotide to the column eluent (400 μl) to reduce the hybridization signal and improve hybridization kinetics.
Statistics
Data were analyzed using linear regression tests, ANOVA, Chi Square tests and Wilcoxon rank-sum tests, where appropriate.
Results
In Vitro Release
HPLC results showed that 96% of the 20 mg of bupivacaine incorporated into a 100 mg PLAM pellet was released within 8 days. Because release rate decreased with time, cumulative release rose toward an asymptote. The cumulative release profile was similar for 12% bupivacaine pellets in 10 ml buffer. Group 2 pellets were found to release approximately 75% of the loaded bupivacaine within 4 days in vitro, as shown in FIG. 2.
In Vivo Neural Block Measurements
Group 1 implants (295±10 mg total PLAM) in seven animals produced sciatic nerve blockade for periods lasting 2-3 days, as shown in FIG. 3a. Dense motor blockade was evident in most animals for two days. Sensory blockade, measured as increased leg-withdrawal latency to heat in comparison to contralateral control leg, was greater than 200% for day 1 and greater than 70%-40% for days 2-3, respectively, as shown in FIG. 3b. Group 2 implants (295±10 mg total PLAM) in six animals produced sciatic nerve blockade for a 4 day period, as shown in FIG. 3c. Motor blockade was dense for 3-4 days in most animals. Sensory blockade increased leg-withdrawal latency greater than 200% for day 1, greater than 100% for day 2 and 3, and greater than 40% for day 4, as shown by FIG. 3d. One of the seven rats receiving a group 2 implant did not recover from the surgical implantation procedure. The animal appeared sluggish and lost weight, and was therefore dropped from the study. Group 3 implants (375±10 mg total PLAM) in six animals produced partial or complete motor blockade for 4 days and sensory blockade for 4-5 days, including leg-withdrawal latencies that increased over 185% for the first 3 days, greater than 100% for day 4 and greater than 30% for day 5, as shown by FIGS. 3e and 3f. No impairments were observed on the contralateral control side, implanted with an equal mass of polymer pellets without drug. These results indicate that the increased mass of the PLAM implant increases the period of blockade, suggesting a dose-response relationship.
Histology
Sciatic nerve histologic examination showed minimal perineural inflammation with a foreign body response consistent with a local response to previous surgery. Using light microscopy, no evidence of axonal degeneration or demyelination was noted either proximal or distal to the implantation site.
Biochemical Assays
Prolonged release of local anesthetic and polymer degradation near the sciatic nerve did not lead to differences in any of several biochemical comparisons made between the side that received PLAM implants and the contralateral control side, two weeks post-implantation (Table 1). There was no significant difference found in tests for: (1) acetylcholine receptor number in gastrocnemius muscle, (2) the level of substance P, a neuromodulator involved in nociception, in lumbar or cervical dorsal root ganglia, or (3) the level of RNA encoding for substance P, preprotachykinin (PPT), in lumbar dorsal root ganglia, using a novel small-sample Northern blot system, as demonstrated by FIG. 4.
TABLE 1______________________________________Biochemistry results of animals withPLAM implants, comparing thebupivacaine-treated leg to thecontralateral control leg.AnalysisControl.sup.a Bupivacaine-Treated.sup.a______________________________________Acetylcholine Receptor 44.6 ± 1 3.3 ± 2.9*in gastrocnemius muscle(femtomole/mg protein)Substance P content in DRG(femtomole/mg protein)Lumbar (n = 7) 0.12 ± 01 0.11 ± 01*Cervical (n = 7) 0.08 ± 01 0.07 ± 01*Substance P mRNA in DRG(PPT/28S rRNA)Lumbar (n = 5) 1.04 ± 09 1.03 ± 05*Cervical (n = 4) 0.77 ± 10 0.87 ± 21*______________________________________ .sup.a (Mean ± S.E.M.) .sup.* p > 0.3, Bupivacainetreated vs control
Plasma Levels
A potential risk of prolonged nerve blockade is systemic accumulation of local anesthetics, leading to convulsion, arrhythmia, and myocardial depression. To examine this risk, plasma concentrations of bupivacaine were measured in five additional rats implanted with Group 1 PLAM pellets (295±5 mg total), at 1, 4, 24, 48, 72 and 96 hours post-implantation. All concentrations were less than 0.1 μg/ml, far below the threshold for toxicity of 305 μg/ml.
In summary, prolonged reversible blockade of the rat sciatic nerve was achieved for periods of 2-6 days in vivo using release of bupivacaine from a bioerodable polymer matrix. The implants were well tolerated by the animals, and produced only mild inflammation consistent with the presence of a foreign body. Recovery of motor and sensory function appeared complete.
EXAMPLE 4
Implantation of PLAMs Containing Anesthetic in Combination with Antiiflammatory
Depending upon the method of preparation, it was common in the previous studies to observe some encapsulation around the PLAM at autopsy two weeks following implantation. Encapsulation involves formation of a fibrous material around foreign bodies. It begins with attempts by granulocytes to phagocytose and incorporate the foreign material during the initial acute inflammatory response. The process of encapsulation through fibrosis is due to histiocytes and fibroblasts, which generate the layers of collagenous connective tissue surrounding the implant. Encapsulation depends upon several factors, including the chemical and physical characteristics of the implant, the mechanical action of the implant, its site in the body and the presence of microorganisms.
The protective function which encapsulation provides may also produce unwanted scarring. An example of this is shown by the studies examining the presence of fibrous capsules around silicon breast implants. Besides forming a large "scar" inside the body, encapsulation may also be a limiting factor in the applicability and usefulness of biodegradable drug delivery systems. Work by Anderson, et al. (J. M. Anderson, H. Niven, J. Pelagalli, L. S. Olanoff, and R. D. Jones, "The role of the fibrous capsule in the function of implanted drug-polymer sustained released systems," J. Biomed. Mater. Res., 15, 889-902 (1981)) has shown that the fibrous capsule which eventually surrounds an implant retards the drug diffusion rate and consequently lowers the local and systemic drug levels. In addition, other studies have shown that the duration of sensory blockade in vivo with bupivacaine impregnated PLAM was less than that expected from the results of PLAMs examined in vitro.
A method which reduces encapsulation is therefore needed for two reasons: (1) to diminish the unwanted consequences of "scarring" and (2) to enhance the release behavior of drug-polymer sustained release systems.
In the present study, the effects of dexamethasone and cis-hydroxyproline on inflammation, encapsulation and duration of sensory and motor blockade following implantation of bupivacaine-impregnated polymer matrices along the sciatic nerves of rats have been determined. Each drug has been shown separately in other studies to act upon different components of the inflammatory process. (L. Christenson, L. Wahlberg, and P. Aebischer, "Mast cells and tissue reaction to intraperitoneally implanted polymer capsules," J. Biomed. Mater. Res., 25, 1119-1131 (1991); L. Christenson, P. Aebischer, P. McMillian, and P. M. Galletti, "Tissue reaction to intraperitoneal polymer implants: species difference and effects of corticoid and doxorubicin," J. Biomed. Mater. Res., 23, 705-718 (1989); D. Ingber and J. Folkman, "Inhibition of angiogenesis through modulation of collagen metabolism," Lab. Invest., 59, 44-51 (1988); and J. P. Iannotti, T. C. Baradet, M. Tobin, A. Alavi, and M. Staum, "Synthesis and characterization of magnetically responsive albumin microspheres containing cis-hydroxyproline for scar inhibition," Orthop. Res. Soc., 9, 432-444 (1991)). Their individual effects on reducing encapsulation and improving drug release behavior were examined in this study.
Methods and Materials
Implants
Copolymers of 1,3-bis(p-carboxy-phenoxy)propane and sebacic acid (20:80) were synthesized as described above. Polymers were repurified by three cycles of the following process:
Polymer was dissolved in chloroform, precipitated with 5 volumes of hexane, the solvents was removed, and the precipitate was washed with diethyl ether. Copolymers were then ground to a fine powder under liquid nitrogen, lyophilized overnight, and stored under N 2 at -20° C. until use.
CHP PLAMs
PLAMs containing 10% and 20% L-cishydroxyproline (CHP) by weight of CPP:SA (20:80) copolymer were produced using the hot melt procedure, as follows:
Dry CHP is added to copolymer and mixed by both vortex and manual stirring with a spatula. The mixture is then transferred to a 1 cc syringe, heated for 10 to 15 minutes at 116°±2° C. until the polymer becomes molten but CHP remains solid with its crystals widely dispersed throughout the polymer. The mixture is then injected into Teflon® tubing. After the PLAM solidifies for 1 h, the PLAM in Teflon® tubing is cut into cylindrical pellets. The pellets are sterilized by gamma irradiation for 1 h and stored sealed at -20° C. until use.
All CHP PLAMs were synthesized using Teflon® tubing (3.1±0.2 mm diameter, denoted "regular bore"). These pellets were cut 1 cm in length and weighed approximately 100 mg. Group 1 animals were implanted with one 10% CHP PLAM pellet on the experimental side. Group 2 animals were implanted with one 20% CHP PLAM pellet on the experimental side and another on the control side.
The protocols and results are shown in Table 3.
TABLE 3______________________________________Description of Groups.Group number Experimental side Control side______________________________________1 1) 10% CHP PLAM Sham 2) 20% bupivacaine PLAM2 1) 20% CHP PLAM 20% CHP PLAM 2) 20% bupivacaine PLAM3a 20% bupivacaine PLAM Sham3b 20% bupivacaine PLAM Sham4 bupivacaine PLAM Control PLAM5 Id-DMS/bupivacaine PLAM Control PLAM6 hd-DMS/bupivacaine PLAM Sham7 hd-DMS PLAM Control PLAM______________________________________
Bupivacaine PLAMs
PLAMs containing 20% crystalline bupivacaine-HCL by weight of CPP:SA 20:80 copolymer were synthesized via the hot melt procedure described above for CHP PLAMs.
Two different-sized diameter Teflon® tubing were used: regular bore (3.1±0.2 mm) and large bore (4.9±0.3 mm). Regular bore pellets were cut 1 cm in length and weighed approximately 100 mg. Large bore pellets were cut 0.5 mm in length and weighed approximately 130 mg. Groups 1, 2 and 3a/3b animals were implanted with 3 regular bore bupivacaine pellets on the experimental side. Group 4 animals were implanted with 3 large bore bupivacaine pellets on the experimental side.
DMS/Bupivacaine PLAMs
PLAMs incorporated both bupivacaine and dexamethasone (DMS) were synthesized via the hot melt procedure described for CHP PLAMs with some differences in initial preparations.
A uniform mixture of DMS and bupivacaine was formed by combining DMS dissolved in 95% ethanol with bupivacaine dissolved in 95% ethanol. The solution was air-dried under the hood at room temperature until the ethanol evaporated and left behind a well-dispersed mixture of dry crystalline DMS and bupivacaine. The crystalline mixture was pulverized under mortar and pestle and combined with copolymer. The rest of the procedures followed those described for CHP PLAMs. All DMS/bupivacaine PLAMs were synthesized using large bore Teflon® tubing.
Two different dosage sets of DMS/bupivacaine PLAMs were produced: high dose (hd) DMS and low dose (ld) DMS. Hd-DMS/bupivacaine PLAMs contained approximately 60 μg DMS per pellet. Ld-DMS/bupivacaine PLAMs contained approximately 15 μg per pellet. Both sets contained 20% bupivacaine by weight. Group 5 animals were implanted with 3 hd-DMS/bupivacaine PLAM pellets on the experimental side. Group 6 animals were implanted with 3 ldDMS/bupivacaine PLAM pellets on the experimental side. The protocols and results are shown in Table 4.
TABLE 4______________________________________Classification of CapsulesGroup No Diffuse Laminar# Type of Side PLAM Type capsule capsule capsule______________________________________1 experimental 10% CHP + 4 bup3b experimental bupivacaine 44 experimental bupivacaine 64 control control 65 control control 1 47 control control 3 25 experimental ld-DMS/bup 56 experimental hd-DMS/bup 57 experimental hd-DMS 5______________________________________
DMS PLAMs
PLAMs containing DMS were synthesized via the hot melt procedure described for CHP PLAMs with some differences in initial preparation, as follows.
A uniform mixture of DMS and copolymer was produced by combining DMS dissolved in chloroform with copolymer dissolved in chloroform. The mixture was air-dried under the hood at room temperature until the chloroform evaporated and left behind a dry well-dispersed mass of DMS and copolymer. The dry mixture was pulverized under mortar and pestle and transferred to syringe. The rest of the procedure followed those described for CHP PLAMs. All DMS PLAMs were synthesized using large bore Teflon® tubing. Group 7 animals were implanted with 3 DMS PLAM pellets on the experimental side.
Control PLAMs
Control PLAMs were synthesized via the hot melt procedure described for CHP PLAMs. Control PLAMs contained only CPP:SA (20:80) copolymer and all pellets were synthesized with large bore Teflon® tubing. Groups 6 and 7 animals were implanted with 3 control PLAM pellets on the control side.
In Vitro Release of Dexamethasone
Tritium labeled dexamethasone ( 3 H-DMS) was purchased from New England Nuclear Corporation (Boston, Mass.). An aliquot consisting of 107 counts was added to a mixture of 200 μg unlabelled DMS and 190 mg bupivacaine dissolved in 95% ethanol. This solution was air-dried under the hood at room temperature until the ethanol evaporated and left behind a well-dispersed mixture of dry crystalline 3 H-labelled DMS, unlabelled DMS and bupivacaine. This dry crystalline mixture was pulverized under mortar and pestle and combined with 650 mg CPP:SA (20:80) copolymer. The rest of the procedure followed those described for CHP PLAMs. All 3 H-DMS/unlabelled DMS/bupivacaine PLAMs were synthesized using large bore Teflon® tubing. Each pellet was placed in 5 mL of sterile 1X PBS (phosphate-buffered saline) containing 1% sodium azide and incubated at 37° C. The incubated 1X PBS media was removed and stored at -20° C., and replaced with 5 ml of fresh sterile 1×PBS at 2h, 6h and 24 h time points and then once daily thereafter for 3 weeks. The 3 H released was counted using a liquid scintillation counter (Rackbeta 1214).
Behavioral Testing
Male Sprague-Dawley rats housed in groups of 4 were habituated to a hotplate of 56° C. both before and after surgery. They were tested between 10 am and 12 pm daily and allowed to adjust to their surroundings in a quiet room at 22°±1° C. for at least 30 minutes before testing. The rat was wrapped in a towel from the waist up for visual obstruction and hinderance of upper body motion. Held in the experimenter's hand, the animal's hindpaw was placed on the hotplate and latencies recorded, starting on contact and ceasing with withdrawal from hotplate, via a foot-switch connected to a computer. If latencies exceeded 12 seconds, the rat's hindpaw was removed to prevent injury. No rats were observed to have inflammation or blisters. Rats were tested for at least two weeks prior to surgery to achieve a consistent baseline latency, and testing continued for two weeks after surgery to confirm complete recovery from sensory blockade.
Motor blockade was rated on a 4-point scale. Animals with a motor block of 4 had a clubbed hindpaw and usually dragged their affected leg when walking. Motor block 3 animals walked normally but had toes that failed to splay when the animal was lifted. Animals with motor block of 2 showed toes that splayed but not as fully as normal or motor block 1 animals.
To better assess intensity of sensory block, hot plate latencies were subdivided into 4 classes: (1) maximum block intensity (MBI), when latency=12 sec, the maximum allowable time the rat's foot can remain on the hot plate before it is manually removed by the experimenter to prevent injury, (2) dense block, when latency=7-11, 3) partial block, when latency=4-7 sec, and 4) no block, when latency was less than 4 sec.
Surgery
All animals were anesthetized with 3.5%-4.0% halothane in oxygen and maintained with 1.5%-2.0% halothane. Anesthesia was achieved within 3-5 minutes post induction. Animals were tested by pinching of tailbase and pawpads to confirm the anesthetic state. The thigh area was shaved and an incision was made directly below the greater trochanter. The hamstrings were gently divided by blunt dissection to expose the sciatic nerve. PLAM pellets were placed adjacent to the sciatic nerve under direct vision in the fascial plane deep to the hamstrings and the site was irrigated with 0.5 cc of antibiotic solution (5000 units/mL penicillin G sodium and 5000 ug/mL streptomycin sulfate) to prevent infection. The most superficial facial layer was closed with a single suture. The edges of the outer skin were approximated and closed with one to two surgical staples.
For all rats, drug-containing PLAMS were implanted on the experimental side. The control (contralateral) side varied among the groups. Group 1 used 10% CHP PLAMs on the control side to compare the effects of bupivacaine and CHP PLAMs vs. CHP PLAMs alone. Groups 2, 3a/3b and 5 received sham operations on the control side to compare the effects of drug vs. both drug-free and PLAM-free states. Sham operations consisted of exposing the sciatic nerve, irrigation of the site with antibiotic solution, and closure of the surgical site without implantation of any PLAM pellets. Groups 4, 6 and 7 used control PLAMs on the control side to compare the effects of drug vs. drug-free PLAM states.
Necropsy
All groups, except groups 2 and 3a, were sacrificed at two weeks by CO 2 asphyxiation. Groups 2 and 3a were sacrificed five days post-surgery. Groups 4, 5 and 6 were given cardiac punctures and blood samples were taken for ACTH and cortisol assays. For autopsy, the skin of the dorsal thigh was removed. A midline transverse cut was made through each successive layer of hamstring muscle to locate the site of encapsulation, if any, and preserve its integrity and architecture. The capsule was excised by blunt dissection and placed in 10% formalin. A 3 cm segment of the sciatic nerve was removed from its exit point at the greater sciatic foramen to its branching point above the dorsal aspect of the knee joint. For light microscopy, a segment was fixed in 10% buffered formalin.
Statistics
All data were analyzed using repeated measure ANOVA, post-hoc paired t-tests, Fisher exact tests and Wilcoxon rank sum tests where deemed appropriate.
Histology
Nerves: For evaluation of sciatic nerves, cross-sections were processed, embedded in paraffin and sectioned at 2 μm and stained with hematoxylin eosin. 5-10 sections were studied via light microscopy by a pathologist in a blinded manner. Each cross-section was evaluated for (1) epineural inflammation, (2) epineural fibrosis, and (3) subperineural fibroblasts. Each parameter was rated on a severity scale of 0-4. A score of 0=no change, 1=mild, 2=moderate, 3=moderate-severe and 4=severe.
Capsules: Encapsulation was evaluated by gross examination at the time of dissection and through photographs by a blinded observer. This evaluation was divided into 3 categories. The first type was characterized by no true capsule. It involved nonspecific, unorganized inflammatory debris surrounding the implantation site. The other two capsule types were classified according to the manner of Ksander, et al. (G. A. Ksander, L. M. Vistnes and D. C. Fogerty, "Experimental effects on surrounding fibrous capsule formation from placing steroid in a silicone bag-gel prosthesis before implantation," Plast & Reconstr. Surg., 62, 873-883 (1978)). The second type was characterized by flimsiness, an ability to be easily deformed and torn, and an irregular dull surface of white to gray color. This type was designated as a diffuse capsule. The third type was characterized by toughness, resistance to deformation by handling and tearing at excision, and a smooth glossy inner surface of yellowish-brown to clear translucence. This type was designated as a laminar capsule. It was a true histological capsule with highly organized, fibrous walls enclosing the implanted pellets, completely separating it from immediate surrounding tissue. A severity scale of 0-4, similar to that described above, was used to rank the degree of inflammation of the perineural fascia and muscle fascia.
Cross-sections of formalin-fixed capsules were examined by light microscopy and rated on a severity scale from 0-4, specifically looking at (1) thickness of capsule wall, (2) proportion of PMN's in relation to other inflammatory cells, (3) proportion of lymphocytes to other inflammatory cells, (4) proportion of plasma cells to other inflammatory cells, (5) proportion of foreign body giant cells to other inflammatory cells, (6) proportion of immature fibroblasts to mature fibroblasts, and (7) extent of collagen deposition in the capsule wall.
Results
In Vitro Release of DMS
The release of DMS from PLAM was nearly linear for the first 8 days and eventually reached a plateau by Day 21. Approximately 60% of DMS was released from PLAM by Days 7-8 and by Day 21, 97% of DMS was released (FIG. 1).
Histology
Capsules
Dexamethasone prevented capsule formation in all groups whose experimental side received DMS-containing PLAM pellets (Groups 5, 6, and 7). In contrast, CHP did not prevent encapsulation. [see Table 3] All groups treated with CHP (Groups 1 and 2) formed capsules around implants by the time of dissection. Groups implanted with bupivacaine PLAMs (Group 3b and 4) and no additive (DMS or CHP) developed capsules around implants. Groups which received control PLAMs (Groups 4, 5 and 7) also formed capsules around implants. DMS-treated sides were significantly different from contralateral control sides implanted with drug-free PLAMs (Group 5 and 7, p<0.0001). They were also statistically different from sides receiving CHP-(Group 1, p=0.0003) and/or bupivacaine-containing PLAM pellets (Group 3b and 4, p<0.0001). Capsules formed from drug-free PLAMs (control PLAMs) were histologically indistinguishable from those that resulted from drug-containing PLAMs (CHP and bupivacaine). This was determined through examination of a variety of inflammatory factors. Capsules produced from drug-containing PLAMs were statistically insignificant from drug-free PLAMs in terms of (1) capsule thickness, (2) acute PMNs, (3) foreign body cells, (4) collagen content, (5) immature fibroblasts, and (6) mature fibroblasts. Two categories produced marginal statistical significance (p=0.0461): chronic round cells and plasma cells. This implied that drug-containing PLAMs may produce slightly more inflammation of the chronic inflammatory type.
Nerves
All groups showed no statistical significance between experimental and control sides in all three inflammatory factors examined: (1) epineural inflammation, (2) epineural fibrosis, and (3) perineural fibroblasts. Comparisons of experimental sides receiving CHP and bupivacaine vs. bupivacaine alone (Group 1 versus Group 3b and Group 2 versus Group 3a) showed no statistical significance. No difference in neural inflammation was found comparing groups receiving 10% CHP vs. 20% CHP (Group 1 versus Group 2) and groups sacrificed Day 5 versus Day 14 (Group 3a versus 3b). Comparison of experimental sides receiving DMS/bupivacaine versus bupivacaine alone (Group 5 versus Group 4 and Group 6 versus Group 4) showed no difference. No difference was also found comparing groups implanted with bupivacaine alone versus DMS alone (Group 4 versus Group 7) and hd-DMS/bupivacaine vs. ld-DMS/bupivacaine (Group 5 versus Group 6). One set, Group 6 versus Group 7, showed statistical significance. Group 6 produced a greater degree of epineural inflammation (p=0.0238) than Group 7. The other two inflammatory factors, epineural fibrosis and perineural fibroblasts, were statistically insignificant for Group 6 versus Group 7.
Sensory and Motor Blockade Among Animals Treated with DMS and CHP
Group 5 (animals implanted with ld-DMS/bupivacaine PLAMs) had the longest sensory and motor blockade. Sensory blockage lasted for a period of 6-7 days with maximum block intensity (latency=12 sec) observed on days 1-5 in all animals, as shown by FIG. 5. Motor blockade lasted for 6-8 days with the densest motor block seen on day 1-5. All animals returned to baseline on Day 8, as shown by FIG. 6a.
Rats implanted with hd-DMS/bupivacaine PLAMs (Group 6) also had sensory block lasting 6-7 days, as shown by FIG. 5. However, maximum block intensity was observed only on days 1-2 in all rats. A plateau of dense block (latency=7-11 sec) was seen on days 3-5. Motor blockade lasted for 3-5 days with the densest motor block occurring on day 1-2, as shown by FIG. 6c.
Group 4 animals (control group receiving large bore bupivacaine PLAMs) had sensory blockade lasting 5-6 days, as shown by FIG. 5. There were no time points when all animals had maximum block intensity simultaneously. However, dense sensory block (latency=7-11 sec) was observed on days 1-4 in all animals. Motor blockade lasted 3-6 days with densest block seen on Days 1-2, as shown by FIG. 6a.
Group 7 rats, who were implanted with hd-DMS PLAMs, showed no sensory and motor block, and all time points could not be distinguished from baseline.
Group 1, 2 and 3a/3b rats, who were implanted with 10% CHP PLAM plus bupivacaine PLAMs, 20% CHP PLAMs and plus bupivacaine PLAMs, and bupivacaine PLAMs alone, respectively, all displayed similar sensory block durations and intensities. All groups showed sensory block durations of 2-4 days with dense block seen on Day 1 and the majority of rats returning to baseline on Days 2-4, as shown by FIG. 7. Motor blockade were similar for Groups 1 and 3a/3b. Duration of motor block lasted for 1-2 days with the densest block observed primarily on day 1. Group 2 had motor blockade lasting for 1-4 days with the densest block also occurring on day 1, as shown by FIGS. 8a, 8b and 8c. One animal from Group 2 was dropped from the study because it did not recover motor-and sensory-wise. One animal from Group 3a was dropped from the study because it did not recover motorwise, although its sensory functions were intact and it returned to baseline.
Plasma Assays for ACTH and Corticosterone
Plasma assays performed on Groups 5, 6 and 7 animals showed no difference in ACTH and corticosterone levels compared to normal values of rats taken at the same period of day and under similar stress-level conditions. Prolonged release of dexamethasone, approximately 5-10 μg per day for 2 weeks, did not cause pituitary suppression of ACTH and consequently, did not decrease plasma levels of corticosterone.
Summary of Results
The present study demonstrates that DMS released from biodegradable polymer matrices can prevent encapsulation around polymer implants seen during autopsy at 2 weeks post-implantation. Sensory and motor blockade is profoundly enhanced in animals treated with DMS. Light microscopy studies show that DMS-treated sides have equivalent neural inflammation to sham operations, control PLAMs or bupivacaine PLAMs.
Modifications- and variations of the present invention, a biodegradable controlled release device for the prolonged and constant delivery of a local anesthetic agent, will be apparent to those skilled in the art from the foregoing detailed description of the invention. Such modifications and variations are intended to come within the scope of the appended claims. | An improved biodegradable controlled release system consisting of a polymeric matrix incorporating a local anesthetic for the prolonged administration of the local anesthetic agent, and a method for the manufacture thereof, are disclosed. The polymers and method of manufacture used to form the PLAMs are selected on the basis of their degradation profiles: release of the topical anesthetic in a linear, controlled manner over a period of preferably two weeks and degradation in vivo with a half-life of less than six months, more preferably two weeks, to avoid localized inflammation. Alternatively, a non-inflammatory can be incorporated into the polymer with the local anesthetic to prevent inflammation. | 62,653 |