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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention is related to a method for transmitting messages in an elevator group control system.
2. Description of the Prior Art
In an elevator communication system, all communication data originating from a separate group controller is not transmitted to a plurality of elevator controllers at almost the same time. If all communication data were transmitted from the group controller to the elevator controllers within a predetermined period, this large communication burden could cause a jam in the processing of the communication data. Accordingly, transmission efficiency is regarded as a major factor in the quality of such a control apparatus.
FIG. 1 is a simplified block diagram of a conventional elevator communication system.
Referring to FIG. 1, the elevator communication system consists of a plurality of elevator controllers 12A-12K, each associated with a floor of a building, to execute elevator-related signaling and control the execution of necessary operations; group controller 11 to execute group-related signaling and dispatch functions; and a common network NET to associate the elevator controllers 12A-12K and the group controller 11.
FIG. 2 is a block diagram illustrating a communication control circuit in the conventional elevator communication system.
As illustrated in FIG. 2, employed in the group controller 11 illustrated in FIG. 1 are a plurality of group communication controllers 21A-21K. A plurality of elevator communication controllers 22A-22K are employed in elevator controllers 12A-12K, respectively, and communicate with the group communication controllers 21A-21K via exclusive communication lines in a one-to-one parallel fashion.
The operation of the elevator communication system described as above, will be explained with reference to FIGS. 3 through 6.
If a passenger who is standing on the 8 th floor selects a hall call such as "down" via a control panel (not shown) associated with one of the elevator controllers 12A-12K the corresponding elevator communication controller 22A-22K recognizes an inputting-signal of hall call and transmits the data to the corresponding group communication controller 21A-21K.
Next, after a predetermined time, the group communication controller 21A-21K retransmits the transmitted data to the corresponding elevator communication controller 22A-22K to execute the operation as ordered. This confirms the correctness of the transmitted data.
In the retransmission operation, the communication data, which is data transmitted from the group communication controller 21A-21K to elevator communication controller 22A-22K or vice versa, consists of 1) data number and 2) associated data. FIG. 3 illustrates a table of communication data stored at the group controller 11 by each group communication controller 21A-21K for a respective elevator communication controller 22A-22K. The data number represents an index indicating a data record for the data transmission, while the region labeled data is where the actual data is stored. For example, in case that a data number "3" is assigned to the transmission data of calling the elevator car from the 1 st to the 8 th floor, the elevator communication controller 22A-22K executes a recording operation and records "3" as the data number in FIG. 3 and "the hall call from 1 to 8 floor" in the data region in FIG. 3. Subsequently, the group communication controllers 21A-21K for the first floor outputs the communication data as retransmission data to the corresponding elevator communication controller 22A-22K.
FIG. 4 illustrates a transmission data storage table stored at each group communication controller 21A-21K with respect to the associated elevator communication controller 22A-22K in the conventional communication system. This table is used to transmit changed data after comparing present data with previous data stored in the group communication controller 21A-21K.
FIG. 5 is a flow chart showing how transmission data, data for transmission to one of the elevator communication controllers 22A-22K from one of the group communication controllers 21A-21K, is created by one of the group communication controllers 21A-21K.
Referring to FIG. 5, the retransmission data is determined in step S1 by one of the group communication controllers 21A-21K, and the data number is initialized by "1" in step S2 (the number "1" is an index indicating a record of the transmission data storage table as illustrated in FIG. 4). For instance, if the data number is "2", a comparative data is "data 2" of the table illustrated in FIG. 4.
Next, a test S3 is performed to determine if any changed data is created with respect to all communication data; namely, determine whether the table of FIG. 3 includes new data. If the test S3 is affirmative, the overall program is returned to a transfer point T1. But if test S3 is negative, a test S4 is executed to determine if the communication data fills the communication data table of FIG. 3. That is to say, if a communication buffer in the group communication controller 21A, 22B, . . . or 21K for the record is not fully filled, the program is returned through a transfer point T2.
But if the test S4 is negative, a test S5 is executed to check if the present data is identical to the data recorded in the transmission table. If not, the relative data number and the actual data are recorded on the record region in the transmission table of FIG. 4 which will be transmitted in step S6. Subsequently, the data number is increased by "1" to process the next data in step S7. But if the test S5 is negative, the step S7 will also be executed.
FIG. 6 is a flow chart showing how the retransmission data is created in the conventional control apparatus.
The flow chart illustrated in FIG. 6 is a subroutine for determining the retransmission data in step S1 of FIG. 5. In FIG. 6, a test ST1 determines if the retransmission data number stored in the group controller 11 is a maximum data number, i.e., if the number is bigger than the largest possible data number for the transmission data storage table of FIG. 4. If the test is affirmative, the retransmission data number is initialized to 1 in step ST2. However, if the test is negative, the data of the transmission data storage table indicated by the retransmission data number is recorded on the data record to be transmitted in step ST3. Subsequently, the data number is increased by "1" in the next data step ST4.
According to the conventional process for creating the retransmission data as described above, it is noted that if the maximum data number recorded on the transmission table is 48 and the transmission period for the data record to be transmitted is 32 ms, the maximum time it takes to retransmit the data record, wherein the data record has already been transmitted, is 1,536 ms (T=48×32 ms).
The number of the data which each of the group communication controllers 21A-21K transmits to the corresponding elevator communication controller 22A-22K is predetermined as 8. So, when the number of the data to be transmitted is 4, another 4 data should be added thereto for transmission.
For that reason, there are drawbacks that the transmission time is delayed, thereby putting a large burden on communication processing.
Further, in case that the elevator cars connected to the group controller 11 are 5 and the communication period is 32 ms, the time it takes to transmit the record for 5 elevator cars is 160 ms (T-5×32 ms), since the group controller 11 has been communicated with each elevator car via the common network NET.
Accordingly, in the conventional elevator communication system, when the records are transmitted, an unnecessary region, where no information is recorded, is also transmitted together because the record length is already predetermined. In the example above, another four records were added to reach the predetermined number of records (i.e., eight), even though only four records needed to be sent. Further, if several elevator cars need to transmit the records at almost the same time, there is a drawback of a heavy burden in the communication process since each elevator car does not recognize the present operations of each elevator controller.
SUMMARY OF THE INVENTION
Therefore, the present invention has been devised to solve the problems involved in the prior art.
These and other objects are achieved by providing a method for transmitting messages in an elevator communication system, comprising: a) selecting, using a group communication controller, a set of elevator cars from a plurality of elevator cars in said elevator communication system; b) comparing present data for said selected set of elevator cars with data in a single table stored by said group communication controller to determine differing data, said differing data being said present data which differs from said data in said single table; and c) transmitting said differing data to said plurality of elevator cars.
BRIEF DESCRIPTION OF THE DRAWINGS
The above object and other features of the present invention will become more apparent by describing the preferred embodiments thereof with reference to the accompanying drawings, in which:
FIG. 1 is a simplified block diagram of a conventional elevator communication system.
FIG. 2 is a simplified block diagram illustrating a communication control circuit in a conventional elevator communication system.
FIG. 3. is a communication data table in a conventional elevator communication system.
FIG. 4 is a transmission data storage table in a conventional elevator communication system.
FIG. 5 is a flow chart showing how a transmission is performed in a conventional elevator communication system.
FIG. 6 is a flow chart showing how transmission data is created in a conventional elevator communication system.
FIG. 7 is a simplified block diagram of an elevator communication system applying a method for transmitting messages according to the present invention.
FIG. 8 is a communication data table according to the present invention.
FIG. 9 is a transmission data storage table according to the present invention.
FIG. 10 is a flow chart illustrating how communication data is created in accordance with the present invention.
FIG. 11 is a flow chart illustrating how the retransmission data is created in accordance with the present invention.
FIG. 12 is a flow chart illustrating how the number of retransmission records is determined in accordance with the present invention.
FIG. 13 is an example of communication data table created for the case of an operation of two elevator cars.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The preferred embodiments of the present invention will now be explained with reference to the accompany drawings.
FIG. 7 is a simplified block diagram of an elevator communication system applying a method for transmitting messages according to the present invention.
Referring to FIG. 7, a plurality of elevator communication controllers 72A-72K, provided in each elevator controller, are associated with a common bus line of a group communication controller 71, provided in a separate group controller. Accordingly, the group communication controller 71 circularly selects one of the elevator communication controllers 72A-72K within a predetermined period and in a predetermined order.
FIG. 8 is a communication data table which is used for transmitting messages created by the group communication controller 71. This table stores all new messages received from or to be transmitted to the elevator communication controllers 72A-72K.
As shown, the communication data includes an elevator number 8A, the number of data 8B, and the number of retransmission data 8C. Such data combinations can be recorded with maximum numbers predetermined thereto, since the corresponding elevator messages created by the group communication controller 71 are stored in one table and can be transmitted to the elevator communication controllers 72A-72K. The elevator number 8A represents an identifying number given to an elevator car which is transmitting a message such as the transmission data, the number of data 8B represents the number of data for the corresponding elevators from a data region which will be described hereinafter, and the number of the retransmission data 8C represents the number of retransmission data for the corresponding elevator cars recorded in a data region which will be described hereinafter. Accordingly, if the data number of all elevator cars are added to the number of retransmission data, the number N of the record will be obtained. Further, the data number 8D represents an index for identifying the data while the data 8E represents a region where the data, which the group controller 71 transmits, are recorded. Therefore, the total number of the records is obtained by summing the total number of the data and the total number of the retransmission data.
FIG. 13 is an example of a communication data table used in the case where two elevators are operated.
FIG. 9 illustrates a transmission data storage table according to the present invention. Such a table is used as a storage region by the group communication controller 71 for transmission data in the communication system, and is used to decrease the network load by minimizing the number of the transmission data. Namely, the group communication controller 71 compares the present data to the data previously stored in the communication data table of FIG. 8, and if the present data differs from the previously stored data, the present data is stored in the transmission data table of FIG. 9.
In FIG. 9, a data number region 9A stores an index for determining a data meaning, the transmission data region 9B is a storage region for the transmission data, the retransmission time region 9C is a storage region of the number of the corresponding transmitted data within the predetermined period, and a priority region 9D is a region storing the priority for retransmitting the data. As a result, the highest priority data is retransmitted first. If the same priority occurs, the data which the group communication controller 71 attempted to transmit the greatest number of times is given higher priority.
Now, the routine illustrated in the flow chart of FIG. 10 will be explained to show how the communication data is created by the group communication controller 71.
First, initialization is caused by power-on-reset and the group communication controller 71 circularly selects the elevator number for each elevator communication controller 72A-72K within a predetermined period and in a predetermined order in step SA1. More specifically, a predetermined number of elevator cars are selected in a predetermined order. Thus, the group communication controller 71 circularly selects one of the elevator car numbers one by one. For instance, assume 5 elevator cars are associated with the group communication controller 71, which are numbered as 1, 2, 3, 4 and 5, and the messages for three cars, e.g., cars 1, 2 and 3 are selected in step SA1 with respect to a first communication. In a similar manner, messages for the elevator cars 4, 5 and 1 will be selected for a in the second communication, messages for the elevator cars 2, 3 and 4 will be selected for a third communication, etc. Next, the number of the retransmission data recorded in the transmission data table (FIG. 9) is set to "0" in step SA2. A test SA3 determines if the communication data for each of the elevator cars selected in step SA1 has been tested for transmission. The data number set in step SA4 is used as a counter of the number of elevator cars tested. When the data number exceeds the predetermined number of elevator cars selected in step SA1, step SA3 determines that all the selected elevator cars have been tested. If the test is affirmative, step SA12 will be executed to determine the number of data for transmission. As discussed in detail below, the number of data for transmission will equal the transmission data number determined in step SA9.
On the other hand, if test SA3 is negative, then initialization of the data number indicating the data number of a record in the transmission data storage table illustrated in FIG. 9, is set as "1" in step SA4.
Next, it is determined whether data number is greater than the predetermined number of elevator cars selected in step SA1. If test SA5 is affirmative, the routine is returned to step SA3. On the other hand, if test SA5 is negative, a test SA6 will be executed to determine if a communication buffer (not shown) storing the transmission data is full. This test compares the transmission data number (see step SA9) to the storage capacity of the communication buffer. If the transmission data number is greater than the storage capacity of the communication buffer, the step SA6 determines that the communication buffer is full. If the test is affirmative, step SA12 will be executed because no more data can be recorded. But if the test SA6 is negative, a test SA7 will be executed.
Test SA7 determines if the present data has changed by comparing the present data with the data stored in the communication data table of FIG. 8. If the data has not changed, step SA11 is executed directly. But if test SA7 is affirmative, that is, the data has changed, it shows that there is a need for communication because the communication data being processed in the group communication controller 71 differs from the data previously stored in the communication data table.
Accordingly, the corresponding data number and the data are recorded in a data region of FIG. 8, and this changed data is also recorded on the transmission data table illustrated in FIG. 9 in step SA8. After step SA8, the number of the transmission data is increased by "1."
Subsequently, the priority for the data stored in the transmission data table of FIG. 9 is arranged in step SA10 as described in detail below, and the number of the data is increased by 1. Next, processing returns to step SA5 and continuously executes steps SA3 through SA11 repeatedly.
Accordingly, as a result of the repeated steps, the test SA3 determines if the communication data is created with respect to all selected elevator cars. If the test is affirmative, a step SA12 is executed to record the number of the transmission data on the region 8B of communication data table illustrated in FIG. 8, and the retransmission data is additionally added in step SA13 and the routine returns.
The retransmission data is determined by executing a subroutine illustrated in FIG. 11.
First, in step SB1, the number of retransmission data is determined for the selected elevator cars in accordance with the flowchart of FIG. 12 described in detail below. At this time, the priority of the data will be determined as below.
Priority 1: previously transmitted data
Priority 2: transmitted data within the predetermined period
Priority 3: non-transmitted data within the predetermined period
Priority 4: retransmitted data within the predetermined period
Priority 100: transmission data at present
If the number of the retransmission data for each elevator car is determined by the routine illustrated in FIG. 12, a test SB2 determines if the number of retransmission data for each selected elevator car has been tested via steps SB3-SB7. If so, the number of the retransmission data for each elevator car is recorded on the region 8C as the number of the retransmission data in the communication data table illustrated in FIG. 8 in step SB8. Then a step SB9 is executed to arrange the retransmission data according to priority such that the priority 100 of the present transmission data is changed to the priority 1 and the retransmission is executed with the highest priority retransmission data in the next period. In this case, the elevator cars processed here are limited to the selected elevator cars selected in step SA1 illustrated in FIG. 10.
If the test in step SB2 is negative, the retransmission data is arranged based on the priority of the transmission data storage table shown in FIG. 9 for processing elevator cars in step SB3, and the retransmission data number is initialized to "1" in step SB4. Next, a test SB5 determines if the retransmission data number is greater than the number of the retransmission data, which is obtained in step SB1 illustrated in FIG. 11, for the elevator car undergoing test. At this time, if the test is affirmative, the program is returned to test SB2 and steps SB2 through SB5 are repeated with respect to the next elevator car.
But if test SB5 is negative, the data indicated by the retransmission data number is recorded in the retransmission data record in step SB6 and the retransmission number is increased by "1" in step SB6A. At this stage, the retransmission data having the highest priority is recorded on the data record in step SB7 since the transmission data table is updated by the highest priority in accordance with the execution of step SB3.
Next, the priority for the retransmission data forming the data record in step SB7 is changed to the priority 4, representing the retransmitted data within the predetermined period as the selected data record which can be transmitted together with the communication data so that the data record is not selected when the next communication data is transmitted.
The number of the retransmission data record is obtained by executing a subroutine illustrated in FIG. 12.
Referring to FIG. 12, first, the number of the available retransmission data record is initialized in step SC1, and the priority is also initialized to the priority 1 in step SC2. Next, a test SC3 determines if a number of the retransmission data has been tested with respect to all priorities. Namely, a predetermined amount of data is transmitted by the group communication controller 71. This predetermined amount less the amount of transmission data determined with respect to FIG. 10 gives the space left for the retransmission data. If the test in step SC3 is affirmative, the program is returned. But if test SC3 is negative, the number of records for the priority being processed are collected in step SC4, wherein the priority of the transmission data storage table illustrated in FIG. 9 is used.
Subsequently, a test SC5 determines if the number of the available data is larger than a sum of the number of the transmission data records of the corresponding priority number. If the test is affirmative, the number of the data records, which is identical to the processing priority in accordance with the execution of searching the transmission data storage table for selected elevator cars in step SA1 illustrated in FIG. 10, is determined as the number of the data for the corresponding elevators. Thus, the total number of the data can be obtained by summing the number of the data and the corresponding records in step SC6.
Next, the priority is increased by "1" in step SC7, and a value, which is obtained by subtracting the number of the available data record assigned by step SC6 from the number of the available data, is used as the number of new available data.
But if the test SC5 is negative, indicating that the number of the record for the processing priority is bigger than that of the available data, the rate-assignment is executed in accordance with the number of the total data obtained by summing the number of the data and the rate of the corresponding records in step SC9.
For instance, in the case that the number of available retransmission data region is 8 and the selected elevator cars are two elevator cars 1 and 2, the number of the retransmission data record for each elevator car illustrated table 2 will be obtained from the given table
TABLE 1______________________________________Elevator No. Priority 1 Priority 2 Priority 3______________________________________1 3 6 82 2 3 12______________________________________
TABLE 2______________________________________Elevator No. Priority 1 Priority 2 Priority 3 Total______________________________________1 3 2 0 52 2 1 0 3______________________________________
Referring to table 2, when the priority 1 is determined, the total number 5 is smaller than the number 8 of the retransmission data region, so assignment will be executed as it is.
Similarly, when the priority 2 is determined, the total number 9 is bigger than the number of the retransmission data region: i.e., 3, so assignment will be executed in accordance with equation (1).
elevator 1: 3×6/9=2
elevator 2: 3×3/9=1 . . . equation (1)
Further, in the case that the number of the records which are available to record on the communication records is 8 and the number of the changed data is 4, only 4 data records are used for the region of the retransmission records.
Accordingly, it is noted that the time it takes to transmit messages having 48 records is 384 ms (32 ms×48/4), while it takes 1,436 ms in the prior art.
Further, assume that the number of the elevator cars associated with the communication system is 5, the communication period is 32 ms, and the data records created from the plurality of elevator cars are circularly transmitted within the predetermined period, for example, 32 ms, and the predetermined order using one data record. In this case, if messages for two elevator cars are transmitted at almost same time, the time it takes to transmit messages of the total 5 of elevator cars is 80 ms (T=32 ms×2.5).
Thus, because of the transmitting method for selecting corresponding elevator circularly, messages for the elevator cars 1 and 2 will be recorded in the data 1, and similarly messages for the cars 3 and 4 in the data 2, messages for the cars 5 and 1 in the data 3, etc.
As described above, the retransmission data record region including the communication data are made of a minimum number of the transmission data after recognizing that the data is changed by causing in each elevator car as well as messages for elevator cars will be transmitted by circularly selecting corresponding elevator in the predetermined order.
Therefore, the transmission speed and capacity are highly increased and the total efficiency in processing communication data is largely improved.
Many modifications and variations of the present invention are possible in light of the above teachings. Therefore, it is to be understood that within the scope of the appended claims, the invention may be practiced otherwise than as specifically described. | The method for transmitting messages in an elevator communication system selects a set of elevator cars from a plurality of elevator cars in the elevator system, and compares present data for the selected set of elevator cars with data stored in a single table. The present data which differs from the data stored in the table is designated as changed or differing data. This differing data is transmitted to the plurality of elevator cars. Along with the differing data, retransmission data ordered according to the priority associated therewith is also transmitted along with the differing data. In this manner, a group communication controller controls the communication for several elevator cars. | 1 |
FIELD
[0001] The present disclosure relates to hybrid vehicles, and more specifically to transmissions for hybrid vehicles.
BACKGROUND
[0002] The statements in this section merely provide background information related to the present disclosure and may not constitute prior art.
[0003] Internal combustion engines produce drive torque that is transferred to a drivetrain. The drive torque is transferred through a transmission that multiplies the drive torque by a gear ratio. Transmissions generally include multiple gear ratios through which the drive torque is transferred. Automatic transmissions automatically shift between gear ratios based on driver input and vehicle operating conditions. Traditionally, automatic transmissions include a forward clutch and a reverse clutch for actuation between forward and reverse driving conditions through the use of a pressurized hydraulic fluid. The hydraulic fluid is typically pressurized during operation of the engine.
[0004] Hybrid powertrains typically include an electric machine and an energy storage device (ESD) such as battery or super capacitor. In one mode, the electric machine drives the transmission using energy stored in the ESD. In another mode, the electric machine is driven by the engine to charge the ESD. When operated in the first mode, the hybrid vehicle may be operated without the use of the engine. When operated without the use of the engine, an auxiliary pressurizing mechanism, such as an electric pump, is typically used to pressurize the hydraulic transmission fluid to provide for engagement of the forward clutch.
SUMMARY
[0005] Accordingly, a transmission for a hybrid vehicle including a combustion engine and an electric propulsion system may include a forward clutch assembly, a fluid chamber, a fluid supply, and a forward clutch holding valve. The forward clutch assembly may include a hydraulically actuated clutch member in communication with the fluid chamber. The forward clutch holding valve may be in communication with the fluid chamber and the fluid supply. The valve may provide communication between the fluid supply and the fluid chamber when in a first position and may seal the fluid chamber when in a second position, thereby maintaining a fixed quantity of fluid within the fluid chamber.
[0006] Further areas of applicability will become apparent from the description provided herein. It should be understood that the description and specific examples are intended for purposes of illustration only and are not intended to limit the scope of the present disclosure.
DRAWINGS
[0007] The drawings described herein are for illustration purposes only and are not intended to limit the scope of the present disclosure in any way.
[0008] FIG. 1 is a schematic illustration of a hybrid vehicle according to the present disclosure;
[0009] FIG. 2 is a functional block diagram illustration of a transmission of the hybrid vehicle of FIG. 1 ;
[0010] FIG. 3 is a schematic illustration of a forward clutch portion of the transmission of FIG. 2 ;
[0011] FIG. 4 is an additional schematic illustration of the forward clutch portion of the transmission of FIG. 2 ; and
[0012] FIG. 5 is a flow chart illustrating operation of the transmission of FIG. 2 .
DETAILED DESCRIPTION
[0013] The following description is merely exemplary in nature and is not intended to limit the present disclosure, application, or uses. For purposes of clarity, the same reference numbers will be used in the drawings to identify similar elements. As used herein, the term module refers to an application specific integrated circuit (ASIC), an electronic circuit, a processor (shared, dedicated, or group) and memory that execute one or more software or firmware programs, a combinational logic circuit, or other suitable components that provide the described functionality.
[0014] Referring now to FIG. 1 , an exemplary hybrid vehicle 10 is schematically illustrated. The hybrid vehicle 10 includes a combustion engine 12 and an electric machine 14 , which selectively drive a transmission 16 . Drive torque may be transmitted from engine 12 and/or electric machine 14 to transmission 16 through a coupling device 18 . Transmission 16 may be an automatic transmission and coupling device 18 may include a torque converter.
[0015] Hybrid vehicle 10 may be operable in first and second modes. Control module 20 may be in communication with and may receive and send control signals to engine 12 and transmission 16 to control operation thereof in the first and second modes. In a first mode of operation, engine 12 may be operated, providing drive toque for hybrid vehicle 10 and/or charging of electric machine 14 . In the second mode, engine 12 may be powered off. In the second mode, drive torque for hybrid vehicle 10 may be provided solely by electric machine 14 . Whether operating in the first or second modes, drive torque is transmitted to transmission 16 in order to drive hybrid vehicle 10 .
[0016] With additional reference to FIG. 2 , a functional block diagram of transmission 16 is illustrated. Transmission 16 may include a fluid source 22 providing hydraulic fluid for transmission 16 . Fluid source 22 may include a pumping mechanism powered by engine 12 for pressurizing the hydraulic transmission fluid for actuation of transmission 16 , as discussed below. Fluid source 22 may be in communication with a control valve 24 and a locking valve 26 . Control valve 24 may be in fluid communication with a forward clutch regulator valve 28 and a reverse clutch regulator valve 30 . Control valve 24 may provide selective communication between fluid source 22 and the forward and reverse clutch regulator valves 28 , 30 . Transmission 16 may be actuated between forward, reverse, and neutral conditions by the pressurized hydraulic fluid provided by fluid source 22 during operation of engine 12 . More specifically, forward and reverse clutch regulator valves 28 , 30 may be in fluid communication with forward and reverse clutch assemblies 32 , 34 . Selectively providing the pressurized hydraulic fluid to forward and reverse clutch assemblies 32 , 34 allows actuation between the forward, reverse, and neutral conditions.
[0017] A forward clutch holding valve 36 may be disposed between and in fluid communication with forward clutch regulator valve 28 and forward clutch assembly 32 . Locking valve 26 may also be in fluid communication with forward clutch holding valve 36 , as discussed below. With additional reference to FIGS. 3 and 4 , forward clutch holding valve 36 may include a valve housing 38 containing a valve 40 therein. Valve housing 38 may include an inlet port 42 , an outlet port 44 , and first and second valve actuation ports 46 , 48 . An inner bore 50 may include first and second portions 52 , 54 housing valve 40 therein.
[0018] Valve 40 may include a central portion 56 having first and second portions 58 , 60 extending therefrom. Central portion 56 may be disposed in bore second portion 54 and may have an outer diameter generally corresponding to the inner diameter of bore second portion 54 . Valve first portion 58 may be disposed in bore first portion 52 and may have an outer diameter generally corresponding to the inner diameter of bore first portion 52 . The outer diameter of valve first portion 58 may be less than the outer diameter of valve central portion 56 creating an annular surface 62 on a first side of central portion 56 . Valve second portion 60 may have an outer diameter that is less than the outer diameter of valve central portion 56 creating an annular surface 64 on a second side of central portion 56 . A biasing member 66 , such as a spring, may extend between a first end 68 of bore second portion 54 and valve annular surface 64 . The outer diameter of valve second portion 60 may be less than the outer diameter of valve first portion 58 . As such, annular surface 64 on the second side of central portion 56 may have a greater surface area than annular surface 62 . First end 68 of bore second portion 54 may act as a first stop for valve 40 , as discussed below.
[0019] Valve housing inlet port 42 may extend into bore first portion 52 . A flow path 70 may extend from an end 72 of bore first portion 52 to outlet port 44 . End 72 may act as a second stop for valve 40 , as discussed below. First and second valve actuation ports 46 , 48 may extend into bore second portion 54 .
[0020] Forward clutch assembly 32 may include a hydraulic chamber 74 , a clutch piston 76 , and a series of clutch plates 78 . Hydraulic chamber 74 may be in communication with clutch piston 76 . Clutch piston 76 may be operably coupled to clutch plates 78 for selective engagement thereof, as discussed below. A first fluid path 80 extends between hydraulic chamber 74 and valve housing outlet port 44 . A second fluid flow path 82 extends between inlet port 42 and forward clutch regulator valve 28 and a third fluid flow path 84 extends between first valve actuation port 46 and forward clutch regulator valve 28 . A fourth fluid flow path 86 extends between second valve actuation port 48 and locking valve 26 .
[0021] With additional reference to FIG. 5 , flow chart 100 generally shows the operation of transmission 16 . As indicated in step 110 , engine 12 is initially operated to allow for pressurization of fluid source 22 , as discussed above. Transmission 16 may then provide for a forward drive condition by providing pressurized fluid from forward clutch holding valve 36 . As indicated at step 112 , forward clutch holding valve 36 may be opened to provide for engagement of forward clutch assembly 32 , as indicated at step 114 .
[0022] More specifically, as seen in FIG. 3 , valve 40 may be displaced to an open position, allowing fluid communication between inlet port 42 and outlet port 44 . Valve 40 may be displaced to the open position by pressurized fluid provided by forward clutch regulator valve 28 entering valve housing 38 at first valve control port 46 and acting upon annular surface 62 of valve 40 . The force created by the pressurized fluid may be greater than that applied by biasing member 66 , resulting in the opening of forward clutch holding valve 36 . Pressurized fluid may therefore travel through first fluid path 80 and into hydraulic chamber 74 , where it acts upon clutch piston 76 , urging clutch plates 78 into engagement.
[0023] As indicated at step 116 , and seen in FIG. 4 , forward clutch holding valve 36 may be closed. Operation of hybrid vehicle 10 may then be operated in an engine-off condition while maintaining engagement of the forward clutch assembly without the use of an auxiliary fluid pump or fluid source. Forward clutch holding valve 36 may be closed before the engine-off condition to maintain fluid pressure in hydraulic chamber 74 . More specifically, locking valve 26 may provide pressurized fluid to bore second portion 54 , resulting in a force being applied on annular surface 64 of valve central portion 56 . The combination of the force applied by the pressurized fluid on annular surface 64 and the force applied by biasing member 66 may be greater than the force applied by the pressurized fluid acting upon annular surface 62 , resulting in displacement of valve 40 to the closed position.
[0024] When in the closed position (seen in FIG. 4 ), valve first portion 58 abuts bore end 72 , sealing outlet port 44 from inlet port 42 . As such, hydraulic chamber 74 is in a sealed condition, where fluid neither exits nor enters, resulting in a generally constant pressure being applied to clutch piston 76 . The pressure in hydraulic chamber 74 is sufficient for engagement of clutch plates 78 by clutch piston 76 when hydraulic chamber 74 is sealed. Therefore, clutch plates 78 remain in an engaged condition when hydraulic chamber 74 is sealed.
[0025] As indicated at step 118 , engine 12 may then be powered off resulting in the pressure provided by locking valve 26 and forward clutch regulator valve 28 being greatly reduced. When in the engine-off condition, valve 40 may be held in the closed position through the force applied by biasing member 66 maintaining engagement of the forward clutch assembly 32 , as indicated at step 120 . As such, forward clutch engagement may be maintained in hybrid vehicle 10 without the use of an auxiliary source of pressurized fluid.
[0026] Those skilled in the art can now appreciate from the foregoing description that the broad teachings of the present disclosure can be implemented in a variety of forms. Therefore, while this disclosure has been described in connection with particular examples thereof, the true scope of the disclosure should not be so limited since other modifications will become apparent to the skilled practitioner upon a study of the drawings, the specification and the following claims. | A transmission for a hybrid vehicle including a combustion engine and an electric propulsion system may include a forward clutch assembly, a fluid chamber, a fluid supply, and a forward clutch holding valve. The forward clutch assembly may include a hydraulically actuated clutch member in communication with the fluid chamber. The forward clutch holding valve may be in communication with the fluid chamber and the fluid supply. The valve may provide communication between the fluid supply and the fluid chamber when in a first position and may seal the fluid chamber when in a second position, thereby maintaining a fixed quantity of fluid within the fluid chamber. | 1 |
[0001] This is a continuation application of co-pending U.S. Ser. No. 11/940,233, now U.S. Pat. No. ______, filed on Nov. 14, 2007, which is entitled Reinforced Skateboard Deck and hereby incorporated by reference in its entirety.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates to the field of skateboard decks, and more specifically, to skateboard decks incorporating destructive force resistant materials.
[0004] 2. Background
[0005] Skateboards are typically used today to ride up, over, and oft of ramps and other structures, and the skateboard deck undergoes considerable stress when the rider and skateboard return to the ground. Skateboard decks have been strengthened by a laminated structure typically a seven-ply hardwood with the grain direction of the plies varied to provide strengthening in more than one direction. Such laminate decks are still subject to failure under significant impacts during typical skateboarding use. It is believed that a common failure of the laminate deck occurs where the top layer of the laminate will fail in tension when loaded, then the second sub-layer below that will in turn fail in tension, and then the next and next, working from the top of the deck to the bottom surface.
[0006] Skateboard decks have also been provided with fiber reinforcement, typically a fiberglass and resin matrix such as epoxy or other thermosetting resin. Fiber reinforced skateboards are known in the art, with some designs placing the fiber reinforcement between the hardwood veneer layers, while other designs have the fiber on the bottom or top major surface of the skateboard. It is believed that the location where a fiber reinforcement has the greatest effect in strengthening against common failure-inducing loads is the top major surface of the skateboard. When fiber reinforcement is placed in such a way as to be firmly and permanently adhered to the top major surface of the skateboard, the common failure mode is prevented from initiating. This is believed to be because the tensile load is distributed over not only the laminate structure of hardwood veneers, but also by augmenting the strength of the laminate structure by the fiber and resin matrix reinforcement. Propagation of rupture of the laminated hardwood veneers is believed to he reduced, because the fibers are both adding stiffness to the structure, and adding overall tensile strength to the skateboard.
[0007] Providing a layer of fiber reinforcement over the entire major surfaces of the skateboard deck has practical drawbacks given the common nature of use of skateboards where the edges of the deck are worn away by contact with the ground. The result of such contact and wearing away is that fibers are exposed at the edge of the deck. These exposed fibers, particularly in the case of glass or carbon fiber can be rigid and sharp. In the case of other fibers, such as aramid, or para-aramids or other engineering thermoplastic fibers, the exposed fibers are typically soft and pliable, but in any case create a cosmetically unattractive edge.
[0008] Therefore, what is needed and heretofore unavailable is a reinforced skateboard deck constructed to resist destructive forces typically occurring during use while protecting the reinforcing elements from wear and tear.
SUMMARY OF THE INVENTION
[0009] In accordance with a preferred embodiment of the present invention, a reinforced skateboard deck may incorporate a board with an upper foot bearing surface and a lower truck mounting surface and at least one layer spaced apart from the truck mounting surface. A protective side barrier further forms a protective sidewall to a reinforced region constructed of a fiber-reinforced material received in an opening in the layer with the protective side barrier and the reinforced region formed of different materials to provide a rupture resistant skateboard deck.
[0010] In one aspect of the present invention, the reinforced region may be constructed of a plurality of overlapping fiber-reinforced materials.
[0011] In another aspect of the present invention, the reinforced region and the protective side barrier are coplanar.
[0012] In yet another aspect of the present invention, the reinforced region and the protective side barrier having differing densities.
[0013] Other aspects of the present invention will become apparent with further reference to the following drawings and detailed description.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] FIG. 1 is a perspective view of the layers of a skateboard deck in accordance with an embodiment of the present description, showing an upper layer formed of a fiber-reinforced layer inlaid within a veneer, and six additional layers, with varying strand orientations, prepared for assembly;
[0015] FIG. 2 is a top plan view of the veneer for the upper layer prior to an initial cutting, showing a typical dimension;
[0016] FIG. 3 is a top plan view of the veneer of FIG. 2 with a central portion removed to provide a side barrier defining a central opening;
[0017] FIG. 4 is a top plan view of the fiber-reinforced layer for the upper layer, showing a typical dimension, prior to an initial cutting;
[0018] FIG. 5 is a top plan view of the fiber-reinforced layer, after cutting to a typical shape, to fit the layer into the central opening of the side barrier;
[0019] FIG. 6 is a top plan view of the fiber-reinforced layer and the side barrier assembled to provide the upper layer;
[0020] FIG. 7 is a perspective view of a removable adhesive tape being applied to the fiber-reinforced layer and the side barrier to hold them together;
[0021] FIG. 8 is an end elevation view of the layers arranged together, including a spacer layer beneath the fiber-reinforced layer, showing a typical dimension;
[0022] FIG. 9 is an end elevation view of a mold pressing the layers together to form a blank skateboard deck which may subsequently be cut to a desired size and shape; and
[0023] FIG. 10 is a perspective view of a skateboard deck press molded to provide a raised nose and tail and cut to a final desired shape.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0024] As shown in FIG. 1 , a skateboard deck, indicated generally at 10 , is typically formed of a series of wood veneer layers 12 , which are stacked and assembled together. Alternatively, other suitable materials, such as thermoplastics, and non-layered constructions may be used.
[0025] An upper layer 14 provides a top surface 16 and a bottom surface 18 . The top surface is typically the top structural (riding or foot bearing) surface of the skateboard deck, although a grip tape or other similar layer may be applied over the top surface. Upper layer 14 includes an inlaid, fiber-reinforced layer 20 that provides a portion of top surface 16 .
[0026] Fiber-reinforced layer 20 is typically formed substantially of woven para-aramid fibers. The fiber-reinforced layer may be made with unidirectional or bi-directional para-aramid fibers loosely woven into a fabric. As an example, layer 20 may include Kevlar®.RTM (resin transfer molded) fabric encased in an adhesive matrix. As an example, the Kevlar® fabric may be substantially saturated with polyurethane, which is then allowed to harden before further processing. Other components of the adhesive matrix would include a resin of epoxy or polyvinyl.
[0027] Fiber-reinforced layer 20 defines an edge 22 (see also FIG. 5 ), and typically has an oval or racetrack shape, although other shapes may be used as desirable for a particular skateboard design.
[0028] Upper layer 14 typically includes a side barrier 24 that also provides a portion of top surface 16 . Preferably, the side barrier and the fiber-reinforced layer together provide the entire top surface but alternatively other structure may provide a part of the top surface. Also preferably, the side barrier extends around the entire edge of the fiber-reinforced layer. Alternatively, the side barrier extends around only a portion of the edge of the fiber-reinforced layer, in which case some other structure may run alongside a portion of the fiber-reinforced layer or no structure as suitable to the desired skateboard design. The side barrier is typically a wood veneer, and as such includes the fibrous material that is naturally found in wood, however, the side barrier typically does not include any fiber reinforcement such as to leave behind a fringe or sharp edge of fibers as may be the case with Kevlar® or glass or carbon fibers. Alternatively, side barrier 24 may be formed from a thermoplastic sheet.
[0029] As best seen in FIGS. 2 and 3 , side barrier 24 is made by starting with a wood veneer blank 26 from which a central portion 28 is removed to provide a central opening 30 , typically in an oval or racetrack shape, but alternatively with any shape suited to the specific skateboard. Thus, central opening 30 is defined by side barrier 24 .
[0030] As best seen in FIGS. 4 and 5 , fiber-reinforced layer 20 is made by starting with a sheet of woven Kevlar® fabric 32 encased in an adhesive matrix, such as by substantial saturation with polyurethane. Sheet 32 is cut into an oval racetrack, or other suitable shape to produce layer 20 , which is preferably closely fitted for central opening 30 of side barrier 24 (see FIG. 6 ).
[0031] Side barrier 24 and fiber-reinforced layer 20 are preferably die cut from blank 26 and sheet 32 , respectively, but any suitable means may be used. With die-cutting, the same press and die may be used to cut both the blank and the sheet. Side barrier 24 and fiber-reinforced layer 20 are typically of equal thickness although some variation is permitted. Alternatively, the fiber-reinforced layer may be substantially thinner, with the difference made up by a spacer layer 34 (see FIGS. 8 and 9 ), typically of the same shape, such as oval, as fiber-reinforced layer 20 . Spacer layer 34 may be affixed, e.g., by adhesive, to the bottom surface of fiber-reinforced layer 20 , and may be cut to shape either separately or together with the fiber-reinforced layer.
[0032] As shown in FIGS. 6 and 7 , after fiber-reinforced layer 20 and side barrier 24 are combined by placing layer 20 within central opening 30 , they may be temporarily held together by application of an adhesive tape 36 , e.g., the Peel A Play tape made by the R Tape Corporation of New Jersey. Adhesive tape 36 may be applied by a heat transfer press.
[0033] As best seen in FIGS. 1 , 8 , and 9 , skateboard deck 10 may include a first lower layer 38 , typically a wood veneer, defining an upper surface 40 and a lower surface 42 . Upper layer 14 , comprising side barrier 24 and fiber-reinforced layer 20 , is affixed, typically by application of adhesive and subsequent press molding at suitable heat and temperature, to first lower layer 38 . Additional lower layers may be included as desired in consideration of desired weight and strength factors. For example, second, third, fourth, fifth, sixth, and seventh lower layers 44 , with ultimate bottom surface 46 , may be affixed successively beneath the first lower layer, typically by application of adhesive and subsequent press molding at suitable heat and temperature.
[0034] Typically the lower layers are wood or other structural material with a strand orientation that is varied from layer to layer. As an example, with seven lower layers, two may be oriented to provide maximum cross board strength, while the remaining five maximize along board strength, although this scheme will be varied as appropriate for the desired performance characteristics.
[0035] FIGS. 1 , 8 , and, 9 also illustrate that fiber-reinforced layer 20 is inlaid within side barrier 14 , and side barrier 14 preferably surrounds substantially all of edge 22 of fiber-reinforced layer 20 . As shown in FIG. 10 , skateboard deck 10 may be press-molded to provide a raised tail 48 and a raised nose 50 and cut to a final desired shape. Furthermore, deck 10 may be drilled for truck mounting holes, and then trucks, bearing and wheels may be mounted to provide a skateboard ready for riding. A grip tape or other suitable tape, stickers or the like may be affixed over the top surface. Preferably the upper surface of fiber-reinforced layer 20 and the upper surface of side barrier 24 are flush with one another, presenting a smooth transition with no visible step.
[0036] Alternatively, upper layer 14 may be formed substantially of an adhesive matrix including a central portion of woven fiber encased therein to provide the fiber-reinforced layer. In this embodiment, the adhesive matrix includes an outer portion without woven fiber to provide the side barrier.
[0037] As described herein, skateboard deck 10 includes a top (or foot bearing) surface 16 for the rider's feet, and a bottom surface 46 for the connection of trucks and wheels. The top surface is provided in part by a fiber-reinforced layer 20 . The top surface is further provided by a side barrier 24 extending around at least a portion of the fiber-reinforced layer.
[0038] Typical thicknesses for the fiber-reinforced layer after saturation with polyurethanes are between about 0.010 to about 0.050-inches. Typical thicknesses for side barrier 14 is between about 0.040 to about 0.065-inches. The thickness of spacer layer 34 typically is adjusted to the appropriate thickness to accommodate the difference between fiber-reinforced layer 20 and side barrier 24 and provide a flush top surface 16 . As an example, where side barrier 14 is 0.060-inches thick, and fiber-reinforced layer 20 is 0.020-includes thick, spacer layer 14 is preferably 0.040-inches in thickness. All of these dimensions may be varied within and beyond these ranges as suited to the particular skateboard design.
[0039] Side barrier 14 may have varying width dimensions relative to skateboard deck 10 and fiber-reinforced layer 20 . The dimensions of the side barrier may be substantially uniform around the edge of the skateboard, or they may vary significantly as desired for specific skateboard characteristics. For example, the side barrier may be narrower along the sides as compared to the nose and tail. Side barrier 14 preferably has a minimum width of 0.125-inches along each long side of the skateboard. Side barrier 14 preferably has a width dimension between about 0.125-inches and about 6-inches adjacent the nose and tail of the skateboard. All of these dimensions may, be varied within and beyond these ranges as suited to the particular skateboard design. With this design, fiber-reinforced layer 20 is inset away from the edge of the skateboard, so that the fibers are shielded from contact when the skateboard edges are scraped on the ground or other surface. Fiber-reinforced layer 20 is preferably inlaid on top surface 16 of deck 10 , and additionally or alternatively may be inlaid on lower surface 42 .
[0040] It will be appreciated that the incorporation of the fiber-reinforced layer 20 and/or the fiber-reinforced layer as bonded to another layer of the deck assists in significantly resisting tensile forces commonly associated with use and improves the overall rupture resistance of the deck. When used at or near the top layer as a part thereof, the effectiveness of this rupture resistance feature increases.
[0041] While the present invention has been described herein in terms of a number of preferred embodiments for skateboard decks, various changes and improvements may also be made to the invention without departing from the scope thereof. The subject matter described herein includes all novel and non-obvious combinations and subcombinations of the various elements, features, functions and/or properties disclosed herein. Similarly, where the claims recite “a” or “a first” element or the equivalent thereof, such claims should be understood to include incorporation of one or more such elements, neither requiring nor excluding two or more such elements. | A reinforced skateboard deck adapted to connect to a set of trucks and wheels to form a skateboard for riding with the deck having a reinforced region constructed to resist rupturing of the deck and a protective side barrier constructed to prevent wear of the reinforced region during use. | 1 |
This application for patent under 35 U.S.C. §111(a) claims priority to Provisional Application Ser. No. 61/377,153 filed on Aug. 26, 2010 under 35 U.S.C. §111(b).
FIELD OF THE INVENTION
The invention relates to methods and compositions, and systems for determining the identity of nucleic acids in nucleotide sequences, and in particular, sequences that contain consecutive repeats of a particular base.
BACKGROUND OF THE INVENTION
Over the past 30 years, the amount of DNA sequence information that has been generated and deposited into Genbank has grown exponentially. Many of the next-generation sequencing technologies use a form of sequencing by synthesis (SBS), wherein specially designed nucleotides and DNA polymerases are used to read the sequence of single-stranded DNA templates in a controlled manner. Pyrosequencing is a form of SBS which allows sequencing of a single strand of DNA by synthesizing the complementary strand along it, one base pair at a time, and detecting which base was actually added at each step.
Rothberg et al. teach the use of large arrays of chemically sensitive FETs (chemFETs) or more specifically ISFETs for monitoring reactions, including for example nucleic acid (e.g., DNA) sequencing reactions, based on monitoring analytes present, generated or used during a reaction. See U.S. Patent Application Publication No. 20100137143, hereby incorporated by reference. More generally, arrays including large arrays of chemFETs may be employed to detect and measure static and/or dynamic amounts or concentrations of a variety of analytes (e.g., hydrogen ions, other ions, non-ionic molecules or compounds, etc.). Rothberg et al. teach the measurement of hydrogen ions, rather than the pyrophosphate normally measured in pyrosequencing.
However, there are types of sequences which are difficult to sequence (even with these newer approaches), and in particular, sequences that contain consecutive repeats of a particular base. What is needed is an improved method which addresses the ability to sequence all types of sequence.
SUMMARY OF THE INVENTION
DNA sequences often have so-called homopolymeric regions (e.g. T-T-T-T-T). Pyrosequencing of DNA template containing the homopolymeric regions produces results which make it very difficult to identify the exact sequence from the data (e.g. is the region T-T-T-T or T-T-T-T-T?) because pyrosequencing is done with unblocked nucleotides and relies on the magnitude of the signal to determine the number of incorporations for the homopolymeric region. This becomes a very large problem as read lengths increase because secondary effects such as non-specific binding reactions and synthesis dephasing are cumulative with the number of incorporation reaction cycles. These effects contribute to the measurement noise and make it more difficult to use a single detector intensity value as an accurate indicator of the number of incorporations in a homopolymeric region. It is also a problem where the sequence contains multiple regions of this type.
The invention relates to methods and compositions, and systems for determining the identity of nucleic acids in nucleotide sequences, and in particular, sequences that contain one or more consecutive repeats of a particular base (so-called homopolymeric regions). In one embodiment, method for sequencing nucleic acids comprising, a) incorporating one or more nucleotides into a plurality of nucleic acids in one or more reaction chambers in contact with one or more ion detectors, wherein said nucleotides comprise a 3′-OH blocking group, said blocking group preventing any further nucleotide incorporation and any further extension of the nucleic acids in which the nucleotide is incorporated unless removed, and b) detecting hydrogen ions released upon nucleotide incorporation by said one or more ion detectors. In one embodiment, said blocking group is a removable chemical moiety. It is not intended that the present invention be limited by the nature of the blocking group. In one embodiment, said removable chemical moiety comprises a disulfide bond. In one embodiment, said removable chemical moiety comprises an azido group. In one embodiment, said removable chemical moiety comprises an azidomethyl ether. In one embodiment, said removable chemical moiety comprises an aminoxy group. In one embodiment, said removable chemical moiety comprises an oxime group. It is also not intended that the present invention be limited to a particular type of sequence with a particular homopolymer region. In one embodiment, a portion of the sequence of said nucleic acid comprises consecutive identical bases of the formula X n , where X is any base and n is a whole number between 3 (e.g. A-A-A, G-G-G, C-C-C, etc.) and 10. In one embodiment, the nucleic acid to be sequenced is immobilized (e.g. on a bead, in a well, etc.) For example, one may immobilize template DNA on a solid surface by its 5′end. Incorporation of the nucleotides typically takes place in a primer which becomes a complementary extension strand of the strand being sequenced. One may accomplish this by annealing a sequencing primer to the nucleic acid (e.g. to a consensus sequence that has been introduced into the nucleic acid to be sequence) and introducing a DNA polymerase (including non-natural polymerases which have been mutated to improve performance, including incorporation of nucleotide analogs with bulky groups).
While the above-described embodiment utilizes the charge coming from the 3′-OH group of an already incorporated nucleotide in the chain (i.e. resulting from the loss of H when the new nucleotide is incorporated), the present invention also contemplates embodiments, where the charge comes from chemical groups designed into the nucleotide. Such embodiments allow for leaving groups or cleavable groups with larger (more easily detectable) charges, including both positive and negative charges. Thus, in another embodiment, the present invention contemplates a method for sequencing nucleic acids comprising, a) incorporating one or more nucleotides into a plurality of nucleic acids in one or more reaction chambers in contact with one or more charge detectors (including ion detectors), wherein said nucleotides comprise a cleavable moiety (or label) and a 3′-OH blocking group, said blocking group preventing any further nucleotide incorporation and any further extension of the nucleic acids in which the nucleotide is incorporated unless removed, b) cleaving said cleavable moiety (or label) under conditions such that a charged moiety is produced, and c) detecting said charged moiety with said one or more charge detectors. In one embodiment, said charged moiety is positively charged. In another embodiment, said charged moiety is negatively charged. Indeed, one type of nucleotide (e.g. T) might have a group that can be cleaved so as to produce a positive charge, while another type of nucleotide (e.g. G) might have a group that can be cleaved so as to produce a negative charge (thereby allowing for the nature of the charge to correlate with the nature/identity of the base). In yet another embodiment, said charged moiety may have a different magnitude for each type of nucleotide. For example, one type of nucleotide (e.g. T) might have one level of positive charge, while another nucleotide (e.g. A) might have two (or three, or four, etc.) times that level of positive charge. These embodiments could be combined such that pyrimidines (C, T, U) have a positive charge, but differ in magnitude, while purines (A and G) have a negative charge, but differ in magnitude. On the other hand, the pyrimidines could have the negative charge, but differ in magnitude, which the purines could have the positive charge, but differ in magnitude. In either case, charge and magnitude of charge would permit identification of the incorporated base.
In one embodiment, there is a wash step prior to step b) which removes unincorporated nucleotides (and any other reagent). It is sufficient that this wash steps remove the majority of excess reagents (and more preferably 90% of such reagents), even if not removing %100. It is not intended that the present invention be limited by the nature of the agent used to cleave the moiety or label. In one embodiment, said label is cleaved enzymatically. In one embodiment, said label is cleaved chemically. It is also not intended that the present invention be limited to a particular type of sequence with a particular homopolymer region. In one embodiment, the present invention contemplates a portion of the sequence of said nucleic acid comprises consecutive identical bases of the formula X n , where X is any base and n is a whole number between 3 and 10. In one embodiment, the cleavable label is attached through a cleavable linker to the base of said nucleotide.
DEFINITIONS
To facilitate understanding of the invention, a number of terms are defined below, and others are found elsewhere in the specification.
The term “plurality” means two or more.
The term “nucleotide sequence” refers to a polymer comprising deoxyribonucleotides (in DNA) or ribonucleotides (in RNA). Nucleotides have a base selected from the group of adenine (A), guanine (G), cytosine (C), thymine (T), and uracil (U).
The term “interrogation position” when made in reference to a nucleotide sequence refers to a location of interest in the sequence, such as the location at which the identity of a nucleic acid is sought to be determined.
The terms “cleavable moiety,” “cleavable marker,” and “cleavable label” are interchangeably used to describe a chemical moiety that, when attached to a composition of interest (e.g. to the base of a nucleotide), acts as a marker for the presence of the composition of interest. The “label” need not be detectable visually (although such embodiments are also contemplated since some dyes have charge). The label is preferably detected by charge (e.g. after cleavage). The present invention envisions labels that would carry a net negative or positive charge. For example, one can use mono, di and tricarboxylic acids (acetic, oxalic, malonic, succinic, citric etc., since they will be deprotonated) attached via a cleavable linker for negative charge (e.g. the cleavable linker attached to the base or another part of the nucleotide). Or one could use mono, di or triamines (since they will be protonated) for positive charge. Finally, one can use labels that would release protons upon cleavage.
The invention's compositions and methods contemplate using modified nucleotides. The terms “nucleotide” and “nucleic acid” refer to constituents of nucleic acids (DNA and RNA) that contain a purine or pyrimide base, such as adenine (A), guanine (G), cytosine (C), uracil (U), or thymine (T)), covalently linked to a sugar, such as D-ribose (in RNA) or D-2-deoxyribose (in DNA), with the addition of from one to three phosphate groups that are linked in series to each other and linked to the sugar. The term “nucleotide” includes native nucleotides and modified nucleotides.
“Native nucleotide” refers to a nucleotide occurring in nature, such as in the DNA and RNA of cells. In contrast, “modified nucleotide” refers to a nucleotide that has been modified by man, such as using chemical and/or molecular biological techniques compared to the native nucleotide. The terms also include nucleotide analogs attached to one or more probes to facilitate the determination of the incorporation of the corresponding nucleotide into the nucleotide sequence. In one embodiment, nucleotide analogues are synthesized by linking a unique label through a cleavable linker to the nucleotide base or an analogue of the nucleotide base, such as to the 5-position of the pyrimidines (T, C and U) and to the 7-position of the purines (G and A), to use a small cleavable chemical moiety to cap the 3′-OH group of the deoxyribose or ribose to make it nonreactive, and to incorporate the nucleotide analogues into the growing nucleotide sequence strand as terminators, such as reversible terminators and irreversible terminators. Detection of the unique label (e.g. by charge) will yield the sequence identity of the nucleotide. Upon removing the label and the 3′-OH capping group, the polymerase reaction will proceed to incorporate the next nucleotide analogue and detect the next base. Other nucleotide analogs that contain markers, particularly cleavable markers, are also contemplated, such as those configured using allyl groups, azido groups, and the like, and which are further described below.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows synthesis of 3′-O-azidomethyl-dNTPs where the steps denote treatment with (i) DMSO, AcOH, Ac 2 O, 48 h; (ii) SO 2 Cl 2 , dry CH 2 Cl 2 , 1-2 h; (iii) NaN 3 in DMF, 3 h; (iv) NH 4 F in MeOH, 16-20 h; (v) (MeO) 3 PO, POCl 3 then (t-Bu 3 NH) 4 P 2 O 7 , TEAB, 1 h; vi) NH 4 OH.
FIG. 2 shows synthesis of 3′-O-azidomethyl-dGTP where the steps denote treatment with (i) DMSO, AcOH, Ac 2 O, 48 h; (ii) Ph 2 NCOCl, DIEA, Pyridine 3 h; (iii) SO 2 Cl 2 , dry CH 2 Cl 2 , 1-2 h; (iii) NaN 3 in DMF, 3 h; (iv) NH 4 F in MeOH, 24 h; (v) (MeO) 3 PO, POCl 3 then (t-Bu 3 NH) 3 P 2 O 7 H, TEAB, 1 h; (vi) NH 4 OH.
FIG. 3 shows exemplary nucleotide structures with 3′-OH group protection that can be cleaved by mild oxidation reactions.
GENERAL DESCRIPTION OF THE INVENTION
The present invention, in one embodiment, contemplates using the blocked nucleotides described herein together with large scale FET arrays for measuring one or more analytes (e.g. ions and charged moieties). In the various embodiments disclosed herein, FET arrays include multiple “chemFETs,” or chemically-sensitive field-effect transistors, that act as chemical sensors. An ISFET is a particular type of chemFET that is configured for ion detection, and ISFETs may be employed in various embodiments disclosed herein. Other types of chemFETs contemplated by the present disclosure include ENFETs, which are configured for sensing of specific enzymes. It should be appreciated, however, that the present disclosure is not limited to ISFETs and ENFETs, but more generally relates to any FET that is configured for some type of chemical sensitivity.
According to yet other embodiments, the present disclosure is directed generally to inventive methods and apparatus relating to the delivery to the above-described large scale chemFET arrays of appropriate chemical samples to evoke corresponding responses. The chemical samples may comprise (liquid) analyte samples in small reaction volumes, to facilitate high speed, high-density determination of chemical (e.g., ion or other constituent) concentration or other measurements on the analyte.
For example, some embodiments are directed to a “very large scale” two-dimensional chemFET sensor array (e.g., greater than 256 k sensors), in which one or more chemFET-containing elements or “pixels” constituting the sensors of such an array are configured to monitor one or more independent chemical reactions or events occurring in proximity to the pixels of the array. In some exemplary implementations, the array may be coupled to one or more microfluidics structures that form one or more reaction chambers, or “wells” or “microwells,” over individual sensors or groups of sensors of the array, and apparatus which delivers analyte samples to the wells and removes them from the wells between measurements. Even when microwells are not employed, the sensor array may be coupled to one or more microfluidics structures for the delivery of one or more analytes to the pixels and for removal of analyte(s) between measurements.
In various embodiments, an analyte of particular interest is hydrogen ions, and large scale ISFET arrays according to the present disclosure are specifically configured to measure pH. In other embodiments, chemFET arrays may be specifically configured to measure pH or one or more other analytes that provide relevant information relating to a particular chemical process of interest. In various aspects, the chemFET arrays are fabricated using conventional CMOS processing technologies, and are particularly configured to facilitate the rapid acquisition of data from the entire array (scanning all of the pixels to obtain corresponding pixel output signals). See U.S. Patent Application Publication No. 20090026082, hereby incorporated by reference.
DESCRIPTION OF PREFERRED EMBODIMENTS
In one embodiment, the nucleotide analogs are exemplified by nucleotide compositions comprising compounds of the following general structure:
Where PG1 stands for protective group that is selectively removable and, and CL stands for cleavable linker, which is also selectively cleavable, and R is selected from the group of H, OH, F, NH 2 . Several particular embodiments of this invention are contemplated. In one embodiment these nucleotide compositions can be incorporated into the nucleic acid by nucleic acids modifying enzymes in a controlled fashion to decode the identity of the bases encoded by the marker moiety M. Once the marker moiety has been cleaved off, identity of the base may be decoded by measuring the change in charge in the reaction chamber due to the released marker moieties. In one embodiment, this invention contemplates the use of the cleavable linkers based on the “trimethyl lock” mechanism or the “1,6-rearrangement” mechanism. The 3′-O-protective groups which act as reversible terminators can also be cleaved off to enable addition of the next nucleotide. This invention contemplates the use of azidomethyl, methylaminoxy, disulfide, aminoxy, oxime and allyl groups as reversible 3′-OH terminators.
Methods for synthesizing exemplary nucleotide analogs that contain cleavable markers configured using azido groups are shown in FIGS. 1 and 2 .
The invention contemplates the use of the cleavable linkers based on the “trimethyl lock” mechanism or the “1,6-rearrangement” mechanism. The 3′-O-protective groups which act as reversible terminators can also be cleaved off to enable addition of the next nucleotide. The invention contemplates the use of azidomethyl, aminooxy, methylaminoxy and allyl groups as reversible 3′-OH terminators.
A. Cleavable Linkers (Cl)
Cleavable linkers are exemplified by trimethyl lock based linkers and 1,6-rearrangement linkers as further described below.
1. Trimethyl Lock Based Linkers
Cleavable linkers are the linkers linking the marker molecule M to the base and these can be selectively cleaved using specific cleaving agents. Specifically, this invention contemplates the use of a “trimethyl lock” structure as the cleavage mechanism. These structures are well known in the chemical arts and have been used before in controlled drug release applications. The general structures of cleavable trimethyl lock based linker utilized in particular embodiments of the present invention are shown below:
The above shows exemplary embodiment A where BASE is selected from any ribo- or deoxyribo-nucleobases: adenosine, cytidine, guanosine, thymidine and analogs, M is a detectable marker, and X is a divalent group selected from NH, O, S.
The above shows exemplary embodiment B where BASE is selected from any ribo- or deoxyribo-nucleobases: adenosine, cytidine, guanosine, thymidine and analogs, M is a detectable marker, and X is NH.
The above shows exemplary embodiment C where BASE is selected from any ribo- or deoxyribo-nucleobases: adenosine, cytidine, guanosine, thymidine and analogs, M is a detectable marker, and X is a divalent group selected from NH, O, S, and Y is a selectively removable protective group.
The above shows exemplary embodiment D where BASE is selected from any ribo- or deoxyribo-nucleobases: adenosine, cytidine, guanosine, thymidine and analogs, M is a detectable marker, X is NH, and Y is an azidomethyl group.
The linkers in the present invention leverage the ability of the trimethyl lock system to create cleavably linked nucleotides.
2. 1,6-Rearrangement Linkers
The invention contemplates another category of cleavable linkers linking the detectable marker moiety to the nucleotide that are based on 1,6 quinone methide rearrangement mechanism (Carl et al. (1981). J. Med. Chem. 24(5):479-480; Duimstra et al. (2005). J. Am. Chem. Soc. 127(37): 12847-12855). These structures are well known in the chemical arts and they have been used before for the controlled drug release applications and for chemical synthesis (Azoulay et al. (2006) Bioorganic & Medicinal Chemistry Letters 16(12): 3147-3149; Murata et al. (2006) Tetrahedron Letters 47(13): 2147-2150). The general structures of cleavable 1,6 rearrangement mechanism based linker utilized in some embodiments of the present invention are shown below:
The above shows exemplary embodiment E, where BASE is selected from any ribo- or deoxyribo-nucleobases: adenosine, cytidine, guanosine, thymidine and analogs, M is a detectable marker and Y is a selectively removable protective group.
The above shows exemplary embodiment F, where BASE is selected from any ribo- or deoxyribo-nucleobases: adenosine, cytidine, guanosine, thymidine and analogs, M is a detectable marker.
The above shows exemplary embodiment G where BASE is selected from any ribo- or deoxyribo-nucleobases: adenosine, cytidine, guanosine, thymidine and analogs, M is a detectable marker, and X is a divalent group selected from the following: NH, O, S.
The above shows exemplary embodiment where BASE is selected from any ribo- or deoxyribo-nucleobases: adenosine, cytidine, guanosine, thymidine and analogs, M is a detectable marker, and X is a divalent group selected from the following: NH, O, S. The cleavage is driven here by the reducing agent and nucleophilic attack of the resulting amino group on the carbonyl followed by cyclization. This mechanism has been used before for the development of protective groups for applications in the carbohydrate and nucleoside chemistry (Wada et al. (2001). Tetrahedron Letters 42(6): 1069-1072; Xu et al. (2002) Carbohydrate Research 337(2): 87-91).
The cleavable linker attachment to the base moiety can be achieved in variety of ways that are well known in the art. Among these is the use of linkers based on 1) propargylamino nucleosides, 2) aminoallyl nucleosides, and 3) propargylhydroxy nucleosides.
B. Protective Groups (PG1)
The invention contemplates nucleotide compositions comprising the following blocking or protective groups (PG1) that reside on the 3′-OH groups of the nucleotides: 1) 3′-O-Azidomethyl ethers, 2) 3′-O-disulfide, 3) 3′-O-methylaminoxy, 4) 3′-aminoxy, 5) 3′-oxime and 6) 3′-O-allyl.
With respect to the 3′-O-Azidomethyl ethers, exemplary protective groups that reside on the 3′-OH groups of the nucleotides that are within the scope of this invention are 3′-O-azidomethyl groups. These groups can be removed using mild reducing agents, such as tri(carboethoxy)phosphine (TCEP).
With respect to the 3′-O-disulfide group, the 3′-O-disulfide group can be removed under mild oxidative conditions, for example using in using mild reducing agents, such as tri(carboethoxy)phosphine (TCEP)
With respect to the 3′-O-methylaminoxy, 3′-aminoxy, and 3′-oxime groups, they can be removed under mild oxidative conditions, for example using in situ generated nitrous acid (such as from sodium nitrite).
As to the 3′-O-allyl group, this protective group can be removed using a variety of reducing agents, including transition metal complexes (Pd, Rh).
Examples of PG1 protective groups are shown in FIG. 3 .
EXPERIMENTAL
The following examples serve to illustrate certain exemplary embodiments and aspects of the present invention and are not to be construed as limiting the scope thereof.
Materials And Methods
The following is a brief description of the exemplary materials and methods used in the following Examples. All solvents and reagents were reagent grades, purchased commercially and used without further purification. Protected nucleosides 5′-O-(tert-butyldimethylsilyl)-2′-deoxythymidine, N 4 -benzoyl-5′-O-tert-butyldimethylsilyl-2′-deoxycytidine, N 6 -Benzoyl-5′-O-tert-butyldimethylsilyl-2′-deoxyadenosine, N 2 -isobutyryl-5′-O-(tert-butyldimethylsilyl)-2′-deoxyguanosine were purchased from CNH Technologies, Inc. All other chemicals were purchased from Sigma-Aldrich.
EXAMPLE 1
Synthesis Of 3′-O-Azidomethyl Nucleotides
The synthesis of 3′-O-azidomethyl-dNPTs is described in FIG. 1 . Briefly, reaction of 5′-O-TBDMS-2′-deoxynucleosides (5) with a mixture of DMSO, acetic acid, and acetic anhydride installed the 3′-O-methylthiomethyl group (3′-O-MTM, 6), which upon treatment with SO 2 Cl 2 converted to activated 3′-O—CH 2 Cl (7). The latter can be monitored in TLC as 3′-OH (5) after dissolving in wet organic solvent due to fast hydrolysis of the —CH 2 Cl group. The 3′-O—CH 2 Cl-2′-deoxynucleoside (7) is then treated with NaN 3 in dry DMF without purification to convert to 3′-O—CH 2 N 3 (8). 3′-O-azidomethyl-2′-deoxynucleosides of A,T, and C (9a-9c) were obtained in good yield after deprotection of the 5′-O-TBDMS group as described in the FIG. 1 . Similar synthesis route for guanosine(G, 9d), lead only very low yield (>10%) due to formation of a number of side reaction products. To circumvent this, a new method was introduced for the synthesis of guanosine analog (14) which is described in the FIG. 2 , which involved protection of the O 6 — group by diphenycarbamoyl group. After protection of this particular group, the intermediate (12-14) became less polar, making easier to purify, and lead good overall yield in the azidomethyl group installation step.
EXAMPLE 2
Synthesis of N 6 -benzoyl-3′-O-(azidomethyl)-dA (9a)
The following describes exemplary synthesis steps for compounds shown in FIG. 1 .
A. Synthesis of N 6 -Benzoyl-3′-O-(methylthiomethyl)-5′-O-(tert-butyldimethylsilyl)-2′-deoxyadenosine (6a)
3.0 g N 6 -Benzoyl-5′-O-tert-butyldimethylsilyl-2′-deoxyadenosine (5a) (6.38 mmol) was dissolved in a mixture consisting of 11.96 mL DMSO, 5.46 mL acetic acid, and 17.55 mL acetic anhydride and stirred at room temperature for 48 h. The reaction mixture was then neutralized treating with a sufficient amount of saturated NaHCO 3 solution and extracted with CH 2 Cl 2 (3×100 mL). The combined organic extract was then washed with a saturated NaHCO 3 solution (100 mL), dried over Na 2 SO 4 , and concentrated under vacuum. The resultant yellowish oil was then purified on silica gel column (Hex: EtOAc/1:1 to 1:4) to obtain the product N 6 -benzoyl-3′-O-(methylthiomethyl)-5′-O-(tert-butyldimethylsilyl)-2′-deoxyadenosine (6a) as white powder in 71% yield (2.4 g, R f 0.6, EtOAc: hex/7:3). HR-MS: obs. m/z 530.2273, calcd. for C 25 H 36 O 4 N 5 SiS 530.2257 [M+H] + . 1 H-NMR (CDCl 3 ): δ H 9.00 (s, 1H), 8.83 (s, 1H), 8.35 (s, 1H), 8.05 (d, J=7.6 Hz, 2H), 7.62 (m, 1H), 7.55 (m, 2H), 6.55 (t, J=7.19 Hz, 1H), 4.73 (m, 2H), 4.68 (m, 1H), 4.24 (m, 1H), 3.88 (dd, J=11.19, 3.19 Hz, 1H), 2.74-2.66 (m, 2H), 2.35 (s, 3H), 0.94 (s, 9H) and 0.13 (s, 6H) ppm.
B. Synthesis of N 6 -benzoyl-3′-O-(azidomethyl)-2′-deoxyadenosine (9a)
To 0.4 g N 6 -benzoyl-3′-O-(methylthiomethyl)-5′-O-(tert-butyldimethylsilyl)-2′-deoxyadenosine (0.76 mmol) dissolved in 7 mL dry CH 2 Cl 2 was treated with 0.4 mL cyclohexene and 155 μL SO 2 Cl 2 (1.91 mmol) at 0° C. for 2 h. During this time the starting material completely converted to 7a which was shown by disappearance of the starting material and appearance of 3′-OH analog (5a) in TLC (EtOAC:Hex/7:3, R f ˜0.3; the 3-CH 2 Cl (7a) could not detected in TLC due to decomposition in TLC plate to 5a). Then solvent was removed by rotary evaporation and kept about 10 minutes in high vacuum pump. Then dissolved in 5 mL dry DMF and treated with 400 mg NaN 3 (6.6 mmol) at room temperature for 3 h. Then the reaction mixture was partitioned in H 2 O/CH 2 Cl 2 , the combined organic part was dried over Na 2 SO 4 and concentrated by rotary evaporation. The crude sample was then dissolved in 5 mL MeOH and treated with 300 mg NH 4 F (8.1 mmol) more than 38 h. Then MeOH was removed by rotary evaporation. After partioning in H 2 O/EtOAc, the combined organic part was dried over Na 2 SO 4 , concentrated, and purified by silica gel column chromatography (100% EtOAc to 98:2, EtOAc/MeOH) resulting 150 mg of 9a as white powder (48% yield in three steps). HR-MS: Obs. m/z 411.1530, calcd for C 18 H 19 O 4 N 8 411.1529 [M+H] + . 1 H-NMR (CDC 3 ): δ H 8.84 (brs, 1H), 8.70 (brs, 1H), 8.08 (m, 1H), 7.76-7.54 (m, 5H), 6.47 (t, J=5.6 Hz, 1H), 4.83 (m, 2H), 4.78 (m, 1H), 4.39 (m, 1H), 4.09 (d, J=12.78 Hz, H 5 ′, 1H), 3.88 (d, J=12.78 Hz, H 5 ″, 1H), 3.09 (m, H 2 ′, 1H), and 2.65 (m, H 2 ″, 1 H) ppm.
EXAMPLE 3
Synthesis of 3′-O-azidomethyl-dT (9b)
The following describes exemplary synthesis steps for compounds shown in FIG. 1 .
A. Preparation of 3′-O-(methylthiomethyl)-5′-O-(tert-butyldimethylsilyl)-2′-deoxythymidine (6b)
2.0 g 5′-O-(tert-butyldimethylsilyl)-2′-deoxythymidine (5b) (5.6 mmol) was dissolved in a mixture consisting of 10.5 mL DMSO, 4.8 mL acetic acid, and 15.4 mL acetic anhydride and stirred for 48 h at room temperature. The mixture was then quenched by treating with a saturated NaHCO 3 solution and extracted with EtOAc (3×100 mL). The combined organic extract was then washed with a saturated solution of NaHCO 3 and dried over Na 2 SO 4 , concentrated under vacuum, and finally purified by silica gel column chromatography (Hex: EtOAc/7:3 to 1:1). The 3′-O-(methylthiomethyl)-5′-O-(tert-butyldimethylsilyl)-2′-deoxythymidine (6b) was obtained as white powder in 75% yield (1.75 g, R f =0.6, hex: EtOAc/1:1). HR-MS: Obs. m/z 417.1890, cald. for C 18 H 33 N 2 O 5 SSi 417.1879 [M+H] + . 1 H-NMR (CDCl 3 ): δ H 8.16; (s, 1H), 7.48 (s, 1H), 6.28 (m, 1H), 4.62 (m, 2H), 4.46 (m, 1H), 4.10 (m, 1H), 3.78-3.90 (m, 2H), 2.39 (m, 1H), 2.14, 2.14 (s, 3H), 1.97 (m, 1H), 1.92 (s, 3H), 0.93 (s, 9H), and 0.13 (s, 3H) ppm.
B. Preparation of 3′-O-(azidomethyl)-2′-deoxythymidine (9b)
To 1.095 g 3′-O-(methylthiomethyl)-5′-O-(tert-butyldimethylsilyl)-2′-deoxythymidine (6b) (2.6 mmol) dissolved in 10 mL dry CH 2 Cl 2 were added 1.33 mL cyclohexene and 284 μL SO 2 Cl 2 (3.5 mmol) at 0° C. and stirred at the ice-cold temperature for 1.5 h. Then the flask temperature was brought to room temperature and transferred to a round bottom flask. The volatiles were removed by rotary evaporation followed by high vacuum pump. Then the crude sample was dissolved in 5 mL dry DMF and 926 mg NaN 3 (15.4 mmol) was added to it and stirred for 3 h at room temperature. The crude sample was dispersed in 50 mL distilled water and extracted with CH 2 Cl 2 (3×50 mL), the organic extracts were combined and dried over Na 2 SO 4 and concentrated by rotary evaporation. The crude sample was then dissolved in MeOH (5 mL) and treated with NH 4 F (600 mg, 16.2 mmol) for 24 h at room temperature. Then reaction mixture was concentrated and partitioned between H 2 O/CH 2 Cl 2 and the combined organic extract was dried over Na 2 SO 4 , concentrated, and purified the product by silica gel column chromatography using Hex: EtOAc/1:1 to 2:5 resulting the final product (9b) as white powders (˜550 mg, 71% yield in three steps, R f =0.3, Hex: EtOAc/1: 1.5). HR-MS: Observed m/z 298.1146, calcd for C 11 H 16 O 5 N 5 298.1151 [M+H] + . 1 H-NMR (CDC 3 ): δ H 8.30 (brs, 1H), 7.40 (s, 1H), 6.14 (t, J=6.8 Hz, 1H), 4.79-4.70 (m, 2H), 4.50 (m, 1H), 4.16 (m, 1H), 4.01-3.84 (m, 2H), 2.45 (m, 2H) and 1.95 (s, 3H) ppm.
EXAMPLE 4
Synthesis of N 4 -Benzoyl-3′-O-(azidomethyl)-dC (9c)
The following describes exemplary synthesis steps for compounds shown in FIG. 1 .
A. Preparation of N 4 -Benzoyl-3′-O-(methylthiomethyl)-5′-O-(tert-butyldimethylsilyl)-2′-deoxycytidine (6c)
3.5 g N 4 -benzoyl-5′-O-tert-butyldimethylsilyl-2′-deoxycytidine (5c) (7.65 mmol) was dissolved in a mixture consisting of 14.7 mL DMSO, 6.7 mL acetic acid, and 21.59 mL acetic anhydride and stirred for 48 h at room temperature. During this period of time, a complete conversion to product was observed by TLC (R f =0.4, EtOAc:hex/10:1). The mixture was then neutralized with a saturated NaHCO 3 solution and extracted with CH 2 Cl 2 (3×100 mL). The combined organic extract was then washed with saturated solution of NaHCO 3 and dried over Na 2 SO 4 , and concentrated under vacuum. The product was then purified by silica gel column chromatography (EtOAc: hex/2:1 to 9:1) to obtain N 4 -benzoyl-3′-O-(methylthiomethyl)-5′-O-(tert-butyldimethylsilyl)-2′-deoxycytidine (6c) as white powder in 73% yield (2.9 g, R f =0.6, EtOAc:hex/9:1). HR-MS: obs. m/z 506.2134, cald. for C 24 H 36 O 5 N 3 SiS [M+H] + . 506.2145. 1 H-NMR (CDCl 3 ): δ H 8.43 (d, J=7.1 Hz, 1H), 7.93 (m, 2H), 7.64 (m, 1H), 7.54 (m, 3H), 6.30 (m, 1H), 4.62 & 4.70 (2×d, J=11.59 Hz, 2H), 4.50 (m, 1H), 4.19 (m, 1H), 3.84 & 3.99 (2×dd, J=11.59 & 2.79 Hz, 2H), 2.72 (m, 1H), 2.21 (m, 1H), 2.14 (s, 3H), 0.99 (s, 9H), and 0.16 (s, 6H) ppm.
B. Preparation of N 4 -Benzoyl-3′-O-(azidomethyl)-2′-deoxycytidine (9c). To 0.5580 g N 4 -benzoyl-3′-O-(methylthiomethyl)-5′-O-(tert-butyldimethylsilyl)-2′-deoxycytidine (6c)
(1.04 mmol) dissolved in 8 mL dry CH 2 Cl 2 were added 0.56 mL cyclohaxene and 220 μL SO 2 Cl 2 (2.7 mmol) at 0° C. and stirred at the ice-cold temperature for 1 h. During this time, the starting material converted to the chlorinated product as shown by the 3′-OH (5c) compound in the TLC. The volatiles were then removed under vacuum and resuspended in dry DMF (5 mL) and treated with NaN 3 (400 mg, 6.6 mmol) and stirred for 2 h at room temperature. The sample was then partitioned between water and CH 2 Cl 2 and the organic extracts were combined and dried over Na 2 SO 4 and concentrated under vacuum. The crude sample was then dissolved in MeOH (5 mL) and treated with NH 4 F (600 mg, 16.2 mmol) for 20 h at room temperature. Then solvent was removed under vacuum and extracted with CH 2 Cl 2 and the organic extract was then dried over Na 2 SO 4 and concentrated under vacuum. The sample was then purified by silica gel column chromatography (Hex:EtOAc 1:4 to 1:10), and the product (9c) was obtained as white powdery substance (˜200 mg, 50% yield in three steps, R f =0.5, EtOAc:Hex/5: 0.5). HR-MS: Obs. m/z 387.1408, calcd for C 17 H 19 O 5 N 6 387.1417 [M+H] + . 1 H-NMR (CDC 3 ): δ H 8.30 (d, J=7.2 Hz, 1H), 7.93 (d, J=7.50 Hz, 1H), 7.66-7.51 (m, 5H), 6.18 (t, J=6.4 Hz, 1H), 4.81-4.68 (m, 2H), 4.52 (m, 1H), 4.25 (m, 1H), 4.08-3.88 (m, 2H), 2.69 (m, 1H), and 2.50 (m, 2H) ppm.
EXAMPLE 5
Synthesis of N 2 -isobutyryl-O 6 -diphenylcarbamoyl-3′-O-azidomethyl-dG (14)
The following describes exemplary synthesis steps for compounds shown in FIG. 2 .
A. Preparation of N 2 -isobutyryl-3′-O-(methylthiomethyl)-5′-O-(tert-butyldimethylsilyl)-2′-deoxyguanosine (11)
5 g of N 2 -isobutyryl-5′-O-(tert-butyldimethylsilyl)-2′-deoxyguanosine (11.0 mmol) dissolved in 21 mL dry DMSO was treated with 10 mL acetic acid and 32 mL acetic anhydride, and stirred for 48 h at room temperature. The crude reaction mixture was then neutralized by adding a K 2 CO 3 solution, and extracted with ethyl acetate (100×3 mL). The combined organic extract was then washed with saturated NaHCO 3 solution, dried over Na 2 SO 4 and concentrated under vacuum. Then reaction mixture was purified by a silica gel column chromatography resulting the product 11 as white powder (3.9 g, 69% yield; R f =0.35, CH 2 Cl 2 :MeOH/20:1). HR-MS: Obs. m/z 512.2344 cald. for C 22 H 38 O 5 N 5 SiS 512.2363 [M+H] + . 1 H-NMR (CDCl 3 ): δ H 12.0 (s, 1H), 8.95 (brs, 1H), 8.09 (s, 1H), 6.24 (t, J=6.8 Hz, 1H), 4.73 (m, 2H), 4.66 (m, 1H), 4.16 (m, 1H), 3.81 (m, 2H), 2.76 (m, 1H), 2.59 (m, 1H), 2.54 (m, 1H), 2.21 (s, 3H), 1.29 (m, 6H), 0.91 (s, 9H), and 0.10 (s, 6H) ppm.
B. Synthesis of N 2 -isobutyryl-O 6 -diphenylcarbamoyl-3′-O-(methylthiomethyl)-5′-O-(tert-butyldimethylsilyl)-2′-deoxyguanosine (12)
To 1.0 g N 2 -isobutyryl-3′-O-(methylthimethyl)-5′-O-(tert-butyldimethylsilyl)-2′-deoxyguanosine (11, 1.95 mmol) dissolved in 22 mL dry pyridine were added diphenylcarbamoyl chloride (0.677 g, 2.92 mmol) and 1.02 mL N,N-diisopropylethylamine, and stirred at room temperature for 3 h under nitrogen atmosphere. The reaction mixture became dark red during this time. The solvent was removed under high vacuum, and product was then purified by silica gel column chromatography using EtOAc:hex/1:1 to 7:3 as mobile phase. The product 12 was isolated as yellowish powder (1.09 g, ˜80% yield; R f =0.7, EtOAc:hex (1:1)). HR-MS: Obs. m/z 707.3068 calcd. for C 35 H 47 O 6 N 6 SiS 707.3047 [M+H] + . 1 H-NMR (CDCl 3 ): δ H 8.25 (s, 1H), 7.94 (brs, 1H), 7.47-7.37 (m, 10H), 6.42 (m, 1H), 4.75 (m, 2H), 4.71 (m, 1H), 4.18 (m, 1H), 3.88-3.70 (m, 2H), 2.80 (m, 1H), 2.60 (m, 1H), 2.19 (s, 3H), 1.30 (d, J=7.2 Hz, 6H), 0.93 (s, 9H) and 0.14 (s, 6H) ppm.
C. Preparation of N 2 -isobutyryl-O 6 -diphenylcarbamoyl-3′-O-azidomethyl-2′-deoxyguanosine (14)
To 786 mg 12 (1.1 mmol) dissolved in 8 mL dry CH 2 Cl 2 was treated with 0.56 mL cyclohexene and 180 μL SO 2 Cl 2 (2.2 mmol) at 0° C. and stirred for 1.5 h at the same temperature. The solvent was then removed by rotary evaporation, and further dried under high vacuum for 10 minutes. The crude product was then dissolved in 5 mL dry DMF and reacted with 600 mg NaN 3 (10 mmol) at 0° C. and stirred at room temperature for 3 h. Reaction mixture was then partitioned H 2 O/CH 2 Cl 2 , the combined organic extract was then dried over Na 2 SO 4 , and concentrated by rotary evaporation. The crude was then dissolved in 5 mL dry MeOH, treated with 500 mg NH 4 F (13.5 mmol) at room temperature for more than 24 h. Then MeOH solvent was removed by rotary evaporation, and partitioned (H 2 O/CH 2 Cl 2 ). The combined organic part was dried over Na 2 SO 4 and concentrated by rotary evaporation and purified by silica gel column chromatography resulting pure product of 14 as white powder (230 mg, ˜36% yield in three steps; hex: EtOAc 1:1 to 1:5, (R f =˜0.3, Hex:EtOAc/1:4). HR-MS: Obs. m/z 588.2343, calcd for C 28 H 30 O 6 N 9 588.2319 [M+H] + . 1 H-NMR (DFM-d 6 ): δ H 8.64 (brs, 1H), 7.48-7.34 (m, 10H), 6.36 (t, J=7.0 Hz), 4.93 (m, 2H), 4.76 (m, 1H), 4.04 (m, 1H), 3.57 (m, 1H), 3.34 (m, 2H), 2.97 (m, 1H), 2.81 (m, 1H), and 1.10 (m, 6H).
EXAMPLE 6
General Method for the Preparation of 3′-O-Azidomethyl-Dntps
The protected 3′-O-azidomethyl nucleoside (0.3 mmol) and proton sponge (75.8 mg; 0.35 mmol) were dried in a vacuum desiccator over P 2 O 5 overnight before dissolving in trimethyl phosphate (0.60 mL). Then freshly distilled POCl 3 (33 μL, 0.35 mmol) was added drop-wise at 0° C. and the mixture was stirred at 0° C. for 2 h. Subsequently, a well-vortexed mixture of tributylammonium pyrophosphate (552 mg) and tributylamine (0.55 mL; 2.31 mmol) in anhydrous DMF (2.33 mL) was added in one potion at room temperature and stirred for 30 min. Triethyl ammonium bicarbonate solution (TEAB) (0.1 M, 15 mL, pH 8.0) was then added and the mixture was stirred for 1 h at room temperature. Then 15 mL of NH 4 OH was added and stirred overnight at room temperature. The resulting mixture was concentrated in vacuo and the residue was diluted with 5 mL of water. The crude mixture was then purified with anion exchange chromatography on DEAE-Sephadex A-25 at 4° C. using a gradient of TEAB (pH 8.0; 0.1-1.0 M). Further purification by RP HPLC to give corresponding target as colorless syrup:
EXAMPLE 7
3′-O-Azidomethyl Nucleotides Cleavage
The 3′-O-azidomethyl group cleavage can be accomplished with a variety of reducing agents such as phosphines. The cleavage agents that are particularly desirable are those that are soluble in aqueous media and do not cause any damage to the DNA. One particularly desirable agent is tri(carboethoxy)phosphine (TCEP).
The 3′-O-azidomethyl nucleotides can be separated from native nucleotides using RP HPLC. In the next experiment, the kinetics of the 3′-O-azidomethyl TTP cleavage was studied. For this purpose, a 1 mM solution of nucleotide was prepared in water and mixed with 50 mM solution of TCEP/400 mM of Tris at pH 8.0 and incubated at 55 deg C. for various periods of time. After the incubation, the reaction was stopped by mixing with 4 M NaOAc at pH=4.3 and an aliquot of reaction mixture (0.5 nmole of nucleotide) was injected and separated on the RP HPLC column. The integrated peak area was then plotted against time. | The invention provides methods and compositions, and systems for determining the identity of nucleic acids in nucleotide sequences, including sequences with one or more homopolymer regions. The methods of the invention include improvements so as to accurately identify sequences, including the difficult homopolymer sequences that are encountered during nucleotide sequencing, such as pyrosequencing. | 2 |
FIELD OF THE INVENTION
The present invention relates to a container for transporting foods and, more particularly, to a plastic container in which a day's worth of prepared food is protected and transported to a consumer.
BACKGROUND OF THE INVENTION
Food services are increasingly providing pre-cooked foods to consumers at locations such as community centers, schools and retirement facilities rather than prepare the foods at the particular location. The pre-cooked food is packaged and transported to the consumers' location and heated, if necessary, to effect the meal service. The use of pre-cooked and packaged foods provides increased safety with regard to the cleanliness of the environment in which the food is prepared.
SUMMARY OF THE INVENTION
The purpose of the present invention is to provide a suitable container for transporting pre-cooked foods sufficient for a day's scheduled meals. The container provides a place for the food and does not suffer the drawbacks of containers presently in use.
The container for transporting foods according to the invention is a parallelepiped formed by a hollow body and a cover, preferably made of plastic material. The container has an interior in which a plurality of spaces and wells are provided for holding food, drinks and cutlery. The container also has a closing strap and cavities facilitating lifting and removal of the cover.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a plan view of the container according to the invention with the cover shown in the closed position;
FIG. 2 is a plan view the container shown in FIG. 1 in an open configuration with the cover removed;
FIG. 3 is an end elevational view of the container shown in FIG. 1;
FIG. 4 is a cross-sectional view taken along line IV--IV of FIG. 1; and
FIG. 5 is a cross-sectional view taken along line V--V of FIG. 1.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
As shown in FIGS. 1, 2 and 3, the container according to the invention is a hollow parallelepiped body 1 provided with a cover 3. Body 1 has a bottom 20, a pair of short side walls 2 and longer side walls 8 which define an inside region 10. Preferably, the container is made of a suitable plastic material which is washable and reusable several times.
As seen in FIG. 2, a central space 5 is provided for containing a stack of dishes (not shown) which provide six courses of meals, for example, three lunch courses and three dinner courses. The dishes are preferably single use dishes, and the food is packed on each dish and heat sealed with suitable plastic material. Central space 5 preferably has a rectangular perimeter 6 which is matched to the shape of the dishes, also preferably rectangular. Two enlargements 7 are positioned on opposite sides of the central space, the enlargements being positioned between the dishes and the longer side walls 8 of the parallelepiped body 1, allowing the dishes to be removed from the container.
Two wells 9 and 11 are positioned along the side of the central space 5, as shown in FIG. 2. Well 9 is preferably circular and is designed to hold a bottle of water, while well 11 is preferably rectangular in shape and designed to hold a paper bag containing wine, such a the brand "Tavernello". A side wall 12 divides the rectangular well 11 from the central space 5 and is provided with a trapezoidal opening 14 (see FIG. 4) to facilitate removal of the paper bag holding the wine.
Two additional wells 13 and 15 are provided on the opposite side of central space 5. Preferably, wells 13 and 15 are rectangular in shape, one well being intended to hold bread and cutlery, the other for holding a serving of fruit. Wells 13 and 15 are separated by a side wall 16 having a "U" shaped opening 18 (see FIG. 5) facilitating removal of the bread and fruit from the wells.
As shown in FIG. 4, cover 3 has an upper perimetrical edge 17 which is interrupted on each of the shorter sides by two respective cavities 19 (only one being shown in FIG. 4). As seen in FIG. 3, cavities 19 are aligned with an external groove 27 which runs along the center line of the bottom 20 of the body 1. The groove accepts a closing strap 29, and the upper part of the strap passes through cavities 19 on the cover 3. The container bottom has a raised portion 22 which extends outwardly and is sized and shaped to interfit with and interengage the perimetrical edge 17 on the cover 3. This allows several containers to be superimposed one above another in a stack for convenient storage and transportation.
A prominence 25 (see FIGS. 4 and 5) is provided on the lower surface of cover 3. The prominence is preferably used to support a thermal plate 26, which is placed on the inside of the container between the cover 3 and the food to maintain the correct temperature inside the container.
FIGS. 4 and 5 also show an inferior edge 21 which extends from the lower surface 4 of cover 3, the edge 21 allowing insertion of the cover 3 into the body 1 facilitating its closing. The upper surface of the cover has a rectangular hollow 23 (see FIG. 1) which allows the strap 29 to act as a handle for lifting and carrying the container.
FIGS. 2 and 3 show a pair of cavities 31 which are provided on each of the shorter sides 2 of the body 1. Preferably, the cavities are positioned in alignment with the center line of the shorter sides. Two cavities are positioned on the cover 3 and the other two are positioned on the side walls of the body 1 beneath the cavities on the cover. The cavities facilitate removing the cover from the body. | Container for transporting foods, parallelepiped, formed by an hollow body (1) and a cover (3), in plastic material, in which interior it is provided a plurality of spaces (5) and/or wells (9, 11, 13, 15) for transporting foods, drinks and cutlery. The container is provided with suitable means for the application of a closing strap (29) and with cavities (31) for taking and lifting the cover (3). | 0 |
FIELD OF THE INVENTION
The present invention relates to novel threads containing at least one element in the form of a helical winding, to their assemblings, particularly in the form of woven fabrics, knits or felts, and to the use of these assemblies as catalyst and/or for recovering the precious metals.
BACKGROUND OF THE INVENTION
The industrial process for preparing nitric acid includes as essential step the oxidation of ammmonia into nitric oxide. This reaction is conducted industrially by passing a mixture of air and ammonia over a metal catalyst generally constituted by platinum or a platinum alloy. The precise conditions of reaction vary little from one installation to the other; the mixture of 10% ammonia and 90% air by volume is preheated to a temperature of 180°-250° C. before passage through the catalyst. The principal reaction:
4NH.sub.3 +5 O.sub.2 →4 NO+6 H.sub.2 O
is effected during the time of contact with the catalyst, with a yield which may attain 96%. This exothermic reaction raises the temperature of the gases and maintains the catalyst at 850°-900° C. The composition of the gases is such that there remains an excess of oxygen after reaction; in the range of temperatures attained, this oxygen forms with the platinum a volatile oxide, which produces a loss of matter from the catalytic cloths. These platinum losses vary, depending on the operating conditions of the installations and are of the order of 50 to 400 mg of platinum per ton of nitric acid produced.
The metallic catalyst is generally in the form of cloths obtained by weaving linear threads. Numerous industrial installations, or burners, thus use platinum and rhodium alloys drawn into threads of 60 or 76 μm diameter, then woven at a rate of 32 threads/cm warpwise and weftwise, to obtain a fabric comprising 1024 stitches/cm 2 . A catalytic bed is constituted by 3 to 40 superposed layers or cloths, this number essentially depending on the operational pressure and the mass flowrate of the gases reduced to the surface unit of the catalytic bed. The diameter of the catalytic cloths attains 5 m in certain burners.
The volatilized platinum may be partially picked up by means of palladium alloy cloths placed immediately beneath the layers of platinum cloths. These palladium alloy cloths are woven products, produced in the same way as the catalytic cloths.
The same catalytic cloths are also employed by the synthesis of hydrocyanic acid by the Andrussow process. The overall reaction is the following:
NH.sub.3 +CH.sub.4 +1.5 O.sub.2 →HCN+3 H.sub.2 O
This exothermic reaction raises the temperature of the gases to 1100° C. The operational conditions are such that there is no excess oxygen and that platinum oxide cannot be formed; the level of the platinum losses is, in this case, very low.
The form of embodiment of the platinum alloy catalysts has remained to this day virtually identical to that developed at the beginning of the 20th century. Certain improvements in the structure of the catalysts have been proposed, but they have not led to a long-lasting industrial exploitation.
French Patent 2 074 921 describes the replacement of about 1/3 to 2/3 of the precious metal cloths by a foraminous structure of non-precious metal, corrosion-resistant and such that the pressure drop is unchanged. This foraminous structure may be made in the form of a metal pad constituted by wires oriented at random.
European Patent 0 275 681 describes a catalyst pack comprising a foraminous layer of fibers of a metal of the platinum group or an alloy containing same and at least one layer of foraminous ceramic material having a coating of at least one of the metals of the platinum group.
French Patent 2 467 629 describes a catalytic bed which comprises an assembly or an agglomeration of fibers of a metal or an alloy of the platinum group.
It should be noted that the examples described in these Patents present the common point of requiring the permanent use of one or more platinum cloths of the prior art to which novel structures are added; the novel structures which are described in these Patents do not present a cohesion and sufficient mechanical properties to be self-supporting. The processes described make it possible to reduce the number of cloths of the prior art used, without being able to replace them entirely.
European Patent 0 364 153 describes the use of a knit obtained by a particular process where the metal wire is associated with a yarn of textile origin, the latter principally contributing an effect of lubrication; the latter is rendered necessary by the intense frictions exerted on the yarn by the knitting machine hooks. The preparation of knits by this process presents economical advantages, but also difficulties in obtaining knits which are sufficiently dense and whose stitches are as small as those of the cloths of the prior art. The maximum width of the webs obtained is only 457 mm, which requires the welding of numerous parallel webs to obtain pieces going up to a diameter of 5 m. Despite these drawbacks, knits are manufactured in accordance with this process, industrially.
The conventional processes of manufacturing metallic cloths, woven fabrics or knits use simple or linear threads. These processes present technological limitations, encountered for example due to the insufficient mechanical properties of certain metals whose threads break too often during manufacture. They also present limitations of principle, such as for example the impossibility of choosing the mass per surface unit, the diameter of the threads and the number of stitches per surface unit, independently.
SUMMARY OF THE INVENTION
The present invention makes it possible to overcome these drawbacks by replacing the linear metal threads conventionally used by threads previously prepared in the form of helical elements.
The use of the threads according to the invention presents an essential advantage which is that of offering a considerable flexibility in the creation of the finished products and of making available new constructional parameters which were not accessible in the prior art. In the products containing the novel threads of the invention, it becomes possible to predetermine the mean mass per m 2 and the thickness of the fabric, independently, without alteration of the pressure drop presented to the flow of the reagent gases.
The present invention makes it possible to produce novel structures of catalyst beds, by using the threads of novel structure hereinabove in replacement of the simple or linear threads which constitute the fabrics of the prior art. Contrary to the majority of the products of the prior art, the products obtained by means of the novel threads according to the invention present the advantage of necessitating no addition of cloths of the prior art in order to be used in the industrial installations for manufacturing nitric acid.
The threads according to the invention are intended for manufacturing products such as metallic cloths, woven fabrics or knits, these products, when they are principally constituted by precious metals, being usable as catalysts for manufacturing nitric acid, hydrocyanic acid, or as device for collecting the precious metals volatilized in the course of the reaction of manufacture of nitric acid.
Threads containing a helical winding of metal are already known. For example, French Patent 2 438 114 describes complex filiform textile elements intended to serve as substrate for a catalytic matter. These elements are constituted by a core of textile fiber of refractory material and of metallic enveloping outer structure.
The helical windings described in French Patent 2 438 114 constitute a means for improving the mechanical properties of certain fabrics of refractory fibers, of the type which are impregnated with catalytic substances to serve as catalyst in heating apparatus. The process described consists in enveloping the fragile fibers by means of a metal thread which constitutes an outer armature. In this process, the quantity of metal thread, inert from the standpoint of catalysis, is selected to cover the surface of the fibers to be reinforced as little as possible: the metallic reinforcement typically covers less than 10% of the surface of the fibers. The articles made according to this process contain a small proportion of metal matter, which is contrary to the purpose aimed at in the manufacture of catalysts for oxidation of ammonia and that the threads according to the invention make it possible to attain.
Thus, according to a first aspect, the invention concerns a novel thread structure containing at least one helical winding of at least one thread constituted by a metal of the platinoid group or an alloy of such a metal.
It will be recalled that the group of platinoids, also called platinum mine metals, is constituted by the following six metals: platinum, ruthenium, rhodium, palladium, osmium and iridium.
More precisely, according to one of its essential characteristics, the invention concerns a thread comprising at least one helically wound filiform element characterized in that it is constituted by a core formed by at least one filiform element around which is helically wound at least one filiform element constituted by a metal of the platinoid group or an alloy of one of these metals.
Thus, the thread according to the invention is constituted by at least one filiform element of which at least one is constituted by metal of the platinoid group or an alloy of one of these metals and is wound helically.
However, insofar as this is not detrimental to the clarity of the description, each filiform element which itself constitutes a thread will be designated hereinafter likewise by the word thread. It is only when there is risk of confusion that the expression "filiform element" will be used.
According to another aspect of the invention, it relates to assemblings of the above threads, in particular cloths, woven fabrics, knits, felts obtained by different techniques such as weaving, knitting, sewing, embroidery.
According to a third aspect, the invention relates to the use of the assemblings of threads according to the invention as catalysts or as devices for recovering the precious metals, in particular in chemical processes employing said precious metals as catalysts.
DESCRIPTION OF THE DRAWINGS
The different aspects of the invention are illustrated in the following description, given with reference to the different figures.
FIG. 1 shows the most simple structure of a thread according to the invention comprising a core around which a thread is helically wound.
FIG. 2 shows a helical winding according to the invention after the core has been eliminated.
FIG. 3 shows an embodiment of the thread according to the invention where the core is constituted by several threads.
FIG. 4 shows another embodiment of the thread according to the invention where one of the threads constituting the core has been eliminated.
FIG. 5 shows another embodiment of the thread according to the invention where the core is constituted by an assembly of threads adapted to be eliminated and non-eliminated.
FIG. 6 reproduces by way of comparison, a photograph of a knit obtained from a linear thread and described in comparative Example 14.
FIG. 7 reproduces a photograph of a knit obtained from a thread according to the invention and described in Example 15.
FIG. 8 reproduces a photograph of a knit obtained in accordance with Example 16.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
On a core or central thread, constituted by one or more threads of different nature or not, there is wound, with turns which are contiguous or not, at least one metal thread of the alloy or metal of which it is desired to obtain the finished product.
FIG. 1 describes the most simple structure of a thread according to the invention in which a thread 20 is helically wound around a thread 10 constituting the core.
The thread 20 is constituted by the active matter necessary for the final use of the product, i.e. for example a platinum alloy in the case of the final use being that of a catalyst, or a palladium alloy if the final use is the collection of the platinum volatilized in a catalytic process employing platinum or one of these alloys as catalyst.
Thread 10 may be:
either a thread of organic, natural or synthetic nature constituted by a matter adapted to be eliminated by dissolution, fusion or combustion, such as for example, cotton, linen, rayon, Nylon, polyester, fibers of alginates,
a thread of an eliminatable matter of inorganic nature such as a metal easily soluble in an acid, such as copper, silver, a metal soluble in a base, such as aluminium, or a meltable metal such as tin and lead alloys,
a thread of an inert, permanent matter in the final use, such as a steel or a refractory stainless alloy,
or a thread of active matter similar to that of thread 20.
Active matter similar to that of thread 20 is understood to mean a metal of the platinoid group or an alloy of one of these metals known for the same catalytic activity in the reaction of manufacture of nitric acid or hydrocyanic acid or for making devices for recovering platinum during the manufacture of nitric acid. It may therefore be question of a platinoid or an alloy of platinoid identical to or different from the one constituting thread 20.
The threads used for making the helical windings 20 of the threads according to the invention are most often, at the start, in the form of a linear thread, of circular section, with a diameter included between 20 and 400 μm. The use of threads whose section is of different shape, such as circular threads rolled or crushed prior to use according to the invention, also forms part of the invention. It is well known to the man skilled in the art that threads thus deformed present an increased specific surface, which favourably affects the catalytic activity.
When manufacturing the catalytic cloths of the prior art, the platinum alloy threads used have a diameter of between 50 and 90 μm, the most wide-spread alloy compositions being the following: platinum alloyed with 5% rhodium, platinum alloyed with 8% rhodium, platinum alloyed with 10% rhodium, platinum alloyed with 5% rhodium and 5% palladium. These same threads are the threads preferred for manufacturing the novel products for use as catalysts according to the invention, the turns of the novel threads having an outer diameter D e included between 110 and 1500 μm, obtained by effecting a winding on a core of diameter included between 10 and 1400 μm. The threads preferred for the construction of the catalytic products according to the invention have an outer diameter D e included between 110 and 500 μm, obtained by effecting a winding on a core of diameter included between 10 and 400 μm.
When manufacturing cloths of the prior art for recovering the volatilized platinum, the threads of palladium alloys used have a diameter of between 50 and 180 μm, the most wide-spread compositions of alloys being the following: palladium alloyed with 5% copper, palladium alloyed with 5% nickel, palladium alloyed with 5 to 20% gold. These same threads are the preferred threads for manufacturing the novel products according to the invention, for the use of recovery of the volatilized platinum, the turns of the novel threads having an outer diameter D e included between included between 110 and 1500 μm, obtained by effecting a winding on a core of diameter included between 10 and 1400 μm. The threads preferred for the construction of the products according to the invention intended for the recovery of the volatilized platinum have an outer diameter D e included between 110 and 750 μm, obtained by effecting a winding on a core whose diameter is included between 10 and 650 μm.
In condensed manner, the threads according to the invention may also be characterized in synthetic manner by the value of their mass per unit of length, this value resulting from the choice of the preceding geometrical parameters. Thus, the preferred threads according to the invention are those whose mass per unit of length is included between 1.5 and 5 times the mass of the linear thread employed in their construction and which are obtained for example with a number of turns such that these turns cover 10% at minimum and 100% at maximum of the surface of the threads of the core. The threads preferred for the construction of the catalytic products and the products intended for recovering the volatilized platinum according to the invention have a mass included between 1.8 and 3 times the mass of the linear thread coming within their construction. The preferred threads according to the invention are also such that the turns cover from 20 to 80% of the surface of the threads of the core, which is also expressed by a distance between the turns included between 0.25 times and 4 times the diameter of the thread which constitutes the winding.
The thread 20, which constitutes the turns of a helix, is generally a single one, but it may itself be composite, or the winding may be constituted by a plurality of threads in parallel, possibly of different natures, which forms part of the invention. Moreover, thread 20, as well as the other threads coming within the construction of a thread according to the invention, does not necessarily have a circular section. It may be useful previously to draw a round thread to transform it into a tape which is used for thread 20; in that case, the thread made according to the invention with such a tape presents a flattened outer surface, which facilitates slide of this thread, such a property being useful if the thread is used in a knitting machine.
FIG. 2 shows the appearance of a thread according to the invention, after elimination of the central thread by any process, leaving only the helically wound thread of active matter. Such a thread is characterized by its outer diameter "D e ", by the diameter "d" of the initial thread, by the inner diameter "D" of the turns and by the pitch "p" of the winding which is the distance between the axes of two adjacent turns. Each of these parameters may be chosen freely, except for the outer diameter D e which is worth D+2d; this freedom constitutes a characteristic and an essential advantage of the invention, procuring a wide latitude for the choice of the mass and the microgeometry of the threads obtained according to the invention and the finished products that these threads produce.
Another advantage of the threads according to the invention is that they present novel properties facilitating use in the operations of manufacturing fabrics by weaving or by knitting; thus, the central thread serving as support is the one which procures the characteristics of tensile strength of the thread of the invention. The central thread may, according to the invention, thus be chosen from the textile fibers having a high elongation at rupture, much higher than that of simple metal threads. The thread according to the invention will thus present the same characteristics of elongation as the textile thread, whilst incorporating in its structure the metal element which will give the finished product the chemical properties sought as catalyst.
The thread prepared according to the invention allows manufacture of cloths, woven fabrics, knits, by all techniques such as in particular weaving, knitting, sewing, embroidery, without having the fragility of a massive metal thread.
It may be chosen to eliminate the central thread before use of the finished product, for example by decomposition, dissolution, fusion, oxidation, or to conserve it up to the instant of final use, which renders the cloths and knits according to the invention easy to manipulate. Depending on the nature of the central thread and the conditions of final use, the central thread may be eliminated rapidly or slowly, and partially or totally.
If it is chosen to eliminate the central thread, the fabric obtained, constituted solely by helical threads, is exaggeratedly elastic and deformable, the turns being able to be drawn easily. Such a fabric lacks rigidity to such a point that it becomes difficult to manipulate without undergoing deformations. To overcome this drawback, one arrangement of the invention consists in introducing an additional thread in the central core, jointly with the thread of eliminatable matter.
This arrangement, which forms part of the invention, is illustrated in FIG. 3 where the core is constituted by threads 10 and 11, on which is wound thread 20, each of threads 10 and 11 being able to be:
either a thread of an eliminatable matter of organic, soluble, meltable or combustible nature, such as a textile fiber,
a thread of an eliminatable matter of inorganic nature, such as a metal which is easily soluble, meltable or oxidizable,
a thread of a matter which is inert and permanent in the final use, such as steel or a refractory stainless alloy,
or a thread of active matter similar to that of thread 20, thread 20 being constituted by the active matter necessary for the final use of the product, i.e. for example a platinum alloy in the case of the final use being that of a catalyst, or a palladium alloy if the final use is the collection of the platinum volatilized in the course of a catalytic process employing platinum or a platinum alloy as catalyst.
We have observed that a thread according to the invention prepared in accordance with the above arrangement, conserves the novel mechanical properties contributed by the invention, namely the characteristic of tensile strength remain those of the most resistant thread introduced in the core of the thread.
FIG. 4 illustrates the case of the thread 11 having been chosen from the eliminatable matters and where it has been eliminated by an appropriate process. The product obtained, which forms part of the invention, is now constituted only by the thread 20 in helical form including in its inner space the thread 10. In this state, the thread 20, free of any constraints, may be freely positioned in the whole available space released by the elimination of thread 11.
It also results from the invention, whereby a thread is prepared, comprising a helical element in the inner space of which a linear thread may be located, that the products, fabrics or knits, prepared with such a thread, present an exceptional behaviour with respect to deformations. In fact, in the case of an effort of traction exerted on a fabric causing rupture of the threads, a fabric of the prior art presents a tear which is an opening through which the reagent gases may pass without contact with the catalytic matter; this is translated by a loss of reaction yield which may lead to stoppage of the exploitation. A fabric prepared with a thread of the invention does not present this drawback; in the case of excessive effort exerted on the fabric, there is firstly produced rupture of the linear threads, if they are present; but the helical threads are only drawn. According to the manufacturing characteristics, such as diameter of the core and pitch of the turns, the helical threads may thus be drawn by several times their length without breaking. The consequence of this is that a fabric prepared with a thread of the invention and subjected to excessive efforts of traction is locally drawn without creating an opening allowing passage of the reaction gases without contact with the active or catalytic matter.
In the case of manufacture in the form of a knit, the preceding thread may be used, comprising a reinforcing thread in the central core. It is also possible to use a helical thread with eliminatable core according to the invention and simultaneously to supply the knitting machine with this thread and a linear reinforcing thread which may be metallic. In that case, in the finished product, the reinforcing thread will at all points be parallel to the axis of the helical thread according to the invention, but outside the helix.
In the two examples above, the linear thread makes it possible to reinforce the knit produced.
According to another embodiment of knits according to the invention, a knit may be produced by means of a linear thread, and a helical thread according to the invention inserted between the stitches of this knit. Such a composite knit presents the advantage of being able to be produced in one sole operation by using, for example, a circular knitting machine provided with two thread supply devices.
In such composite knits, the linear thread used may either be a thread of platinoid or platinoid alloy of nature identical to that used for the helical winding, or a thread of refractory material inert at the temperature of use of the catalyst.
In the case of weaving, it suffices to introduce a proportion of linear threads among the threads according to the invention, this proportion being able to be different in the warp and in the weft.
These linear threads are constituted either by threads of platinoid or platinoid alloy of the same type as those used for effecting the helical winding, or by threads constituted by a refractory alloy.
The use of a helical thread whose core contains a linear reinforcing thread is also part of the invention, and such embodiments are described in the Examples hereinafter.
FIG. 5 schematically shows the case of a thread according to the invention whose core is constituted by a plurality of threads, here three threads 10, 11, 12, possibly of different nature, certain being able to be eliminated and others not.
It is also possible according to the invention, previously to manufacture the central thread in a more elaborate form, such as a strand of eliminatable threads and non-eliminatable threads.
Another variant of threads according to the invention in which the core of the thread is formed both of eliminatable and non-eliminatable material, consists in using, as thread constituting the core of the thread of the invention, a thread constituted by a non-eliminatable matter coated with an eliminatable matter, the coating being able to be obtained by any process such as varnishing, coating, electrophoresis, galvanic deposit, by which a thread of a non-eliminatable matter is coated with an eliminatable matter.
The following Examples are given purely by way of illustration of the invention and its advantages.
EXAMPLES
With a view to illustrating the present invention, in non-limiting manner, some descriptive examples of practical embodiment of the threads obtained and their uses, are given hereinbelow.
Examples 1 to 6 demonstrate an essential advantage of the invention which is the freedom in the choice of the mass and of the geometry of the threads. Similarly, the practical production of the fabrics of Examples 7 to 12 demonstrates that this advantage also exists for the products manufactured with the threads of the invention. The threads according to the invention make it possible to obtain, by way of example, fabrics of which the mass per m 2 is from 1.25 to 3 times greater than that of the cloths of the prior art, these limits being in no wise that of the invention. This advantage is obtained by employing the same threads as those which constitute the cloths of the prior art, and by incorporating them as filiform elements to show at least one helical element constituting the threads according to the invention.
Another property of the threads of the invention when they are employed in the weaving technique is that they allow several possible constructions to obtain the same mass per m 2 of the finished products. This property is illustrated by Examples 9 and 12 which concern the manufacture of cloths whose mass per m 2 is close to 1100 g. Example 9 uses a warp comprising 32 threads/cm, whilst in Example 12, the warp comprises only 16 threads/cm, the weft threads always being at 24/cm; the lesser quantity of matter in the warp is compensated by using a heavier thread weftwise, such increase in mass of the weft thread having been obtained by increasing the number of turns to the cm in the preparation of the weft thread according to the invention. This property constitutes an advantage contributed by the threads of the invention to the weaving technique, as they make it possible to reduce the number of the warp threads and therefore substantially to reduce the warp assembly time and therefore the manufacturing costs.
This embodiment of the threads according to the invention, which has the apparent effect of increasing the quantity of matter present in each m 2 of fabric, is not translated by a reduction in the transparency and an increase in the pressure drop, as would occur by increasing the number of threads of a fabric of the prior art. The specific property that the threads according to the invention procure is that they make it possible to prepare thicker products than those which are obtained by weaving linear threads; in fact, the products made become veritably three-dimensional, their thickness being able to be chosen freely from the value of the diameter "D" of the core serving for the winding. When weaving fabrics of the prior art, the thickness depends only on the diameter of the threads, the mechanical tension applied during weaving and on the weaving pattern: the thickness of a fabric of the prior art is twice the diameter of the threads in straight weaving and about three times the diameter of the threads in herringbone weaving.
The practical embodiment of the fabrics of Examples 8 to 12 has made it possible to discover two other advantages of the products according to the invention over the products of the prior art.
A novel property of the fabrics prepared with the threads of the invention is that they present an increased rigidity which renders very difficult their deformation in the sense of the bisectrices of the directions of the warp threads and of the weft threads, whilst this type of deformation is very easy with the fabrics of the prior art. This property results in that a circular cloth according to the invention has the advantage of conserving its circular shape after handlings, whilst a cloth of the prior art manipulated without precautions easily becomes oval.
This property is the consequence of the imbrication of the warp threads which are linear threads in our Examples, between the turns of the weft threads, which are helical threads according to the invention.
The second advantage precisely concerns the contact between the reagent gases and the threads of active matter. In a cloth of the prior art, there are numerous points of intersection with punctual contact between the weft threads and the warp threads; there is exactly one intersection of threads per stitch, these stitches being most usually 1024/cm 2 in number, when the cloth comprises 32 warp threads and 32 weft threads/cm. It is well known to the man skilled in the art that an examination of the worn catalytic cloths with a scanning microscope reveals that the points of intersection and the close zone which surrounds them are regions hardly active from the standpoint of catalysis as these zones constitute anfractuosities in which the reagent gases only diffuse with difficulty. In a cloth of the prior art, the intersections of threads are therefore hardly active zones which contain a fraction of surface of the threads which remains hardly or not useful on contact of the gases with the threads.
In a cloth woven with a thread according to the invention, comprising an element in helical form, the intersections of threads, referred to the unit of mass, are less numerous, at equal meshing, than in a cloth of the prior art; this is simply due to the fact that the helix turns included between two intersections represent a larger quantity of matter than the simple linear thread which would replace this helix. Moreover, the use of the threads according to the invention allows a reduction in the number of the warp threads and of the weft threads, whilst making it possible to manufacture denser fabrics than the fabric of the prior art, as Examples 7 to 11 show. It follows that the threads according to the invention allow a considerable reduction in the number of effective points of intersection between threads, and therefore better use of the surface of the threads used. Moreover, in the case of products woven with threads of the invention, the geometrical orientation of the points of intersection between threads is different from that which is presented by the prior products; in fact, in the prior products, the points of intersection always lie beneath a thread, which creates an effect of shading and renders them hardly accessible to the gaseous current which must surround this thread; in a fabric containing threads of the invention for weft threads and linear threads for the warp, the orientation of the helix turns is almost orthogonal with respect to the preceding case; it follows that the points of intersection of threads present their opening directly in the direction of the gaseous current and that they may therefore be more efficient for the contacts with the reaction gases.
In summary, the threads according to the invention allow a reduction in the density of the points of intersection, referred to the unit of mass, as well as an improvement in the circulation of the gases in the remaining points of intersection. These properties are together translated by an increase in the surface available for the exchanges with the gaseous phase, as well as by an improvement in the diffusion towards this surface, with the consequence for the final use of a substantial increase in the catalysis yield and an increase in the life duration of the catalytic cloths. In the case of applying the threads of the invention to the cloths of palladium alloy used for collecting the volatilized platinum, the advantage procured is an improved efficiency of collection.
Furthermore, Example 15 clearly shows the specific gain in mass obtained for a composite knit made by associating a simple thread and a thread according to the invention with respect to the knit obtained on the same machine with a simple linear thread and described in Comparative Example 14.
The present invention is applicable to the preparation of felts, woven fabrics, knits or any assemblings of threads of precious metals and alloys thereof which are used as catalytic mass for the manufacture of nitric acid, or hydrocyanic acid, or as device for collecting the precious metals volatilized during these reactions.
EXAMPLE 1
A thread of platinum alloy with 8% rhodium, with a diameter of 76 μm, which has a mass of 92 mg/m, is wound around a thread of cotton of caliber 60 at a rate of 70 turns/cm. The thread obtained has a diameter of 320 μm and a mass of 450 mg/m comprising 36 mg of cotton per meter.
EXAMPLE 2
A thread of palladium alloy with 5% copper, with a diameter of 76 μm, which has a mass of 53 mg/m, is wound around a thread of cotton of caliber 60 at a rate of 70 turns/cm. The thread obtained has a diameter of 320 μm and a mass of 320 mg/m, comprising 36 mg of cotton per meter.
EXAMPLE 3
A thread of cotton of caliber 60 and a thread of platinum alloy with 8% rhodium, with a diameter of 76 μm, are disposed in parallel. A second thread of platinum alloy with 8% rhodium, of 76 μm diameter, is wound around the two preceding threads at a rate of 70 turns/cm. The thread obtained has a flattened profile; its apparent diameter is from 300 to 350 μm and its mass is 570 mg/m, comprising 36 mg of cotton per meter.
EXAMPLE 4
A thread of cotton of caliber 60 and a thread of palladium alloy with 5% copper, with a diameter of 76 μm, which has a mass of 53 mg/m, are disposed in parallel. A second thread of palladium alloy with 5% copper, of 76 μm diameter, is wound around the two preceding threads at a rate of 70 turns/cm. The thread obtained has a flattened profile; its apparent diameter is from 300 to 350 μm and its mass is 380 mg/m, comprising 36 mg of cotton per meter.
EXAMPLE 5
A thread of cotton of caliber 60 and a thread of platinum alloy with 8% rhodium, with a diameter of 76 μm, are disposed in parallel. A second thread of platinum alloy with 8% rhodium, with a diameter of 76 μm, is wound around the two preceding threads at a rate of 35 turns/cm. The thread obtained has a diameter of 300 μm and a mass of 400 mg/m, comprising 36 mg of cotton per meter.
EXAMPLE 6
A thread of cotton of caliber 60 and a thread of palladium alloy with 5% copper, with a diameter of 76 μm, which has a mass of 53 mg/m, are disposed in parallel. A second thread of palladium alloy with 5% copper, with a diameter of 76 μm, is wound around the two preceding threads at a rate of 35 turns/cm. The thread obtained has a flattened profile; its apparent diameter is from 300 to 350 μm and its mass is 230 mg/m, comprising 36 mg of cotton per meter.
Examples 1 to 6 demonstrate the first essential advantage of the invention, which is that of procuring a considerable freedom of construction by the choice of the mass and the microgeometry of the threads that the invention produces, as a function of the outer diameter D e , the diameter "d" of the initial thread, the inner diameter "D" of the turns, determined by the structure of the central thread and of the pitch "p" of the winding which is the distance between the axes of two adjacent turns.
A preferred industrial method for manufacturing the threads described in the Examples is the use of a wrapping machine. However, this preferred method is in no way limiting, the threads according to the invention also being able to be obtained by other processes such as winding on a mandrel; in that case, the helix obtained is disengaged by sliding out of the mandrel as it is formed. A hollow mandrel may make it possible to introduce one or more threads inside the helix, without these threads serving as winding support.
To complete the illustration of the present invention, in non-limiting manner, some descriptive Examples of practical embodiment of the finished products which may be manufactured by means of the novel threads according to the invention, are given hereinbelow.
EXAMPLE 7
The thread of Example 3, constituted by a thread of platinum alloy with 8% rhodium, with a diameter of 76 μm, wound at a rate of 70 turns/cm around a thread of cotton and by a thread of platinum alloy with 8% rhodium, with a diameter of 76 μm, is used for manufacturing a fabric, by means of a manual weaving loom.
In this way, a woven cloth is produced, comprising warp threads distant by 6.35 mm and contiguous weft threads. A disc of 70 mm diameter of this fabric contains a mass of precious metals of 7.0 g, or a mass of 1820 g/m 2 . By way of comparison, the fabric of the prior art prepared with the same thread, which is woven with 32 threads/cm warpwise and weftwise, and which comprises 1024 stitches/cm 2 , has a mass of 620 g/m 2 .
The fabric of this Example, prepared by means of a thread according to the invention, may be used as catalytic cloth in an ammonia oxidation installation, replacing 3 cloths of the prior art.
EXAMPLE 8
The thread of Example 5, constituted by a thread of platinum alloy with 8% rhodium, with a diameter of 76 μm, wound at a rate of 35 turns/cm about a thread of cotton and by a thread of platinum alloy with 8% rhodium, with a diameter of 76 μm, is used for manufacturing a fabric, by means of an industrial weaving loom 2.50 m wide.
The thread according to the invention is used as weft thread, the warp threads being simple threads, of the same alloy, 76 μm diameter. The fabric obtained comprises 32 warp threads/cm and 24 weft threads/cm. The average mass of this fabric is 1211 g/m 2 , viz. 95% more than the mass of 620 g/m 2 of the fabric of the prior art prepared with the same thread, and woven with 32 threads/cm warpwise and weftwise. The thickness of the fabric obtained with the thread of the invention is 340 μm, whilst the fabric of the prior art has a thickness of 210 μm, slightly more than double the diameter of the threads.
The fabric of this Example prepared by means of a thread according to the invention may be used as catalytic cloth in an ammonia oxidation installation, replacing 2 cloths of the prior art.
EXAMPLE 9
The thread of Example 5, constituted by a platinum alloy with 8% rhodium, 76 μm diameter, wound at a rate of 35 turns/cm around a thread of cotton and by a thread of platinum alloy with 8% rhodium, 76 μm diameter, is used for manufacturing a fabric, by means of an industrial weaving loom 2.50 m wide.
The thread according to the invention is used as weft thread, the warp threads being simple threads, of the same alloy, 76 μm diameter. The fabric obtained comprises 32 warp threads/cm and 21 weft threads/cm. The average mass of this fabric is 1098 g/m 2 , viz. 77% more than the mass of 620 g/m 2 of the fabric of the prior art prepared with the same thread, and woven with 32 threads/cm warpwise and weftwise. The thickness of the fabric obtained with the thread of the invention is 340 μm, whilst the fabric of the prior art has a thickness of 210 μm, slightly more than double the diameter of the threads.
The fabric of this Example, prepared by means of a thread according to the invention, may be used as catalytic cloth in an ammonia oxidation installation, 2 thicknesses of this novel fabric being able to replace 2 cloths of the prior art.
EXAMPLE 10
The thread of Example 6, constituted by a thread of palladium alloy with 5% copper, 76 μm diameter, wound at a rate of 35 turns/cm around a thread of cotton and by a thread of palladium alloy with 5% copper, 76 μm diameter, is used for manufacturing a fabric by means of an industrial weaving loom 2.50 m wide.
The thread according to the invention is used as weft thread, the warp threads being simple threads, of the same alloy, 76 μm diameter. The fabric obtained comprises 32 warp threads/cm and 19 weft threads/cm. The average mass of this fabric is 575 g/m 2 , viz. 47% more than the mass of 390 g/m 2 of the fabric of the prior art woven with 32 threads/cm warpwise and weftwise, prepared with the same thread. The thickness of the fabric obtained with the thread of the invention is 340 μm, whilst the fabric of the prior art has a thickness of 210 μm, slightly more than double the diameter of the threads.
The fabric of this Example, prepared by means of a thread according to the invention, may be used as cloth for recovering the volatilized platinum in an ammonia oxidation installation, its capacity of absorption of platinum being about 1.5 times that of a cloth of the prior art.
Examples 7 to 10 above describe embodiments of products using threads of the invention and, apart from a thread of cotton, including only precious metals of homogeneous composition. It is also possible to create products including threads of precious metals according to the invention associated with threads of common metals, as shown by Example 11 in descriptive and non-limiting manner.
EXAMPLE 11
The thread of Example 5, constituted by a thread of platinum alloy with 8% rhodium, 76 μm diameter, wound at a rate of 35 turns/cm around a thread of cotton and by a thread of platinum alloy with 8% rhodium, 76 μm diameter, is used for manufacturing a fabric by means of an industrial weaving loom 2.50 m wide.
The thread according to the invention is used as weft thread, the warp threads being simple threads, of a refractoy alloy such as Kanthal (Registered Trademark of the firm Bulten-Kanthal AB), 60 μm diameter. The fabric obtained comprises 16 warp threads/cm and 21 weft threads/cm. The average mass of this fabric is 822 g/m 2 , decomposing into 788 g of threads of platinum alloy with 8% rhodium and 34 g of threads of refractory alloy. The catalytically active part of this fabric, namely the 788 g of threads of plating alloy with 8% rhodium, represent a mass per m 2 greater by 27% than the mass of 620 g/m 2 of the fabric of the prior art prepared with the same thread and woven with 32 threads/cm warpwise and weftwise. The thickness of the fabric obtained with the thread of the invention is 340 μm, whilst the fabric of the prior art has a thickness of 210 μm, slightly more than double the diameter of the threads.
The fabric of this Example prepared by means of a thread according to the invention to which is added a refractory thread, may be used as catalytic cloth in an ammonia oxidation installation, 4 thicknesses of this novel fabric being able to replace 5 cloths of the prior art.
EXAMPLE 12
A thread according to the invention is constituted by a thread of platinum alloy with 8% rhodium, 76 μm diameter, wound at a rate of 42 turns/cm around a thread of cotton and by a thread of platinum alloy with 8% rhodium, of 76 μm diameter; its mass is 480 mg/m. It is used for manufacturing a fabric, by means of an industrial weaving loom 2.50 m in width.
The thread according to the invention is used as weft thread, the warp threads being simple threads, of the same alloy, 76 μm diameter. The fabric obtained comprises 16 warp threads/cm and 21 warp threads/cm. The average mass of this fabric is 1092 g/m 2 , viz. 76% more than the mass of 620 g/m 2 of the fabric of the prior art prepared with the same thread, and woven with 32 threads/cm warpwise and weftwise. The thickness of the fabric obtained with the thread of the invention is 340 μm, whilst the fabric of the prior art has a thickness of 210 μm, slightly more than double the diameter of the threads.
The fabric of this Example, prepared by means of a thread according to the invention, may be used as catalytic cloth in an ammonia oxidation installation, 2 thicknesses of this novel fabric being able to replace 3 cloths of the prior art.
EXAMPLE 13
The thread of Example 5, constituted by a thread of platinum alloy with 8% rhodium, 76 μm diameter, wound at a rate of 25 turns/cm around a thread of cotton and by a thread of platinum alloy with 8% rhodium, 76 μm diameter, is used for manufacturing a knit by means of an industrial knitting machine with a diameter of 600 mm.
The thread according to the invention is used as single thread for supplying this machine, which comprises 12 needles/cm. The tubular knit obtained has a flat width of 1880 mm, it comprises 12 stitches/cm and 9 rows/cm, viz. 108 stitches per cm 2 . The average mass of this knit is 780 g/m 2 , viz. 26% more than the mass of 620 g/m 2 of the fabric of the prior art prepared with the same thread, and woven with 32 threads/cm warpwise and weftwise. The thickness of the knit obtained with the thread of the invention is 700 μm, whilst the fabric of the prior art has a thickness of 210 μm, slightly more than double the diameter of the threads.
The fabric of this Example, prepared by means of a thread according to the invention, may be used as catalytic cloth in an ammonia oxidation installation, 3 thicknesses of this novel fabric being able to replace 4 cloths of the prior art.
EXAMPLE 14 (Comparative)
A simple thread of platinum alloy with 5% rhodium, with 76 μm diameter, is used for supplying a circular knitting machine with a diameter of 700 mm, equipped with gauge 24 needles. The mechanism of this machine is adapted to obtain the simplest knit, or jersey.
The use of 1250 g of thread made it possible to obtain a tubular knit 2.21 m long and with a diameter of 650 mm representing a surface of 4.52 m 2 . The photograph reproduced in FIG. 6 shows the macrostructure of this knit magnified 25 times. The specific mass of this knit is 276 g/m 2 By way of comparison, the fabric of the prior art prepared with the same thread, which is woven with 32 threads per cm warpwise and weftwise, and which comprises 1024 stitches per cm 2 has a mass of 620 g/m 2 .
EXAMPLE 15
A simple thread of platinum alloy with 5% rhodium, with a diameter of 76 μm, is used in the same way as in Example 14 for supplying a circular knitting machine with a diameter of 700 mm, equipped with gauge 24 needles.
Furthermore, a thread according to the invention is prepared in the following manner: 2 threads of cotton of caliber 60 are disposed in parallel. A thread of platinum alloy with 5% rhodium, of 76 μm diameter, is wound around the two preceding threads at a rate of 35 turns per cm. The thread obtained has a mean diameter of 300 μm and a mass of 295 mg per meter, comprising 72 mg of cotton.
The knitting machine is provided with a second supply device which receives the thread according to the invention: under these conditions, it is possible to obtain a composite knit associating the simple thread, which constitutes a network disposed according to the description of Example 14, and the thread according to the invention, which is inserted between the meshes of the preceding network. The photograph reproduced in FIG. 7 shows the macrostructure of the knit obtained, magnified 25 times, after the threads of cotton included in the thread according to the invention have been eliminated by combustion. The specific mass of this knit is 645 g/m 2 , composed of 276 g/m 2 of simple thread arranged in jersey form as described in Example 14 and of 369 g/m 2 of thread according to the invention which are disposed in parallel at a rate of 15 threads per cm.
The knit obtained in this Example has a specific mass very close to that of a fabric of the prior art prepared with the same thread, which is woven with 32 threads per cm warpwise and weftwise, to attain a mass of 620 g/m 2 .
EXAMPLE 16
A simple thread of an alloy for electrical resistors such as GILPHY 70 (Registered Trademark of the firm IMPHY), with a diameter of 80 μm and a mass of 41 mg per meter, is used in the same manner as in Example 14 for supplying a circular knitting machine with a diameter of 700 mm, equipped with gauge 24 needles.
Furthermore, a thread according to the invention is prepared in the following manner: 2 threads of cotton of caliber 60 are disposed in parallel. A thread of platinum alloy with 5% rhodium, of 76 μm diameter, is wound around the two preceding threads at a rate of 55 turns per cm. The thread obtained has a mean diameter of 300 μm and a mass of 405 mg per meter, comprising 72 mg of cotton.
The knitting machine is provided with a second supply device which receives the thread according to the invention: under these conditions, it is possible to obtain a composite knit associating the simple thread, which constitutes a network arranged according to the description of Example 14, and the thread according to the invention, which is inserted between the meshes of the preceding network. The photograph reproduced in FIG. 8 shows the macrostructure of the knit obtained, magnified 25 times, after the threads of cotton included in the thread of the invention have been eliminated by combustion; this macrostructure is identical to that of Example 15. The specific mass of this knit is 703 g/m 2 , composed of 123 g/m 2 of GILPHY 70 thread arranged in jersey form as described in Example 14, and 580 g/m 2 of thread of platinum alloy with 5% rhodium according to the invention which are disposed in parallel at a rate of 15 threads per cm.
The knit obtained in this Example has a specific mass in precious metal contained therein very close to that of a fabric of the prior art prepared with the same thread, which is woven with 32 threads per cm warpwise and weftwise, to attain a mass of 620 g/m 2 . | A wire comprising at least one helically wound wire element is disclosed. The helical winding consists of a platinoid or platinoid alloy wire (20). Also disclosed are assemblies of these wires (20) such as knitted materials, fabrics and felts, and the use of said assemblies as catalysers in the reaction for preparing nitric or cyanhydric acid, and to recover precious metals from these catalysers. | 1 |
This is a division of application Ser. No. 579,939 filed Feb. 14, 1984, now abandoned, and this is a continuation-in-part of application Ser. No. 507,906 filed June 27, 1983, now abandoned, which is a continuation of Ser. No. 917,696 filed June 21, 1978, now abandoned.
The invention relates to an absorbent facing and to a process for producing the same.
FIELD OF THE INVENTION
Absorbent facings are often employed in such articles as disposable diapers, dressings, bandages, incontinent pads, sanitary products, and the like. An ideal absorbent facing would permit liquid to pass through it from a source to the absorbent material behind the facing, but would prevent liquid from flowing in the reverse direction. To state this desirable property in another way, it would be desirable to have an absorbent facing exhibit "one-way valve" characteristics to aqueous liquids.
DESCRIPTION OF THE PRIOR ART
A number of approaches have been employed to impart one-way valve characteristics to the facings of absorbent materials. One such method is described by Kozak, in U.S. Pat. No. 3,814,101, in which the absorbent material is faced with a polymeric film having a repeating pattern of indentations or dimples and slits in the film.
In Surowitz, U.S. Pat. No. 3,307,545, a non-adherent dressing is described in which an absorbent material is faced with a polymer film having a pattern of depressions therein, with the depressions having openings to the absorbent material. The stated purpose of the facing of Surowitz is to prevent a dressing from adhering to a wound.
Canadian Patent No. 731,336 discloses a diaper or similar protective garment having a plastic sheet facing for an absorbent core, said facing having a plurality of spaced apart regions, each of which is rendered liquid-permeable by a plurality of minute perforations therein.
SUMMARY OF THE INVENTION
Broadly, the process for producing an absorbent facing material that is provided by this invention comprises the steps of:
(a) superimposing a thin polymer film and a first web comprising absorbent fibers, to form a second web having said thin polymer film on one face and said first web on the other face;
(b) heating said second web to a temperature such that said polymer film is formable;
(c) while said second web is so heated, simultaneously applying shearing and compressive forces to said second web to form said polymer film into a coating on said first web, said coating comprising a fine pattern of continuous areas which lie between and interconnect discontinuous areas, wherein the polymer in the continuous areas comprises a continuous or substantially continuous coating on the surface of said first web, and wherein most of the polymer in the discontinuous areas is coated on individual fibers; and
(d) cooling the coated web thus formed to cool the polymer below its forming temperature.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic view in elevation of one type of apparatus that can be employed to carry out the process of the invention;
FIG. 2 is a scanning electron micrograph of one type of absorbent facing material of the invention shown at a magnification of 75×;
FIG. 3 is a scanning electron micrograph of another type of absorbent facing material of the invention, shown at a magnification of 140×;
FIG. 4 is a scanning electron micrograph of a facing made in accordance with Surowitz, U.S. Pat. No. 3,307,545, shown at a magnification of 70×;
FIG. 5 is a further enlarged scanning electron micrograph of a portion of the facing of FIG. 4, shown at a magnification of 170×;
FIG. 6 is a perspective view of a sanitary napkin which utilizes the absorbent facing material of the invention;
FIG. 7 is a perspective view of a disposable diaper which utilizes the absorbent facing material of the invention;
FIGS. 8 and 9 are cross-sectional views at 50× of the Surowitz facing and facing of Example 1, respectively;
FIGS. 10 and 11 are top plan views at 20× of the Surowitz facing and the facing of Example 1, respectively;
FIGS. 12 and 13 are top perspective views at 100× of the Surowitz facing and the facing of Example 1, respectively; and
FIGS. 14 and 15 are enlargements of views 12 and 13, shown at 200×.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to FIG. 1, there is shown an apparatus that can be employed to carry out the process of the invention. In carrying out the process, a polymer film 10 and a fibrous web 14 composed principally of absorbent fibers are taken off suitable supply rolls 12, 16, which are mounted for rotation on bearings 13, 17 mounted in suitable framing F. The film 10 and fibrous web 14 are superimposed and are passed through the nip of a pair of counter-rotating rolls 18, 20. The rolls are mounted for rotation on bearings 19, 23 mounted in suitable framing F, and are driven by suitable drive mechanisms 21, 25. The bottom roll 18 that is in contact with the fibrous web 14 has a smooth, uniform surface. Said bottom roll 18 is heated. The top roll 20 that is in contact with the polymer film 10 has a resilient surface that has a pattern of continuously arranged recessed areas (grooves) and discontinuously arranged raised areas disposed uniformly over the surface of the roll 20. As a general rule, the grooves will usually be from about 0.002 inch to about 0.05 inch wide, and from about 0.001 inch to about 0.035 inch deep. Preferably, the resilient roll 20 is moving at a peripheral speed slightly higher than the peripheral speed of the smooth roll 18. Peripheral speed ratios of from about 1.1:1 to 1.5:1 are suitable. After passing through the nip of the rolls 18, 20, the polymer film is formed into a coating on the fibrous web, with the coating comprising a fine pattern of continuous areas which lie between and interconnect discontinuous areas, wherein the polymer in the continuous areas comprises a continuous or substantially continuous coating on the surface of the fibrous web, and wherein the polymer in the discontinuous areas is coated on individual fibers.
The apparatus that can be employed to carry out the process of this invention is similar to the apparatus disclosed by Kalwaites, in U.S. Pat. No. 3,881,381.
A wide variety of thin films can be employed in the invention. The preferred films are made from olefin polymers, such as polyethylene, both high and low density, polypropylene, ethylene copolymers such as ethylene/vinyl acetance, ethylene/ethyl acrylate, and others such as ethylene/methyl acrylate. It is desirable to employ a film having a thickness of from about 1/4 mil to about 1 1/4 mils. In one preferred aspect, a corona-treated polyethylene film is used in order to achieve improved adhesion between the film and the fibrous web.
The fibrous web employed in the invention is composed predominantly of absorbent fibers. (By "absorbent fibers" is meant those fibers that have an affinity for aqueous liquids.) The web can contain cellulosic fibers such as wood pulp, cotton, and rayon, or other hydrophilic fibers such as polyvinyl alcohol fibers or normally hydrophobic fibers such as polyester or polypropylene that have been treated by known methods to make them hydrophilic. It is generally preferred that the web be composed mostly of short or papermaking fibers, although textile length fibers can be employed. Minor amounts of non-absorbent fibers can be employed if desired. The web can be a loosely formed dry laid product, or it can be wet laid. If desired, the fibrous web can be lightly bonded. The binder can be viscose or other hydrophilic binder, it can be an acrylic binder, polyvinyl acetate, ethylene-vinyl acetate copolymer, SBR rubber, or the like. If desired, the binder can be cross-linkable. The binders that can be employed are well-known in the art. The web can be overall saturated with binder, or it can be print or spot bonded. The web can contain a small proportion of thermoplastic fibers, which can be used as binding means by calendering, or the like. While it is generally preferred to employ rather light weight webs (of the order of 1/2 to 2 1/2 ounces per square yard), the invention can be employed with heavier webs.
The temperature of the heated roll 18 is sufficient to increase the temperature of the film 10 to at least the forming temperature of the polymer in the film 10. The precise temperature employed in particular cases will depend upon factors such as the nature of the polymer in the film 10, the speed of the webs in passing through the nip, the thickness or weight of the fibrous web 14, the pattern of engraving on the resilient roll 20, and similar factors. As an illustration, when 1/2 mil low density polyethylene film is employed, the peripheral speed of the smooth roll 18 is about 6 feet per minute, and the peripheral speed of the resilient roll 20 is about 8 feet per minute, a temperature of from about 260° to about 390° F. in the smooth roll 18 has been found to be useful. Preferably, the temperature in the smooth roll 18 is from about 275° to about 370° F. in this case.
The resilient roll 20 is usually at a temperature below the forming temperature of the polymer in the film 10. Again, this will vary from one polymer to another, speed of the web, and the like, but for the conditions stated above using the 1/2 mil polyethylene film and the speeds stated above, a temperature in the resilient roll 20 of from about 150° to about 220° F. has been found useful. Preferably, the temperature in the resilient roll 20 is from about 170° to 215° F. for these conditions.
As is seen from the breadth of the temperature ranges indicated above, the exact temperature employed has not been found to be narrowly critical. The important factors are to heat the film to its forming temperature, and to avoid sticking of the film to the resilient roll. It is well within the ordinary skill of the art to determine optimum temperatures in particular cases.
The resilient roll will ordinarily have a Durometer Shore A hardness of from about 45 to about 90. The surface of this roll can be of rubber; either hydrocarbon rubber or silicone rubber would be suitable. The surface of the resilient roll is engraved with a regular pattern of lines. As a general rule, the engraved pattern would be such as to provide from about 100 to about 10,000 openings (i.e., raised areas) per square inch of surface.
Pressure is maintained on the two rolls 18, 20 in order to provide a pressure at the nip of from about 5 to about 90 pounds per linear inch. The pressure can be provided by suitable hydraulic means such as those that are well known in the art.
After the coated web 26 passes through the nip of the rolls 18, 20, the polymer coating cools below the forming temperature of the polymer.
The coated web 26 is collected on a suitable wind-up 28, that is mounted for rotation on bearings 30 mounted on suitable framing F, and driven by a suitable drive mechanism 32.
In some cases, such as when operating at relatively high speeds, it may be desirable to preheat the fibrous web 14. This can be done by passing the web 14 around a preheating roll 22, which is mounted for rotation on bearings 27 mounted on suitable framing F. The web 14 passes around idler rolls 24a, 24b before and after the preheating roll 22.
The invention is further illustrated by the following examples:
EXAMPLE 1
Using an apparatus substantially as shown in FIG. 1 (without the preheating roll), an absorbent facing was made from 1/2 mil polyethylene film (density: 0.92 to 0.923, melt index: 5 to 7) and a fibrous web composed of 75 weight percent wood pulp ("Alphanier F", from the Rayonier Corporation) and 25 weight percent rayon (1-9/16 inch, 1.5 denier), overall saturation bonded with Hycar 2600×120 (an acrylic latex containing a small amount of polymerized N-methylolacrylamide cross-linker). The web weighed about 1 1/4 ounces per square yard, and was made in accordance with the procedure described in Example IV of Liloia et al, U.S. Pat. No. 3,663,348.
The resilient roll had a silicone rubber surface with a Durometer Shore A hardness of about 60, and was engraved with a continuous pattern of recessed lines 0.020 inch wide and 0.018 inch deep, with 16 lines per inch running in the longitudinal direction (i.e., parallel to the longitudinal axis of the roll) and 20 lines per inch in the transverse direction. The smooth roll had a steel surface. The surface of the smooth roll was maintained at about 285° F., and the surface of the resilient roll reached an equilibrium temperature of about 180° F., by appropriate heat exchange means. The pressure at the nip was about 40 pounds per linear inch. The periphery of the smooth roll was moving at a speed of 6 feet per minute, and the periphery of the resilient roll was moving at a speed of 8 feet per minute.
A scanning electron micrograph (at about 75×) of the absorbent facing made in this Example 1 is shown in FIG. 2. The absorbent facing product 33 has a fine pattern of continuous areas 34 wherein the polyethylene is present as a continuous coating on the surface of the web. These continuous areas 34 correspond to the pattern of recessed lines engraved on the surface of the resilient roll. In between the continuous areas 34 are discontinuous areas 36 wherein most of the polyethylene is present as a coating on individual fibers.
Aqueous fluids readily pass through the coated surface of this absorbent facing product 33 to the absorbent fibers beneath the surface, but the fluids do not readily flow in the reverse direction.
EXAMPLE 2
An absorbent facing was made using the same materials as those described in Example 1, and using substantially the same procedure except that the resilient roll had a pattern of 100 recessed lines per inch engraved in both the longitudinal and transverse directions. The lines were 0.00255 inch wide and 0.00118 inch deep. The surface temperature of the heated smooth roll was about 360° F., and the resilient roll had a surface temperature of about 200° F. A scanning electron micrograph (at about 140×) of the absorbent facing product 38 is shown in FIG. 3. The product 38 has a fine pattern of continuous areas 40 in which the polyethylene is present as a substantially continuous coating on the surface of the web. These continuous areas 40 correspond to the pattern of engraved recessed lines on the surface of the resilient roll. In between the continuous areas 40 are discontinuous areas 42 in which most of the polyethylene is coated on the surface of individual fibers
Aqueous liquids readily flow through this absorbent facing from the polymer-coated side, but do not readily flow in the reverse direction.
CONTROL EXAMPLE 1
The process of Example 1 was repeated except that the resilient roll employed had a smooth surface. The resulting product was simply a web of fibers having a continuous film of polyethylene loosely adhered to the surface thereof. Thus, the surface could not be penetrated by aqueous liquids.
CONTROL EXAMPLE 2
When an open net of polyethylene is calendered to the surface of the fibrous web described in Example 1, no one-way valve characteristics are obtained Aqueous fluid flows readily in both directions.
CONTROL EXAMPLE 3
Scanning electron micrographs of a product made in accordance with the teachings of Surowitz in U.S. Pat. No. 3,307,545 are shown in FIGS. 4 and 5. It is seen that the product has a substantially continuous coating 44 of plastic film, with a plurality of recesses 46. One of the recesses 46a plastic film is shown in greater magnification in FIG. 5. It is seen that in the recess, the plastic film is present as a substantially continuous coating 48 containing a pattern of holes or openings 50. The holes 50 are concentrated in the central (lowest) portion of the recesses 46.
In FIG. 6 there is shown a sanitary napkin 52 which utilizes the absorbent facing material of the invention. The napkin 52 contains an absorbent core 54, which may comprise absorbent fibrous material such as comminuted wood pulp fibers, cotton linters, rayon fibers, cotton staples, and the like. The core 54 of the napkin 52 is enveloped by a layer 56 of the absorbent facing material of the invention. The napkin 52 will also normally contain a fluid impervious layer (not shown) on the side normally worn away from the body.
In FIG. 7, there is shown a disposable diaper 58 which employs the facing material of the invention. The diaper 58 comprises an absorbent core 60, a fluid impervious layer 62, and a layer 64 of the absorbent facing of the invention.
FIGS. 8 through 15 further distinguish the absorbent facing material of the present invention from that of Surowitz in U.S. Pat. No. 3,307,545. FIGS. 8 and 9 depict the cross-sectional views at 50× of the Surowitz facing of FIGS. 4 and 5, and the facing of Example 1, respectively. FIGS. 10 and 11 are top plan views of the Surowitz facing of FIGS. 4 and 5, and the facing of Example 1, respectively. As can be seen in the Surowitz products in FIGS. 8 and 10, the product has a substantially continuous coating of plastic film 44 with a plurality of recesses 46. One of the recesses 46b is shown in greater magnification in FIGS. 12 and 14 and will be described more completely below. In FIGS. 9 and 11, it may be noted that the absorbent facing material 36 of the present invention, and specifically, of Example 1, comprises a fine pattern of continuous areas 34 which lie between and interconnect discontinuous areas 36. As may be seen in both FIGS. 9 and 11, the polymer in the continuous areas comprises in at least substantially continuous coating on the surface of the web, and no part of the continuous coating is recessed down into the web. One of the discontinuous areas 36b is shown in greater magnification in FIGS. 13 and 14 and will be described more completely below.
FIGS. 12 and 14 give a top perspective view at 100× and 200×, respectively, of the Surowitz facing shown in FIGS. 4, 5, 8, and 10, and show at greater magnification one of the recesses 46b as seen in FIGS. 12 and 14, the continuous coating of plastic film and the recess extends down into the web, leaving the surface of the web. The plastic film is present in a substantially continuous coating 78 containing a pattern of holes or openings 80 in the central (lowest) portion of the recesses FIGS. 13 and 15 show at greater magnification, one of the discontinuous areas 36a of the absorbent dressing of Example 1. As may be seen in both FIGS. 13 and 15, the polymer in the continuous areas 34 which lie between and interconnect the discontinuous area 36, comprise a substantially continuous coating on the surface of the web, and do not recess into the web. As also shown in FIGS. 13 and 15, the polymer in the discontinuous areas 36a is coated on the individual fibers of the web.
While a sanitary napkin and a disposable diaper have been shown, there are various other types of absorbent products in which the absorbent facing of the invention can be employed. These include tampons, underpads, surgical dressings or bandages, and the like. The absorbent facing of the invention is particularly useful as a surgical dressing or bandage because body fluids pass through it quite readily, but the facing has excellent non-sticking or wound-release properties.
EXAMPLE 3
An absorbent facing was made using the same materials as those described in Example 2, and using the same equipment and substantially the same procedure except that the resilient roll was heated instead of the smooth roll and the pressure at the nip was about 60 pounds per linear inch. The temperature of the resilient roll was about 245° F., and the smooth roll reached a temperature of about 200° F. Excellent absorbent facings were made which had one-way valve characteristics with respect to aqueous liquids, using both 1/3-mil and 1/2-mil polyethylene film.
EXAMPLE 4
Example 3 was repeated using a pressure at the nip of about 5 pounds per linear inch. A good absorbent facing was made.
EXAMPLE 5
Example 4 was repeated except that the fibrous web was a polypropylene fiber web weighing about 4 ounces per square yard, which had been treated to make the fibers hydrophilic. A good absorbent facing was produced.
In Examples 3-5, wherein the resilient roll instead of the smooth roll is heated, lower temperatures than those set forth above in the specification can be used because the heat does not have to pass through the fibrous web. | An absorbent facing is disclosed which has significant one-way valve characteristics for aqueous fluids. The facing is produced by a process which comprises the steps of: (a) superimposing a thin polymer film and a first web comprising absorbent fibers, to form a second web; (b) heating the second web to a temperature such that the polymer film is in a formable state; (c) while the said second web is so heated, simultaneously applying shearing and compressive forces to the second web to form said polymer film into a coating on said first web, the coating comprising a fine pattern of continuous areas which lie between and interconnect discontinuous areas, wherein the polymer in the continuous areas comprises a continuous or substantially continuous coating on the surface of said first web, and wherein most of the polymer in the discontinuous areas is coated on individual fibers; and (d) cooling the coated web thus formed to cool the polymer below its forming temperature. | 0 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the priority benefit under 35 U.S.C. §119(e) of U.S. Provisional Application No. 61/428,653, filed Dec. 30, 2010; U.S. Provisional Application No. 61/493,447, filed Jun. 4, 2011; U.S. Provisional Application No. 61/550,889, filed Oct. 24, 2011; and U.S. Provisional Application No. 61/556,142, filed Nov. 4, 2011, the entire contents of which are hereby incorporated by reference and should be considered a part of this specification.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] In general, the disclosure relates to methods and apparatuses for filtering blood. The filtration systems can be catheter-based for insertion into a patient's vascular system.
[0004] 2. Description of the Related Art
[0005] Thromboembolic disorders, such as stroke, pulmonary embolism, peripheral thrombosis, atherosclerosis, and the like, affect many people. These disorders are a major cause of morbidity and mortality in the United States and throughout the world. Thromboembolic events are characterized by an occlusion of a blood vessel. The occlusion can be caused by a clot which is viscoelastic (jelly-like) and is comprised of platelets, fibrinogen, and other clotting proteins.
[0006] Percutaneous aortic valve replacement has been in development for some time now and stroke rates related to this procedure are between four and twenty percent. During catheter delivery and valve implantation plaque or other material may be dislodged from the vasculature and may travel through the carotid circulation and into the brain. When an artery is occluded by a clot or other embolic material, tissue ischemia (lack of oxygen and nutrients) develops. The ischemia will progress to tissue infarction (cell death) if the occlusion persists. Infarction does not develop or is greatly limited if the flow of blood is reestablished rapidly. Failure to reestablish blood-flow can lead to the loss of limb, angina pectoris, myocardial infarction, stroke, or even death.
[0007] Occlusion of the venous circulation by thrombi leads to blood stasis which can cause numerous problems. The majority of pulmonary embolisms are caused by emboli that originate in the peripheral venous system. Reestablishing blood flow and removal of the thrombus is highly desirable.
[0008] Techniques exist to reestablish blood flow in an occluded vessel. One common surgical technique, an embolectomy, involves incising a blood vessel and introducing a balloon-tipped device (such as a Fogarty catheter) to the location of the occlusion. The balloon is then inflated at a point beyond the clot and used to translate the obstructing material back to the point of incision. The obstructing material is then removed by the surgeon. While such surgical techniques have been useful, exposing a patient to surgery may be traumatic and is best avoided when possible. Additionally, the use of a Fogarty catheter may be problematic due to the possible risk of damaging the interior lining of the vessel as the catheter is being withdrawn.
[0009] A common percutaneous technique is referred to as balloon angioplasty where a balloon-tipped catheter is introduced into a blood vessel, typically through an introducing catheter. The balloon-tipped catheter is then advanced to the point of the occlusion and inflated in order to dilate the stenosis. Balloon angioplasty is appropriate for treating vessel stenosis but is generally not effective for treating acute thromboembolisms.
[0010] Another percutaneous technique is to place a microcatheter near the clot and infuse Streptokinase, Urokinase, or other thrombolytic agents to dissolve the clot. Unfortunately, thrombolysis typically takes hours or days to be successful. Additionally, thrombolytic agents can cause hemorrhage and in many patients the agents cannot be used at all.
[0011] Another problematic area is the removal of foreign bodies. Foreign bodies introduced into the circulation can be fragments of catheters, pace-maker electrodes, guide wires, and erroneously placed embolic material such as thrombogenic coils. Retrieval devices exist for the removal of foreign bodies, some of which form a loop that can ensnare the foreign material by decreasing the size of the diameter of the loop around the foreign body. The use of such removal devices can be difficult and sometimes unsuccessful.
[0012] Moreover, systems heretofore disclosed in the art are generally limited by size compatibility and the increase in vessel size as the emboli is drawn out from the distal vascular occlusion location to a more proximal location near the heart. If the embolectomy device is too large for the vessel it will not deploy correctly to capture the clot or foreign body, and if too small in diameter it cannot capture clots or foreign bodies across the entire cross section of the blood vessel. Additionally, if the embolectomy device is too small in retaining volume then as the device is retracted the excess material being removed can spill out and be carried by flow back to occlude another vessel downstream.
[0013] Various thrombectomy and foreign matter removal devices have been disclosed in the art. Such devices, however, have been found to have structures which are either highly complex or lacking in sufficient retaining structure. Disadvantages associated with the devices having highly complex structure include difficulty in manufacturability as well as difficulty in use in conjunction with microcatheters. Recent developments in the removal device art features umbrella filter devices having self folding capabilities. Typically, these filters fold into a pleated condition, where the pleats extend radially and can obstruct retraction of the device into the microcatheter sheathing.
[0014] Extraction systems are needed that can be easily and controllably deployed into and retracted from the circulatory system for the effective removal of clots and foreign bodies. There is also a need for systems that can be used as temporary arterial or venous filters to capture and remove thromboemboli generated during endovascular procedures. The systems should also be able to be properly positioned in the desired location. Additionally, due to difficult-to-access anatomy such as the cerebral vasculature and the neurovasculature, the systems should have a small collapsed profile.
[0015] The risk of dislodging foreign bodies is also prevalent in certain surgical procedures. It is therefore further desirable that such emboli capture and removal apparatuses are similarly useful with surgical procedures such as, without limitation, cardiac valve replacement, cardiac bypass grafting, cardiac reduction, or aortic replacement.
SUMMARY OF THE INVENTION
[0016] One aspect of the disclosure is a catheter-based endovascular system and method of use for filtering blood that captures and removes particles caused as a result of a surgical or endovascular procedures. The method and system include a first filter placed in a first vessel within the patient's vascular system and a second filter placed in a second vessel within the patient's vascular system. In this manner, the level of particulate protection is thereby increased.
[0017] One aspect of the disclosure is an endovascular filtration system and method of filtering blood that protects the cerebral vasculature from embolisms instigated or foreign bodies dislodged during a surgical procedure. In this aspect, the catheter-based filtration system is disposed at a location in the patient's arterial system between the site of the surgical procedure and the cerebral vasculature. The catheter-based filtration system is inserted and deployed at the site to capture embolisms and other foreign bodies and prevent their travel to the patient's cerebral vasculature so as to avoid or minimize thromboembolic disorders such as a stroke.
[0018] One aspect of the disclosure is an endovascular filtration system and method of filtering blood that provides embolic protection to the cerebral vasculature during a cardiac or cardiothoracic surgical procedure. According to this aspect, the filtration system is a catheter-based system provided with at least a first filter and a second filter. The first filter is positioned within the brachiocephalic artery, between the aorta and the right common carotid artery, with the second filter being positioned within the left common carotid artery.
[0019] One aspect of the disclosure is a catheter-based endovascular filtration system including a first filter and a second filter, wherein the system is inserted into the patient's right brachial or right radial artery. The system is then advanced through the patient's right subclavian artery and into the brachiocephalic artery. Alternately, the system may be inserted directly into the right subclavian artery. At a position within the brachiocephalic trunk between the aorta and the right common carotid artery, the catheter-based system is manipulated to deploy the first filter. The second filter is then advanced through or adjacent to the deployed first filter into the aorta and then into the left common carotid artery. Once in position within the left common carotid artery the catheter-based system is further actuated to deploy the second filter. After the surgical procedure is completed, the second filter and the first filter are, respectively, collapsed and withdrawn from the arteries and the catheter-based filtration system is removed from the patient's vasculature. In an alternate embodiment, either or both the first and second filters may be detached from the filtration system and left inside the patient for a therapeutic period of time.
[0020] One aspect of the disclosure is a catheter-based filtration system comprising a handle, a first sheath, a first filter, a second sheath and a second filter. The first and second sheaths are independently actuatable. The handle can be a single or multiple section handle. The first sheath is translatable relative to the first filter to enact deployment of the first filter in a first vessel. The second sheath is articulatable from a first configuration to one or more other configurations. The extent of articulation applied to the second sheath is determined by the anatomy of a second vessel to which access is to be gained. The second filter is advanced through the articulated second sheath and into the vessel accessed by the second sheath and, thereafter, deployed in the second vessel. Actuation of the first sheath relative to the first filter and articulation of the second filter is provided via the handle. In some embodiments, the handle includes a locking mechanism configured to lock the first sheath relative to the second sheath. In certain embodiments, the handle also includes a distal flush port.
[0021] In some aspects of the disclosure, the second filter is carried on a guiding member having a guidewire lumen extending therethrough. In certain aspects, the guiding member is a catheter shaft. A guiding member having a guidewire lumen allows the user to precisely deliver the second filter by advancing the filter system over the guidewire. The guiding member can be configured to have increased column strength to aid advancement of the second filter. In some aspects, the guiding member includes a flexible portion to better position the second filter within the vessel.
[0022] In some aspects the first sheath is a proximal sheath, the first filter is a proximal filter, the second sheath is a distal sheath, and the second filter is a distal filter. The proximal sheath is provided with a proximal hub housed within and in sliding engagement with the handle. Movement of the proximal hub causes translation of the proximal sheath relative to the proximal filter. The distal sheath includes a distal shaft section and a distal articulatable sheath section. A wire is provided from the handle to the distal articulatable sheath section. Manipulation of the handle places tension on the wire causing the distal articulatable sheath section to articulate from a first configuration to one or more other configurations. The articulatable distal sheath is capable of rotation, translation, and deflection (both in a single plane and both partially in a first plane and partially in a second, different plane). In some embodiments, the handle includes a locking mechanism to prevent the articulatable distal sheath from deviating from a desired configuration. In certain embodiments, the locking mechanism may lock automatically when the operator actuates a control or releases the handle.
[0023] In some aspects the proximal filter and the distal filter are both self-expanding. The proximal filter and the distal filter both may comprise an oblique truncated cone shape. Movement of the proximal sheath relative to the proximal filter causes the proximal filter to expand and deploy against the inside wall of a first vessel. The distal filter is then advanced through or adjacent to the distal shaft and distal articulatable sheath into expanding engagement against the inner wall of a second vessel. In some embodiments, a tethering member extends from the proximal sheath to the proximal filter to help draw the proximal filter opening toward the first vessel wall.
[0024] Another aspect of the disclosure is a single filter embolic protection device comprising a single filter device comprising a sheath, a filter shaft, and a filter assembly. In some aspects, the filter assembly is designed to accommodate a catheter-based device passing between the filter and the vessel wall. In certain embodiments, the filter assembly may include a channel, a gap, or an inflatable annulus. The filter assembly may also include one or more filter lobes. In another embodiment, the filter assembly may resemble an umbrella having a plurality of tines and a filter element connecting each tine. The filter assembly may alternatively include a plurality of overlapping filter portions, wherein a catheter may pass between a first filter portion and a second filter portion of the filter assembly.
BRIEF DESCRIPTION OF THE DRAWINGS
[0025] FIG. 1 illustrates an exemplary prior art catheter being advanced through a portion of a subject's vasculature.
[0026] FIGS. 1A-1D illustrate an exemplary dual filter system.
[0027] FIGS. 1E and 1F illustrate exemplary proximal filters.
[0028] FIGS. 2A-2D illustrate an exemplary method of delivering and deploying a dual filter system
[0029] FIGS. 3-5 illustrate a portion of an exemplary delivery procedure for positioning a blood filter.
[0030] FIGS. 6A and 6B illustrate an exemplary embodiment of an articulating distal sheath.
[0031] FIGS. 7A-7C illustrate a portion of an exemplary filter system.
[0032] FIGS. 8A-8C illustrate an exemplary pull wire.
[0033] FIGS. 9A-9C show an exemplary embodiment of a distal sheath with slots formed therein.
[0034] FIGS. 9D-9E show an exemplary embodiment of a distal sheath capable of deflecting in multiple directions.
[0035] FIGS. 9F and 9G illustrate exemplary guidewire lumen locations in the distal sheath.
[0036] FIGS. 10A and 10B illustrate a portion of exemplary distal sheath adapted to be multi-directional.
[0037] FIGS. 11A-11E illustrate merely exemplary anatomical variations that can exist.
[0038] FIGS. 12A and 12B illustrate an exemplary curvature of a distal sheath to help position the distal filter properly in the left common carotid artery.
[0039] FIGS. 13A and 13B illustrate alternative distal sheath and distal shaft portions of an exemplary filter system.
[0040] FIG. 14 illustrates a portion of an exemplary system including a distal shaft and a distal sheath.
[0041] FIGS. 15A-15D illustrate alternative embodiments of the coupling of the distal shaft and distal sheath.
[0042] FIG. 16 illustrates an exemplary embodiment of a filter system in which the distal sheath is biased to a curved configuration.
[0043] FIG. 17 illustrates a portion of an alternative filter system.
[0044] FIGS. 18A and 18B illustrate an exemplary proximal filter.
[0045] FIGS. 19A-19C , 20 A- 20 B, 21 , 22 A-B illustrate exemplary proximal filters.
[0046] FIGS. 23A-23F illustrate exemplary distal filters.
[0047] FIGS. 24A-24C illustrate exemplary embodiments in which the system includes at least one distal filter positioning, or stabilizing, anchor.
[0048] FIGS. 25A-25D illustrate an exemplary embodiment of coupling a distal filter to a docking wire inside of the subject.
[0049] FIGS. 26A-26G illustrate an exemplary method of preparing an exemplary distal filter assembly for use.
[0050] FIGS. 27A and 27B illustrate an exemplary embodiment in which a guiding member, secured to a distal filter before introduction into the subject is loaded into an articulatable distal sheath.
[0051] FIGS. 28A-28E illustrate an exemplary distal filter assembly in collapsed and expanded configurations.
[0052] FIGS. 29A-29E illustrate a portion of an exemplary filter system with a lower delivery and insertion profile.
[0053] FIGS. 30A and 30B illustrate a portion of an exemplary filter system.
[0054] FIGS. 31A-31C illustrate an exemplary over-the-wire routing system that includes a separate distal port for a dedicated guidewire.
[0055] FIGS. 32A-32E illustrate an exemplary routing system which includes a rapid-exchange guidewire delivery.
[0056] FIGS. 33A-D illustrates a filter system which includes a tubular core member.
[0057] FIGS. 34A-C illustrate a filter system with a flexible coupler.
[0058] FIGS. 35A-E illustrate alternate designs for a flexible coupler.
[0059] FIGS. 36A-C illustrate a method of using a tethering member.
[0060] FIGS. 36D-E illustrate attachment points for a tethering member.
[0061] FIGS. 37A-D illustrate multiple embodiments for a tethering member.
[0062] FIGS. 38A-D illustrate multiple embodiments for an aortic filter designed to form a seal around a catheter.
[0063] FIGS. 39A-C illustrate an aortic filter system having multiple aortic filters.
[0064] FIGS. 40A-B exemplify multiple embodiments for an aortic filter.
[0065] FIGS. 41A-B illustrate an aortic filter having an inflatable annulus.
[0066] FIG. 42 illustrates a distal portion of an exemplary filter system.
[0067] FIGS. 43-46 illustrate exemplary control handles of the blood filter systems.
[0068] FIGS. 47A-H illustrate cross-sectional portions of an exemplary control handle.
[0069] FIG. 48 depicts an alternative control handle with a rotary tip deflection control.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0070] Although certain preferred embodiments and examples are disclosed below, inventive subject matter extends beyond the specifically disclosed embodiments to other alternative embodiments and/or uses, and to modifications and equivalents thereof. Thus, the scope of the claims appended hereto is not limited by any of the particular embodiments described below. For example, in any method or process disclosed herein, the acts or operations of the method or process can be performed in any suitable sequence and are not necessarily limited to any particular disclosed sequence. Various operations can be described as multiple discrete operations in turn, in a manner that can be helpful in understanding certain embodiments; however, the order of description should not be construed to imply that these operations are order dependent. Additionally, the structures described herein can be embodied as integrated components or as separate components. For purposes of comparing various embodiments, certain aspects and advantages of these embodiments are described. Not necessarily all such aspects or advantages are achieved by any particular embodiment. Thus, for example, various embodiments can be carried out in a manner that achieves or optimizes one advantage or group of advantages as taught herein without necessarily achieving other aspects or advantages as can also be taught or suggested herein.
[0071] The disclosure relates generally to intravascular blood filters used to capture foreign particles. In some embodiments the blood filter is a dual-filter system to trap foreign bodies to prevent them from traveling into the subject's right and left common carotid arteries, while in other embodiments, the blood filter is a single filter system. The filter systems described herein can, however, be used to trap particles in other blood vessels within a subject, and they can also be used outside of the vasculature. The systems described herein are generally adapted to be delivered percutaneously to a target location within a subject, but they can be delivered in any suitable way, and need not be limited to minimally-invasive procedures.
[0072] Filter systems in accordance with the present invention can be utilized to reduce the occurrence of emboli entering the cerebral circulation as a consequence of any of a variety of intravascular interventions, including, but not limited to, transcatheter aortic-valve implantation (TAVI), surgical valve repair or replacement, atrial fibrillation ablation, cardiac bypass surgery, or transthoracic graft placement around the aortic arch. For example, the present filter or filters may be placed as described elsewhere herein prior to a minimally invasive or open surgical repair or replacement of a heart valve, such as the mitral or aortic valve. The filter system may alternatively be placed prior to cardiac ablation such as ablation of the pulmonary vein to treat atrial fibrillation. Ablation may be accomplished using any of a variety of energy modalities, such as RF energy, cryo, microwave or ultrasound, delivered via a catheter having a distal end positioned within the heart. The present filter systems may alternatively be placed prior to cardiac bypass surgery, or prior to transthoracic graft placement around the aortic arch, or any of a variety of other surgeries or interventions that are accompanied by a risk of cerebral embolization.
[0073] In one application, the filter systems described herein are used to protect the cerebral vasculature against embolisms and other foreign bodies entering the bloodstream during a cardiac valve replacement or repair procedure. To protect both the right common carotid artery and the left common carotid artery during such procedures, the system described herein enters the aorta from the brachiocephalic artery. Once in the aortic space, there is a need to immediately navigate a 180 degree turn into the left common carotid artery. In gaining entry into the aorta from the brachiocephalic artery, use of prior art catheter devices 1 will tend to hug the outer edge of the vessel 2 , as shown in FIG. 1 . To then gain access to the left common carotid artery 3 with such prior art devices can be a difficult maneuver due to the close proximity of the two vessels which may parallel one another, often within 1 cm of separation, as shown in, for example, FIGS. 1-5 . This sharp turn requires a very small radius and may tend to kink the catheter reducing or eliminating a through lumen to advance accessories such as guidewires, filters, stents, and other interventional tools. The catheter-based filter systems described herein can traverse this rather abrupt essentially 180 degree turn to thereby deploy filters to protect both the right and left common carotid arteries.
[0074] FIGS. 1A-1C illustrate an exemplary filter system having control handle portion 5 and filter system 10 . In some embodiments, control handle portion 5 may include a distal flush port 4 . Filter system 10 includes proximal sheath 12 , proximal shaft 14 coupled to expandable proximal filter 16 , distal shaft 18 coupled to distal articulatable sheath 20 , distal filter 22 , and guiding member 24 . FIG. 1B illustrates proximal filter 16 and distal filter 22 in expanded configurations. FIG. 1C illustrates the system in a delivery configuration, in which proximal filter 16 (not seen in FIG. 1C ) is in a collapsed configuration constrained within proximal sheath 12 , while distal filter 22 is in a collapsed configuration constrained within distal articulatable sheath 20 .
[0075] FIG. 1D is a sectional view of partial system 10 from FIG. 1C . Proximal shaft 14 is co-axial with proximal sheath 12 , and proximal region 26 of proximal filter 16 is secured to proximal shaft 14 . In its collapsed configuration, proximal filter 16 is disposed within proximal sheath 12 and is disposed distally relative to proximal shaft 14 . Proximal sheath 12 is axially (distally and proximally) movable relative to proximal shaft 14 and proximal filter 16 . System 10 also includes distal sheath 20 secured to a distal region of distal shaft 18 . Distal shaft 18 is co-axial with proximal shaft 14 and proximal sheath 12 . Distal sheath 20 and distal shaft 18 , secured to one another, are axially movable relative to proximal sheath 12 , proximal shaft 14 and proximal filter 16 . System 10 also includes distal filter 22 carried by guiding member 24 . In FIG. 1D distal filter 22 is in a collapsed configuration within distal sheath 22 . Guiding member 24 is coaxial with distal sheath 20 and distal shaft 18 as well as proximal sheath 12 and proximal shaft 14 . Guiding member 24 is axially movable relative to distal sheath 20 and distal shaft 18 as well as proximal sheath 12 and proximal shaft 14 . Proximal sheath 12 , distal sheath 20 , and guiding member 24 are each adapted to be independently moved axially relative to one other. That is, proximal sheath 12 , distal sheath 20 , and guiding member 24 are adapted for independent axial translation relative to each of the other two components.
[0076] In the embodiments in FIGS. 1A-1F , proximal filter 16 includes support element or frame 15 and filter element 17 , while distal filter 22 includes support element 21 and filter element 23 . The support elements generally provide expansion support to the filter elements in their respective expanded configurations, while the filter elements are adapted to filter fluid, such as blood, and trap particles flowing therethrough. The expansion supports are adapted to engage the wall of the lumen in which they are expanded. The filter elements have pores therein that are sized to allow the blood to flow therethrough, but are small enough to prevent unwanted foreign particles from passing therethrough. The foreign particles are therefore trapped by and within the filter elements.
[0077] In one embodiment, filter element 17 is formed of a polyurethane film mounted to frame 15 , as shown in FIGS. 1E and 1F . Film element 17 can measure about 0.0001 inches to about 0.1 inches in thickness. In some embodiments, the film thickness measures between 0.005 and 0.05, or between 0.015 and 0.025. In some situations, it may be desirable to have a filter with a thickness less than 0.0001 or greater than 0.1 inches. Other polymers may also be used to form the filter element, in the form of a perforated sheet or woven or braided membranes. Thin membranes or woven filament filter elements may alternatively comprise metal or metal alloys, such as nitinol, stainless steel, etc.
[0078] Filter element 17 has through holes 27 to allow fluid to pass and will resist the passage of the embolic material within the fluid. These holes can be circular, square, triangular or other geometric shapes. In the embodiment as shown in FIG. 1E , an equilateral triangular shape would restrict a part larger than an inscribed circle but have an area for fluid flow nearly twice as large making the shape more efficient in filtration verses fluid volume. It is understood that similar shapes such as squares and slots would provide a similar geometric advantage. In certain embodiments, the filter holes are laser drilled into the filter membrane, but other methods can be used to achieve a similar result. In some embodiments filter holes 27 are between about 1 micron and 1000 microns (1 mm). In certain embodiments, the hole size is between 1 micron and 500 microns. In other embodiments, the hole size is between 50 microns and 150 microns. However, the hole size can be larger, depending on the location of the filter within the subject and the type of particulate sought to be trapped in the filter.
[0079] In several embodiments, frame element 15 can be constructed of a shape memory material such as Nitinol, or other materials such as stainless steel or cobalt super alloy (MP35N for example) that have suitable material properties. Frame element 15 could take the form of a round wire or could also be of a rectangular or elliptical shape to preserve a smaller delivery profile. In one such embodiment, frame element 15 comprises Nitinol wire where the hoop is created from a straight piece of wire and shape set into a frame where two straight legs run longitudinally along the delivery system and create a circular distal portion onto which the filter film will be mounted. The circular or loop portion may include a radiopaque marker such as a small coil of gold, platinum iridium, or other radiopaque marker for visualization under fluoroscopy. In other embodiments, the frame element may not comprise a hoop, but include a spinal element disposed across a longitudinal length of the filter element. In still other embodiments, the filter element may not include a frame element.
[0080] The shape of the filter opening or frame elements 15 , 17 may take a circular shape when viewed axially or other shape that apposes the vessel wall. In some embodiments, such as those illustrated in FIGS. 1E , 1 F and 25 D, the shape of frame element 15 and filter element 17 are of an oblique truncated cone having a non-uniform or unequal length around and along the length of the conical filter 16 . In such a configuration, much like a windsock, the filter 16 would have a larger opening (upstream) diameter and a reduced ending (downstream) diameter. The unconstrained, fully expanded filter diameter can measure between 3 mm and 30 mm, but in some embodiments, the diameter may be less than 3 mm or greater than 30 mm. In some embodiments, the diameter may range between 10-25 mm or between 15-20 mm. The length of the filter may range between 10 mm and 50 mm, but the length of the filter may be less than 10 mm or greater than 50 mm. In some embodiments, the length may range between 10 mm and 30 mm or between 30 mm and 50 mm. In one embodiment, the diameter of the filter opening could measure about 15-20 mm in diameter and have a length of about 30-50 mm. A selection of different filter sizes would allow treatment of a selection of patients having different vessel sizes.
[0081] In some embodiments the material of the filter element is a smooth and/or textured surface that is folded or contracted into a small delivery catheter by means of tension or compression into a lumen. A reinforcement fabric 29 , as shown in FIG. 1F , may be added to or embedded in the filter to accommodate stresses placed on the filter material by means of the tension or compression applied. This will also reduce the stretching that may occur during delivery and retraction of filter element 17 . This reinforcement material 29 could be a polymer or metallic weave to add additional localized strength. This material could be imbedded into the polyurethane film to reduce its thickness. In one particular embodiment, this imbedded material could be a polyester weave mounted to a portion of the filter near the longitudinal frame elements where the tensile forces act upon the frame and filter material to expose and retract the filter from its delivery system. In some embodiments, the film measures between 0.0005 and 0.05, between 0.0025 and 0.025, or between 0.0015 and 0.0025 inches thick. In certain embodiments, the thickness is between 0.015 and 0.025 inches. In some situations, it may be desirable to have a filter with a thickness less than 0.0001 or greater than 0.1 inches. In some embodiments, the reinforcement fabric has a pore size between about 1 micron and about 1000 microns. In certain embodiments, the pore size is between about 50 microns and about 150 microns. While such an embodiment of the filter elements has been described for convenience with reference to proximal filter element 17 , it is understood that distal filter element 23 could similarly take such form or forms.
[0082] As shown in FIG. 1B , proximal filter 16 has a generally distally-facing opening 13 , and distal filter 22 has a generally proximally-facing opening 19 . The filters can be thought of as facing opposite directions. As described in more detail below, the distal sheath is adapted to be steered, or bent, relative to the proximal sheath and the proximal filter. As the distal sheath is steered, the relative directions in which the openings face will be adjusted. Regardless of the degree to which the distal sheath is steered, the filters are still considered to having openings facing opposite directions. For example, the distal sheath could be steered to have a 180 degree bend, in which case the filters would have openings facing in substantially the same direction. The directions of the filter openings are therefore described if the system were to assume a substantially straightened configuration, an example of which is shown in FIG. 1B . Proximal filter element 17 tapers down in the proximal direction from support element 15 , while distal filter element 23 tapers down in the distal direction from support element 21 . A fluid, such as blood, flows through the opening and passes through the pores in the filter elements, while the filter elements are adapted to trap foreign particles therein and prevent their passage to a location downstream to the filters.
[0083] In several embodiments, the filters are secured to separate system components. In the embodiment in FIGS. 1A-1D , for example, proximal filter 16 is secured to proximal shaft 14 , while distal filter 22 is secured to guiding member 24 . In FIGS. 1A-1D , the filters are secured to independently-actuatable components. This allows the filters to be independently positioned and controlled. Additionally, the filters are collapsed within two different tubular members in their collapsed configurations. In the embodiment in FIGS. 1A-1D , for example, proximal filter 16 is collapsed within proximal sheath 12 , while distal filter 22 is collapsed within distal sheath 20 . In the system's delivery configuration, the filters are axially-spaced from one another; however, in an alternative embodiment, the filters may be positioned such that a first filter is located within a second filter. For example, in FIG. 1D , distal filter 22 is distally-spaced relative to proximal filter 16 .
[0084] In some embodiments the distal sheath and the proximal sheath have substantially the same outer diameter (see, e.g., FIGS. 1C and 1D ). When the filters are collapsed within the sheaths, the sheath portion of the system therefore has a substantially constant outer diameter, which can ease the delivery of the system through the patient's body and increase the safety of the delivery. In FIG. 1D , distal and proximal sheaths 20 and 12 have substantially the same outer diameter, both of which have larger outer diameters than the proximal shaft 14 . Proximal shaft 14 has a larger outer diameter than distal shaft 18 , wherein distal shaft 18 is disposed within proximal shaft 14 . Guiding member 24 has a smaller diameter than distal shaft 18 . In some embodiments the proximal and distal sheaths have an outer diameter between 3 French (F) and 14 F. In certain embodiments, the outer diameter is between 4 F and 8 F. In still other embodiments, the outer diameter is between 4 F and 6 F. In some embodiments the sheaths have different outer diameters. For example, the proximal sheath can have a size of 6 F, while the distal sheath has a size of 5 F. In an alternate embodiment the proximal sheath is 5 F and the distal sheath is 4 F. A distal sheath with a smaller outer diameter than the proximal sheath reduces the delivery profile of the system and can ease delivery. In some methods of use, the filter system is advanced into the subject through an incision made in the subject's right radial artery. In a variety of medical procedures a medical instrument is advanced through a subject's femoral artery, which is larger than the right radial artery. A delivery catheter used in femoral artery access procedures has a larger outer diameter than would be allowed in a filter system advanced through a radial artery. Additionally, in some uses the filter system is advanced from the right radial artery into the aorta via the brachiocephalic trunk. The radial artery has the smallest diameter of the vessels through which the system is advanced. The radial artery therefore limits the size of the system that can be advanced into the subject when the radial artery is the access point. The outer diameters of the systems described herein, when advanced into the subject via a radial artery, are therefore smaller than the outer diameters of the guiding catheters (or sheaths) typically used when access is gained via a femoral artery.
[0085] FIG. 6A illustrates a portion of a filter delivery system in a delivery configuration. The system's delivery configuration generally refers to the configuration when both filters are in collapsed configurations within the system. FIG. 6B illustrates that the distal articulating sheath is independently movable with 3 degrees of freedom relative to the proximal sheath and proximal filter. In FIG. 6A , proximal sheath 60 and distal sheath 62 are coupled together at coupling 61 . Coupling 61 can be a variety of mechanisms to couple proximal sheath 60 to distal sheath 62 . For example, coupling 61 can be an interference fit, a friction fit, a spline fitting, end to end butt fit or any other type of suitable coupling between the two sheaths. When coupled together, as shown in FIG. 6A , the components shown in FIG. 6B move as a unit. For example, proximal sheath 60 , proximal shaft 64 , proximal filter 66 , distal shaft 68 , and the distal filter (not shown but within distal sheath 62 ) will rotate and translate axially (in the proximal or distal direction) as a unit. When proximal sheath 60 is retracted to allow proximal filter 66 to expand, as shown in FIG. 6B , distal sheath 62 can be independently rotated (“R”), steered (“S”), or translated axially (“T”) (either in the proximal “P” direction or distal “D” direction). The distal sheath therefore has 3 independent degrees of freedom: axial translation, rotation, and steering. The adaptation to have 3 independent degrees of freedom is advantageous when positioning the distal sheath in a target location, details of which are described below.
[0086] FIGS. 2A-2D illustrate a merely exemplary embodiment of a method of using any of the filter systems described herein. System 10 from FIGS. 1A-1D is shown in the embodiment in FIGS. 2A-2D . System 10 is advanced into the subject's right radial artery through an incision in the right arm. The system is advanced through the right subclavian artery and into the brachiocephalic trunk 11 , and a portion of the system is positioned within aorta 9 as can be seen in FIG. 2A (although that which is shown in FIG. 2A is not intended to be limiting).
[0087] Proximal sheath 12 is retracted proximally to allow proximal filter support element 15 to expand to an expanded configuration against the wall of the brachiocephalic trunk 11 , as is shown in FIG. 2B . Proximal filter element 17 is secured either directly or indirectly to support element 15 , and is therefore reconfigured to the configuration shown in FIG. 2B . The position of distal sheath 20 can be substantially maintained while proximal sheath 12 is retracted proximally. Once expanded, the proximal filter filters blood traveling through the brachiocephalic artery 11 , and therefore filters blood traveling into the right common carotid artery 7 . The expanded proximal filter is therefore in position to prevent foreign particles from traveling into the right common carotid artery 7 and into the cerebral vasculature.
[0088] Distal sheath 20 is then steered, or bent, and distal end 26 of distal sheath 20 is advanced into the left common carotid artery 13 , as shown in FIG. 2C . Guiding member 24 is thereafter advanced distally relative to distal sheath 20 , allowing the distal support element to expand from a collapsed configuration to a deployed configuration against the wall of the left common carotid artery 13 as shown in FIG. 2D . The distal filter element is also reconfigured into the configuration shown in FIG. 2D . Once expanded, the distal filter filters blood traveling through the left common carotid artery 13 . The distal filter is therefore in position to trap foreign particles and prevent them from traveling into the cerebral vasculature.
[0089] In several embodiments, the proximal and distal filter elements or frame elements comprise elastic or shape memory material causing the filters to expand as they exit their respective sheaths. In other embodiments, mechanical or hydraulic mechanisms may be used to expand each filter element. Once the filters are in place and expanded, an optional medical procedure can then take place, such as a valvuloplasty and/or replacement heart valve procedure. Any plaque or thrombus dislodged during the heart valve procedure that enters into the brachiocephalic trunk or the left common carotid artery will be trapped in the filters.
[0090] The filter system can thereafter be removed from the subject (or at any point in the procedure). In an exemplary embodiment, distal filter 22 is first retrieved back within distal sheath 20 to the collapsed configuration. To do this, guiding member 24 is retracted proximally relative to distal sheath 20 . This relative axial movement causes distal sheath 20 to engage strut 28 and begin to move strut 28 towards guiding member 24 . Support element 21 , which is coupled to strut 28 , begins to collapse upon the collapse of strut 28 . Filter element 23 therefore begins to collapse as well. Continued relative axial movement between guiding member 24 and distal sheath 20 continues to collapse strut 28 , support element 21 , and filter element 23 until distal filter 22 is retrieved and re-collapsed back within distal sheath 20 (as shown in FIG. 2C ). Any foreign particles trapped within distal filter element 23 are contained therein as the distal filter is re-sheathed. Distal sheath 20 is then steered into the configuration shown in FIG. 2B , and proximal sheath is then advanced distally relative to proximal filter 16 . This causes proximal filter 16 to collapse around distal shaft 18 , trapping any particles within the collapsed proximal filter. Proximal sheath 12 continues to be moved distally towards distal sheath 20 until in the position shown in FIG. 2A . The entire system 10 can then be removed from the subject.
[0091] In any of the embodiments mentioned herein, the filter or filters may alternatively be detached from the delivery catheter, and the delivery catheter removed leaving the filter behind. The filter or filters can be left in place permanently, or retrieved by snaring it with a retrieval catheter following a post procedure treatment period of time. Alternatively, the filters may remain attached to the catheter, and the catheter may be left in place post procedure for the treatment period of time. That treatment period may be at least one day, one week, three weeks, five weeks or more, depending upon the clinical circumstances. Patients with an indwelling filter or filters may be administered any of a variety of thrombolytic or anticoagulant therapies, including tissue plasminogen activator, streptokinase, coumadin, heparin and others known in the art.
[0092] An exemplary advantage of the systems described herein is that the delivery and retrieval system are integrated into the same catheter that stays in place during the procedure. Unloading and loading of different catheters, sheaths, or other components is therefore unnecessary. Having a system that performs both delivery and retrieval functions also reduces procedural complexity, time, and fluoroscopy exposure time. In addition, only a minimal portion of the catheter is in the aortic arch, thus greatly reducing the change of interference with other catheters.
[0093] FIGS. 7A-7B illustrate a perspective view and sectional view, respectively, of a portion of an exemplary filter system. The system includes distal shaft 30 and distal articulatable sheath 34 , coupled via coupler 32 . FIG. 7B shows the sectional view of plane A. Distal sheath 34 includes steering element 38 extending down the length of the sheath and within the sheath, which is shown as a pull wire. The pull wire can be, for example without limitation, stainless steel, tungsten, alloys of cobalt such as MP35N®, or any type of cable, either comprised of a single strand or two or more strands. Distal sheath 34 also includes spine element 36 , which is shown extending down the length of the sheath on substantially the opposite side of the sheath from steering element 38 . Spine element 36 can be, for example without limitation, a ribbon or round wire. Spine element 36 can be made from, for example, stainless steel or Nitinol. Spine element 36 resists axial expansion or compression of articulatable sheath 34 upon the application of an actuating axial pull or push force applied to steering element 38 , allowing sheath 34 to be deflected toward configuration 40 , as shown in phantom in FIG. 7A . FIG. 7C shows an alternative embodiment in which distal sheath 33 has a non-circular cross section. Also shown are spine element 35 and steering element 37 .
[0094] FIGS. 8A-8C illustrate views of exemplary pull wire 42 that can be incorporated into any distal sheaths described herein. Plane B in FIG. 8B shows a substantially circular cross-sectional shape of pull wire 42 in a proximal portion 44 of the pull wire, while plane C in FIG. 8C shows a flattened cross-sectional shape of distal portion 46 . Distal portion 46 has a greater width than height. The flattened cross-sectional shape of distal portion 46 provides for an improved profile, flexibility, and resistance to plastic deformation, which provides for improved straightening.
[0095] FIGS. 9A-C show an alternative embodiment of distal sheath 48 that includes slots 50 formed therein. The slots can be formed by, for example, grinding, laser cutting or other suitable material removal from distal sheath 48 . Alternatively, the slots can be the openings between spaced apart coils or filars of a spring. The characteristics of the slots can be varied to control the properties of the distal sheath. For example, the pitch, width, depth, etc., of the slots can be modified to control the flexibility, compressibility, torsional responsiveness, etc., of distal sheath 48 . More specifically, the distal sheath 48 can be formed from a length of stainless steel hypotubing. Transverse slots 50 are preferably formed on one side of the hypotubing, leaving an opposing spine which provides column strength to avoid axial compression or expansion upon application of an axial force to the pull wire and also limits deflection to a desired single plane or predetermined planes.
[0096] FIG. 9B shows a further embodiment of the distal sheath in greater detail. In this embodiment distal sheath 48 includes a first proximal articulatable hypotube section 49 . Articulatable hypotube section 49 is fixed to distal shaft 30 (not shown in FIG. 9A ). A second distal articulatable section 51 is secured to first proximal section 49 . Pull wire 38 extends from the handle through distal shaft section 49 and is affixed to a distal portion of distal shaft portion 51 . This embodiment allows for initial curvature of distal sheath proximal section 49 in a first direction such as away from the outer vessel wall in response to proximal retraction of the pull wire 38 . Distal sheath distal section 51 is then articulated to a second curvature in a second, opposite direction. This second curvature of distal shaft section 51 is adjustable based upon tension or compression loading of the sheath section by pull wire 38 . Alternatively, a first pull wire can be attached at a distal portion of section 49 and a second pull wire can be attached at a distal portion of section 51 to allow independent deflection of the two deflection sections.
[0097] As shown in FIG. 9B , pull wire 38 in a single pull wire embodiment crosses to an opposite side of the inner lumen defined by sections 49 and 51 from the slots 50 as it transitions from the first distal sheath proximal section 49 to second distal sheath distal section 51 . As best shown in FIG. 9C , distal sheath proximal section 49 would articulate first to initialize a first curve, concave in a first direction as the slots 50 compress in response to proximal retraction of the pull wire 38 . As the tension on pull wire 38 is increased and the slots bottom out, distal sheath distal section 51 begins to form a second curve concave in a second direction opposite to the direction of the first curve, due to pull wire 38 crossing the inner diameter of the lumen through distal sheath sections 49 and 51 . As can be seen in FIG. 9C , as it nears and comes to the maximum extent of its articulation, distal sheath distal section 51 can take the form of a shepherd's staff or crook.
[0098] Distal sheath proximal section 49 could take the form of a tubular slotted element or a pre-shaped curve that utilizes a memory material such as Nitinol or any other material exhibiting suitable properties. In some embodiments outer diameter of distal sheath proximal section 49 is between 0.02 inches and 0.2 inches. In certain embodiments, the outer diameter is between 0.05 inches and 0.1 inches, or between 0.06 inches and 0.075 inches. In some embodiments, the inner diameter of distal sheath proximal section 49 is between 0.02 inches and 0.2 inches. In certain embodiments, the inner diameter is between 0.03 inches and 0.08 inches or between 0.05 inches and 0.07 inches. In several embodiments, the length of distal sheath proximal section 49 may measures between 0.1 inches and 2.5 inches. In some embodiments, the length of distal sheath proximal section 49 may measure between about 0.50 inches and 1 inch or between 0.6 inches and 0.8 inches. In certain embodiments, the length of distal sheath proximal section 49 may be longer than 2.5 inches. It is understood that these sizes and proportions will vary depending on the specific application and those listed herein are not intended to be limiting. Transverse slots 50 can measure from about 0.002 inches to about 0.020 inches in width (measured in the axial direction) depending on the specific application and the degree of curvature desired. In some embodiments the slots can measure less than 0.002 inches or greater than 0.02 inches. In certain embodiments, the slots 50 can measure about 0.002 inches to 0.01 inches or between 0.006 and 0.01 inches.
[0099] The curvature of proximal section 49 may be varied from about 0 degrees to 90 degrees or more depending on the width and number of the slots 50 . In several embodiments, the maximum degree of deflection ranges from about 15 degrees to about 75 degrees, from about 45 degrees to about 60 degrees. Commencement of deflection of distal section 51 can occur prior to, simultaneously with or following commencement of deflection of proximal section 49 based upon the relative stiffness of the sections or configuration of the pull wire as will be apparent to those of skill in the art.
[0100] The distal sheath is configured such that the maximum net curvature between the primary axis of the catheter prior to any deflection and the distal tip axis is between about 90 and about 220 degrees. In other embodiments, the maximum deflection is between about 120 degrees and about 200 degrees, or between about 150 degrees and about 180 degrees. When the distal sheath is in its curved configuration, with a net deflection from the primary axis of at least about 150 degrees, the lateral distance between the primary axis and the distal tip ranges from about 5 mm to about 15 mm.
[0101] The position of at least a second group of slots 50 may also be rotationally displaced about the axis of the tube with respect to a first group of slots to allow a first portion of the distal sheath to bend in a first plane and a second portion of the distal sheath to bend out-of-plane to access more complex anatomy as shown in FIGS. 9D and 9E . The second set of slots 50 may be displaced circumferentially from the first set of slots by about 5 degrees to about 90 degrees. In certain embodiments, the slots are displaced from about 15 to 60 degrees or from about 20 to about 40 degrees. The curvature of the out of plane curve may vary from about 20 degrees to about 75 degrees, but in some embodiments, the out of plane curvature may be less than 20 degrees or greater than 75 degrees. In several embodiments, the curvature of the out of plane curve is from about 20 degrees to 40 degrees, from about 30 degrees to about 50 degrees, from about 40 degrees to about 60 degrees, or from about 50 degrees to 75 degrees. Alternatively, this out-of-plane bend could be achieved by prebending the tube after laser cutting the slots to create a bias or by any other method which would create a bias. The shape could also be multi-plane or bidirectional where the tube would bend in multiple directions within the same section of laser cut tube.
[0102] In several embodiments, distal sheath distal section 51 is a selectable curve based upon the anatomy and vessel location relative to one another. This section 51 could also be a portion of the laser cut element or a separate construction where a flat ribbon braid could be utilized. It may also include a stiffening element or bias ribbon to resist permanent deformation. In one embodiment it would have a multitude of flat ribbons staggered in length to create a constant radius of curvature under increased loading.
[0103] In some embodiments, distal sheath 34 incorporates a guidewire lumen 58 through which a guidewire may pass as shown in FIG. 9F . Alternatively, in FIG. 9G , the guidewire lumen is coaxial with guiding member lumen 59 . Removing the guidewire lumen from the wall of distal sheath 34 has the added benefit of increasing the distal sheath luminal cross sectional area, reducing deployment and retrieval forces, and increasing the capacity for debris within the distal sheath.
[0104] FIGS. 10A and 10B illustrate a portion of exemplary distal sheath 52 that is adapted to be multi-directional, and is specifically shown to be bi-directional. Distal sheath 52 is adapted to be steered towards the configurations 53 and 54 shown in phantom in FIG. 10A . FIG. 10B is a sectional view in plane D, showing spinal element 55 and first and second steering elements 56 disposed on either side of spinal element 55 . Steering elements 56 can be similar to steering element 38 shown in FIG. 7B . The steering elements can be disposed around the periphery of distal sheath at almost any location.
[0105] Incorporating steerable functionality into tubular devices is known in the area of medical devices. Any such features can be incorporated into the systems herein, and specifically into the articulatable distal sheaths.
[0106] In some embodiments the distal sheath includes radiopaque markers to visualize the distal sheath under fluoroscopy. In some embodiments the distal sheath has radiopaque markers at proximal and distal ends of the sheath to be able to visualize the ends of the sheath.
[0107] An exemplary advantage of the filter systems described herein is the ability to safely and effectively position the distal sheath. In some uses, the proximal filter is deployed in a first bodily lumen, and the distal filter is deployed in a second bodily lumen different than the first. For example, as shown in FIG. 2D , the proximal filter is deployed in the brachiocephalic trunk and the distal filter is deployed in a left common carotid artery. While both vessels extend from the aortic arch, the position of the vessel openings along the aortic arch varies from patient-to-patient. That is, the distance between the vessel openings can vary from patient to patient. Additionally, the angle at which the vessels are disposed relative to the aorta can vary from patient to patient. Additionally, the vessels do not necessarily lie within a common plane, although in many anatomical illustrations the vessels are typically shown this way. For example, FIGS. 11A-11C illustrate merely exemplary anatomical variations that can exist. FIG. 11A is a top view (i.e., in the superior-to-inferior direction) of aorta 70 , showing relative positions of brachiocephalic trunk opening 72 , left common carotid artery opening 74 , and left subclavian opening 76 . FIG. 11B is a side sectional view of aortic 78 illustrating the relative angles at which brachiocephalic trunk 80 , left common carotid artery 82 , and left subclavian artery 84 can extend from aorta 78 . FIG. 11C is a side sectional view of aorta 86 , showing vessel 88 extending from aorta 86 at an angle. Any or all of the vessels extending from aorta 86 could be oriented in this manner relative to the aorta. FIGS. 11D and 11E illustrate that the angle of the turn required upon exiting the brachiocephalic trunk 92 / 100 and entering the left common carotid artery 94 / 102 can vary from patient to patient. Due to the patient-to-patient variability between the position of the vessels and their relative orientations, a greater amount of control of the distal sheath increases the likelihood that the distal filter will be positioned safely and effectively. For example, a sheath that only has the ability to independently perform one or two of rotation, steering, and axial translation may not be adequately adapted to properly and safely position the distal filter in the left common carotid artery. All three degrees of independent motion as provided to the distal sheaths described herein provide important clinical advantages. Typically, but without intending to be limiting, a subject's brachiocephalic trunk and left carotid artery are spaced relatively close together and are either substantially parallel or tightly acute (see, e.g., FIG. 11E ).
[0108] FIGS. 12A and 12B illustrates an exemplary curvature of a distal sheath to help position the distal filter properly in the left common carotid artery. In FIGS. 12A and 12B , only a portion of the system is shown for clarity, but it can be assumed that a proximal filter is included, and in this example has been expanded in brachiocephalic trunk 111 . Distal shaft 110 is coupled to steerable distal sheath 112 . Distal sheath 112 is steered into the configuration shown in FIG. 12B . The bend created in distal sheath 112 , and therefore the relative orientations of distal sheath 112 and left common carotid artery 113 , allow for the distal filter to be advanced from distal sheath 112 into a proper position in left common carotid 113 . In contrast, the configuration of distal sheath 114 shown in phantom in FIG. 12A illustrates how a certain bend created in the distal sheath can orient the distal sheath in such a way that the distal filter will be advanced directly into the wall of the left common carotid (depending on the subject's anatomy), which can injure the wall and prevent the distal filter from being properly deployed. Depending on the angulation, approach angle, spacing of the openings, etc., a general U-shaped curve (shown in phantom in FIG. 12A ) may not be optimal for steering and accessing the left common carotid artery from the brachiocephalic trunk.
[0109] In some embodiments the distal sheath is adapted to have a preset curved configuration. The preset configuration can have, for example, a preset radius of curvature (or preset radii of curvature at different points along the distal sheath). When the distal sheath is articulated to be steered to the preset configuration, continued articulation of the steering element can change the configuration of the distal sheath until is assumes the preset configuration. For example, the distal sheath can comprise a slotted tube with a spine extending along the length of the distal sheath. Upon actuation of the steering component, the distal sheath will bend until the portions of the distal sheath that define the slots engage, thus limiting the degree of the bend of the distal sheath. The curve can be preset into a configuration that increases the likelihood that the distal filter will, when advanced from the distal sheath, be properly positioned within the left common carotid artery.
[0110] FIGS. 13A and 13B illustrate alternative distal sheath and distal shaft portions of an exemplary filter system. FIGS. 13A and 13B only show distal shaft 120 and distal sheath 122 for clarity, but the system may also includes a proximal filter (not shown but has been deployed in brachiocephalic trunk). The distal shaft/distal sheath combination has a general S-bend configuration, with distal shaft 120 including a first bend 124 in a first direction, and distal sheath 122 configured to assume bend 126 in a second direction, wherein the first and second bends form the general S-bend configuration. FIG. 13B shows distal sheath 122 pulled back in the proximal direction relative to the proximal filter to seat the curved distal sheath against the bend. This both helps secure the distal sheath in place as well as reduces the cross sectional volume of the filter system that is disposed with the aorta. The distal shaft and distal sheath combination shown in FIGS. 13A and 13B can be incorporated into any of the filter systems described herein.
[0111] Exemplary embodiments of the delivery and deployment of a multi-filter embolic protection apparatus will now be described with reference to FIGS. 2A-2D , 13 A, 13 B, 14 , 1 , 3 , 4 and 5 . More particularly, the delivery and deployment will be described with reference to placement of the filter system in the brachiocephalic and left common carotid arteries. The preferred access for the delivery of the multi-filter system 10 is from the right radial or right brachial artery, however other access locations such as the right subclavian artery are possible. The system is then advanced through the right subclavian artery to a position within the brachiocephalic artery 11 . At this point, proximal filter 16 may be deployed within into expanding engagement with the inner lining of brachiocephalic artery 11 . Alternatively, access to the left common carotid could be gained prior to deployment of proximal filter 16 . Deployment of proximal filter 16 protects both the brachiocephalic artery 11 and the right common carotid artery 7 against emboli and other foreign bodies in the bloodstream.
[0112] Entry into the aortic space, as illustrated in FIG. 3 , is then accomplished by further advancement of the system from the brachiocephalic trunk. During this step, the filter system will tend to hug the outer portion of the brachiocephalic trunk as shown in FIG. 4 . Initial tensioning of pull wire 38 causes distal sheath 48 to move the catheter-based filter system off the wall of the brachiocephalic artery just before the ostium or entrance into the aorta, as shown in FIG. 4 . As the catheter path will hug the outer wall of the brachial cephalic artery, a curve directed away from this outer wall will allow additional space for the distal portion of the distal sheath to curve into the left common carotid artery, as shown in FIG. 5 .
[0113] The width of slots 50 will determine the amount of bending allowed by the tube when tension is applied via pull wire 38 . For example, a narrow width slot would allow for limited bending where a wider slot would allow for additional bending due to the gap or space removed from the tube. As the bending is limited by the slot width, a fixed shape or curve may be obtained when all slots are compressed and touching one another. Additional features such as chevrons may be cut into the tube to increase the strength of the tube when compressed. Other means of forming slots could be obtained with conventional techniques such as chemical etching, welding of individual elements, mechanical forming, metal injection molding or other conventional methods.
[0114] Once in the aortic space, the distal sheath is further tensioned to adjust the curvature of the distal shaft distal section 51 , as shown in FIG. 9B . The amount of deflection is determined by the operator of the system based on the particular patient anatomy.
[0115] Other techniques to bias a catheter could be external force applications to the catheter and the vessel wall such as a protruding ribbon or wire from the catheter wall to force the catheter shaft to a preferred position within the vessel. Flaring a radial element from the catheter central axis could also position the catheter shaft to one side of the vessel wall. Yet another means would be to have a pull wire external to the catheter shaft exiting at one portion and reattaching at a more distal portion where a tension in the wire would bend or curve the catheter at a variable rate in relation to the tension applied.
[0116] This multi-direction and variable curvature of the distal sheath allows the operator to easily direct the filter system, or more particularly, the distal sheath section thereof, into a select vessel such as the left common carotid artery or the left innominate artery. Furthermore, the filter system allows the operator to access the left common carotid artery without the need to separately place a guidewire in the left common carotid artery. The clinical variations of these vessels are an important reason for the operator to have a system that can access differing locations and angulations between the vessels. The filter systems described herein will provide the physician complete control when attempting to access these vessels.
[0117] Once the distal sheath is oriented in the left common carotid, the handle can be manipulated by pulling it and the filter system into the bifurcation leaving the aortic vessel clear of obstruction for additional catheterizations, an example of which is shown in FIG. 12B . At this time, distal filter 22 can be advanced through proximal shaft 14 and distal shaft 18 into expanding engagement with left common carotid artery 13 .
[0118] FIG. 14 illustrates a portion of an exemplary system including distal shaft 130 and distal sheath 132 . Distal sheath is adapted to be able to be steered into what can be generally considered an S-bend configuration, a shepherd's staff configuration, or a crook configuration, comprised of first bend 131 and second bend 133 in opposite directions. Also shown is rotational orb 134 , defined by the outer surface of the distal sheath as distal shaft 130 is rotated at least 360 degrees in the direction of the arrows shown in FIG. 14 . If a typical aorta is generally in the range from about 24 mm to about 30 mm in diameter, the radius of curvature and the first bend in the S-bend can be specified to create a rotational orb that can reside within the aorta (as shown in FIG. 14 ), resulting in minimal interference with the vessel wall and at the same time potentially optimize access into the left common carotid artery. In other distal sheath and/or distal shaft designs, such as the one shown in FIG. 12A , the rotational orb created by the rotation of distal shaft 110 is significantly larger, increasing the risk of interference with the vessel wall and potentially decreasing the access into the left common carotid artery. In some embodiments, the diameter of the rotation orb for a distal sheath is less than about 25 mm.
[0119] Referring back to FIG. 12A , distal sheath 112 , in some embodiments, includes a non-steerable distal section 121 , an intermediate steerable section 119 , and a proximal non-steerable section 117 . When the distal sheath is actuated to be steered, only steerable portion 119 bends into a different configuration. That is, the non-steerable portions retain substantially straight configurations. The distal non-steerable portion remains straight, which can allow the distal filter to be advanced into a proper position in the left common carotid artery.
[0120] While FIG. 12A shows distal sheath 112 in a bent configuration, the distal sheath is also positioned within the lumen of the aorta. In this position, the distal sheath can interfere with any other medical device or instrument that is being advanced through the aorta. For example, in aortic valve replacement procedures, delivery device 116 , with a replacement aortic valve disposed therein, is delivered through the aorta as shown in FIG. 12B . If components of the filter system are disposed within the aorta during this time, delivery device 116 and the filter system can hit each other, potentially damaging either or both systems. The delivery device 116 can also dislodge one or both filters if they are in the expanded configurations. The filter system can additionally prevent the delivery device 116 from being advanced through the aorta. To reduce the risk of contact between delivery device 116 and distal sheath 112 , distal sheath 112 (and distal shaft 110 ) is translated in the proximal direction relative to the proximal filter (which in this embodiment has already been expanded but is not shown), as is shown in FIG. 12B . Distal sheath 112 is pulled back until the inner curvature of distal sheath 112 is seated snugly with the vasculature 115 disposed between the brachiocephalic trunk 111 and the left common carotid artery 113 . This additional seating step helps secure the distal sheath in place within the subject, as well as minimize the amount of the filter system present in the aortic arch. This additional seating step can be incorporated into any of the methods described herein, and is an exemplary advantage of having a distal sheath that has three degrees of independent motion relative to the proximal filter. The combination of independent rotation, steering, and axial translation can be clinically significant to ensure the distal filter is properly positioned in the lumen, as well as making sure the filter system does not interfere with any other medical devices being delivered to the general area inside the subject.
[0121] An additional advantage of the filter systems herein is that the distal sheath, when in the position shown in FIG. 12B , will act as a protection element against any other medical instruments being delivered through the aorta (e.g., delivery device 116 ). Even if delivery device 116 were advanced such that it did engage distal sheath 112 , distal sheath 112 is seated securely against tissue 115 , thus preventing distal sheath 112 from being dislodged. Additionally, distal sheath 112 is stronger than, for example, a wire positioned within the aorta, which can easily be dislodged when hit by delivery device 116 .
[0122] FIGS. 15A-15D illustrate alternative embodiments of the coupling of the distal shaft and distal sheath. In FIG. 15A distal shaft 140 is secured to distal sheath 142 by coupler 144 . Shaft 140 has a low profile to allow for the collapse of the proximal filter (see FIG. 1C ). Shaft 140 also has column strength to allow for axial translation, has sufficient torque transmission properties, and is flexible. The shaft can have a support structure therein, such as braided stainless steel. For example, the shaft can comprise polyimide, Polyether ether ketone (PEEK), Nylon, Pebax, etc. FIG. 15B illustrates an alternative embodiment showing tubular element 146 , distal shaft 148 , and distal sheath 150 . Tubular element 146 can be a hypotube made from stainless steel, Nitinol, etc. FIG. 15C illustrates an exemplary embodiment that includes distal shaft 152 , traction member 154 , and distal sheath 156 . Traction member 154 is coupled to shaft 152 and shaft 152 is disposed therein. Traction member 154 couples to shaft 152 for torquebility, deliverability, and deployment. Traction member 154 can be, for example without limitation, a soft silicone material, polyurethane, polyimide, or other material having suitable properties. FIG. 15D shows an alternative embodiment in which the system includes bushing 162 disposed over distal shaft 158 , wherein distal shaft 158 is adapted to rotate within bushing 162 . The system also includes stop 160 secured to distal shaft 158 to substantially maintain the axial position of bushing 162 . When the system includes bushing 162 , distal sheath 164 can be rotated relative to the proximal sheath and the proximal filter when the distal sheath and proximal sheath are in the delivery configuration (see FIG. 1B ).
[0123] FIG. 16 illustrates an exemplary embodiment of filter system 170 in which distal sheath 172 is biased to a curved configuration 174 . The biased curved configuration is adapted to facilitate placement, delivery, and securing at least the distal filter. As shown, the distal sheath is biased to a configuration that positions the distal end of the distal sheath towards the left common carotid artery.
[0124] FIG. 17 illustrates a portion of an exemplary filter system and its method of use. FIG. 17 shows a system and portion of deployment similar to that shown in FIG. 2D , but distal sheath 182 has been retracted proximally relative to guiding member 190 and distal filter 186 . Distal sheath 182 has been retracted substantially from the aortic arch and is substantially disposed with the brachiocephalic trunk. Guiding member 190 can have preset curve 188 adapted to closely mimic the anatomical curve between the brachiocephalic trunk and the left common carotid artery, thus minimizing the amount of the system that is disposed within the aorta. As shown, distal sheath 182 has been retracted proximally relative to proximal filter 180 .
[0125] FIG. 18A is a perspective view of a portion of an exemplary embodiment of a filter system, while FIG. 18B is a close-up view of a portion of the system shown in FIG. 18A . The distal sheath and the distal filter are not shown in FIGS. 18A and 18B for clarity. The system includes proximal filter 200 coupled to proximal shaft 202 , and push rod 206 coupled to proximal shaft 202 . A portion of proximal sheath 204 is shown in FIG. 18A in a retracted position, allowing proximal filter 200 to expand to an expanded configuration. Only a portion of proximal sheath 204 is shown, but it generally extends proximally similar to push rod 206 . The proximal end of proximal shaft 202 is beveled and defines an aspiration lumen 216 , which is adapted to receive an aspirator (not shown) to apply a vacuum to aspirate debris captured within distally facing proximal filter 200 . Push rod 206 extends proximally within proximal sheath 204 and is coupled to an actuation system outside of the subject, examples of which are described below. Push rod 206 takes up less space inside proximal sheath 204 than proximal shaft 202 , providing a lower profile.
[0126] The system also includes proximal seal 214 disposed on the outer surface of proximal shaft 202 and adapted to engage the inner surface of the proximal sheath. Proximal seal 214 prevents bodily fluids, such as blood, from entering the space between proximal sheath 204 and proximal shaft 202 , thus preventing bodily fluids from passing proximally into the filter system. The proximal seal can be, for example without limitation, a molded polymer. The proximal seal can also be machined as part of the proximal shaft, such that they are not considered two separate components.
[0127] In some specific embodiments the push rod is between 0.001 inches and 0.05 inches in diameter. In some embodiments, the diameter is between 0.01 inches and 0.025 inches in diameter. The pushrod can be constructed from any number of polymeric or metal materials, such as stainless steel. The proximal shaft can be, for example without limitation, an extruded or molded plastic, a hypotube (e.g., stainless steel), machined plastic, metal, etc.
[0128] Proximal filter 200 includes filter material 208 , which comprises pores adapted to allow blood to pass therethrough, while debris does not pass through the pores and is captured within the filter material. Proximal filter 200 also includes strut 210 that extends from proximal shaft 202 to expansion support 212 . Expansion support 212 has a generally annular shape but that is not intended to be limiting. Proximal filter 200 also has a leading portion 220 and a trailing portion 222 . Leading portion 220 generally extends further distally than trailing portion 222 to give filter 200 a generally canted configuration relative to the proximal shaft. The canted design provides for decreased radial stiffness and a better collapsed profile. Strut 210 and expansion support 212 generally provide support for filter 200 when in the expanded configuration, as shown in FIG. 18A .
[0129] FIGS. 19A-19C illustrate exemplary embodiments of proximal filters and proximal shafts that can be incorporated into any of the systems herein. In FIG. 19A , filter 230 has flared end 232 for improved filter-wall opposition. FIG. 19B shows proximal shaft 244 substantially co-axial with vessel 246 in which filter 240 is expanded. Vessel 246 and shaft 244 have common axis 242 . FIG. 19C illustrates longitudinal axis 254 of shaft 256 not co-axial with axis 252 of lumen 258 in which filter 250 is expanded.
[0130] FIGS. 20A and 20B illustrate an exemplary embodiment including proximal filter 260 coupled to proximal shaft 262 . Filter 260 includes filter material 264 , including slack material region 268 adapted to allow the filter to collapse easier. Filter 260 is also shown with at least one strut 270 secured to shaft 262 , and expansion support 266 . As shown in the highlighted view in FIG. 20B , filter 260 includes seal 274 , radiopaque coil 276 (e.g., platinum), support wire 278 (e.g., Nitinol wire), and filter material 264 . Any of the features in this embodiment can be included in any of the filter systems described herein.
[0131] FIG. 21 illustrates an exemplary embodiment of a proximal filter. Proximal filter 280 is coupled to proximal shaft 282 . Proximal filter 280 includes struts 286 extending from proximal shaft 282 to strut restraint 288 , which is adapted to slide axially over distal shaft 284 . Proximal filter 280 also includes filter material 290 , with pores therein, that extends from proximal shaft 282 to a location axially between proximal shaft 282 and strut restraint 288 . Debris can pass through struts 286 and become trapped within filter material 290 . When proximal filter 280 is collapsed within a proximal sheath (not shown), struts 286 elongate and move radially inward (towards distal shaft 284 ). Strut restraint 288 is adapted to move distally over distal shaft 284 to allow the struts to move radially inward and extend a greater length along distal shaft 284 .
[0132] FIGS. 22A and 22B illustrate an exemplary embodiment of a proximal filter that can be incorporated into any filter system described herein. The system includes proximal filter 300 and proximal sheath 302 , shown in a retracted position in FIG. 22A . Proximal filter 300 includes valve elements 304 in an open configuration in FIG. 22A . When valve elements 304 are in the open configuration, foreign particles 306 can pass through opening 308 and through the valve and become trapped in proximal filter 300 , as is shown in FIG. 22A . To collapse proximal filter 300 , proximal sheath 302 is advanced distally relative to proximal filter 300 . As the filter begins to collapse, the valve elements are brought closer towards one another and into a closed configuration, as shown in FIG. 22B . The closed valve prevents extrusion of debris during the recapture process.
[0133] The distal filters shown are merely exemplary and other filters may be incorporated into any of the systems herein. FIG. 23A illustrates a portion of an exemplary filter system. The system includes guiding member 340 (distal sheath not shown), strut 342 , expansion support 344 , and filter element 346 . Strut 342 is secured directly to guiding member 340 and strut 342 is secured either directly or indirectly to expansion support 344 . Filter material 346 is secured to expansion support 344 . Distal end 348 of filter material 346 is secured to guiding member 340 .
[0134] FIG. 23B illustrates a portion of an exemplary filter system. The system includes guiding element 350 , strut support 352 secured to guiding element 350 , strut 354 , expansion support 356 , and filter material 358 . Strut support 352 can be secured to guiding element 350 in any suitable manner (e.g., bonding), and strut 354 can be secured to strut support 352 in any suitable manner.
[0135] FIG. 23C illustrates a portion of an exemplary filter system. The system includes guiding element 360 , strut support 362 secured to guiding element 360 , strut 364 , expansion support 366 , and filter material 368 . Expansion support 366 is adapted to be disposed at an angle relative to the longitudinal axis of guiding member 360 when the distal filter is in the expanded configuration. Expansion support 366 includes trailing portion 362 and leading portion 361 . Strut 364 is secured to expansion support 366 at or near leading portion 361 . FIG. 23D illustrates an exemplary embodiment that includes guiding member 370 , strut support 372 , strut 374 , expansion support 376 , and filter material 378 . Expansion support 376 includes leading portion 373 , and trailing portion 371 , wherein strut 374 is secured to expansion element 376 at or near trailing portion 371 . Expansion support 376 is disposed at an angle relative to the longitudinal axis of guiding member 370 when the distal filter is in the expanded configuration.
[0136] FIG. 23E illustrates an exemplary embodiment of a distal filter in an expanded configuration. Guiding member 380 is secured to strut support 382 , and the filter includes a plurality of struts 384 secured to strut support 382 and to expansion support 386 . Filter material 388 is secured to expansion support 386 . While four struts are shown, the distal filter may include any number of struts.
[0137] FIG. 23F illustrates an exemplary embodiment of a distal filter in an expanded configuration. Proximal stop 392 and distal stop 394 are secured to guiding member 390 . The distal filter includes tubular member 396 that is axially slidable over guiding member 390 , but is restricted in both directions by stops 392 and 394 . Strut 398 is secured to slidable member 396 and to expansion support 393 . Filter material 395 is secured to slidable member 396 . If member 396 slides axially relative to guiding member 390 , filter material 395 moves as well. Member 396 is also adapted to rotate in the direction “R” relative to guiding member 390 . The distal filter is therefore adapted to independently move axially and rotationally, limited in axial translation by stops 392 and 394 . The distal filter is therefore adapted such that bumping of the guiding member or the distal sheath will not disrupt the distal filter opposition, positioning, or effectiveness.
[0138] As shown in FIGS. 23A-23B , in some embodiments, the strut 342 , 354 has a straight configuration. A straight configuration may allow for a shorter attachment between the filter and the guiding member. In other embodiments, as shown in FIGS. 23C-23D , the strut 364 , 374 , takes a curved configuration. In still other embodiments, the strut has two or more curves. For example, the strut may take a sinusoidal configuration and transition from a first curve to the opposite curve to aid in transition to the filter frame. In some embodiments, the first curve may have a larger radius than the opposite curve. In still other embodiments, the first curve may have a smaller radius than the opposite curve.
[0139] FIGS. 24A-24C illustrate exemplary embodiments in which the system includes at least one distal filter positioning, or stabilizing, anchor. The positioning anchor(s) can help position the distal anchor in a proper position and/or orientation within a bodily lumen. In FIG. 24A the system includes distal filter 400 and positioning anchor 402 . Anchor 402 includes expandable stent 404 and expandable supports 406 . Supports 406 and filter 400 are both secured to the guiding member. Anchor 402 can be any suitable type of expandable anchor, such as, for example without limitation, stent 404 . Anchor 402 can be self-expandable, expandable by an expansion mechanism, or a combination thereof. In FIG. 24A , stent 404 can alternatively be expanded by an expansion balloon. Anchor 402 is disposed proximal to filter 400 . FIG. 24B illustrates an embodiment in which the system includes first and second anchors 412 and 414 , one of which is proximal to filter 410 , while the other is distal to filter 410 . FIG. 24C illustrates an embodiment in which anchor 422 is distal relative to filter 420 .
[0140] In some embodiments the distal filter is coupled, or secured, to a guiding member that has already been advanced to a location within the subject. The distal filter is therefore coupled to the guiding member after the distal filter has been advanced into the subject, rather than when the filter is outside of the subject. Once coupled together inside the subject, the guiding member can be moved (e.g., axially translated) to control the movement of the distal filter. In some embodiments the guiding member has a first locking element adapted to engage a second locking element on the distal filter assembly such that movement of the guiding member moves the distal filter in a first direction. In some embodiments the distal filter assembly has a third locking element that is adapted to engage the first locking element of the guiding member such that movement of the guiding member in a second direction causes the distal filter to move with the guiding member in the second direction. The guiding member can therefore be locked to the distal filter such that movement of the guiding member in a first and a second direction will move the distal filter in the first and second directions.
[0141] By way of example, FIGS. 25A-25D illustrate an exemplary embodiment of coupling the distal filter to a docking wire inside of the subject, wherein the docking wire is subsequently used to control the movement of the distal filter relative to the distal sheath. In FIG. 25A , guide catheter 440 has been advanced through the subject until the distal end is in or near the brachiocephalic trunk 441 . A docking wire, comprising a wire 445 , locking element 442 , and tip 444 , has been advanced through guide catheter 440 , either alone, or optionally after guiding wire 446 has been advanced into position. Guiding wire 446 can be used to assist in advancing the docking wire through guide catheter 440 . As shown, the docking wire has been advanced from the distal end of guide catheter 440 . After the docking wire is advanced to the desired position, guide catheter 440 , and if guiding wire 446 is used, are removed from the subject, leaving the docking wire in place within the subject, as shown in FIG. 25B . Next, as shown in FIG. 25C , the filter system, including proximal sheath 448 with a proximal filter in a collapsed configuration therein (not shown), distal sheath 450 , with a distal filter assembly (not shown) partially disposed therein, is advanced over wire 445 until a locking portion of the distal filter (not shown but described in detail below) engages locking element 442 . The distal filter assembly will thereafter move (e.g., axially) with the docking wire. Proximal sheath 448 is retracted to allow proximal filter 454 to expand (see FIG. 25D ). Distal sheath 450 is then actuated (e.g., bent, rotated, and/or translated axially) until it is in the position shown in FIG. 25D . A straightened configuration of the distal sheath is shown in phantom in FIG. 25D , prior to bending, proximal movement, and/or bending. The docking wire is then advanced distally relative to distal sheath 450 , which advances distal filter 456 from distal sheath 450 , allowing distal filter 456 to expand inside the left common carotid artery, as shown in FIG. 25D .
[0142] FIGS. 26A-26D illustrate an exemplary method of preparing an exemplary distal filter assembly for use. FIG. 26A illustrates a portion of the filter system including proximal sheath 470 , proximal filter 472 is an expanded configuration, distal shaft 474 , and articulatable distal sheath 476 . Distal filter assembly 478 includes an elongate member 480 defining a lumen therein. Elongate member 480 is coupled to distal tip 490 . Strut 484 is secured both to strut support 482 , which is secured to elongate member 480 , and expansion support 486 . Filter element 488 has pores therein and is secured to expansion support 486 and elongate member 480 . To load distal filter assembly 478 into distal sheath 476 , loading mandrel 492 is advanced through distal tip 490 and elongate member 480 and pushed against distal tip 490 until distal filter assembly 478 is disposed within distal sheath 476 , as shown in FIG. 26C . Distal tip 490 of the filter assembly remains substantially distal to distal sheath 476 , and is secured to the distal end of distal sheath 476 . Distal tip 490 and distal sheath 476 can be secured together by a frictional fit or other type of suitable fit that disengages as described below. Loading mandrel 492 is then removed from the distal filter and distal sheath assembly, as shown in FIG. 26D .
[0143] FIG. 26E illustrates docking wire 500 including wire 502 , lock element 504 , and distal tip 506 . Docking wire 500 is first advanced to a desired position within the subject, such as is shown in FIG. 25B . The assembly from FIG. 26D is then advanced over docking wire, wherein distal tip 490 is first advanced over the docking wire. As shown in the highlighted view in FIG. 26F , distal tip 490 of the distal filter assembly includes first locking elements 510 , shown as barbs. As the filter/sheath assembly continues to be distally advanced relative to the docking wire, the docking wire locking element 504 pushes locks 510 outward in the direction of the arrows in FIG. 26F . After lock 504 passes locks 510 , locks 510 spring back inwards in the direction of the arrows shown in FIG. 26G . In this position, when docking wire 500 is advanced distally (shown in FIG. 26F ), lock element 504 engages with lock elements 510 , and the lock element 504 pushes the distal filter assembly in the distal direction. In this manner the distal filter can be distally advanced relative to the distal sheath to expand the distal filter. Additionally, when the docking wire is retracted proximally, locking element 504 engages the distal end 512 of elongate member 480 and pulls the distal filter in the proximal direction. This is done to retrieve and/or recollapse the distal filter back into the distal sheath after it has been expanded.
[0144] FIGS. 27A and 27B illustrate an exemplary embodiment in which guiding member 540 , secured to distal filter 530 before introduction into the subject is loaded into articulatable distal sheath 524 . The system also includes proximal filter 520 , proximal sheath 522 , and distal shaft 526 . FIG. 27B shows the system in a delivery configuration in which both filters are collapsed.
[0145] FIGS. 28A-28E illustrate an exemplary distal filter assembly in collapsed and expanded configurations. In FIG. 28A , distal filter assembly 550 includes a distal frame, which includes strut 554 and expansion support 555 . The distal frame is secured to floating anchor 558 , which is adapted to slide axially on elongate member 564 between distal stop 560 and proximal stop 562 , as illustrated by the arrows in FIG. 28A . The distal filter assembly also includes membrane 552 , which has pores therein and is secured at its distal end to elongate member 564 . The distal filter assembly is secured to a guiding member, which includes wire 566 and soft distal tip 568 . The guiding member can be, for example, similar to the docking wire shown in FIGS. 26A-26E above, and can be secured to the distal filter assembly as described in that embodiment.
[0146] The floating anchor 558 allows filter membrane 552 to return to a neutral, or at-rest, state when expanded, as shown in FIG. 28A . In its neutral state, there is substantially no tension applied to the filter membrane. The neutral deployed state allows for optimal filter frame orientation and vessel apposition. In the neutral state shown in FIG. 28A , floating anchor 558 is roughly mid-way between distal stop 560 and proximal stop 562 , but this is not intended to be a limiting position when the distal filter is in a neutral state.
[0147] FIG. 28B illustrates the distal filter being sheathed into distal sheath 572 . During the sheathing process, the distal filter is collapsed from an expanded configuration (see FIG. 28A ) towards a collapsed configuration (see FIG. 28C ). In FIG. 28B , distal sheath 572 is moving distally relative to the distal filter. The distal end of the distal sheath 572 engages with strut 554 as it is advanced distally, causing the distal end of strut 554 to moves towards elongate member 564 . Strut 554 can be thought of as collapsing towards elongate member 564 from the configuration shown in FIG. 28A . The force applied from distal sheath 572 to strut 554 collapses the strut, and at the same time causes floating anchor 558 to move distally on tubular member 564 towards distal stop 560 . In FIG. 28B , floating anchor 558 has been moved distally and is engaging distal stop 560 , preventing any further distal movement of floating anchor 558 . As strut 554 is collapsed by distal sheath 572 , strut 554 will force the attachment point between strut 554 and expansion support 555 towards tubular member 564 , beginning the collapse of expansion support 555 . Distal sheath 572 continues to be advanced distally relative to the distal filter (or the distal filter is pulled proximally relative to the distal sheath, or a combination of both) until the distal filter is collapsed within distal sheath 572 , as is shown in FIG. 28C . Filter membrane 552 is bunched to some degree when the filter is in the configuration shown in FIG. 28C . To deploy the distal filter from the sheath, guiding member 566 is advanced distally relative to the distal sheath (or the distal sheath is moved proximally relative to the filter). The distal portions of filter membrane 552 and expansion support 555 are deployed first, as is shown in FIG. 28D . Tension in the filter membrane prevents wadding and binding during the deployment. When strut 554 is deployed from the distal sheath, expansion support 555 and strut 554 are able to self-expand to an at-rest configuration, as shown in FIG. 28E . Floating anchor 558 is pulled in the distal direction from the position shown in FIG. 28D to the position shown in FIG. 28E due to the expansion of strut 554 .
[0148] FIGS. 29A-29E illustrate a portion of an exemplary filter system with a lower delivery and insertion profile. In FIG. 29A , the system includes proximal sheath 604 with a larger outer diameter than distal sheath 602 . In some embodiments proximal sheath 604 has a 6 F outer diameter, while distal sheath 602 has a 5 F outer diameter. A guiding member including distal tip 606 is disposed within the distal sheath and the proximal sheath. FIG. 29B illustrates tear-away introducer 608 , with receiving opening 610 and distal end 612 . Introducer is first positioned within a subject with receiving opening 610 remaining outside the patient. As shown in FIG. 29C , the smaller diameter distal sheath is first advanced through the receiving opening of introducer 608 until the distal end of the distal sheath is disposed distal relative to the distal end of the introducer. The introducer is then split apart and removed from the subject, as shown in FIG. 29D . The filter system can then be advanced distally through the subject. The introducer can be a 5 F introducer, which reduces the insertion and delivery profile of the system.
[0149] The embodiments in FIGS. 25A-25B above illustrated some exemplary systems and methods for routing filter systems to a desired location within a subject, and additional exemplary embodiments will now be described. FIGS. 30A and 30B illustrate an exemplary embodiment similar to that which is shown in FIGS. 27A and 27B . The filter system shows distal filter 650 and proximal filter 644 in expanded configurations. Proximal sheath 642 has been retracted to allow proximal filter 644 to expand. Distal filter, which is secured to guiding member 648 , are both advanced distally relative to distal articulating sheath 640 . The filter system does not have a dedicated guidewire that is part of the system, but distal sheath 640 is adapted to be rotated and steered to guide the system to a target location within the subject.
[0150] FIGS. 31A-31C illustrate an exemplary over-the-wire routing system that includes a separate distal port for a dedicated guidewire. A portion of the system is shown in FIG. 31B , including distal articulating sheath 662 and proximal sheath 660 (the filters are collapsed therein). FIG. 31B is a highlighted view of a distal region of FIG. 31A , showing guidewire entry port 666 near the distal end 664 of distal sheath 662 . FIG. 31C is a sectional view through plane A of distal sheath 662 , showing guidewire lumen 672 , spine element 678 , distal filter lumen 674 , and steering element 676 (shown as a pull wire). Guidewire lumen 672 and distal filter lumen 674 are bi-axial along a portion of distal sheath, but in region 670 guidewire lumen 672 transitions from within the wall of distal sheath 662 to being co-axial with proximal sheath 660 .
[0151] To deliver the system partially shown in FIGS. 31A-31C , a guidewire is first delivered to a target location within the subject. The guidewire can be any type of guidewire. With the guidewire in position, the proximal end of the guidewire is loaded into guidewire entry port 666 . The filter system is then tracked over the guidewire to a desired position within the subject. Once the system is in place, the guidewire is withdrawn from the subject, or it can be left in place. The proximal and distal filters can then be deployed as described in any of the embodiments herein.
[0152] FIGS. 32A-32E illustrate an exemplary routing system which includes a rapid-exchange guidewire delivery. The system includes distal articulating sheath 680 with guidewire entry port 684 and guidewire exit port 686 . The system also includes proximal sheath 682 , a distal filter secured to a guiding member (collapsed within distal sheath 680 ), and a proximal filter (collapsed within proximal sheath 682 ). After guidewire 688 is advanced into position within the patient, the proximal end of guidewire 688 is advanced into guidewire entry port 684 . Distal sheath (along with the proximal sheath) is tracked over guidewire 688 until guidewire 688 exits distal sheath 680 at guidewire exit port 686 . Including a guidewire exit port near the entry port allows for only a portion of the guidewire to be within the sheath(s), eliminating the need to have a long segment of guidewire extending proximally from the subject's entry point. As soon as the guidewire exits the exit port, the proximal end of the guidewire and the proximal sheath can both be handled.
[0153] FIG. 32B shows guidewire 688 extending through the guidewire lumen in the distal sheath and extending proximally from exit port 686 . Guidewire 688 extends adjacent proximal sheath 682 proximal to exit port 686 . In FIG. 32B , portion 690 of proximal sheath 682 has a diameter larger than portion 692 to accommodate the proximal filter therein. Portion 692 has a smaller diameter for easier passage of the proximal sheath and guidewire. FIG. 32C shows a sectional view through plane 32 C- 32 C of FIG. 32B , with guidewire 688 exterior and adjacent to proximal sheath 682 . Proximal filter 694 is in a collapsed configuration within proximal sheath 682 , and guiding member 696 is secured to a distal filter, both of which are disposed within distal shaft 698 .
[0154] FIG. 32D shows relative cross-sections of exemplary introducer 700 , and distal sheath 680 through plane 32 D- 32 D. Distal sheath 680 includes guidewire lumen 702 and distal filter lumen 704 . In some embodiments, introducer 700 is 6 F, with an inner diameter of about 0.082 inches. In comparison, the distal sheath can have a guidewire lumen of about 0.014 inches and distal filter lumen diameter of about 0.077 inches.
[0155] FIG. 32E shows a sectional view through plane 32 E- 32 E, and also illustrates the insertion through introducer 700 . Due to the smaller diameter of portion 692 of proximal sheath 682 , guidewire 688 and proximal sheath 682 more easily fit through introducer 700 than the distal sheath and portion of the proximal sheath distal to portion 692 . The size of the introducer may vary depending on the diameter of the filter system. The introducer may range in size from 4 F to 15 F. In certain embodiments, the size of the introducer is between 4 F and 8 F. Guidewire 688 may vary in diameter between 0.005 and 0.02 inches or between 0.01 and 0.015 inches. In some situations, it may be desirable to have a guidewire smaller than 0.005 inches or larger than 0.02 inches in diameter. The smaller diameter proximal portion 692 of proximal sheath 682 allows for optimal sheath and guidewire movement with the introducer sheath. In certain aspects, it may be desirable for the cross-section of proximal filter deployment member 697 to take a non-circular shape to reduce the profile of proximal sheath 682 . Guiding member 696 and distal sheath pull wire 676 are both disposed through distal shaft 698 .
[0156] In certain embodiments, the guiding member is a core wire. Use of a core wire may be desirable to decrease the diameter of the filter system. A core wire is also flexible and able to access tortuous anatomies. The material and diameter of the guiding member may vary depending on the desired level of column strength or flexibility. In certain embodiments, the core wire may be tapered such that a distal section of the core wire has a smaller diameter than a proximal section of the core wire to increase flexibility at the distal section.
[0157] In certain clinical scenarios, it may be desirable for the guiding member to take the form of a tubular core member having a guidewire lumen running therethrough. In several embodiments, the tubular core member is a catheter shaft. The presence of the guidewire lumen allows the user to deliver the filter system to the correct position by advancing the filter system over the guidewire. A tubular core member allows the user to select an appropriate guidewire for the procedure rather than restricting the user to the wire core shaft. A guiding member having a guidewire lumen can potentially reduce the delivery profile of the filter system by not requiring separate lumens for the guiding member and the guidewire.
[0158] FIG. 33A illustrates filter system 700 having tubular core member 720 extending along an elongate axis of filter system 700 and slidably disposed through distal shaft 716 . The distal end of tubular core member 720 is positioned in a distal, atraumatic tip 740 of filter system 700 , while the proximal end of tubular core member 720 is positioned in the control handle. The proximal end of tubular core member 720 is connected to an actuation mechanism capable of advancing tubular core member 720 distally or retracting tubular core member 720 proximally with respect to distal shaft 716 . Distal filter assembly 726 may be mounted on a distal section of tubular core member 720 . Proximal filter 704 and distal filter 726 are illustrated as formed from a plurality of struts such as a woven wire or laser cut basket, however any of the polymeric membrane filters disclosed elsewhere herein may be used in filter system 700 .
[0159] In certain embodiments, tubular core member 720 defines a guidewire lumen 745 . Tubular core member 720 may have a distal guidewire entry port at the distal end of tubular core member 720 and a proximal guidewire exit port at the proximal end of tubular core member 720 . In other embodiments, the proximal guidewire port may be positioned at any position along the length of the tubular core member.
[0160] The length of tubular core member 720 may range from about 50 cm to about 300 cm. In some embodiments, the length may be less than 50 cm; while in other embodiments, the length may be greater than 300 cm. In several embodiments, the length of tubular core member 720 is between about 50 and about 150 cm, between about 75 and about 125 cm, or between about 100 cm and about 150 cm. The inner diameter of tubular core member 720 may range from about 0.01 to about 0.075 cm. In other embodiments, the inner diameter of tubular core member 720 is less than 0.01 cm; while in still other embodiments, the inner diameter is greater than 0.075 cm. The outer diameter of tubular core member 720 may range from about 0.025 to about 0.1 cm. In certain embodiments, the outer diameter of tubular core member 720 is less than 0.025 cm; while in other embodiments, the inner diameter is greater than 0.1 cm.
[0161] In certain clinical scenarios, it may be desirable to increase the column strength of tubular core member 720 , thus improving support and pushability to aid advancement of distal filter assembly 726 out of distal sheath 718 . In certain scenarios, tubular core member 720 may be constructed from a material stiffer than the material from which distal shaft 716 is constructed. A stiffer tubular core member 720 can help improve the column strength of filter system 700 . The tubular core member 720 may be constructed from metallic materials such as stainless steel, Nitinol, cobalt chromium (MP35N), or other alloys used in medical devices. Alternatively, tubular core member 720 may be constructed from a polymer construction such as nylon, polyester, polypropylene, polyimide, or other polymers exhibiting similar properties. In some embodiments, tubular core member 720 may be constructed from a combination of metallic materials and polymeric materials. In some embodiments, the inner diameter of tubular core member 720 is either coated with or constructed of a lubricious polymer (e.g. HDPE, PTFE, FEP, etc.). In still other embodiments, tubular core member may include reinforcements. For example, a ribbon or other stiffening member may extend along a section of tubular core member 720 . Alternatively, tubular core member 720 may have a multi-lumen profile, a first lumen for a guidewire and a second lumen for a stiffening mandrel. Tubular core member 720 may also transition from a multi-lumen profile to a single lumen profile to increase flexibility along the single lumen section of the tubular core member. In still other embodiments, tubular core member 720 may include one or more longitudinal strands dispersed within the tubular core member shaft to improve tensile strength. In some embodiments, tubular core member 720 may have a braided or coiled shaft to increase column strength. In certain embodiments, the braid consists of both metallic and polymer materials. In other embodiments, the braid consists of only metal; while in still other embodiments, the braid consists of only polymer materials.
[0162] In other clinical scenarios, it may be desirable to provide more flexibility in certain sections or along the entire length of tubular core member 720 . When filter system 700 is deployed in a curved lumen, a rigid tubular core member 720 or other guiding member may pull the leading portion 732 of distal filter 736 away from the vessel wall if the distal region of tubular core member 720 or other guiding member lacks sufficient flexibility to deflect relative to filter system 700 in a tortuous anatomy.
[0163] In certain embodiments, tubular core member 720 may be constructed from a more flexible material. In other embodiments, a first portion of tubular core member 720 may be constructed from a flexible material, while a second portion of tubular core member 720 is constructed from a stiffer material. Alternatively, removal of portions of tubular core member 720 may provide greater flexibility along certain sections of tubular core member 720 . For example, a series of slots, cuts, or a spiral pattern may be cut into a section of tubular core member 720 to provide a flex zone having a greater flexibility than proximal and distal adjacent portions of tubular core member 720 . The pattern of cuts may vary along the tubular core member shaft to vary flexibility along tubular core member 720 . The flexible portion may alternatively comprise a coil, helix, or interrupted helix. In other embodiments, a first portion of the tubular core member may also have a thinner wall than a second portion of the tubular core member. In still other embodiments, tubular core member 720 may be tapered to increase stiffness along a first section of the tubular core member and increase flexibility along a second section of the tubular core member.
[0164] In certain embodiments, a distal section of tubular core member 720 may be more flexible than a proximal section of the tubular core member 720 using any of the methods discussed above. The length of the flexible distal section may measure from about 5 cm to about 50 cm, from about 10 to about 40 cm, or from about 15 to about 25 cm. In other embodiments, the flexible distal section may be less than 5 cm or greater than 50 cm.
[0165] Several embodiments may include a flexible coupler 722 to allow distal filter assembly 726 to deflect relative to the rest of filter system 700 . In several embodiments, tubular core member 720 includes a flexible coupler 722 positioned proximal to distal filter assembly 726 . In several embodiments, flexible coupler 722 defines a lumen through which a guidewire may pass. In some embodiments, flexible coupler 722 is spliced into a gap along tubular core member 720 . In some embodiments, tubular core member 720 may comprise a distal tubular core member and a proximal tubular core member. The distal end of the proximal tubular core member may be joined to the proximal end of flexible coupler 722 , while the proximal end of the distal tubular core member is joined to the distal end of flexible coupler 722 . In still other embodiments, tubular core member 720 and flexible coupler 722 are integrally formed such as by providing core member 720 with a plurality of transverse slots as is described elsewhere herein.
[0166] In some clinical scenarios, it may be desirable for flexible coupler 722 to be more flexible than tubular core member 720 , while still demonstrating properties strong enough to resist deformation under tensile loads. Flexible coupler 722 may be constructed from materials, such as polymers, multiple polymers, Nitinol, stainless steel, etc. In certain embodiments, flexible coupler 722 may be created by piercing, slotting, grooving, scoring, cutting, laser cutting or otherwise removing material from a tubular body to increase flexibility. Alternatively, a flexible coupler 722 may be integrally formed with tubular core member 720 using any of the above mentioned patterns. In another embodiment, flexible coupler 722 is created by thinning a portion of tubular core member 720 to create a more flexible region. Flexible coupler 722 may also be deformed into a serrated or bellows shape without removing any material from the tubular body. Any of the other methods discussed above to increase the flexibility of tubular core member 720 may also be applied.
[0167] In some embodiments, a flexible section 738 of tubular core member 722 may be configured to be more flexible than a proximal section of tubular core member 722 . In some aspects, flexible section 738 is positioned distal to flexible coupler 722 . The length of flexible section 738 may measure from about 5 mm to about 50 mm, from about 10 to about 30 mm, or from about 20 to about 40 mm. In other embodiments, the flexible distal section may be less than 5 mm or greater than 50 mm.
[0168] FIGS. 33B-D illustrate cross sections at various positions along the dual filter system depicted in FIG. 33A . FIG. 33B illustrates a cross section of filter system 700 , proximal to proximal filter assembly 704 . Guidewire 721 is disposed through a lumen defined by tubular core member 720 , and tubular core member 720 is disposed through a lumen defined by distal shaft 716 . In certain embodiments, at least a portion of distal sheath 718 may be articulated via pull wire 737 . FIG. 33B shows that at least a portion of pull wire 737 may be disposed through distal shaft 716 , but external to tubular core member 720 . In some embodiments, at least a portion of pull wire 737 may pass through a lumen embedded in at least a portion of the distal shaft wall or distal sheath wall. In FIG. 33B , a portion of distal shaft 716 may be disposed through a lumen defined by proximal shaft 701 . Proximal filter frame 714 may extend through a lumen embedded in at least a portion of the proximal filter shaft wall 701 . Proximal filter shaft 701 is disposed through a lumen defined by proximal sheath 702 .
[0169] FIG. 33C depicts a cross section distal to the cross section depicted in FIG. 33B through distal sheath 718 . Distal sheath is illustrated in a simplified form, but typically will include all of the deflection mechanisms of FIGS. 9A-9E , discussed above. FIG. 33C shows guidewire 721 disposed through a lumen defined by tubular core member 720 . At least a portion of tubular core member 720 is disposed through a lumen defined by distal sheath 718 . As depicted in 33 C, at least a portion of distal sheath 718 may be provided with a reinforcement such as an embedded coil or braid 719 to improve torqueing capabilities. In some embodiments, the entire length of distal sheath 718 may comprise a reinforcing element such as a braid. Pull wire 737 may extend through a lumen extending through at least a portion of the distal sheath 718 , and distal sheath spinal element 741 may extend through at least a portion of distal sheath 718 . In some embodiments, the outer diameter of distal sheath 718 is substantially similar to the outer diameter of proximal sheath 702 . In other embodiments, distal sheath 718 extends through a lumen defined by proximal sheath 702 .
[0170] FIG. 33D depicts a cross section distal to the cross-section depicted in FIG. 33C . FIG. 33D shows guidewire 721 disposed through a lumen defined by tubular core member 720 . Tubular core member 720 is coaxial with flexible coupler 722 . In certain embodiments, the diameter of flexible coupler 722 may be larger than the diameter of tubular core member 720 . In other embodiments, flexible coupler 722 may have the same diameter as tubular core member 720 . In still other embodiments, the diameter of flexible coupler 722 may be smaller than the diameter of tubular core member 720 . In certain embodiments, the flexible coupler may not be a separate component.
[0171] As shown in FIGS. 34A-C , a tubular core member 720 coupled with a flexible coupler 722 has the advantage of providing improved column strength along a substantial length of the filter system 700 , but providing the flexibility necessary for distal filter assembly 726 to position itself independent of the position of distal shaft 716 . Flexible coupler 722 allows distal filter frame element 728 to create a better seal against the vessel wall to help prevent embolic debris from flowing between distal filter 736 and the vessel wall.
[0172] A filter system having a flexible coupler 722 is deployed similarly to the method described in FIGS. 2A-2D . In one embodiment, as distal sheath 718 is advanced into the left common carotid artery, tubular core member 720 is advanced distally relative to distal sheath 718 . FIG. 34B illustrates filter system 700 after tubular core member 720 is advanced into the left common carotid artery. Distal filter 736 expands and flexible coupler 722 deflects relative to filter system 700 such that distal filter frame element 728 is circumferentially apposed to the vessel wall. Strut 724 may be proximally retracted as desired to tilt the frame element 728 to improve the fit of the distal filter 736 within the vessel.
[0173] In certain embodiments, the stiffness of tubular core member 720 may be further reduced during use by the operator by withdrawing the guidewire until the distal end of the guidewire is proximal to flexible coupler 722 such that the guidewire is no longer disposed within flexible coupler 722 , thus reducing stiffness.
[0174] FIGS. 35A-B illustrate a tubular body 750 suitable for use as a flexible coupler 722 . A tubular body 750 having a proximal end 754 and a distal end 756 may be formed by wrapping a ribbon or wire around a mandrel or by laser cutting a tube with a spiral pattern to form a coil. The width of spaced regions 752 a,b between each adjacent coil loop 751 may be different in an unstressed orientation depending on the desired properties. In some embodiments, it may be desirable to provide greater flexibility, in which case, spaced region 752 b should be wider to allow for a greater range of movement. In certain clinical scenarios, it may be desirable to provide smaller spaced regions 752 a between each coil portion 751 to help prevent a first edge 753 a and a second edge 753 b of each coil portion 751 from dislodging plaque from the vessel wall or damaging the vessel wall. In an alternate embodiment, a flexible coupler 722 having wider spaced regions 752 a between each coil portion 751 may be covered by a thin sheath such as shrink wrap tubing to provide flexibility and protect the vessel wall from flexible coupler 722 .
[0175] In FIG. 35C , a tubular body 760 having a proximal end 764 and a distal end 766 is laser cut with a plurality of slots 762 , each slot 762 having a first end 768 a and a second end 768 b . In some embodiments, two or more slots 762 form a circumferential ring 771 around flexible coupler 722 . In several embodiments, a plurality of circumferential rings 771 is laser cut into a tubular body 760 . The plurality of circumferential rings 771 may be staggered such that a first slot of a first circumferential ring is misaligned from a first slot of a second circumferential ring. The plurality of slots 762 are configured such that flexible coupler 722 flexes angularly while retaining good torque resistance and tensile displacement resistance.
[0176] FIG. 35D depicts a flexible coupler 722 constructed from a tubular body 770 having a proximal end 774 and a distal end 776 . Tubular body 770 is laser cut with a spiral pattern, the spiral pattern having a plurality of interlocking ring portions, wherein a first interlocking ring portion 778 a interlocks with a complementary second interlocking ring portion 778 b . Flexible coupler 722 has an interlocking pattern designed to resist axial deformation (stretching) when placed in tension. FIG. 35E illustrates flexible coupler 722 also having interlocking ring portions 778 . In this embodiment, an axial element 784 is positioned across an interlocking feature 782 to improve the axial stiffness of flexible coupler 722 when subject to tensile loading.
[0177] Although the above mentioned embodiments were discussed in connection with a tubular core member, the same properties may be applied to any other guiding member. The guiding member may incorporate any of the above mentioned properties alone, or in combination, to manipulate flexibility and column strength along the guiding member shaft. The embodiments may also be used in connection with the proximal filter or any other catheter-based system.
[0178] In certain clinical scenarios, it may be desirable for the filter opening to circumferentially appose the vessel wall. This helps prevent debris from flowing past the filter. In a straight lumen, a filter can achieve good apposition with the vessel wall, thus preventing plaque or blood clots from flowing past the filter when it is deployed in a vessel. In contrast, when a filter is deployed in a curved lumen, the filter frame element can settle into a number of different rotational orientations in the lumen. In some clinical scenarios, when the filter is deployed in a curved lumen, it is possible for the filter frame element to pull away from the vessel wall particularly on the inner radius thus leading to poor apposition and blood leakage past the filter.
[0179] In current settings, practitioners may seek to overcome this poor positioning by using contrast injections and fluoroscopic imaging in one or more views. The filter is then either re-sheathed and redeployed or rotated or repositioned without re-sheathing, a process that can dislodge plaque from the vessel wall or otherwise damage the vessel. Neither of these solutions is satisfactory due to the extended procedure time and the increased possibility of vessel damage due to increased device manipulation.
[0180] In certain scenarios, it may be advantageous to add a tethering member to a filter assembly. FIGS. 36A-E illustrate tethering member 842 attached to proximal filter assembly 804 . Tethering member 842 is configured to draw proximal filter frame element 814 closer to the vessel wall in order to form a seal with the inner surface of the vessel. Proper apposition of proximal filter assembly 804 relative to the vessel wall prevents debris from flowing past proximal filter assembly 804 . This can be achieved with a flexible tethering member (e.g. monofilament polymer, braided polymer, suture, wire, etc.) or with a rigid or semi-rigid member such as nitinol, thermoplastic, stainless steel, etc.
[0181] Tethering member 842 has a first end 844 and a second end 846 . In FIG. 36A , the first end 844 of tethering member 842 is affixed to proximal sheath 802 , while the second end 846 of tethering member 842 is affixed to proximal filter assembly 804 . In some embodiments, tethering member 842 is affixed to filter frame element 814 ; while in other embodiments, tethering member 842 is affixed to proximal filter 806 . FIGS. 36B-C illustrate how tethering member 842 laterally deflects the frame 814 and pulls filter frame element 814 toward the vessel wall when the operator retracts proximal sheath 802 . Proximally retracting tethering member 842 allows the operator to control the deflection and angle of proximal filter frame element 814 . In other embodiments, tethering member 842 can be actuated passively rather than actively (i.e. by the operator) by forming tethering member 842 from an elastic material or spring in order to elastically pull the edge of proximal filter frame element 814 toward the vessel wall.
[0182] In still other embodiments, the second end 846 of tethering member 842 may be attached to a feature disposed along proximal filter 806 . For example, in FIG. 36E , the second end 846 of tethering member 842 is connected to a rib 848 formed on proximal filter 806 . In still other embodiments, the first end 844 of tethering member 842 may be attached to an elongate member such as a pull wire slidably disposed along the length of the catheter system to a control actuator in the control handle. This allows the operator to control the deflection of proximal filter frame element 814 independently from proximal sheath 802 .
[0183] In certain embodiments, it may be preferable to attach a distal end of tethering member 842 to a single location on proximal filter assembly 804 . Alternatively, as shown in FIG. 36D , it may be preferable to attach the distal end of tethering member 842 to two or more positions on proximal filter assembly 804 .
[0184] In order to facilitate sheathing and to minimize tangling when proximal filter assembly 804 is collapsed into proximal sheath 802 , tethering member 842 may be twisted to form a coil 849 , as shown in FIG. 37A . Twisted portion 849 retracts and stays out of the way when proximal filter assembly 804 is sheathed, and twisted portion 849 will untwist and straighten as the operator deploys proximal filter assembly 804 . The design is also helpful for controlling the slack in tethering member 842 during sheathing and unsheathing. Tethering member 842 may be formed from a heat deformable polymer and applying heat to deform the polymer into a twisted configuration. Tethering member may alternatively be formed from nitinol or any other material having suitable properties. In other embodiments, it may be preferable for tethering member 842 to form a coil ( FIG. 37B ), pre-formed to particular shapes ( FIG. 37C ), or have two or more tethering members ( FIG. 37D ). One or more tethering members may be formed into any other design that may decrease the likelihood that tethering member 842 will become tangled with other catheters or devices.
[0185] Although the previously discussed tethering members have been discussed in connection with proximal filter assemblies, a tethering member may be used in connection with a distal filter, other filter devices, or any intraluminal device that may desirably be laterally displaced, tilted or otherwise manipulated into a desired orientation, such as to improve alignment including improving apposition with a vessel wall.
[0186] In some clinical scenarios, it may be desirable to place a single filter in a blood vessel. Any of the above mentioned features of the dual filter embodiments may be applied to the single filter embodiments described below, including, but not limited to, filter design, sheath articulation, or guiding member flexibility or column strength. In addition, filter systems described herein can be utilized in connection with a variety of intravascular interventions. The embodiments described below will be discussed in connection with a TAVI procedure, but the filter systems may be used with other intravascular or surgical interventions such as balloon valvuloplasty, coronary artery bypass grafting, surgical valve replacement, etc. and should not be construed as limited to the TAVI procedure.
[0187] In certain situations, it may be desirable to position the filter in the aorta, distal to the aortic valve but proximal to the brachiocephalic artery ostium, such that the entire arterial blood supply can be filtered. The aortic filter may also be positioned in the aorta, between the right brachiocephalic artery ostium and the left carotid artery ostium. In other scenarios, the aortic filter may be positioned between the left carotid artery ostium and the left subclavian artery ostium, while in still other clinical situations may make it preferable to position the aortic filter in the descending aorta, distal to the left subclavian artery ostium. In some cases, an aortic filter can be positioned in the aorta in combination with brachiocephalic and left carotid artery filters in order to capture all embolic debris.
[0188] An aortic filter can be positioned at various locations along a catheter system. In one embodiment, the aortic filter can be positioned on a catheter separate from the TAVI or pigtail catheter and inserted through the left or right brachial artery or the right or left femoral artery. Using a separate aortic filter catheter decreases the overall diameter of the TAVI catheter and allows the operator to position the aortic filter independently from aortic valve. Further, the aortic filter will not dislodge plaque along the vessel wall when the TAVI catheter is repositioned or rotated.
[0189] In another embodiment, the aortic filter can be positioned on the TAVI catheter shaft, proximal to the valve prosthesis. To decrease the size of the overall catheter system, the diameter of the TAVI catheter system proximal to the valve prosthesis may be reduced in size. This embodiment decreases the number of total devices in the operating environment, thus decreasing the likelihood that devices will get tangled.
[0190] In yet another embodiment, the aortic filter may be positioned on the TAVI introducer. This embodiment enables the operator to position the aortic filter independently from the position of the TAVI catheter. The filter is also less likely to dislodge plaque along the vessel wall when the TAVI catheter is repositioned or rotated. Introducing the aortic filter on the TAVI introducer also decreases the total number of catheters into the operating environment.
[0191] In still another embodiment, the aortic filter is positioned on a pigtail catheter shaft, proximal to the pigtail. Affixing the aortic filter to the pigtail catheter does not increase the overall diameter of the TAVI system or add any additional catheters into the operating environment.
[0192] In one embodiment, the aortic filter is positioned on an extended pigtail introducer sheath. This embodiment enables the operator to position the aortic filter separately from the location of the pigtail without adding any additional catheters into the operating environment. Positioning the aortic filter on the pigtail introducer sheath also does not increase the overall diameter of the TAVI system. Further, the aortic filter will not dislodge plaque along the vessel while when the pigtail and/or TAVI catheter is repositioned or rotated.
[0193] Various methods can be used to perform a TAVI procedure in connection with an aortic filter. In one method, the aortic filter is positioned as early as possible in the procedure at any location in the aorta previously described, and the aortic filter may be deployed using any of the above mentioned devices. The TAVI catheter may then be inserted through the filter and the TAVI implantation is performed. Afterward, the TAVI catheter and aortic filter are removed.
[0194] In an alternative method, a guidewire is positioned through the aorta and the pigtail catheter is inserted into the aorta. A TAVI catheter can then be advanced to a position just proximal of where the aortic filter will be deployed. The aortic filter may be deployed at any position described above. Using any of the previously discussed embodiments, a catheter carrying an aortic filter deploys an aortic filter in the aorta. The aortic filter also forms a seal against both the TAVI catheter and the vessel wall such that debris cannot flow past the filter. After the aortic filter is deployed, the TAVI catheter is advanced to the implant location and the implant procedure is performed. When the procedure is over, the TAVI catheter is withdrawn just proximal to the filter such that the operator can retrieve the aortic filter. The aortic filter, TAVI, and pigtail catheters are then all withdrawn from the operating environment. These steps are not limited to the order in which they were disclosed. For example, the TAVI catheter may be advanced to the implant location before the aortic filter is deployed.
[0195] FIG. 38A depicts a TAVI catheter 933 that is deployed across an aortic filter assembly 904 in the aorta 999 . In some scenarios, aortic filter assembly 904 may not fully appose the TAVI catheter shaft, thus leaving room for debris to flow between the TAVI catheter 933 and the vessel wall. In these scenarios, it may be preferential to configure aortic filter assembly 904 to appose TAVI catheter 933 and prevent substantially all debris from flowing past aortic filter assembly 904 without significantly degrading filter capture performance. It may also be preferential to modify aortic filter assembly 904 in scenarios where TAVI catheter 933 passes through aortic filter assembly 904 .
[0196] FIG. 38B illustrates an aortic filter assembly 904 designed to pass over a guidewire 907 or other guiding member. Aortic filter assembly 904 may have a channel 909 on the exterior surface of aortic filter assembly 904 . Channel 909 is constructed such that a TAVI deployment catheter or other catheter may pass through channel 909 . The operator may also rotate aortic filter assembly 904 such that the TAVI catheter properly passes through channel 909 . The control handle may indicate the rotational location of channel 909 help the operator correctly orient aortic filter 904 . Alternatively, channel 909 may have at least one or two radiopaque markers to enable identification of channel 909 using fluoroscopy.
[0197] FIG. 38C depicts aortic filter assembly 904 having a leading edge 911 and a trailing edge 913 . Aortic filter assembly 904 passes over a guidewire 907 or other guiding member. Leading edge 911 overlaps trailing edge 913 to form an overlapping portion 935 . The control handle may indicate the location of overlapping portion 935 so the operator can torque aortic filter assembly 904 to position overlapping portion 935 over the TAVI or other catheter shaft. Overlapping portion 935 may have a radiopaque marker to allow the operator to monitor aortic filter placement under fluoroscopy.
[0198] FIG. 38D depicts an aortic filter assembly 904 designed to pass over a guidewire 907 or other guiding member. Aortic filter 904 has a first filter portion 915 and a second filter portion 917 , second filter portion 917 having a first edge 917 a , and a second edge 917 b . The first edge 917 a and the second edge 917 b of second filter portion 917 overlap first filter portion 915 to form a joint 914 . The control handle may indicate the location of joint 914 so the operator can torque aortic filter assembly 904 to position joint 914 against the shaft of the TAVI catheter. As the operator advances a catheter-based device across aortic filter 904 , second filter portion 917 caves inward such that joint 914 forms a seal around the catheter shaft. Aortic filter assembly 904 may include a radiopaque marker to allow the operator to identify joint 914 under fluoroscopy.
[0199] FIGS. 39 A-C depict an aortic filter device having two or three or four or more aortic lobes or filters. Each aortic filter lobe 904 a,b,c is joined together along a first side 919 of each aortic filter lobe 904 a,b,c . Aortic filter lobes 904 a,b,c join together about a longitudinal axis of the aortic filter system. The aortic filter system is configured such that a TAVI catheter 933 or other catheter-based device may pass between a first aortic filter assembly 904 b and a second aortic filter assembly 904 c . The first and second aortic filters 904 b,c forming a seal around the TAVI catheter 933 , thus preventing debris from flowing past the aortic filter system.
[0200] FIG. 40A depicts generally conical aortic filter assembly 904 resembling an umbrella. Aortic filter 904 may pass over a guidewire 907 or other guiding member. Aortic filter assembly 904 has a plurality of self-expanding tines 923 , each tine having a proximal end and a distal end. Each tine joins together at a first end 903 of aortic filter assembly 904 . In addition, a filter portion 925 is suspended between tines 923 . Filter portion 925 may be fairly inflexible or flexible to stretch over the TAVI catheter 933 or other catheter-based device. When an operator advances TAVI catheter 933 past aortic filter assembly 904 , TAVI catheter 933 passes between a first tine 923 and a second tine 923 such that a filter portion 925 stretches over TAVI catheter 933 to form a seal between filter portion 925 and TAVI catheter 933 .
[0201] Alternatively, FIG. 40B depicts an aortic filter assembly 904 resembling a flower. In one embodiment, aortic filter assembly 904 has two or more petals 943 arranged in a circular array that allow TAVI catheter 933 or other catheter-based device to pass between petals 943 . Petals 943 may overlap one another to create a seal between adjacent petals 943 . Petals 943 also create a seal around TAVI catheter 933 as the catheter passes between petals 943 . The shape of each petal 943 may include an arch to better accommodate the circular shape of the aorta. Each petal 943 may have a length between two to six centimeters. Although in some embodiments, the length may be less than in two centimeters; while in still other embodiments, the length may be greater than six centimeters. In one embodiment, the individual petals are comprised of a frame 944 that is covered with a filter element 945 . The frame 944 may be constructed of a shape memory material such as Nitinol, or other material such as stainless steel, cobalt supper alloy (MP35N for example) that has suitable material properties. The filter element 945 may be constructed of a polyurethane sheet that has been pierced or laser drilled with holes of a suitable size. Other polymers may also be used to form the filter element, in the form of a perforated sheet or woven or braided membranes. Thin membranes or woven filament filter elements may alternatively comprise metal or metal alloys, such as nitinol, stainless steel, etc.
[0202] Any of the aortic filter assemblies described above may also include frame element 914 formed from a material suitable to form a tight seal between aortic filter assembly 904 and TAVI catheter 933 or other catheter-based device as the filters fill under systolic blood pressure.
[0203] FIGS. 41A-B depicts an aortic filter assembly 904 having an inflatable portion 927 defining a distal opening 912 of aortic filter 906 . In some embodiments, inflatable portion 927 forms a continuous ring. Inflatable portion 927 forms a seal against the vessel wall such that debris cannot pass between aortic filter assembly 904 and the vessel wall. Inflatable portion 927 may also form a seal against a TAVI catheter passed between aortic filter assembly 904 and the vessel wall.
[0204] As depicted in FIG. 41A , inflatable portion 927 and filter element 906 may form a channel 929 on an exterior surface of aortic filter assembly 904 through which a catheter-based device may pass. Channel 929 forms a seal against the catheter such that debris may not flow between the aortic filter assembly 904 and the catheter.
[0205] FIG. 41B illustrates an inflatable portion 927 having a gap 931 through which a catheter-based device may pass. Filter element 906 may also form a channel on the exterior surface of the aortic filter assembly 904 through which the catheter may pass.
[0206] In an embodiment which includes an inflatable annulus or other support, the inflatable support is placed in fluid communication with a source of inflation media by way of an inflation lumen extending throughout the longitudinal length of the catheter shaft. Once the filter has been positioned at a desired site, the annulus can be inflated by injection of any of a variety of inflation media, such as saline. The inflation media may thereafter be aspirated from the filter support, to enable collapse and withdraw of the filter. The inflation media may include a radiopaque dye to help the operator locate the inflatable annulus under fluoroscopy.
[0207] Although the filter systems described above were discussed in connection with a single filter system, the filter designs may also be used in connection with a dual filter system.
[0208] FIG. 42 depicts one embodiment of a filter assembly that may be used in connection with any filter-based device, including the dual filter and single filter systems described above. Filter assembly 926 may comprise a filter membrane 936 , a filter frame element 928 , and at least one radiopaque marker. Filter membrane may 936 may be constructed from a polyurethane film or any other polymer or material exhibiting suitable properties. In some embodiments, a laser or other mechanism may be used to create at least one filter hole in the filter membrane through which blood may flow. The at least one filter hole is small enough such that a blood clot or piece of embolic debris exceeding a predetermined dimension cannot pass through. The filter membrane may be formed into a conical or other shape by heat sealing a first edge of the filter membrane to a second edge of the filter membrane, although other methods may be used to join a first edge of the filter membrane to a second edge of the filter membrane. In several embodiments, filter assembly 926 may also include flexible coupler 922 .
[0209] A frame element 928 may be shaped from a Nitinol wire, but, as discussed in earlier paragraphs, the frame element may be shaped from any other suitable material or textured to exhibit desired properties. In some embodiments, at least one radiopaque marker is incorporated into filter assembly 926 . In one embodiment, a 90/10 platinum/iridium coil marker is positioned around frame element 928 and bonded with an adhesive. Alternatively, other types of radiopaque markers may be integrated into or affixed to frame element 928 . Other methods of affixing the radiopaque marker may also be used.
[0210] In several embodiments, filter assembly 926 includes a strut tubing 924 . Strut tubing 924 may be constructed from PET heat shrink tube, polyimide tube, or any other material exhibiting suitable properties. In one embodiment, strut tubing 924 is affixed to one or more legs of frame element 928 with an adhesive, although other means for affixation may also be used. Additional mechanisms may also be used to reinforce the adhesive or other means of affixation. Alternatively, strut tube 924 may be slipped over one or more portions of the frame element 928 and may additionally be bonded in place.
[0211] In some embodiments, filter membrane 936 may be attached to frame element 928 by heat-sealing a first portion of filter membrane 936 to a second portion of filter membrane 936 to form a sleeve through which frame element 928 may pass. An adhesive may be used to reinforce the bond between the frame element and the filter membrane. Other mechanisms may also be used to affix frame element 928 to filter membrane 936 . Additional mechanisms may also be used to reinforce the adhesive or other affixation mechanism.
[0212] In some embodiments, frame element 928 is attached to a filter shaft 920 via a stainless steel crimp 998 , although other mechanisms may be used to affix frame element 928 to a filter shaft 920 . Additional affixation methods may also be used to reinforce the stainless steel crimp 998 or other mechanism.
[0213] In several embodiments, a cannulated distal tip 940 having an atraumatic distal end with a guidewire exit port is joined to the distal end of filter shaft 920 .
[0214] FIG. 43 illustrates a proximal portion of an exemplary filter system. The portion shown in FIG. 43 is generally the portion of the system that remains external to the subject and is used to control the delivery and actuation of system components. Proximal sheath 1010 is fixedly coupled to proximal sheath hub 1012 , which when advanced distally will sheath the proximal filter (as described herein), and when retracted proximally will allow the proximal filter to expand. The actuation, or control, portion also includes handle 1016 , which is secured to proximal shaft 1014 . When handle 1016 is maintained axially in position, the position of the proximal filter is axially maintained. The actuation portion also includes distal sheath actuator 1022 , which includes handle 1023 and deflection control 1020 . Distal sheath actuator 1022 is secured to distal shaft 1018 . As described herein, the distal articulating sheath is adapted to have three independent degrees of motion relative to the proximal sheath and proximal filter: rotation, axially translation (i.e., proximal and distal), and deflection, and distal sheath actuator 1022 is adapted to move distal sheath 1018 in the three degrees of motion. Distal sheath 1018 is rotated in the direction shown in FIG. 43 by rotating distal sheath actuator 1022 . Axial translation of distal sheath occurs by advancing actuator 1022 distally (pushing) or by retracting actuator 1022 proximally (pulling). Distal sheath 218 is deflected by axial movement of deflection control 1020 . Movement of deflection control 1020 actuates the pull wire(s) within distal sheath 1018 to control the bending of distal sheath 1018 . Also shown is guiding member 1024 , which is secured to the distal filter and is axially movable relative to the distal sheath to deploy and collapse the distal filter as described herein. The control portion also includes hemostasis valves 1026 , which in this embodiment are rotating.
[0215] FIG. 44 illustrates an exemplary 2-piece handle design that can be used with any of the filter systems described herein. This 2-piece handle design includes distal sheath actuator 1046 , which includes handle section 1048 and deflection control knob 1050 . Deflection control knob 1050 of distal sheath actuator 1046 is secured to distal shaft 1054 . Axial movement of distal sheath actuator 1046 will translate distal shaft 1054 either distally or proximally relative to the proximal filter and proximal sheath. A pull wire (not shown in FIG. 44 ) is secured to handle section 1048 and to the distal articulatable sheath (not shown in FIG. 44 ). Axial movement of deflection control knob 1050 applies tension, or relieves tension depending on the direction of axial movement of deflection control knob 1050 , to control the deflection of the distal articulatable sheath relative to the proximal filter and proximal sheath 1044 , which has been described herein. Rotation of distal sheath actuator 1046 will rotate the distal sheath relative to the proximal filter and proximal sheath. The handle also includes housing 1040 , in which proximal sheath hub 1042 is disposed. Proximal sheath hub 1042 is secured to proximal sheath 1044 and is adapted to be moved axially to control the axial movement of proximal sheath 1044 .
[0216] FIG. 45 illustrates another exemplary embodiment of a handle that can be used with any of the filter systems described herein. In this alternate embodiment the handle is of a 3-piece design. This 3-piece handle design comprises a first proximal piece which includes distal sheath actuator 1061 , which includes handle section 1063 and deflection control knob 1065 . Deflection control knob 1065 of distal sheath actuator 1061 is secured to distal shaft 1067 . Axial movement of distal sheath actuator 1061 will translate distal shaft 1067 either distally or proximally relative to the proximal filter and proximal sheath. A pull wire (not shown in FIG. 45 ) is secured to handle section 1063 and to the distal articulatable sheath (not shown in FIG. 45 ). Axial movement of deflection control knob 1065 applies tension, or relieves tension depending on the direction of axial movement of deflection control knob 1065 , to control the deflection of the distal articulatable sheath relative to the proximal filter and proximal sheath 1069 . Rotation of distal sheath actuator 1061 will rotate the distal sheath relative to the proximal filter and proximal sheath 1069 . The handle design further includes a second piece comprising central section 1060 which is secured to proximal shaft 1071 . A third distal piece of this handle design includes housing 1062 . Housing 1062 is secured to proximal sheath 1069 . Housing 1062 is adapted to move axially with respect to central section 1060 . With central section 1060 held fixed in position, axial movement of housing 1062 translates to axial movement of proximal sheath 1069 relative to proximal shaft 1071 . In this manner, proximal filter 1073 is either released from the confines of proximal sheath 1069 into expandable engagement within the vessel or, depending on direction of movement of housing 1062 , is collapsed back into proximal sheath 1069 .
[0217] FIG. 46 depicts another embodiment of a control handle. The control handle has a proximal filter control 1100 and a distal filter control 1102 . To deploy the device, the distal shaft of the catheter is fed over a guidewire and manipulated into position in the patient's anatomy. To deploy the proximal filter, the proximal filter sheath control 1120 is withdrawn proximally while holding the proximal filter handle 1118 stationary. The proximal filter sheath control 1120 is a sliding control; however, any other control such as a rotating knob, a pivoting lever, etc. may be used to withdraw the sheath.
[0218] When the proximal filter is properly deployed, the distal filter contained in the distal sheath is advanced distally and positioned in the target location by advancing the distal filter control 1102 while holding the proximal filter control 1100 stationary. During this positioning process, the distal filter control 1102 can be advanced, retracted or rotated relative to the proximal filter control 1100 , and as needed, the deflection of the distal sheath may be controlled by actuating the distal sheath deflection control 1112 relative to the distal filter sheath handle 1110 . The distal sheath deflection control 1112 is a pivoting control; however, any other control such as a rotating knob, a sliding knob, etc. may be used to deflect the sheath. Once the sheath containing the collapsed distal filter is positioned correctly, the position of the distal filter control 1102 is locked relative to the proximal filter control 1100 by tightening the proximal handle hemostasis valve 1116 . Next, the distal filter may be deployed by advancing the guiding member 1108 by grasping the distal filter Luer fitting 1104 until the filter is deployed. The position and orientation of the distal filter may be adjusted by advancing, retracting or rotating the distal filter Luer fitting 1104 relative to the distal filter sheath handle 1110 . Finally, the position of the distal filter may be fixed relative to the distal filter sheath handle 1110 by tightening the distal handle hemostasis valve 1106 . To remove the device upon completion of the procedure, the aforementioned procedure is reversed.
[0219] FIGS. 47A through 471 illustrate cross-sections through the control handle illustrated in FIG. 46 , taken along the section lines indicated in FIG. 46 .
[0220] FIGS. 47A-B depict cross-sectional areas of proximal filter control 1100 . The distal shaft 1108 is disposed through a lumen defined by the articulating distal sheath 1114 . In these figures, the articulating distal sheath 1114 is disposed through a lumen defined by the proximal filter shaft 1124 , and the proximal filter shaft is disposed through a lumen defined by the front handle 1118 .
[0221] FIG. 47C depicts a cross-sectional area of a distal section of distal filter control 1102 . In FIG. 47C , articulating distal sheath 1114 is disposed through a lumen defined by the rear handle 1110 as shown in FIG. 47C . FIG. 47D shows a cross-sectional view proximal to the cross-section shown in FIG. 47C . In FIG. 47D , guiding member 1108 is disposed through a lumen defined by the rear handle 1110 . Guiding member 1108 defines a lumen 1128 through which a guidewire may pass. FIG. 47E shows a cross-sectional view proximal to the cross-section shown in FIG. 47D . The guiding member 1108 is coaxial with a stainless steel hypotube 1130 . Hypotube 1130 reinforces the guiding member 1108 .
[0222] FIG. 47F depicts a longitudinal cross-section of proximal filter control 1100 . At the distal end of proximal filter control 1100 , there is a nose piece 1132 holding the front handle 1118 together. Proximal to nose piece 1132 there is a proximal filter sheath control 1120 to actuate the proximal filter sheath and deploy the proximal filter. The proximal filter sheath control is associated with a locking mechanism 1126 to prevent unintentional filter deployment and to actuate a sealing mechanism to prevent blood leakage. The locking mechanism 1126 comprises a locking element 1134 , an elastomeric seal 1138 , a spring 1136 , and a nut 1140 for holding locking mechanism 1126 together. In certain embodiments, squeezing the proximal filter sheath control 1120 will release the locking element 1134 between the proximal sheath 1122 and proximal filter shaft 1124 .
[0223] FIGS. 47G-H depicts a longitudinal cross section of distal filter control 1102 . At a distal section of the distal filter control 1102 , there is a mechanism to actuate articulating distal sheath 1114 . The actuation mechanism includes an axially movable deflection lever 1112 pivoting on distal sheath pivot 1146 . The distal sheath deflection lever 1112 is connected to the distal sheath pull wire at attachment point 1150 . The pull wire is disposed through channel 1148 . Proximal to rear handle 1110 there is a distal handle hemostasis valve 1106 . Distal handle hemostasis valve 1106 comprises elastomeric seal 1152 and HV nut 1154 . Distal filter shaft 1108 and hypotube 1130 extend proximally from distal filter control 1102 and terminate at distal filter luer lock fitting 1104 .
[0224] An alternative control handle uses a rotating screw drive mechanism to deflect a distal end of a distal articulating sheath is shown in FIG. 48 . In certain clinical scenarios, it may be desirable to include a mechanism that prevents the articulating sheath from unintentionally deflecting when the operator releases the handle. The mechanism incorporates a lead screw 1214 which is inherently self-locking in that tip deflection will be locked wherever the handle control is released by the operator. A rotating screw drive mechanism provides an easy to manufacture design to control the pivot of the articulating sheath. The rate of deflection of the tip is controlled by the pitch of the screw threads 1218 , thus rapid deflection of the tip, which can lead to unintentional vessel damage, can be prevented.
[0225] While specific embodiments have been described herein, it will be obvious to those skilled in the art that such embodiments are provided by way of example only. Numerous variations, changes, and substitutions will now occur to those skilled in the art without departing from that which is disclosed. It should be understood that various alternatives to the embodiments described herein may be employed in practicing the disclosure. | Single filter and multi-filter endolumenal methods and systems for filtering fluids within the body. In some embodiments a blood filtering system captures and removes particulates dislodged or generated during a surgical procedure and circulating in a patient's vasculature. In some embodiments a filter system protects the cerebral vasculature during a cardiac valve repair or replacement procedure. | 0 |
BACKGROUND AND SUMMARY OF THE INVENTION
Stronger articles can be made by blow molding if the plastic material is bi-axially oriented. This requires stretching the material in different directions while the material is at its "orientation temperature" which is the temperature at which crystallization begins.
In order to obtain some cooling of the parison in the injection mold, the temperature of the molten plastic is reduced by leaving the parisons in the injection mold while they are cooled by inside cooling through the core rods and outside cooling by contact with cooled walls of the injection mold cavities.
Further control of the temperature is obtained by indexing the core rods to a temperature control station at which the core rods are located in chambers through which air circulates. In the preferred construction, the air circulation chambers are cylindrical with clearance around all sides of the core rods, and air is introduced at a center region and discharges from both ends of the chambers. In order to prevent flow by gravity of the parison material toward the bottom sides of the core rods while the material is soft, the core rods are rotated while in the temperature-controlling chambers; and this rotation also equalizes the cooling effect of the air which is introduced into the cooling chambers.
From a temperature control station, the parisons may be indexed to a pre-blow station where the parison is stretched circumferentially and axially by a initial blowing operation; or the parison can be transferred directly to the final blow station where it is blown to the final dimensions of the article being made on the machine. From the blow mold, the blown articles are transferred to a stripper station at which they are removed from the core rods and the core rods are indexed to the injection station to receive a new set of parisons. The blowing, stripping and indexing back to the injection station are conventional and well-understood in the blowing machine art.
Other objects, features and advantages of the invention will appear or be pointed out as the description proceeds.
BRIEF DESCRIPTION OF DRAWING
In the drawing, forming a part hereof, in which like reference characters indicate corresponding parts in all the views:
FIG. 1 is a diagrammatic top plan view showing a molding machine made in accordance with this invention;
FIG. 2 is a diagrammatic sectional view taken on the line 2--2 of FIG. 1;
FIG. 3 is an enlarged front view taken on the line 3--3 of FIG. 1;
FIG. 4 is a sectional view taken on the line 4--4 of FIG. 3; and
FIG. 5 is a diagrammatic view showing the sprockets on the core rods and the chain which the sprockets on the core rods engage when the core rods move downward to the level of the treating station, this engagement allowing movement of the chain to cause the sprockets on the cores and as well as the parisons, to rotate, the view being an enlarged sectional view on line 5--5 of FIG. 1.
DESCRIPTION OF PREFERRED EMBODIMENT
FIG. 1 is a diagrammatic plan view of a blow molding machine having an injection station 10; a parison treating station 12; a blowing station 14; and a stripper station 16. Core rods 18 extend from side faces of indexing head 20 which moves intermittently through 90° angular movements about a shaft 22; and which raises and lowers in order to lift the core rods 18 clear of the lower sections of molds at the various stations.
Mechanism for raising and lowering the shaft 22 and for rotating it intermittently about its axis is indicated diagrammatically by the gear box 24; the rotary movement being indicated by the arrow 26 and the vertical movement being indicated by the arrows 28. Power to the gear box is supplied by an electric motor 30. All of the structure except the treating station 12 is conventional and no further description of it is necessary for a complete understanding of this invention.
FIG. 2 is a sectional view taken through a mold 32 at the injection station 10. Plastic in a molten state is discharged from a plasticizer 34 into a manifold in the mold 32 where it is distributed to mold cavities, indicated by the reference characters 36.
The core rods 18 (FIG. 1) extend into the cavities of the injection mold 32 and are coated with molten plastic to form parisons along the lengths of the core rods 18 which extend into the cavities. The mold 32 has a lower fixed section 32a which is attached to the frame of the blow molding machine. An upper mold section 32b is movable toward and from the fixed section 32a in order to open the mold when the core rods are to be lifted clear of the fixed section 32a and rotated angularly to the next station of the blow molding machine. There are cooling chambers 38 in the upper and lower sections of the mold 32, and these cooling chambers 38 have hoses 40 for the entrance and discharge of water or other cooling fluid into and out of the mold sections 32a and 32b. This structure shown in FIG. 2 is also conventional and is used in the same way as in other blow molding machines, except that the parisons may remain in the mold 32 somewhat longer than is conventional, and the cooling fluid circulated through the chambers 38 and hoses 40 may be at somewhat lower temperature in order to have the plastic, of which the parison is composed, come from the mold at somewhat lower temperature than is ordinarily used.
Since the temperature of the parison depends, to some extent, upon the material used for the blow molding operation, and since orientation temperatures of different materials are not the same, the use of the mold 32 for reducing the parison temperature more than usual may not be necessary, as will be explained more fully in connection with the description of the parison treating station 12.
FIG. 3 shows the treating station 12 which includes a housing having an upper section 42 and a lower section 44. The lower section 44 is secured to a stationary frame 46 of the blow molding machine by fastening means (not shown). The upper section 42 is movable toward and from the lower section 44 in the same manner as the molds open and close. In FIG. 3, hydraulic motors 48 having pistons 50 secured to the upper section 42 are representative of power means for opening and closing the housing at the parison treating station 12. This housing differs from a mold only in that the housing has chambers 52 which are open at both ends, whereas mold cavities are closed except for the cylindrical passage through which the core rod extends. A section through the middle chamber 52 is shown in FIG. 4. the chamber 52 is preferably cylindrical, and the core rod 18 extends into the chamber 52 and it is substantially coaxial thereto. The parison, indicated by the reference character 56 is of substantially smaller diameter than the chamber 52, so that air introduced into the chamber 52 through a passage 58 circulates over the surface of the parison 56, as indicated by the arrows 60, and discharges from both ends of the chamber 52, so as to cool the parison 56 as evenly as possible.
FIG. 3 shows all of the chambers 52 supplied with air through passages 58 extending upward from a manifold 62, which is supplied with air through a centrifugal blower 64 driven by a motor 66 with a speed control 68 for driving the blower 64 faster or slower as necessary to obtain the desired amount of cooling. This treating station 12 is representative of means for bringing the parison 56 to an orientation temperature so that when the indexing head 20 makes its next angular movement, and carries the parison 56 from the treating station 12 to the blow station 14 (FIG. 1), the stretching of the parison at the blow station 14, with the plastic of the parison at orientation temperature, produces a container with biaxial orientation which makes the container much stronger than if blown at other temperatures.
Since the objective of all blow molding machines is to obtain finished products in the largest quantities for the time of operation, the length of time that the core rods remain at any of the operational stations is reduced as much as possible. With the present invention, the parisons are formed in the injection station 10 by coating the core rods 18 which are in the cavities of the injection mold. Upon completion of the injection operation, the mold 32 opens and the indexing head 20 moves upward to clear the bottom section of the mold 32 and shift the core rods 18, with the parisons on them, to the treating station 12. All of the necessary cooling of the parisons could be done in the injection mold, but if this required that the injection cycle be twice as long, it is evident that the production of the machine would be cut in half. The treating station 12 increases the production of the machine by making it possible to have the injection cycle short; but one of the problems of the prior art has been that when the parisons are removed from the injection mold at a very high temperature, the material of the plastic is softer and the plastic tends to move downward by gravity around the sides of the core rod so that it becomes thicker on the underside than on the upperside. Such a distribution of the material of the parison makes it impossible to blow a satisfactory container.
This invention permits the core rods, with the parison still soft, to be removed from the injection mold 32 and brought to the treating station 12 where the core rods 18 are rotated during treating to eliminate any sagging of the parison material to the underside of the core rod.
FIG. 5 shows each of the core rods 18 with a sprocket wheel 70 secured to the core rod at a location between the indexing head 20 and any of the other structure at the operational stations 10, 12, 14 and 16. When the core rods 18 move into position between the open sections of the housing at the station 12, and the indexing head 20 then lowers to position the core rods 18 and parisons 56 on the center line of the chambers 52, the sprockets 70 engage a chain 74 which is located immediately below the sprockets 70. This sprocket chain 74 is an endless chain which runs around driving sprockets 76 at locations beyond the core rods. One of the sprockets 76 has a drive shaft 78 rotated by a motor 80 at a speed regulated by a speed controller 82 when the motor is turned on during the treating cycle.
Thus during the entire time that the parisons 56 are in the chambers 52 of the treating station, the parisons are rotated so that any sagging of the plastic of the parisons is compensated by the sagging plastic being carried around to the upper side of the core rod. The chain 74 is driven at the speed necessary to eliminate sagging, and this speed depends upon the kind of material used for the parison but can be easily adjusted by watching the parisons as the machine operates and by determining the uniformity of the side walls of the containers that are blown at the blow station 14.
The parisons at the treating station 12 are cooled to a temperature which will result in the parisons being at orientation temperature at the time that the blowing operation is begun at the blow station 14. Some little additional heat is lost as the core rods and their parisons move from the treating station 12 to the blow station 14. The cooling time at the treating station 12 should be synchronized with the injection cycle in the mold 32, and the amount of cooling in the chambers 52 (FIG. 4) can be regulated to some extent by the temperature of the air supplied to the blower 64 and by the quantity of air passing through the chambers 52 which is in turn regulated by increasing or decreasing the speed of the motor 66. However, the velocity of air through the chambers 52 must be kept at a moderate value so that it does not move the molten material of the parison 56 axially along the parison away from the midpoint of the parison where the air conduit 58 introduces the air into the chamber 52.
The rate at which the sprocket wheels 70 rotate the core rods 18 is regulated by a motor and gear train 90 which has a speed controller 92 for increasing or decreasing the speed of the driving sprocket 76 at the end of the drive shaft 78.
Core rods with internal cooling are well known and such core rods can be used with the present invention in combination with the treating station 12 so that the parison can be cooled more uniformly, to orientation temperature, by withdrawing heat from both the outside and inside surfaces of the parison simultaneously.
The preferred embodiment of the invention has been illustrated and described, but changes and modifications can be made and some features can be used in different combinations without departing from the invention as defined in the claims. | This blow molding machine overcomes the tendency of the parison to sag toward the bottom side of the core or for air currents to unevenly cool the parison, while at the same time allowing the parison to be cooled from the core side and then outside to the desirable orienting temperature, so that at the subsequent blow, or stretch-blow station, a bi-axially oriented container is produced having uniform wall distribution. As a means of intensifying the cooling on the outside, in order to speed up the operation, provisions are made to enclose the parison with an open end cylinder having means of introducing a flow of air in a tangential manner so that it circulates around the parison as the parison is rotated. | 1 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to an apparatus for soaking and cleaning articles with a cleaning solution, and more particularly, to an immersion washer apparatus having means for removing and disposing of contaminants and refuse during a recycling and solution recovery process.
2. Description of the Related Art
During maintenance, repair and rebuilding operations in virtually all industrial and commercial environments, it is necessary to wash a wide variety of parts and articles in order to remove grease, oil, dirt and other contaminants. To remove contaminants, various solvents and aqueous cleaning solutions are used in a variety of cleaning machines and assemblies. Some parts and articles are cleaned in spray washer machines of the type set forth in my previous U.S. Pat. No. 5,277,208. Still other parts, particularly smaller parts, are washed using a solvent in a sink type apparatus, of the type set forth in my previous U.S. Pat. No. 5,349,974. There are however many parts, articles and devices which need to be immersed and soaked in a cleaning solution, particularly those having blind holes and crevices which are difficult to clean. Examples of these types of articles include radiators, engine blocks and transmissions. Presently, these types of articles, comprising blind holes and crevices, are soaked in a tank containing cleaning solution for a period of time. The articles are then removed from the tank and brushed and rinsed to remove loose contaminants such as grease, oil, rust and dirt. In a short period of time, after soaking several articles, it can be appreciated that the cleaning solution becomes saturated with contaminants. Eventually, the entire charge of cleaning solution in the tank needs to be disposed of and replaced with clean solution. In a busy facility, this may need to be done one or more times a week. When changing the cleaning solution, the contaminated solution must be taken away and disposed of in a manner complying with EPA contaminant disposal guidelines. This procedure is inefficient, costly and time consuming, leaving a busy manufacturing or repair facility with no other alternative than to perform parts cleaning operations using dirty, contaminated cleaning solution for extended periods of time.
Accordingly, there is a definite need in all industries requiring parts cleaning during maintenance, manufacturing, repair and rebuilding operations, for an immersion washer apparatus having means for recycling the cleaning solution by regularly removing contaminants from the solution and disposing of contaminants and refuse on site during normal operation of the apparatus and in a manner complying with EPA disposal guidelines.
SUMMARY OF THE INVENTION
The present invention is directed to an immersion washer apparatus for washing articles such as radiators, engine blocks, transmissions and virtually any articles, particularly those having blind holes and crevices.
More particularly, the present invention includes a primary cleaning chamber for containing a predetermined charge of aqueous cleaning solution therein. During normal operations, a pump draws the cleaning solution from a bottom sweep in the cleaning chamber and delivers the cleaning solution to a drainage trough having a filtration sheet pulled thereacross. The cleaning solution is deposited on the filtration sheet and, upon passing therethrough, contaminants are removed from the solution. A sensor activates movement and replacement of saturated sections of the filtration sheet upon detecting a raise of fluid level in the drainage trough due to an inability of the solution to easily pass through the saturated filtration sheet.
An electronic or gas heater supplies heat to an oxidation chamber for thermal oxidation of refuse placed therein, including the used saturated filtration sheet sections. The hot flue gasses resulting from the thermal oxidation process are directed through a heat transfer duct which at least partially surrounds the primary cleaning chamber. Heat is transferred to the solution in the cleaning chamber as the hot flue gasses pass through the heat transfer duct and exit through a flue stack.
An article support assembly includes a platform for supporting the articles to be cleaned thereon, the platform being movable between a raised position and a lowered position within the cleaning chamber to facilitate immersion of the articles in the cleaning solution. The platform and articles thereon can be agitated to cause movement of the articles relative to the solution and thereby promoting more thorough cleaning of the articles.
Many aqueous cleaning solutions employ the use of coagulants or flocculants to gather and clump contaminants such as oils and grease into clusters which are then more easily separable from the cleaning solution. Some coagulants and flocculants act near the surface of the aqueous solution for lighter contaminants, while others act near the bottom to clump together heavier contaminants. Because coagulant and flocculant agents are generally somewhat delicate by nature, they cannot be passed through pumps, such as centrifugal pumps, because the violent turbulence will cause breakup of the charges in the agents. To address this concern, the present invention employs the use of a vacuum chamber which is specifically designed to draw both surface coagulants and flocculants as well as bottom coagulants and flocculants from the primary cleaning chamber without disturbing the charges in the various agents. From the vacuum chamber, the coagulant and/or flocculant agents are lead through a transfer conduit and deposited onto the filtration sheet in the drainage trough.
During normal operations, the cleaning solution is drawn through a sweep arm which rotates about a 360 degree movement on the extreme bottom of the cleaning chamber. In order to move contaminants which have settled on the bottom into the sweep zone of the sweep arm for pickup, the present invention further employs the use of a bottom wash system which includes a three-way valve for redirecting the discharge from the pump. Rather than the discharge being directed to the drainage trough for filtering, the three-way valve facilitates directing of the discharge of solution from the pump to bottom flush jets which wash the bottom and push bottom contaminants into the sweep zone of the bottom sweep, and thus, together with the sweep arm, achieving complete cleaning and removal of contaminants from the bottom of the cleaning chamber.
Accordingly, with the foregoing in mind it is a primary object of the present invention to provide an immersion washer apparatus for use in cleaning various articles during maintenance, repair and rebuilding operations, and particularly articles having blind holes and crevices, wherein the apparatus includes means for recovering and recycling of aqueous cleaning solution used therein, removing contaminants therefrom and providing on-site disposal means for disposing of the contaminants and refuse.
It is another object of the present invention to provide an immersion washer apparatus, as described above, which provides a practical and economical means of complying with Environment Protection Agency contaminate disposal guidelines.
It is a further object of the present invention to provide an immersion washer apparatus providing means for regularly and constantly removing contaminants from the cleaning solution during operation thereof, and further providing self-contained means for disposal of contaminants and refuse in a manner which complies which EPA disposal guidelines.
It is still a further object of the present invention to provide an immersion washer apparatus which eliminates the need to regularly dispose of large volumes of contaminated cleaning solution.
It is yet another object of the present invention to provide an immersion washer apparatus which is relatively inexpensive and requires minimal maintenance.
It is still a further object of the present invention to provide an immersion washer apparatus which complies with all government imposed safety requirements.
It is still a further object of the present invention to provide an immersion washer apparatus which employs several means of removing and disposing of contaminants during normal operation thereof.
These and other objects and advantages of the present invention will be more readily apparent in the description which follows.
BRIEF DESCRIPTION OF THE DRAWINGS
For a fuller understanding of the nature of the present invention, reference should be had to the following detailed description taken in connection with the accompanying drawings in which:
FIG. 1 is a front, top perspective view of the immersion washer apparatus of the present invention;
FIG. 2 is a front elevation, in partial section, of the immersion washer apparatus;
FIG. 3 is an isolated view, shown in perspective, of an article support assembly of the present invention;
FIG. 4 is a partially exploded and isolated view, shown in perspective, of a pump and bottom wash system of the present invention; and
FIG. 5 is an isolated view, shown in perspective, of an oxidation chamber and cleaning solution purification assembly of the washer apparatus of the present invention.
Like reference numerals refer to like parts throughout the several views of the drawings.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to the several views of the drawings and initially FIGS. 1 and 2, there is generally illustrated the immersion washer apparatus 10 of the present invention. The apparatus 10 includes a primary cleaning chamber 12 surrounded by front, rear and opposite side walls and a bottom floor 13. The primary cleaning chamber 12 may further include a lid 14 for covering an open top thereof. The cleaning chamber 12 is specifically sized and configured to contain a predetermined quantity of cleaning solution, preferably an aqueous cleaning solution, for immersing articles to be cleaned therein.
A filter means 20 is provided for removing contaminants from the cleaning solution and includes a filtration sheet 22 which is pulled from a supply source 24, such as a roll. The filtration sheet extends from the supply source 24 across a drainage trough 23, wherein cleaning solution deposited on the filtration sheet is caused to be transferred through the filtration sheet 22 and removing contaminants in the process. A fluid level sensor 26 in the drainage trough 23 senses when the cleaning solution in the trough 23 reaches a predetermined level due to saturation of the filtration sheet 22 with contaminants, and thus impeding passage of the cleaning solution through the filtration sheet. Upon sensing the cleaning solution reaching a predetermined level, the fluid level sensor 26 activates a roller motor 28 causing rollers 29 to be rotated and thus pulling the filtration sheet 22 from the supply source 24 so that the saturated portion of the filtration sheet is removed from the trough 23 and a clean section of filtration sheet is positioned in the trough 23.
Referring to FIGS. 1, 2 and 4, there is illustrated pump means 30 for transferring the cleaning solution from the primary cleaning chamber to the drainage trough 23 for discharge on the filtration sheet 22. Once having passed through the filtration sheet 22, the cleaning solution returns to the primary cleaning chamber 12. In accordance with a preferred embodiment, the pump means 30 includes pump motor 31 and centrifugal pump 32. An intake line 34 extends from a lower channel 35, below the cleaning chamber bottom floor 13, in fluid flow communication therewith. An opposite end of the input line 34 leads to the intake of centrifugal pump 32. An output line 36 extends from an output of centrifugal pump 32 to a three-way valve 38. The three-way valve 38 is specifically structured to control direction of fluid flow from the output line 36 to either a filter delivery line 40 leading to the drainage trough 23 or, alternatively, to a bottom wash return line 42 leading to a bottom wash jet assembly 44 on the bottom floor 13 of the primary wash chamber 12. The bottom wash jet assembly 44 includes opposite jet wash channels 46, 46' positioned and disposed on opposite sides of the wash chamber floor 13 as best seen in FIG. 2. Referring now to FIG. 4, the opposite jet wash channels 46, 46' are interconnected in fluid communication with one another and the return line 42 by a channel 48. The opposite jet wash channels 46, 46' include openings 47 along an inboard lower edge 49, forming an opening between the lower inboard edge 49 and the bottom floor 13 for discharge of the cleaning solution across the bottom floor 13 of the wash chamber 12. Accordingly, operation of the three-way valve 38 by movement of level 39 serves to selectively direct flow of the cleaning solution from the pump 32 to either the filter means 20 or to the bottom jet wash assembly 44. This serves to wash the bottom floor 13 of accumulated sediment, forcing the bottom sediment (contaminants) into a central sweep zone defined by a circumferential area through which a bottom sweep arm 50 rotates. The bottom sweep arm 50 is disposed in fluid flow communication with the lower channel 35 and, preferably includes opposite arm portions 51, 51'. Each of the arm portions 51, 51' includes fluid intake means (such as apertures) on a lower portion thereof for intake of the cleaning solution and bottom sediment therethrough for subsequent transfer through the bottom channel 35, and to intake line 34, when the pump means 30 is activated, as illustrated by the arrows in FIG. 2.
With reference to FIGS. 2 and 3, there is generally illustrated article support means 60 for supporting articles to be cleaned in the primary cleaning chamber 12. The article support means 60 includes a platform 62 having a back plate 63 and support base 64 preferably comprised of a metal grate. The support base 64 is specifically positioned and disposed to support the articles to be cleaned thereon, the platform 62 being sized and configured to be lowered down into an interior of the primary cleaning chamber 12, so that the articles can by completely immersed in the cleaning solution. To facilitate raising and lowering of the platform 62, a lead screw 66 extends vertically from a motor 67 above the cleaning chamber 12 and terminating at or near the bottom floor 13. A ball screw or like coupling 65 is movably engaged on the lead screw 66, such that upon selective rotation of the lead screw 66, clockwise or counterclockwise, by motor 67, the ball screw coupling 65 is caused to be moved up and down along the length of the lead screw 66. The ball screw coupling 65 is attached to a back of the plate 63 of the platform 62, so that upon rotation of lead screw 66 the platform 62 is caused to be selectively raised or lowered within the cleaning chamber 12. Guide rollers 68 attached to the back plate 63 ride within a guide channel 69 to stabilize vertical movement of the platform 62 during raising and lowering.
The platform 62, and articles supported thereon, can be agitated by various means in order to cause movement of the cleaning solution relative to surfaces and crevices of the articles, thereby promoting washing by loosening and/or removing contaminants therefrom. In a preferred embodiment, the platform 62 is agitated by quick start and stopping of the motor 67, causing the platform to be raised and then lowered a short distance near a lower portion of the cleaning chamber 12.
Heating means 80 are provided for supplying heat to a thermal oxidation chamber 84 at temperatures preferably in excess of 1,500 degrees fahrenheit. In a preferred embodiment, the heating means 80 includes a fan forced electronic heater 82 interconnected to an open port 83 leading to the thermal oxidation chamber 84, whereupon heat is force fed therein, as indicated by the arrows in FIG. 5. Other heat generating means, such as a gas heater, could be used. The thermal oxidation chamber 84 is specifically sized and configured to receive refuse, including contaminated filtration sheets from the filter means 20 therein. A tray for holding the filtration sheets and other refuse can be used in order to promote thermal oxidation by heat convection, whereupon the refuse disintegrates slowly at high temperatures emitting close to zero harmful emissions. A cleaning solution burn-off assembly 86 includes a valve 87 controlled by solenoid 88. A fluid transfer line 89 extends from the cleaning chamber 12 to the valve 87, which is normally closed when the burner 82 is not operating. Upon operation of the burner 82 for a predetermined period of time, a heat sensor 90 attached to the burner 82 senses that the heater 82 is operating and triggers the solenoid 88 which opens the valve 87. When the valve 87 is open, cleaning solution, containing contaminants, is released through the delivery line 91 leading to the interior of the thermal oxidation chamber 84. An orifice 92 can be provided in the delivery line 91 to achieve a controlled release of cleaning solution into the thermal oxidation chamber 84. As the cleaning solution is deposited in the thermal oxidation chamber 84, the high temperatures cause the liquid to immediately vaporize, whereupon metal deposits and other contaminant solids are deposited in a tray 93 in the thermal oxidation chamber 84. Thus, an additional means of removing contaminants from the cleaning solution and disposing of the contaminants in a environmentally sound manner is provided. Between the filter means 20 and the cleaning solution burnoff assembly 86, a substantial amount of contaminants are regularly removed and disposed of during normal operation. Water, cleaning detergents and various coagulant agents would be added as needed to maintain predetermined control standards and fluid level in the cleaning chamber 12.
Referring to FIG. 2, there is shown a heat transfer duct 96 which interconnects with the thermal oxidation chamber 84 to receive hot flue gases generated therein during thermal oxidation or from just the continuous operation of heater 82. The heat transfer duct 96 passes through the cleaning chamber 12 interior, along a side and the back thereof, and interconnecting with a flue gas exhaust stack 98 through which flue gases are exhausted to atmosphere. Heat from the hot flue gases passing through the duct 96 is transferred to the cleaning solution surrounding the portion of the duct 96 within the cleaning chamber 12.
In order to remove coagulants and flocculants from the cleaning solution in the cleaning chamber 12, while preventing breakup of the charges in the coagulant/flocculant agents, a vacuum chamber 100 is provided to draw both surface coagulants/flocculants as well a bottom coagulants/flocculants from the cleaning chamber 12 in a non-turbulent manner. To achieve negative pressure in the vacuum chamber 100, a vacuum pump 102 is used, interconnecting to the chamber 100 and structured to draw air therefrom. A bottom suction conduit 104 includes an upper end located within the interior of the vacuum chamber 100 and an opposite lower end disposed in fluid communication within the channel 35 below the cleaning chamber 12. A second upper level suction conduit 106 includes an upper end within the interior of the vacuum chamber and a lower end within the upper interior portion of the cleaning chamber 12. A filter 107 may be provided on the lower end of the conduit 106 to prevent intake of large particles. A delivery conduit 108 has a first end disposed at a lower portion of the vacuum chamber 100 interior and an opposite end leading to the drainage trough 23. The upper ends of each of the respective conduits 104, 106, 108 (within the vacuum chamber 100) are normally closed by individual valve members 110 disposed in blocking engagement on the open top ends of the conduit 104, 106 and 108. The valve members 110 are each independently interconnected with respective linkages 112 leading to corresponding actuators 114 on a top of the vacuum chamber 100. The actuators 114 are each structured to move the respective linkage 112, on demand, to raise and lower the respective valve member 110 into and out of blocking engagement on the open end of the conduits 104, 106 and 108. In this manner, with a negative pressure in the vacuum chamber 100 creating a suction, release of the valve members 110 on the bottom and upper level suction conduits 104, 106 will serve to selectively draw cleaning solution and coagulants/flocculants from either the bottom or surface of the cleaning solution in the cleaning chamber 12. Upon returning to atmospheric pressure in the vacuum chamber 100, the collected cleaning solution and coagulants/flocculants therein can be released through the delivery conduit 108 by raising the respective valve member 110 on the open end thereof. The collected cleaning solution and coagulants are thereafter lead through the delivery conduit 108 and deposited on the filtration sheet 22.
Control means 120 are provided on a control console 122 for facilitating selective control of the movement of the platform between the raised and lowered positions, as well as agitation of the platform. Further, the control means 120 facilitates control of the vacuum chamber 100, including selective control of each of the actuators 114 and the vacuum pump 102. Finally, the control means 120 enables actuation of the pump means 30 and heater 82 during normal start-up operation.
While the invention has been shown and described in what is considered to be a pratical and preferred embodiment, it is recognized that departures may be made within the spirit and scope of the following claims which, therefore, should not be limited except within the Doctrine of Equivalents.
Now that the invention has been described, | An apparatus for soaking and cleaning articles in a cleaning solution includes a primary cleaning chamber for containing a predetermined volume of the cleaning solution therein and a filter assembly including a filtration sheet pulled from a supply across a drainage trough for removing contaminants from the cleaning solution. A sensor activates movement and replacement of saturated sections of the filtration sheet upon detecting a rise of fluid level in the drainage trough. A fan forced electronic heater supplies heat to an oxidation chamber for thermal oxidation of refuse placed therein, the resulting flue gasses being directed through a heat transfer duct, wherein heat is transferred to the solution contained in the cleaning chamber; the flue gasses exiting through a flue stack. An article support assembly includes a platform for supporting the articles to be cleaned thereon, the platform being movable between a raised position and a lowered position within the cleaning chamber to facilitate immersion of the articles in the cleaning solution. The platform and articles thereon can be agitated to cause movement relative to the cleaning solution and thereby promoting more thorough cleaning. | 1 |
FIELD OF THE INVENTION
The present invention relates generally to the dispensing of viscous food products and, more particularly, to the use of a rotatable discharge assistant operative to dispense, from a container such as a squeeze bottle, a viscous food product along an arcuate path.
BACKGROUND OF THE INVENTION
Squeeze bottles for storing and dispensing viscous, flowable food products such as syrups, jellies, and condiments are well known. Generally, such bottles include a container made of a plastic or other easily deformable material and define an interior cavity for receiving and storing the food product. The container may further define a neck portion disposed at one end of the container that is attached to a dispensing closure assembly. A typical dispensing closure assembly includes a cap that is threadedly connected to the neck of the container at one end, and has a single outlet tip that faces outwardly from the container at the other end. During use, the container is inverted and squeezed to dispense the viscous food product from the tip orifice onto a target food item as a directed stream.
Conventional dispensing closures define an orifice having a circular cross section sized to provide the user with flexibility to apply a desired amount of product to the target food item. A softer squeezing of the container will yield a lower mass flow rate out of the tip. Accordingly, in order to accommodate those who wish to apply only a small amount of condiment to the food product, the tips are generally designed with a small cross section. Those who desire an additional amount of condiment can squeeze harder and, typically, make several passes at the food product. This can be a time consuming and often messy procedure. Further, one squeeze may not provide a sufficient amount of pressure to dispense condiment over the length of time necessary to conduct several passes, thereby necessitating multiple squeezes and a resulting non-uniform volume of dispensed condiment across the food product.
There is a need for a discharge assistant usable in combination with a conventional container that enables one to apply a sufficient and consistent amount of an edible viscous food product, such as a condiment, to a target food item.
SUMMARY OF THE INVENTION
The aforementioned need is addressed, and an advance is made in the art, by a dispensing system configured to dispense a viscous, flowable food product such, for example, as a condiment. The dispensing system comprises an axially extending container that defines an opening and an interior chamber for receiving and storing the food product. A discharge assembly is coupled to the container, the discharge assembly being dimensioned and arranged to spin, relative to the container, as it receives the viscous food product from the interior chamber. The spinning motion of the discharge assembly, accompanied by a linear movement of the container itself relative to a target food item, allows the user to cleanly and evenly distribute the flowable food material onto the target item in an attractive, helical (or more broadly speaking, curvilinear) deposit pattern.
An illustrative embodiment of the discharge assembly includes a first section defining an interior cavity, the first section also defining both an inlet opening dimensioned and arranged to establish fluid communication between the interior cavity and the interior chamber, and an outlet opening dimensioned and arranged to allow food product flowing under pressure to exit the interior cavity as a stream as said first section spins.
A typical configuration for a dispensing system constructed in accordance with the present invention employs a squeeze bottle as the container, wherein squeezing the deformable sidewall of the container causes the food material to flow from the interior chamber into the interior cavity of the discharge assembly. In accordance with an especially preferred embodiment of the invention, the same squeezing force which causes the edible material to flow is also used to produce rotary motion of the discharge assembly. To this end, the discharge assembly may include a plurality of vanes disposed within the interior cavity, the vanes being dimensioned and arranged to convert energy imparted by flowing food product impinging thereon into forces driving rotary motion of the discharge assembly.
The discharge assembly may be further configured with a pivotably movable nozzle member having a distal section defining a nozzle orifice and having a substantially spherical proximal section retained in fluid communication with the outlet opening, whereby a user can control at least one of a diameter and a pitch of said helical deposit pattern by selecting an appropriate angular position of the nozzle member. The location of the nozzle member may be offset relative to a central axis of rotation of the discharge assembly. Alternatively, the nozzle member may be positioned coaxially with the central axis of rotation, the latter configuration having the advantage of permitting the user to select between an angled orientation suited for producing helical deposit patterns on a target food item and a non-pivoted orientation which enables the consumer to direct the flow along a rectilinear deposit path.
BRIEF DESCRIPTION OF THE DRAWINGS
The details of the present invention, both as to its construction and operation can best be understood with reference to the accompanying drawings, in which like numerals refer to like parts, and in which:
FIG. 1 is a side elevation view depicting a viscous edible food material dispensing system in accordance with an illustrative squeeze bottle embodiment of the present invention, the system being equipped with a discharge assembly adapted to rotate automatically, as the edible material is discharged, to produce a helical deposit pattern;
FIG. 2 is a partial, side elevation view, in cross section, depicting the internal construction of an illustrative embodiment of a rotatable discharge assembly;
FIG. 3A is broken apart, perspective view depicting the internal construction of an exemplary, rotating discharge assembly for use in realizing the illustrative embodiment of FIG. 2 ; and
FIG. 3B is a perspective view depicting final assembly of the exemplary rotating nozzle assembly of FIG. 3A ;
DETAILED DESCRIPTION OF THE INVENTION
The accompanying Figures and this description depict and describe embodiments of a discharge assistant adapted for use with a conventional container in accordance with the present invention, and features and components thereof. The present invention also encompasses a method of making and using embodiments of the discharge assistant. As used herein, the phrases or terms “discharge assistant,” “dispensing closure assembly,” “discharge assembly” and the like are intended to encompass a structure or structures configured to dispense an edible, viscous material such, for example, as a condiment like ketchup or mustard, onto a target food item in a manner other than as a continuous rectilinear (“straight-line”) deposit pattern or as a series of brief rectilinear pulses. It is important to note, however, that viscous food product dispensing systems in accordance with the present invention can, if an optional mode of operation is desired, be configured to dispense product in a continuous or broken rectilinear deposit pattern if the consumer so selects. It should also be noted that any references herein to front and back, right and left, top and bottom and upper and lower are intended for convenience of description, not to limit the present invention or its components to any one positional or spacial orientation.
With regard to fastening, mounting, attaching or connecting components of the present invention to form the dispensing system as a whole, unless specifically described otherwise, such are intended to encompass conventional fasteners such as threaded connectors, snap rings, detent arrangements, pins and the like. Components may also be connected by adhesives, glues, welding, ultrasonic welding, and friction fitting or deformation, if appropriate, and appropriate liquid and/or airtight seals or sealing devices may be used. Electronic portions of the device may use conventional, commercially available electronic components, connectors and devices such as suitable wiring, connectors, printed circuit boards, microchips, pressure sensors, liquid level sensors, inputs, outputs and the like. Unless specifically otherwise disclosed or taught, materials for making components of the present invention may be selected from appropriate materials such as metal, metallic alloys, natural and man-made fibers, vinyls, plastics and the like, and appropriate manufacturing or production methods including casting, pressing, extruding, molding and machining may be used.
With regard to the manner in which viscous food material is urged to flow toward a discharge opening, it should be borne in mind that although the various embodiments described herein incorporate a squeeze bottle configuration in which material flows when a deformable sidewall of a flexible container is squeezed, the invention is not limited to such configurations. For example, rigid container in conjunction with a motorized or manual pump mechanism may be used. It suffices to say that the manner in which forces for causing the edible product to be ejected from the container is of no particular consequence to the inventor herein except insofar as manufacturing cost, simplicity and ease of use are always considerations to be borne in mind.
Turning now to FIG. 1 , an illustrative embodiment of a viscous food dispensing system 10 in accordance with the present invention is depicted. The depicted squeeze bottle embodiment includes an axially extending container 12 having an elongated cylindrical side wall 14 extending axially along axis of extension A—A. A base 16 is disposed at the one axial end of the side wall 14 that seals the bottom of the container 12 . A neck 28 ( FIG. 2 ) is integrally connected to the axially upper end of the container 12 , and is defined by a reduced diameter compared to that of side wall 14 . Neck 28 includes a threaded outer surface 29 ( FIG. 2 ). An internal void or chamber 22 is thus collectively defined by side wall 14 and base 16 for housing a volume of flowable liquid material. Examples of such flowable liquid material include condiments such as ketchup, mustard, mayonnaise, relish, or the like that may be poured into the neck 28 of container 12 .
Container 12 can be made of a transparent or translucent plastic such as polypropylene or polyethylene to enable the user to gauge the amount and type of material in the container to determine when the container 12 is to be refilled (or discarded, as the case may be). Alternatively, the plastic may be color coded to identify the type of material. The plastic is also preferably resilient so as to enable the user to squeeze the container 12 and thus provide an internal pressure suitable to force a directed stream of material out of the container and towards a desired food product. As noted previously, it should be understood that other means for urging the food material toward a discharge opening may be employed.
With reference to both FIGS. 1 and 2 , it will be seen that a discharge assembly 30 is removably connected to the neck 28 , and includes a first section indicated generally at 32 , and a second section indicated generally at 34 . Second section 34 is adapted for fixed connection to container 12 and, to that end, includes a cylindrical flange 36 that extends axially inwardly from the radially outer edge of a substantially radially extending plate 38 . The inner surface 42 of flange 36 is threaded and is configured to be removably connected to the container 12 by the threaded outer surface of neck 28 once the container 12 has been filled with the desired material. The outer surface 43 of flange 36 is preferably textured to enable a user to easily grip discharge assembly 30 for attaching the same to, and removing the same from, container 12 . As best seen in FIG. 2 , second section further includes a first conduit assembly indicated generally at reference number 46 . The axially upper surface 47 of first conduit assembly 46 is seated on the axially lower surface of plate 38 and defines a central flow conduit 48 dimensioned and arranged to receive and transport the flowable liquid material into the first section 32 , as will now be described in greater detail.
Unlike second section 34 , which is adapted to be secured to container 12 , first section 32 of discharge assembly 30 is dimensioned and arranged to rotate relative to container 12 . Automatic rotation of discharge assembly section 32 to produce a helical deposit effect can be achieved in a variety of ways. By way of illustrative example, an illustrative discharge assembly constructed in accordance with motorized embodiments of the invention may include a motorized drive assembly (not shown) responsive to depression of a trigger or, alternatively, to actuation of an on/off selector switch, and drivingly engageable with appropriate gearing coupled to first section 32
In accordance with an especially preferred embodiment of the present invention, however, the force for spinning section 32 of discharge assembly 30 is provided via the pressurized material traversing flow conduit 48 . An exemplary structure adapted to utilize this force is depicted in FIGS. 2–3B and will now be described in detail. As seen in FIG. 2 , first section 32 of discharge assembly 30 comprises a first half 56 and a second half 58 which, when assembled into the configuration shown in FIGS. 3A and 3B , define an interior cavity 50 ( FIGS. 2 and 4 ) within which is disposed a flow diverter assembly indicated generally at 52 .
With reference to both FIGS. 2 and 3A , it will be seen that flow diverter assembly 52 has a proximal end 60 dimensioned and arranged to be received and retained within conduit 48 of first conduit assembly. First conduit assembly 46 and flow diverter assembly 52 are fastened together in a conventional manner such, for example, as by a suitable adhesive. Accordingly, fluid diverter assembly 52 is not a moving part but, rather, is stationary despite being disposed within interior cavity 50 . Fluid material exiting the discharge orifice 48 of first conduit assembly 46 enters an inlet 68 ( FIG. 3A ) defined at the proximal end 60 of flow diverter assembly 52 . The center of first section 56 defines an axial opening 57 through which proximal end 60 is inserted. To prevent fluid material from leaking out of interior cavity 50 , O-rings or other suitable gaskets may be utilized in a conventional manner at the interface between moving parts and bushings may be incorporated as required to prevent axial movement of rotatable first section 32 relative to the fixed section 34 of discharge assembly 30 .
In any event, and with particular reference to FIG. 3A , it will be seen that defined within the interior axial surface 59 of second half 58 are a plurality of vanes 70 . As best seen in FIG. 2 , liquid entering inlet opening 68 of flow diverter assembly 52 exits via a pair of exit openings indicated generally at 72 and 74 . As will be readily appreciated by those skilled in the art, exit opening 72 and 74 are dimensioned and arranged so as to cause corresponding jets of liquid to impinge upon the surfaces of vanes 70 , thereby initiating rotation of first section 32 .
With particular reference to FIG. 3B , it will be seen that spinning of first section 32 in the direction of arrow R and about a rotational axis parallel to axis A—A of container 12 ( FIG. 1 ), enables the contents of container 12 to be deposited along a helical deposit path. As used herein, the phrase helical deposit path is intended to refer to any path having a curvilinear component which is transverse to the direction in which the container, as container 12 , is moved. An illustrative deposit pattern is indicated generally at P in FIG. 3B .
In any event, and with continued reference to FIGS. 1–3B , it will seen that discharge assembly 30 further includes a pivotably movable nozzle member 80 having a distal section defining a nozzle orifice 82 and having a substantially spherical proximal section 84 retained in fluid communication with interior cavity 50 of first section 32 . Such a structure is advantageous in that it gives the user a high degree of flexibility and creativity. As will be readily appreciated by those skilled in the art, the closer the nozzle tip is to the center of rotation, the smaller the arc covered during each period of rotation. Of course, if such flexibility is not a design constraint, then it is of course possible to integrally form a nozzle member directly as part of second section 32 . In that regard, it is contemplated that a nozzle member so constructed may be configured to extend forward at any desired angle relative to the axis of rotation of rotatable discharge assembly 30 . It is further contemplated that multiple nozzle members may be included so as to cause to simultaneous streams to be helically wound about the axis of nozzle assembly rotation.
Finally, although the nozzle member 80 depicted in the illustrative embodiment is shown in a position that is offset relative to the axis of rotation of first section 32 , it should be emphasized that by placing the nozzle member 80 at the center of rotation would allow a dual mode of dispensing. That is, by aligning the discharge opening 82 so that it is coaxial with the axis or rotation (axis A—A in FIG. 1 ), it is possible to obtain a rectilinear mode of operation in which linear movement of the system 10 yields a hall rectilinear deposit path notwithstanding rotation of first section 32 . Conversely, pivoting nozzle member out of axial alignment with the rotational axis of first section 32 will produce the helical/curvilinear deposit path as previously described.
From the foregoing, it will be understood that when the user inverts the container 12 containing a flowable liquid material and directs the nozzle 80 at a food product and applies a squeezing pressure to container 12 , the material will be forced through outlet channel 82 and dispensed as a spiral or straight line stream.
While the particular food product dispensing system and methods as herein shown and described in detail are fully capable of attaining the above-described objects of the invention, it is to be understood that they are merely illustrative embodiments of the present invention and are thus merely representative of the subject matter which is broadly contemplated by the present invention, that the scope of the present invention fully encompasses other embodiments which may become obvious to those skilled in the art, and that the scope of the present invention is accordingly to be limited by nothing other than the appended claims. | A dispensing system for dispensing a viscous, flowable food product such, for example, as a condiment, comprises an axially extending container that defines an opening and an interior chamber for receiving and storing the food product. A discharge assembly is coupled to the container, the discharge assembly being dimensioned and arranged to spin, relative to the container, as it receives the viscous food product from the interior chamber. The spinning motion of the discharge assembly, accompanied by a linear movement of the container itself relative to a target food item, allows the user to cleanly and evenly distribute the flowable food material onto the target item in an attractive, curvilinear deposit pattern. Optionally, the discharge assembly may be configured with a pivoting nozzle that can be moved from a position for obtaining a helical (curvilinear) deposit pattern to a position for obtaining a rectilinear deposit pattern. | 1 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to the field of treating biomass to enhance its value or rank. More particularly, the invention concerns a process for the treatment of biomass, especially coal, to efficiently convert the selected feed stock from low rank into a high grade fuel capable of increased heat release per unit of fuel. This is accomplished in part by driving off most on the moisture trapped in low grade coal. The process simultaneously scrubs the coal of pollutants or impurities, many of which are organic volatiles, which are also referred to as by-products.
[0003] These by-products are largely combustible and can provide the heat energy required to operate the inventive process after start up in a manner similar to that of a petroleum refinery refining crude oil to produce clean fuels. The removed by-products are recycled into products such as roofing tar, and chemical feed stocks. The organic volatiles are light hydrocarbons that can be used as gaseous fuels, first to power the process after startup, with the remaining organic volatiles being separately processed for other applications. The process further renders the coal into a low smoke generating fuel to make its use more acceptable for domestic purposes such as cooking and home heating. Finally, the inventive process reduces the weight of the coal, which reduces the cost to transport the treated coal to the location where it is burned as fuel.
[0004] The process is an energy conservation measure on several different levels. The process increases rank of the coal making it a more effective fuel, removes moisture, uses the by-products removed from the feed stock to power the inventive process, produces treated by-products for other applications such as gaseous fuels that contain more useful energy, and reduces the weight of the coal to reduce energy consumption in transporting the coal to its combustion site. The process also recycles heat to further lower fuel consumption in operating the process. The inventive process is principally designed for use with sub-bituminous and lignitic coal, but it is equally applicable to biomass such as wood waste, shells, husks, and other combustible material of organic origin.
[0005] 2. Description of the Prior Art
[0006] Biomass is one of the largest and most readily available energy sources known to man. Biomass is found in immature forms, such as wood, shells, husks and peat. Vast amounts of biomass are also available in the form of lignite, sub-bituminous, bituminous and anthracite coal. Man has been releasing the energy trapped in these materials ever since he discovered and was able to control fire. The inefficient release of these vast energy reserves, however, has resulted in a degradation of the quality of the atmosphere and the environment, and some believe it contributes significantly to global warming. The increasing demand for energy, created by man's insatiable appetite for the products made available by an industrialized society, have created a need to release this energy in a safe, clean and environmentally responsible manner.
[0007] It is known to treat coal with the application of heat in a controlled environment to increase its rank. The present invention is actually a significant improvement over Hunt, U.S. Pat. No. 6,447,559. Hunt teaches treating coal in an inert atmosphere to increase its rank. In the preent invention, coal is first heated to a temperature of 400° F. in an inert atmosphere to produce coal having only 2-5% moisture, then heated in an inert atmosphere to 1500° F. to produce coal having only 1-2% moisture and a mass reduction of up to 30%, to produce coal having less than 2% moisture and a volatiles content of less than 25%, then cooling the coal in an oxygen-free and dry atmosphere, and finally collecting it.
[0008] The prior art preceding Hunt had recognized that heating coal removes moisture and enhances the rank and BTU content of the coal. It was also previously recognized that this pyrolysis activity altered the complex hydrocarbons present in coal to a simpler set of hydrocarbons. This molecular transformation resulted in a more readily combustible coal, but an unstable product. The prior processes took several hours to complete, which made them slow and costly in both capitalization and productions costs. Hunt greatly shortened the processing time of the prior art preceding Hunt.
[0009] But Hunt does not recognize either the use of by-products to power the process, or the ability to “farm” a great number of by-products for constructive use outside of the process. Hunt is also a horizontal process, while the present invention is a vertical process that can take advantage at certain points of gravity is moving the coal from one zone to another. Energy conservation is achieved by the present process on multiple levels, and environmental conservation is achieved both in the process facility and by the cleaner burning coal after being processed.
SUMMARY OF THE INVENTION
[0010] Bearing in mind the foregoing, a principal object of the present invention is to improve upon prior art coal upgrading processes that utilize heat and pressure to remove moisture and volatile matter from coal by minimizing the creation of unstable products that are prone to moisture re-absorption, size degradation, and spontaneous combustion.
[0011] Another principal object of the present invention is to improve the rank of low grade coal by converting it into a high grade fuel capable of increased heat release per unit of fuel and doing so with the by-products of the process such as organic volatiles that are light hydrocarbons that are fuel to power the process after startup.
[0012] Another object of the present invention is to improve the rank of low grade coal using a process that is energy conserving on several levels, i.e., the increased rank of the coal makes it a more effective fuel, removes moisture, uses the by-products removed from the feed stock to power the inventive process, produces treated by-products for other applications such as gaseous fuels that contain more useful energy, and reduces the weight of the coal to reduce energy consumption in transporting the coal to its combustion site.
[0013] A further object of the invention is to produce a clean burning coal by removing pollutants so that burning the coal minimizes air pollution rendering the coal a more environmentally acceptable fuel.
[0014] An additional object of the present invention is to render the coal into a low smoke generating fuel to make its use more acceptable for domestic purposes such as cooking and home heating by removing toxic pollutants.
[0015] A further object of the present invention is to reduce the inefficient release of energy reserves in the faint of biomass such as coal to, in turn, reduce degradation of the quality of the atmosphere and the environment, and reduce global warming.
[0016] Another object of the present invention is to release biomass energy in a safe, clean and environmentally responsible manner.
[0017] An additional object of the invention is to provide places in the world like China having ever increasing energy needs with a way to utilize its significant coal deposits in a way that has a positive impact with other nations concerned with air pollution and global warming.
[0018] A related object of the invention is to provide nations like China who already use coal for heating and cooking in homes with a way to improve the health of its citizens by minimizing smoke and exposure to pollutants when burning coal in a home.
[0019] Other objects and advantages will be apparent to those skilled in the art upon reference to the following descriptions and drawings.
[0020] In accordance with a principal aspect of the present invention, a process produces a clean burning fuel from low grade coal. This clean fuel is similar to coal, moisture resistant, stable, and has a higher heating value per unit mass, as compared to the feed stock coal. The clean coal fuel may be handled and combusted like coal in coal-fired power plants, industrial boilers, and homes; however, it produces fewer or none of the emissions of harmful air pollutants that are commonly associated with coal burning devices. The inventive process treats coal prior to its combustion and removes about 90 percent of the pollutants inherent in coal that are responsible for creating smog and unhealthy air.
[0021] These pollutants are removed within 6 to 18 minutes, many of which may be recycled into products such as roofing tar, chemical feed stocks, and light hydrocarbons that can be used as gaseous fuels. The final product is optionally formed into briquettes for use in homes where coal is used for cooking and heating. Because of their clean burning characteristics, the use of these briquettes significantly improves the health of those who have previously been exposed to toxic fumes from burning uncleaned coal in their homes.
[0022] In accordance with a secondary aspect of the present invention, the process uses a different approach where it uses a multi-stage heating process to gradually heat the coal under controlled residence times and atmospheres to produce a stable product with an increased BTU content—this is a unique and distinguishing aspect of this process over its competitors. The mix of gasses in each zone is proprietary to the inventive process and ensures that the coal loses its volatile matter without combusting itself to produce a clean coal fuel.
[0023] The apparatus is comprised of three chambers, each of which is considered a zone. Coal is gradually heated in the first two chambers (zones) and then cooled in the last chamber (zone). Each heating zone may be viewed as a stand-alone partial gasification chamber. Coal is heated under controlled temperatures, residence time, and ambient pressure as it progresses through each zone. Process variables in each zone are adjusted to suit desired end product specifications.
[0024] The feed stock coal is crushed to a typical size distribution for utility coal and fed into Zone 1. The temperature and residence time in this zone is sufficient to remove surface moisture from the coal. The coal moves into the second zone where the temperature and retention time are maintained to remove any remaining moisture and low and high boiling volatiles, air toxics (including mercury, arsenic, and some sulfur oxides) are removed. The third zone is a cooling zone where the coal is cooled in a controlled atmosphere. Cooling is conducted at a rate which does not compromise the structural integrity of the coal. After exiting from zone 5, the product coal typically has a moisture content <2% and a volatile content between 5-15%. These two parameters may be varied to suit utility requirements by altering processing conditions.
[0025] A gas collection manifold in each chamber captures all moisture and volatile matter released from the coal during processing. A gas separator separates the light hydrocarbons that are directed back to the burners that heat the zones. Heavier gases separated from the lighter gases are collected in a separate vessel for subsequent sale or conversion to synthetic fuels and chemical feed stocks.
[0026] The processing plant has been designed to improve the quality of mined coal by approximately 30%, depending on the quality of the incoming coal. This is achieved through the removal of both surface and inherent moisture plus volatile matter from within the coal. This volatile matter contains most of the contaminants and, once removed, leaves the remaining coal to burn cleanly. The process is designed to utilize a minimum amount of energy and time to improve the coal in a safe and consistent manner.
[0027] The facility includes a seven day storage capacity of coal in both the raw and finished coal piles. The coal feed stock is delivered to the facility and shipped from the facility by truck or rail. The incoming trucks or rail cars proceed to an unloading station where the contents are dumped into a receiving bunker. Coal from the bunker is conveyed to a stacker where the coal is distributed and packed into a storage pile.
[0028] A coal reclaimer harvests coal from the storage pile and conveys it to a conveyor/tripper located above the in-process storage silos. The storage silos store approximately 2.5 hours worth of coal for each processing unit. The conveyor/tripper delivers coal to the silos on a continuous basis. After the coal is processed, it is delivered to the processed coal conveyor at a temperature of 200° F. and conveyed to the finished product stacker where it is compacted and stored in the processed coal pile. From the processed coal pile, the coal is reclaimed and conveyed to rail cars for shipment.
[0029] All gasses generated by the different process units are sent to a central gas processing unit where heavy hydrocarbons are separated and condensed into a liquid that is stored and shipped by rail to an oil refinery for further processing. The remaining gasses are separated and four main streams are generated. The first gas stream is carbon dioxide that is recycled back to the coal processing units; the second stream consists of methane and ethane and is sent back to the coal processing units and used as a fuel to heat the coal. The third stream is propane which is condensed and stored as a liquid both for start up of the inventive process and for back up for the fuel gas system. A propane/air mixer produces a fuel gas equivalent BTU mix. The fourth gas stream consists of pentanes and heavier hydrocarbons and is condensed and shipped to a refinery via truck for further processing or sale.
[0030] The facility includes coal handling equipment to receive, store and reclaim the coal from a coal feed stock pile for processing. The coal is delivered to in-process storage bunkers located above the processing equipment. From the storage bunkers the coal flows by gravity into the process equipment and is fed into chutes by a series of screw conveyors that deliver a full width layer of coal to the processing equipment. The processing equipment consists of a series of vibratory feeders that convey a 4-inch deep bed of coal through the two heating chambers or zones and the cooling chamber or zone as described above.
[0031] In the first heating chamber, the coal is preferably heated from ambient to a temperature of 400° F. or more. The heating occurs under a blanket of carbon dioxide. Hot carbon dioxide is supplied to the first heating chamber through a fluidized bed built into the bed of the vibratory feeder. The carbon dioxide picks up moisture and some hydrocarbon gasses and delivers them to the gas cleaning module for separation of dust and moisture and further processing.
[0032] The coal is delivered to the second heating chamber where gas fired heaters heat the coal from 400° F. to 1500° F. or more. Carbon dioxide is fed above the bed of the vibratory feeder. The carbon dioxide picks up additional moisture and a larger amount of hydrocarbon gasses. The gas mixture is delivered to the gas cleaning module for further processing.
[0033] The cooling chamber consists of a vibratory feeder moving the coal from one end of the vibratory feeder to the other while being exposed to a stream of cool carbon dioxide that has been fed into the unit. Carbon dioxide is reclaimed from the process at the gas cleaning module.
[0034] Carbon dioxide recycled and cooled from the first heating chamber which has been cooled and de-humidified is supplied to this cooling chamber through a fluidized bed built into the bed of the vibratory feeder. The exhaust gasses from the cooling chamber are heated and re-circulated to the first heating chamber, thereby recycling the heat.
BRIEF DESCRIPTION OF THE DRAWINGS
[0035] Various other features of the invention will become apparent to those skilled in the art from the following discussion taken in conjunction with the appended drawings in which:
[0036] FIG. 1 is the primary schematic diagram of the process showing the product flow. through the facility, partial circulation of carbon dioxide through the process, and the gas separation unit that receives and separates by-products of the process.
[0037] FIG. 2 is a cross sectional view of the first heating chamber or zone.
[0038] FIG. 3 is a cross sectional view of the second heating chamber or zone.
[0039] FIG. 4 is a cross sectional view of the cooling chamber or zone.
[0040] FIG. 5 is the secondary schematic diagram showing the thermal trail of the carbon dioxide through the process facility.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0041] As required, detailed embodiments of the present invention are disclosed herein; however, it is to be understood that the disclosed embodiments are merely exemplary of the invention which may be embodied in various forms. Therefore, specific structural and functional details disclosed herein are not to be interpreted as limiting, but merely as a basis for the claims to be appended later and as a representative basis for teaching one skilled in the art to variously employ the present invention in virtually any appropriately detailed structure.
[0042] Reference will be made herein to the drawings in which like characteristics and features of the present invention shown in the various figures are designated by the same reference numerals.
[0043] The apparatus includes three chambers, each of which is considered a zone. Coal is gradually heated in the first two chambers (zones) and then cooled in the last chamber (zone). Each heating zone may be viewed as a stand-alone partial gasification chamber. Coal is heated under controlled temperatures, residence time, and ambient pressure as it progresses through each zone. Process variables in each zone are adjusted to suit desired end product specifications.
[0044] Coal is first crushed and graded using conventional crushing machines, i.e. a Gundlach double roll crusher or a McClanahan type crusher to reduce the feedstock to an average 90% passing 2 inches. It is then screened to remove any—¼″ material and transferred via a bucket conveyor to zone 1. Zone 1 contains a vibratory bed that moves the coal along at a controlled rate to match the residence time for this zone. The vibratory bed is heated with hot carbon dioxide that is fed in from the bottom of the bed. The temperature of zone 1 is maintained at around 400° F., which removes most of the surface moisture from the coal.
[0045] At the end of the bed, the coal is deposited onto the second vibratory bed (zone 2) via a chute utilizing gravity to save energy. As coal enters zone 2, it is heated by gas fired heaters that maintain the temperature of the zone at about 1500° F. Coal passes through this zone for a few minutes to remove any remaining moisture and any low-boiling volatile matter from the coal. The retention time of the coal in zones 1 and 2 varies depending upon the initial moisture and volatile content of the coal feed and the desired moisture/volatile content of the final product. Typical residence times are on the order of 3-5 minutes per zone.
[0046] The coal in the second heating chamber (zone 2), is heated by a series of gas fired heaters tc temperatures as high as 1,500° F. The carbon dioxide fed into zone 2 picks up additional moisture and the remaining heavier volatile gases emanating from the coal. This gaseous mixture is eventually delivered to the gas separation section. Between zones 1, 2, and 3, the coal loses the bulk of its volatile matter and undergoes some shrinkage as it losses a portion of its mass. Typically, weight loss is in the range of 15-35% of the coal's initial mass, but weight loss is largely dependent upon the characteristics of the feed coal, zone temperature, residence time, and other factors. These influencing factors are integrated into the overall process control system that monitors these parameters and adjusts them accordingly to obtain the desired final product.
[0047] Control of the gaseous mixture inside each zone is critical to the successful operation of the process. When coal is heated to the above mentioned temperatures, its moisture and volatile matter are driven off from the coal macerals. The expansion of the volatile matter at increasing temperature creates fissures and voids within the coal structure. If expansion is too rapid, these fissures can split the coal and the entire coal undergoes size degradation. Other undesirable characteristics are moisture re-absorption and spontaneous combustion after the coal reaches ambient temperature. However, the inventive process monitors the gaseous mix inside each heating zone to control the rate of removal of these volatile elements.
[0048] This is accomplished by creating a dynamic phase equilibrium between the solid/liquid and gaseous forms of the volatile matter inside the coal via an inert atmosphere created in part by the volatized materials from the coal and the introduction of an external, non-oxidizing, inert gas such as carbon dioxide or nitrogen. The chambers are provided with entry and exit ports for the admission and retrieval of such gases. The residence time, the type, and individual amounts of gasses circulated within each zone are predetermined for each feed coal and used as control parameters in the process. The oxygen content of the gasses within each zone is typically less than 2% oxygen.
[0049] Another effect of the atmosphere provided within each zone is to ensure that the coal maintains most of its natural structural integrity and resists the tendency to disintegrate into fines (particles less than ¼″), even though the coal may be more fragile due to some loss of mass. The processed coal is ready for transfer by a chute using a gravity feed to the cooling zone (zone 3). The gravity feed saves energy.
[0050] In zone 3, the coal is cooled by exposing it to a dry inert gas that is free of oxygen. In the process design, the cooling chamber (zone 3) consists of a vibratory feeder moving the coal from one end of the vibratory feeder to the other while being exposed to a stream of cool carbon dioxide that has been reclaimed from the process at the gas separation section. This carbon dioxide is recycled from zone 1 after it had been cooled and de-humidified and supplied to zone 3 through a fluidized bed built into the bed of the vibratory feeder. The exhaust gasses from the cooling section are heated and re-circulated to zone 1. Control systems ensure that the cooling stream of carbon dioxide only contains 0.25 to 0.75% oxygen, by volume, with a moisture content of less than 1% by weight, and flows counter current to direction of flow of the coal.
[0051] From zone 3, the coal is now ready for shipment to utility and industrial markets. If needed, fines may be removed from the coal by screening so that the finished product has a size range of ¼″ to 2″.
[0052] The fines are optionally converted into briquettes for home use or used as fuel to supply heat for the process. Alternatively, the fines are sold to a third party for processing into briquettes for home use. The end result is the production of clean burning, low smoke coal briquettes that have strong structural make up, moisture resistant, long shelf life and are cost effective.
[0053] What follows is a description of the individual pieces of equipment. The vibratory feeders are, for the most part, standard pieces of equipment designed to move solid products by inducing vibration on a flat bed. Because of the high temperatures involved in the process, the vibrating beds are lined with refractory materials. The vibrating bed is mounted on springs and the vibration is generated by an eccentric arm mounted on a shaft and driven by an electric motor. The electric motor is controlled by a variable frequency drive in order to modulate the speed of the conveyor. The vibratory feeder bed is provided with a metal skirt that is immersed in a sand seal in order to prevent the carbon dioxide atmosphere inside the enclosure from escaping.
[0054] The heaters comprise natural gas burners mounted on the walls of the chamber. The fuel/air mixture is controlled to maintain a constant exit temperature. As the amount of combustible gas produced by the process increases within the chamber, the external gas feed to the burner is reduced and combustion air is controlled to sustain combustion and maintain the exit temperature of the gas. Any excess hydrocarbons being generated by the process are carried by the carbon dioxide to the chemical section for processing.
[0055] Heat, from external sources, is supplied to the process in three discrete, independent locations. All heat addition locations utilize propane as the start up fuel, produced by the gas plant installed as a part of the process. Propane is stored at the facility.
[0056] The first heat addition location is the CO2 fired heater which raises the temperature of the CO2 stream going to first heating chamber. This fired heater raises the CO2 from an inlet temperature of 522° F. to a CO2 discharge temperature of 938° F. A burner utilizing propane/ethane-methane as the burner fuel provides the necessary heat. The burner is equipped with both a vendor furnished Combustion Control System (CCS) and Burner Management System (BMS).
[0057] The burner temperature profile and consequently the burner heat release are chosen such that the requisite CO2 temperature rise can be achieved. Given the relatively high CO2 inlet temperature, the flue gas exhaust temperature out of the fired heater is also elevated. A flue gas to combustion air heat exchanger is installed to preheat burner combustion air with the flue gas exiting the fired heater to reduce burner fuel demand. An un-insulated metal stack is installed downstream of the combustion air preheater to discharge the flue gas to ambient.
[0058] The second heat addition location is the gas fired heater heating the coal going to the second chamber. This fired heater raises the incoming coal from the first chamber to a coal discharge temperature of 1500° F. Burners fueled with propane/ethane-methane provide the necessary heat. The burners are also equipped with a vendor furnished Combustion Control System (CCS) and BMS. The burner temperature profile and consequently the burner heat release are chosen such that the requisite CO2 temperature rise can be achieved. Given the high flue gas exit temperature, the system includes a flue gas to combustion air heat exchanger to raise incoming combustion air temperature. An un-insulated metal stack is installed downstream of the combustion air preheater to discharge the flue gas to ambient. One of the main advantages of the process is that it recycles 100% of the heat removed from the coal during the cooling process to heat the first heating section of the process.
[0059] Centrifugal fans are utilized to move the process gas through the system. The fans are of the radial blade type and, in some cases, are made from specialty metals to handle the high temperatures and corrosive nature of the gasses being conveyed.
[0060] The dust collector is utilized to separate any dust from the process gas and water vapor being generated in the first heating chamber. The dust collector is of the bag type and the bags are made of material suitable for temperatures up to 400° F. Normally, compressed air is utilized to shake the bags but in this case carbon dioxide is utilized in order to keep an oxygen starved atmosphere in the process. Because of the hot, humid and corrosive environment, all internal parts in contact with the process stream are made of stainless steel.
[0061] The water separator consists of a finned water coil with a large drain pan that condenses the moisture from the process gas stream and drains it. Cooling water for the coil is provided by a condenser water system consisting of cooling towers and circulating pumps.
[0062] The cooling towers are the counterflow type and are sized to cool water from 115° F. down to 85° F. at an ambient wet bulb of 78° F. The condenser water system provides cooling to the coal processing as well as the gas processing side of the system. Cooling tower fans utilize electrical reversing relays to reverse rotation on the fans in case of icing during winter.
[0063] The condenser water pumps are of the vertical turbine type and are located in a wet well at the cooling tower structure where the water cooled by the towers is collected. The pumps discharge water into a piping system that conveys the water to cooling coils and heat exchangers throughout the facility. The pumps are controlled by variable speed drives to control the amount of water flowing through the system and minimize energy consumption in winter.
[0064] Metal chutes conveying coal from one area of the process to another are lined with refractory materials suitable for handling coal as well as the temperatures generated by the process. Vibratory feeders are housed inside refractory enclosures that are under a slight negative pressure generated by the fans exhausting the gasses from the enclosure. The carbon dioxide atmosphere of course prevents the coal from igniting in the presence of oxygen above 400° F.
[0065] The gas by-products from the coal heating chambers consist of those materials contained in the combined streams exiting the first and second chambers. These are the volatiles driven from the coal at the various temperature levels and the gas that is being used as a heat transfer medium being used to heat and cool the coal at various stages. The heat transfer gas is carbon dioxide, but nitrogen is also contemplated.
[0066] At the low temperature level, i.e. 400° F., volatiles consist primarily of surface moisture. At 1500° F., the volatiles consist of moisture within the coal and light hydrocarbons, hydrogen, carbon dioxide, carbon monoxide, hydrogen sulfide, and ammonia. At the highest temperatures, heavier hydrocarbon, liquids are driven off. Much of the hydrocarbons are deficient in hydrogen, consisting of alkenes and aromatics. In addition to hydrocarbons, the volatiles consist of such contaminant inorganics that are released at higher temperatures, i.e. 2,000° F. Such inorganic contaminants consist of chlorine, mercury, arsenic, etc.
[0067] The purpose of the gas module is to remove contaminants and separate various components into saleable and transportable products. These products will be discussed in the products section. Another important purpose is to separate carbon dioxide for recycle back to the coal drying section for its use as a heat medium. Of critical importance to the design of the gas plant is the composition of the volatiles driven from the coal at the various stages of the cleaning process.
[0068] The following are the products from the gas plant: Fuel gas. This consists of C4-material, i.e., methane, ethane, ethylene, butanes, and butylenes. This is used in the coal plant burners as fuel gas. This gas is amine treated, and is relatively free of H2S.
[0069] Propane, propylenes. The coal plant requires a source of fuel for startup. For this reason, C3s separation and storage is provided. Excess C3s above that required for the coal plant startup is sold, such as to a refinery as feedstock to a refinery Alkylation unit.
[0070] Butanes, butylenes. This is a liquid product stream, and storage facilities are provided, This is optionally used as fuel or as a product to be sold, such as to a refinery as feedstock to a refinery Alkylation unit.
[0071] Heavy Liquid, C5 plus liquid. This is described in more detail below.
[0072] Sulfur. Described below.
[0073] CO2. CO2 is a makeup to the inert gas which is used as a heating medium in the coal cleaning section.
[0074] CO. Carbon monoxide is widely used in the chemical industry as the material to produce polyurethane or polycarbonate.
[0075] Individual processes are
[0076] Contaminant removal.
[0077] Solid adsorbents remove vapor contaminants such as mercury from gas to very low levels. This is accomplished with two or more adsorbent vessels. As one adsorbent vessel has filled with contaminants, it is brought offline to have the spent adsorbent replaced with fresh adsorbent. Solid contaminants such as arsenic are removed from the liquids thru filtration.
[0078] Hydrocarbon treating.
[0079] The removal of H2S from fuel gas is accomplished via amine treating. In this process, H2S is absorbed from the gas in an adsorption column by a specific type of amine. The purified gas is then sent to further processing or used as fuel gas. The H2S absorbed by the amine is then sent to a stripping column were H2S is driven off as a concentrated stream. The lean amine is then recycled back to the absorber. The H2S stripped from the amine is then sent to a sulfur recovery unit.
[0080] CO2 removal.
[0081] Removal of CO2 is by 2 nd stage amine separation. The amine that was used for H2S removal was selective for H2S, leaving CO2 in the gas.
[0082] CO removal.
[0083] Carbon monoxide is captured in a process involving absorption/desorption using a solvent containing cuprous aluminum chloride in toluene.
[0084] Water removal.
[0085] Water is collected from various locations within the gas plant. These include the adsorbent driers, water boots from the separators. The water is sour, and consequently is treated in a sour water stripper. H2S and ammonia dissolved in the water is stripped and combined with the acid gas from the amine treater, and together sent to sulfur recovery.
[0086] The treated gas containing C4 minus material is sent to the light gas separation section. In this section, methane/ethane is first separated using a refrigerated J-T process. This includes an adsorbent dehydrator, propane chiller, cold separator, and de-ethanizer column operating at −30° F. The bottoms product from the de-ethanizer is sent to a depolarizer and debutanizer where propanes/propylenes and butanes/butylenes are separated, respectively. The bottoms product from the debutanizer contain the C5 plus hydrocarbons which combine with the main separator liquid and sent to liquid product storage for subsequent sale.
[0087] The heavy liquid (C5 plus material) consists of a wide boiling range material ranging from light naphtha to diesel and heavier. It is hydrogen deficient and highly aromatic. It contains oxygen bearing hydrocarbons such as ethers, aldehydes, esters, and ketones. It is a stabilized material suitable for storage and transportation to a petroleum/petrochemical refinery for further processing. To avoid gum formation, it is stored in a relatively air free environment, that being an insulated, gas blanketed storage tank.
[0088] A final by-product is sulfur. It is captured from the H2S that is produced in the sour water stripper and amine units of the gas plant, and processed in a Claus unit to produce elemental sulfur. The Claus unit produces sulfur by reacting H2S over a catalyst with air. The reaction is highly exothermic, resulting in production of high pressure steam generated in a waste heat boiler. This steam is integrated in other sections of gas plant and used for heating. The excess steam could also be used with a turbine to generate electricity.
[0089] Sulfur is stored and transported both as a liquid and solid. It is a solid when cooled and formed into briquettes that are more easily transported to facilities for further processing, i.e., fertilizer, sulfuric acid, etc.
[0090] Turning finally to the drawing, FIG. 1 is the primary schematic diagram of the process showing the product flow. through the facility, partial circulation of carbon dioxide through the process, and the gas separation unit that receives and separates by-products of the process.
[0091] The schematic of the process is shown generally at 10 . Raw coal 12 that has already been crushed to size and graded elsewhere at the facility (not shown) is loaded into a hopper/feeder 14 . It is then fed at 16 to the first zone chamber 18 where it is heated to 400° F. using hot carbon dioxide gas that enters the chamber 18 at 20 . This drives off moisture, which is carried out of the chamber 18 by the exiting carbon dioxide at 22 .
[0092] The 400° F. temperature coal then exits the chamber 18 at 24 and moves to the second zone chamber 26 . There is heated to 1500° F. using gas fired burners described in connection with FIG. 3 . At this temperature, by-products are driven out of the coal in the form of volatile matter The volatile matter passes to a gas separation unit 28 at 30 . It is carried there by carbon dioxide that enters second zone chamber 26 at 32 .
[0093] In the gas separation unit 28 , various by-products are separated from each other and discharged into different streams. The first such stream is methane and ethane at 34 . The methane and ethane is recycled at 36 back to second zone chamber 26 where it is burned in gas fired burners to heat the coal to 1500° F. in an oxygen free environment. Thus the first by-product at least partially fuels the inventive process, which was not taught by Hunt, the primary prior art reference. The second stream is propane at 38 . At least some of the propane produced by the process is stored at the facility because it is used for heating at startup. Left over amounts can be sold as a by-product of the process. The next stream is heavy carbons at 40 which can be sold to others for chemical feedstocks. The penultimate stream is pentane and heavier hydrocarbons at 42 , also saleable to others. The final stream 44 is to separate out the carrier carbon dioxide for recycling back at 32 to second zone chamber 26
[0094] The coal heated to 1500° F. in second zone chamber 26 exits that chamber at 46 and passes to third zone chamber 48 , where it is cooled in a dry and oxygen free environment. The carbon dioxide that carries moisture out of the first zone chamber 18 at 22 is directed to gas cleaning module 50 , where the carbon dioxide is dehumidified. After some other steps described in connection with FIG. 5 , the carbon dioxide enters third zone chamber 48 at 52 , where it is used to cool the coal down to about 200° F. Then the cleaned coal is discharged at 54 from the process for storage and delivery to users. The carbon dioxide, which is heated by cooling the coal in third zone chamber 48 exits that chamber at 56 and is returned at 20 to the first zone chamber 18 to heat the coal therein to 400° F. as described earlier.
[0095] FIG. 2 is a cross sectional view of the first heating chamber or zone 18 . Coal 12 enters the chamber 18 at 16 and is moved on a vibratory feeder 58 which includes a fluidized bed 60 . Hot carbon dioxide enters at 20 and is fed into the fluidized bed 60 to heat the coal and absorb the moisture. The dried coal heated to 400° F. then exits first zone chamber 18 at 24 enroute to the second zone chamber 26 as seen in FIG. 3 . The carbon dioxide and moisture combination exit at 22 enroute to the gas cleaning module 50 as seen in FIG. 1 .
[0096] FIG. 3 is a cross sectional view of the second heating chamber or zone 26 into which coal 12 enters at 24 and is moved on vibratory feeder 58 which includes fluidized bed 60 . In this chamber, the coal 12 is heated to 1500° F. by gas fired burners 62 . Carbon dioxide enters the chamber 26 at 32 , picks up by-products given off the coal 12 by the 1500° F. temperature, and leaves zone 26 at 64 enroute to the gas separation unit 28 seen in FIG. 1 . The 1500° F. temperature coal leaves zone 26 at 46 enroute to the third zone 48 seen in FIG. 4 .
[0097] FIG. 4 is a cross sectional view of the cooling chamber or third zone 48 . Coal at a temperature of 1500° F. enters the third zone 48 at 46 . Coal 12 is moved on vibratory feeder 58 which includes fluidized bed 60 . Carbon dioxide, which has been cooled by the apparatus described in connection with FIG. 5 , enters zone 3 at 52 . The cooled carbon dioxide is fed to the fluidized bed 60 , and cools the coal 12 to 200° F., at which temperature combustion cannot occur when the coal is again exposed to oxygen. The coal 12 then exits the cooling zone 48 at 54 for storage and shipment to users. The carbon dioxide is, of course, heated in the course of cooling the coal, reaching a temperature 522° F. The heated coal exits cooling zone 48 at 56 .
[0098] FIG. 5 is the secondary schematic diagram showing the thermal trail of the carbon dioxide through the process facility. The carbon dioxide heated to 522° F. in the cooling zone 48 exits that zone at 56 . It is then directed to a CO2 gas fired burner 66 which raises the temperature of the CO2 to 938° F. The gas fired burner 66 utilizes propane/ethane-methane as the burner fuel. The carbon dioxide at a temperature of 938° F. is then directed at 20 to the first zone 18 where it is used to heat incoming raw coal 12 to 400° F. as described earlier in connection with FIG. 2 . This results in conservation of energy because a substantial amount of the heat of the process obtained from cooling the coal in the cooling zone 48 is recycled into heating incoming raw coal in the first zone 18 .
[0099] The carbon dioxide thereafter exits the first zone 18 at 22 and then is sent to a dust collector 68 to be cleansed of dust for later use in the process. The carbon dioxide leaves the dust collector at 70 using centrifugal fan 72 , and is sent to a counterflow heat exchanger 74 which it enters at 76 . The heat exchanger 74 is used to cool the carbon dioxide for later use in the cooling zone 48 .
[0100] The heat exchanger 74 receives cooled water from a cooling tower 78 . Cooled water is maintained in a reservoir 80 and is sent to the heat exchanger 74 using pump 82 . Cooled water enters the heat exchanger at 84 and leaves it at 86 . The water is warmed in the heat exchanger 74 by cooling the carbon dioxide. The warmed water is then directed to the cooling tower 78 where it passes through spray nozzles 88 and film file 90 to be cooled again. It then returns to resevoir 80 . The cooled carbon dioxide exits the heat exchanger 74 at 92 and sent using centrifugal fan 94 to the cooling zone 48 which it enters at 52 to cool the coal from 1500° F. to 200° F. as described previously in connection with FIG. 4 .
[0101] While the invention has been described, disclosed, illustrated and shown in various terms or certain embodiments or modifications which it has assumed 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 hereto appended. | The present process produces a clean burning coal from low grade coal and has a higher heating value per unit mass, as compared to the feed stock coal. The clean coal may be used in coal-fired power plants, industrial boilers, and homes since it produces fewer or none of the emissions commonly associated with coal burning devices. The process treats coal prior to its combustion and removes about 90 percent of the pollutants. These pollutants are removed within 6 to 18 minutes, many of which may be recycled into products such as roofing tar, chemical feed stocks, and light hydrocarbons that can be used as gaseous fuels. The final product is suitable for use in homes where coal is used for cooking and heating, and significantly improves the health of those who have previously been exposed to toxic fumes from burning uncleaned coal in their homes. The process is fueled by its own by-products, recycles heat, and reduces coal weight to save energy in transporting it to the user. | 2 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The invention relates generally to improvements in extraction devices and methods for using same, designed specifically for removing aquatic weeds from waterways, and the like. More specifically, the invention pertains to an apparatus adapted to be immersed underwater having a portion on its distal end which is remotely deployable from a withdrawn position into an extended position for rotational entanglement with the target aquatic weed and removal of same by its roots.
[0003] 2. Description of the Prior Art
[0004] U.S. Pat. No. 4,852,337, issued to Peterson, shows a method and an apparatus for removing aquatic plants from around docks and boating areas. The device employed is a rake with flexible teeth interconnected by a resilient strand of filament. A primary pull rope 28 and a back pull rope 30 are used to maneuver the rake into position, engage the plant, and then pull it out by its roots.
[0005] Another arrangement, designed for engaging underwater plants or roots for anchoring purposes, is shown in U.S. Pat. No. 2,983,243, granted to Bowers et al. This device relies upon a remotely controlled gripping hook to grasp onto an underwater portion of a plant or a root so that a small boat can be anchored in place.
[0006] A mechanical weed remover is disclosed in U.S. Pat. No. 4,547,010, issued to Camp. This device employs a length-adjustable pole, provided with a hand operated lever at one end, and pivotally actuated weed-gripping jaws on the other end. The two mechanisms are interconnected by a cable.
[0007] Another approach to removing weeds is illustrated in U.S. Pat. No. 2,025,254, granted to Stuart. This weeder has a sharp end 1 , utilized in a first step to cut the weed. Then, the user employs a gripping and lifting blade B to effect the removal of the severed portion of the weed. A wire or cable may be used to interconnect the lever 13 with the blade B.
[0008] A weed extraction apparatus is shown in Patent Application Publication U.S. 2002/0073679, filed by Schench-Williams. A lever on the upper end of a bar is connected to a cable. The cable, in turn, is interconnected to two scissor-like claws. A pair of springs maintains the lever in a position normally perpendicular to the bar and the claws in a position normally open.
[0009] Yet another weeding tool is disclosed in U.S. Pat. No. 3,272,548, granted to Taylor. Normally closed, spring-loaded jaws are provided on the lower end of a tubular handle 12 . A trigger 18 is provided on the handle's upper end. A rod 24 interconnects the trigger to the jaws. The trigger is used to open the jaws while the roots of the weed are dislodged by rotating and manipulating the jaws. Then, upon release of the trigger, the spring urges the jaws into a closed position, engaging the weed for withdrawal.
[0010] Nevertheless, there remains a need for a pole-like apparatus which has a proximate end above the water surface and a distal end which can be immersed underwater for engagement with otherwise unreachable, submersed portions of an aquatic plant or weed.
[0011] The need also exists for an underwater weeding apparatus employing weed engaging means on its distal end which can remotely be deployed by the user, from a withdrawn position to an extended position, to enhance its ability to become entangled with the weed. And, once the weed is so engaged, it can mechanically be removed by its roots and drawn to the water's surface by the device, through the application of pulling and agitating forces.
[0012] And, the need exists for an underwater weeding apparatus having the weed engaging means which can be manipulated from a withdrawn position to an extended position for weed extraction, and then from an extended position into a withdrawn position after the weed has been removed from the water, so the apparatus can be disengaged from the weed.
[0013] These and other objects of the apparatus and method of the present invention will be described in greater detail below.
SUMMARY OF THE INVENTION
[0014] An apparatus and a method for removing rooted aquatic plants or weeds is disclosed. The apparatus comprises an elongated pole provided with a remotely operated arm, or other forms of weed engaging means, at its distal end. A lever is provided on the proximate end of the pole, having an operative interconnection to the arm. Remote control of the arm is thereby accomplished, providing selective movement of the arm from a withdrawn position to an extended position, generally perpendicular to the pole, and from an extended position to a withdrawn position, generally parallel to the pole.
[0015] With the weed engaging means in the withdrawn position, the user pushes the distal end of the pole underwater, until it enters the submersed tendrils of the targeted aquatic weed. The remote control lever is then activated, deploying the arm into an extended position, generally perpendicular to the pole. Simultaneously, the user begins to rotate the pole until resistance to further rotation is detected. This indicates that the tendrils of the weed have been engaged by the arm.
[0016] The user then applies pushing and pulling forces on the pole, until the roots of the weed are extracted from the soil. This is detected by the abrupt reduction of resistance to the pulling, and may sometimes be accompanied by bubbles making their way to the surface. These bubbles are caused by the release of oxygen, when the roots of the weed are removed from the underwater soil.
[0017] Continued rotation of the pole while pulling upwardly maintains the entire weed under control while it is brought to the surface of the water. At that point the weed may be pulled completely out of the water, and placed on the dock or the shore. Lastly, the weed engaging means is moved into a withdrawn position, so the pole can easily be removed from the weed tendrils.
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] FIG. 1 is a perspective view of the apparatus for extracting weeds, with the weed engaging means in a withdrawn position;
[0019] FIG. 2 is a view as in FIG. 1 , but with the weed engaging means in an extended position;
[0020] FIG. 3 is a fragmentary perspective view of the median portion of the pole, showing the length adjustability feature and the locking pin;
[0021] FIG. 4 is a fragmentary perspective view of the remote control lever, showing both the unlocked position and the locked position in broken line;
[0022] FIG. 5 is a fragmentary, perspective view of one embodiment of the weed engaging means located on the distal end of the pole, the withdrawn and extended positions being shown in broken line;
[0023] FIG. 6 is a cross-sectional view taken on the line 6 - 6 , in FIG. 5 ;
[0024] FIG. 7 is a perspective view showing the apparatus being rotated, with its weed engaging means in an extended position for engaging the underwater tendrils of an aquatic plant;
[0025] FIG. 8 is a fragmentary perspective view of the aquatic weed after the apparatus has been rotated to engage the tendrils;
[0026] FIG. 9 is a view as in FIG. 8 , but showing pulling and pushing forces being alternatively applied to the apparatus and upon the aquatic weed;
[0027] FIG. 10 is a view as in FIG. 9 , but showing the oxygen bubbles being released as the weed's roots are extracted from the soil;
[0028] FIG. 11 is a perspective view showing the aquatic weed being lifted vertically out of the water, after the roots have been pulled free from the soil;
[0029] FIG. 12 is a perspective view showing the extracted aquatic weed being pulled onto a dock;
[0030] FIG. 13 is a perspective view showing the apparatus being withdrawn from the weed tendrils, after the weed engaging means has been moved into a withdrawn position;
[0031] FIG. 14 is a fragmentary, cross-sectional view of an alternative construction for the weed engaging means, showing the arms in a withdrawn position;
[0032] FIG. 15 is a fragmentary, cross-sectional view of the lever mechanism shown at the upper end of FIG. 14 ;
[0033] FIG. 16 is a fragmentary, cross-sectional view of the weed engaging means shown in FIG. 14 , but with the arms in an extended position;
[0034] FIG. 17 is a cross-sectional view as in FIG. 15 , but with the lever mechanism rotated into lower position; and,
[0035] FIG. 18 is a fragmentary perspective view of yet another embodiment for the weed engaging means, employing a switch, a battery, and an electrical solenoid having a normally extended position.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0036] Making particular reference to FIG. 1 , an apparatus 11 for the removal of a aquatic weeds is shown. Apparatus 11 comprises an elongated pole 12 , having a proximate end 13 and a distal end 14 . Pole 12 preferably has telescoping capabilities, so it can easily be adjusted in length for the job at hand For that purpose, a knurled locking ring 16 is provided to apply compressive forces to the juncture between the upper and lower segments of the pole 12 , at the appropriate time. For additional securing, a locking pin 17 is also provided, once a selected aperture 18 in the upper pole segment becomes aligned with the pin bore 19 in the lower pole segment. (See, FIG. 3 ).
[0037] Weed engaging means 21 is mounted on the distal end 14 , with a first construction thereof being shown most clearly in FIGS. 5 and 6 . This first construction of weed engaging means 21 comprises a hinge 22 , having an elongated arm 23 as one side thereof. Arm 23 is movable from a withdrawn position, in which the axis of arm 23 is generally parallel to or coincident with the axis of pole 12 , to an extended position in which the axis of arm 23 is generally perpendicular to the axis of pole 12 . The other side 24 of hinge 22 extends into and is mounted within distal end 14 by means of nut and bolt assemblies 26 . It is apparent that arm 23 could also be pivotally mounted directly upon distal end 14 , thereby eliminating the need for hinge 22 .
[0038] To effect the desired movement of arm 23 , remote control means 27 is provided. In one embodiment, remote control means 27 comprises a hinge 28 , having a fixed portion 29 attached to the side of pole 12 , intermediate proximate end 13 distal end 14 . Hinge 28 also includes a movable handle portion 31 , shown most clearly in FIG. 4 . Handle portion 31 has an adjacent end pivotally mounted on the pole 12 by means of the pivot in hinge 28 , and a remote end for grasping by the user. Handle portion 31 is also mechanically interconnected to arm 23 by a cable 32 . As shown in FIG. 1 , when handle portion 31 is in a released position cable 32 is generally slack, allowing arm 23 to assume a withdrawn position. However, when handle portion 31 is raised upwardly into a locked position, the cable 32 raises arm 23 upwardly into an extended position. (See, FIG. 2 ).
[0039] A keeper 33 is provided to maintain handle portion 31 against the pole 12 , in its locked position. Keeper 33 is preferably made from a piece of semi-rigid wire, formed into a loop generally conforming to the circumferential configuration of the pole but including a flat corresponding to portion 31 . (See, FIG. 4 ). The dimensions of keeper 33 are such that it can be slipped down and snugly over the handle portion 31 in its locked position, but can also be raised upwardly to release portion 31 when desired.
[0040] An alternative embodiment of weed engaging means 21 and remote control means 27 are illustrated in FIGS. 14-17 . In this arrangement, weed engaging means 21 comprises a first arm 34 , a second arm 36 , and a strip 37 therebetween. Arms 34 and 36 are generally the same size as arm 23 , discussed above, but must have a transverse dimension such that the two arms can be withdrawn and fitted within pole 12 , as shown in FIG. 14 . In this configuration, weed engaging means is in a withdrawn position. Strip 37 is made from a piece of resilient, flexible material, such as spring metal or plastic. A cylindrical connector plug 38 has a lower end connected to a median portion of strip 37 , and an upper end connected to a rod 39 .
[0041] Rod 39 extends through pole 12 until it reaches rotatable lever assembly 41 . Rod 39 and lever assembly 41 comprise an alternative embodiment for remote control means 27 . Lever assembly 41 includes a lever 42 , a bearing 43 , a shaft 44 , and a disc 46 . As shown in FIGS. 14 and 16 , the upper end of rod 39 is eccentrically mounted upon the peripheral portion of disc 46 . When lever 42 is pointed downwardly, as shown in FIG. 15 , rod 39 is in a fully raised position, drawing up connector plug 38 . Strip 37 is also drawn upwardly, folding first arm 34 and second arm 36 into generally parallel relation, with their upper ends nested within distal end 14 of pole 12 .
[0042] When lever 42 is rotated 180° so it is pointed upwardly, as shown in FIGS. 16 and 17 , rod 39 is in a fully lowered position, driving connection plug 38 downwardly. As strip 37 emerges from distal end 14 , its spring action deploys arms 34 and 36 outwardly from respective sides of pole 12 . In this configuration, weed engaging means 21 is in an extended position. It is apparent that more arms and strips could readily be added to the connection plug, to provide multiple sets of arms. It is also apparent that spring loaded wires, or other deployable structures, could be substituted for the arms, providing an equivalent function and result.
[0043] FIG. 18 depicts an additional embodiment for weed engaging means 21 and remote control means 27 . As to weed engaging means 21 , this additional embodiment comprises arm 47 mounted to distal end 14 by means of pivot 48 . In FIG. 18 , arm 47 is shown in a position intermediate its withdrawn position, where it is axially aligned with pole 12 , and its extended position, where it is perpendicular to the axis of pole 12 . The alternative embodiment for remote control means 27 is generally comprises electro-mechanical elements, namely, battery 49 , switch 51 , power leads 52 , and solenoid 53 . An actuator shaft 54 extends from the lower end of solenoid 53 and interconnects to one side of arm 47 . Shaft 54 is pivotally connected at both ends, to allow shaft 54 to withdraw and extend without binding as arm 47 is moved from one position to the other.
[0044] Solenoid 53 is spring-loaded internally, to have a normally extended position when it is de-energized. Thus, with no electrical current passing through solenoid 53 , shaft 54 will be extended, placing arm 47 into a withdrawn position. However, when switch 51 is moved into its on position, electrical current will pass from battery 49 , through power leads 52 , to actuate solenoid 53 . Shaft 54 will then be withdrawn, which will pivot arm 47 outwardly into an extended position.
[0045] The method of extracting an aquatic weed 56 , particularly using the apparatus 11 described above, is shown in FIGS. 7-13 , inclusive. Typically, the target aquatic weed 56 to be extracted will be an invasive, non-native species, such as egeria densa. However, the apparatus and method disclosed herein can be used advantageously to remove any aquatic weed, irrespective of whether it is invasive, non-native, or rooted. Egeria densa and similar weeds or plants are particularly troublesome, because they grow rapidly, are not controlled through natural means, and can actually spread through harvesting. In other words, if only the tops of such weeds are removed, the plant will continue to grow from the remaining root portion, and regenerate. Also, fragments of harvested plants can continue to grow, re-root, and spread into new locations. When waterways become filled with this species, boating operations are impaired as propellers become entangled in the weeds. Slips in boat docks may be clogged with weed material, making vessel docking and departure operations more difficult.
[0046] Thus, the user 57 , standing on a dock 58 , begins the operation by grasping the pole 12 and pushing its distal end 14 below the surface of the water 59 , toward the top of a target aquatic weed 56 . At this juncture, the distal end 14 of the pole 12 is located either in or adjacent the submersed tendrils 61 of the targeted aquatic weed 56 , while the proximate end 13 of the pole 12 remains above the surface of the water 59 in the hands of the user 57 .
[0047] The user 57 then deploys the weed engaging means 21 , by actuating remote control means 27 thereby moving weed engaging means 21 from a withdrawn position to an extended position. Depending upon the density of the weed, it may also be desirable to deploy the weed engaging means 21 before the distal end 14 is completely engaged with the weed tendrils 61 . The more dense the weed material, the more desirable it will be to delay this step, until the distal end 14 is at least partially within the mass of the tendrils 61 .
[0048] As the pole 12 sinks farther into the weed 56 , the pole 12 is rotated, either clockwise or counter-clockwise, so that the weed engaging means 21 more fully engages and becomes entangled with the weed tendrils 61 . The user 57 will feel resistance to further rotation, when the weed 56 has been fully engaged and wound up by the apparatus 11 . (See, FIG. 8 ). It has also been observed that the cable 32 also becomes entangled with the tendrils 61 , assisting in this operation.
[0049] Pulling forces are then applied to the pole 12 , and those forces are directly transferred to the body of the weed and its roots 62 , still secured in the soil 63 . If forces which are either abrupt or too great are applied, the tendrils may break, thereby losing the opportunity to remove the entire weed 56 . Downward pushing forces may also be applied to the pole 12 , alternating with the pulling forces, to urge the roots 62 from their hold on the soil 63 . (See, FIG. 9 ).
[0050] By observing the surface of the water 59 , the user 57 may see oxygen bubbles 64 which have been released from the soil 63 as the roots 62 are extracted. (See, FIG. 10 ). This is a good sign that the roots 62 are in the process of being released by the soil 63 . At the same time, the user 57 will feel a lessening to pulling resistance, as the roots 62 give way. Through continuing rotation of the pole 12 , while straight up pulling forces are applied, the entire weed 56 will be maintained under control while it is brought to the surface of the water 59 . This rotation of the weed 56 will also help to cleanse a certain amount of mud off the roots 62 , making removal of the weed 56 from the water an easier process.
[0051] FIG. 11 shows the weed 56 being removed from the water, with all tendrils 61 and roots 62 intact. Typically, the weed 56 is dragged onto the dock 58 , and laid out for drying. As a final step, shown in FIG. 13 , the user 57 again employs the remote control means 27 , to move the weed engaging means 21 into a withdrawn position. This facilitates the easy removal of the apparatus 11 from the main body of the weed 56 . | An apparatus and method for removing rooted aquatic weeds. An elongated pole includes a remotely operated arm at its distal end. The arm is movable from a disengaged position to an engaged position. The user pushes the distal end of the pole underwater, until it enters the tendrils of a target weed. The remote control is activated, deploying the arm into an engaged position, generally perpendicular to the pole. Simultaneously, the user begins to rotate the pole until resistance to further rotation is detected. This indicates that the tendrils of the weed have been engaged by the arm. Pushing and pulling forces are applied to the pole, until the user detects that the roots of the weed have been extracted from the soil. Continued rotation of the pole while pulling upwardly brings the weed to the water surface, where it may be pulled completely out of the water. | 0 |
PRIOR APPLICATION
This application is a continuation in part of U.S. patent application Ser. No. 871,076 filed June 5, 1986, now abandoned.
BACKGROUND OF THE INVENTION
The most common preparative HPLC columns have simply been tubes into which a packing medium is introduced and the bed allowed to settle by means of vibration and solvent flow. This method has been cumbersome and has had problems in the area of reproducibility. Other methods have been introduced to overcome these limitations but have their drawbacks. One method embodies radial compression in which the medium in a flexible tube is placed in a chamber and squeezed by pneumatic or hydraulic pressure. An obvious limitation to this method is the durability of the flexible tube, especially when in contact with various solvents used during the chromatographic process.
Other methods use some form of axial compression in which a a member acts on one end of the column bed to compress it. These methods have limitations in that the friction of the packing medium acting on the wall of the column causes somewhat of a compression gradient in the bed, thus resulting in a more tightly packed bed closest to the member end. Another limitation to this method has been pressure so that it is limited in use to only the larger particle size and less efficient packing medium.
It is the purpose of this invention to provide a column so structured as to insure reproducible bed regardless of the particle size of the medium used by nonuniformly decreasing the cross-section of the bed in the axial direction.
It is the further purpose of this invention to also compress the bed from one end in conjunction with decreasing the cross-section of the bed to maintain the bed efficiency over a long period of time and as the column is being used.
SUMMARY OF THE INVENTION
An HPLC column comprising a hollow cylindrical barrel provided with closures (caps) at its opposite ends defining therewith a closed chamber for receiving a packing bed of liquid chromatography particulate material, said closures containing openings and, respectively, an inlet opening at one end and an outlet opening at the other end, an elongate plunger mounted in the barrel with its ends extending therefrom, said plunger being movable axially within the barrel and embodying an axially-extending tapered portion extending from the inlet end toward the outlet end and means at one end of the plunger closest to the outlet end of the barrel and extending therefrom operative to move the plunger axially within the chamber to adjust the compaction of the particulate material within the closed chamber.
In an improved version of the HPLC column according to this invention, a cylinder moveable within the barrel is also provided to urge one end of the media bed within the barrel towards the other end of the barrel. As shown in the improved embodiment, the cylinder is coupled to the plunger (spindle) for movement therewith to apply force to the chromatography media bed.
According to the method of preparing the column for use, the particulate media is introduced into the column about the plunger, the caps secured in place, the bed slowly wetted with solvent appropriate to the type of packing, and the nut located at the end of the plunger is tightened to torque value such that the pressure does not exceed that which would crush the particulate material. In the improved version of this invention, a cycliner is coupled to the plunger and one end of the media bed is in engagement therewith to push on the inlet end of the bed as force is applied to the bed by the tapered plunger as it is moved towards the outlet end of the barrel.
As used herein, the term HPLC column means a high performance liquid chromatography column also sometimes referred to as a high pressure liquid chromatography column. Reference may be had to U.S. Pat. No. 4,582,608 which discloses an HPLC column for information purposes.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will now be described with reference to the accompanying drawings, wherein:
FIG. 1 is a vertical section of the HPLC colums disposed in a position with its inlet end at the top of the figure and its outlet end at the lower end portion of the figure;
FIG. 2 is an expanded cross-sectional view of a portion of the end cap at the inlet end of the column of FIG. 1;
FIG. 3 is an expanded cross-sectional view of a flow distributor head at the inlet end which fits into the end cap of FIG. 2;
FIG. 4 is a top plan view of the head shown in FIG. 3;
FIG. 5 is an expanded top plan view of the distributor flow plate at the inlet end of the column shown in FIG. 1;
FIG. 6 is a cross-sectional view taken along line 6--6 in FIG. 5;
FIG. 7 is a bottom plan view of the plate of FIG. 5;
FIG. 8 is an expanded top plan view of the distributior support plate at the outlet end of the column of FIG. 1;
FIG. 9 is a sectional view taken along line 9--9 in FIG. 8;
FIG. 10 is a bottom plan view of the distributor plate shown in FIG. 8;
FIG. 11 is a cross-sectional view of a different flow distribution head to take the place of the head shown in FIGS. 3 and 4;
FIG. 12 is a cross-sectional view of an improved HPLC column according to the invention;
FIG. 13 is an enlarged cross-sectional view with parts broken away of the improved column of FIG. 12;
FIG. 14 is a sectional view taken along line 14--14 of FIG. 13;
FIG. 15 is a top plan view of the flow distributor head of FIG. 12; and
FIG. 16 is a top plan view of the flow distributor plate of FIG. 12.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to the drawings, FIG. 1, the HPLC column according to this invention comprises a hollow cylindrical barrel 10 of uniform inside diameter having an inner wall 10-1 provided with closures 12 and 14 at its upper and lower ends, respectively, which, in conjunction with the inner wall of hollow cylindrical barrel 10, define a closed chamber 16 within which particulate material M is introduced. The barrel at the upper (inlet) end is provided by an annular collar 18 welded thereto and a cap 20 is detachably secured to the collar 18 by bolts 22. Similarly, the barrel at the lower (outlet) end is provided by a welded collar 24 and a cap 26 is secured thereto by bolts 28. Centrally of the cap 20, there is provided an opening 30 and centrally of the cap 26, there is provided an opening 32 in alignment with the opening 30. The caps 20 and 26 are provided with recesses 34 and 36 concentric with the openings 30 and 32. An elongate plunger (spindle) 38 is mounted within the barrel with its opposite ends extending, respectively, through the openings 30 and 32 and is axially supported therein by glands e.g., teflon ring comprising a packing 40 disposed in the recess 34 and held therein by a threaded nut 42 and a packing e.g., teflon ring 44 held in the recess 36 by a nut 46. Gaskets 48 and 50 are disposed between the respective collars and caps.
The upper cap 20 is provided with an inlet passage 52, the inner end of which terminates close to the axis of the plunger (spindle) 38 and the cap 26 is provided with an outlet passage 54, the inner end of which is closely adjacent the axis of the plunger. Desirably, distributors 60 and 61 are recessed into the caps at the opposite ends of the barrel to insure inform distribution and collection of the solvent as is conventional. See for example U.S. Pat. No. 4,582,608 for a typical distributor.
In accordance with the invention, the spindle (plunger) 38 is provided with portion 56a which extends through the cap 20. A tapered e.g., conical portion 56b having about 3.02° of taper and which extends from the cylindrical portion 56a partway through the chamber and a cylindrical portion 56c of smaller diameter than the cylindrical portion 56a extending the remainder of the way through the chamber and through the cap 26. The tapered e.g., conically-shaped portion 56b of the plunger is located centrally of the barrel within the column of particulate medium (media) contained therein comprising the bed of packing disposed therein and provides, when adjusted axially within the column, for applying pressure to the particulate medium (media) both radially and axially and has for its purpose the achievement of a uniform and reproducible packing of the particulate material. To effect longitudinal movement of the spindle (plunger) 38 and, hence, adjustment of the packing pressure, the spindle has at its lower end, externally of the barrel, a threaded portion 56 about which there is disposed a shroud 58, one end of which bears against the cap 26 and the other end of which contains an opening through which the threaded portion 56 extends and to which a nut 60 is applied. By rotating the nut 60, the spindle may be drawn downwardly within the barrel to exert both axial and radial pressure on the particulate material within the barrel.
The particulate material is introduced into the barrel about the spindle, the end caps secured in place and the bed of particulate material slowly wetted with a solvent appropriate to the type of packing, whereupon the nut 60 is tightened to a torque value such that the pressure on the packing media does not exceed 300 pounds per square inch or other predetermined value to prevent crushing of the particulate material. The forces created by the conical plunger have both vertical and horizontal components which result in a very uniform and reproducible packed bed.
Reference should now be had to FIGS. 2 to 7 which illustrates the member 20 and shows the inlet 52 for fluid entering the column, the inlet having a circumferential channel 52-1 which provides fluid to the distributor 60. The distributor 60 comprises a head 60-1 which has holes 60-1a in alignment with channel 52-1 and a dome shaped portion 60-1c. The fluid passes through the holes 60-1a and is then applied to the distribution plate 60-2 top having the holes 60-2a at a position of the plate offset from the holes 60-2a so that the fluid dosen't go directly through hole 60-1a and then directly through holes 60-2a. Thereafter the fluid containing the sample passes into distribution channels 60-2b aligned with the holes 60-2a and hence through a conventional frit plate (disc) 60-3 e.g. a conventional scintered type having a 2 porosity such as may be purchased from Mott Metalurgical Farmington, Conn.
FIGS. 8 to 10 illustrate the support plate 61-1 (at outlet end) having holes 61-1a on the side facing the particulate media bed M. Fluid from the bed first passes through a frit or scintered porous disc 61-1 e.g. 2 porosity in contact with the support plate 61-1 (see FIG. 1). Fluid from the channels 61-2b passes into the outlet 54 via circumferential channel 54-1.
It should be understood that the exact nature of the inlet distributor 60 and the outlet distributor 61 can vary as would be apparent to those skilled in the art.
In FIG. 11, there is shown yet another distributor head with holes 70-1 having a ring like circumferential dome 70-2 which can be used in the aforementioned column incorporating the packing apparatus of this invention.
Reference should now be had to FIGS. 12 to 16 which illustrates an improved version of the HPLC column previously described.
In these FIGS. 12 to 16, the HPLC column comprises a hollow cylindrical barrel provided with closures at its opposite ends defining therewith a closed chamber for receiving a packing bed of particulate material (media bed). The closures contain centrally-located, axially-aligned openings and an outlet at one end, an elongate plunger (spindle) mounted in the barrel with its ends extending therefrom through said axial openings. Gaskets are disposed in the openings about the plunger, said plunger being movable axially within the barrel and embodying an axially-extending conical portion coupled to a cylindrical segment at the inlet end. The plunger extends from the inlet end toward the outlet end and there is provided means at one end of the plunger externally of the cap at that end operative to move the plunger and cylindrical segment axially within the chamber to adjust the compaction of the particulate material within the chamber and means at the opposite end of the plunger to provide an inlet for solvent and sample flow. The means for effecting axial movement of the plunger comprises a thread on the plunger externally of the one end, and a nut threaded onto the threaded end of the plunger against the piston. The cylindrical segment at the inlet end of the plunger preferably includes two split teflon guide-rings and a high pressure teflon graphite piston seal which make intimate contact with the internal wall of the hollow cylindrical barrel wall and means to provide inlet for an evenly distributed flow over the top of the packing bed. Gasketing is preferably provided by recesses concentric with the openings within which sealing elements are disposed and held compacted about the plunger by nuts threaded into the recesses against the gaskets.
According to the method of preparing the column for use, the plunger along with the inlet end cap is secured in place, the column is inverted, the particulate media is introduced into the column about the plunger with the outlet cap removed and then the outlet and cap is secured, the column returned to its normal upright position (as shown in FIG. 12) the bed slowly wetted with solvent appropriate to the type of packing and the nut located at the end of the plunger is tightened to torque value such that the pressure does not exceed that which would crush the particulate material as the cylinder (cylindrical segment) and plunger are drawndownwardly.
More particularly, these FIGS. 12 to 16 shown an HPLC column 100 according to this invention comprises a hollow cylindrical barrel 110 of uniform inside diameter provided with closures 112 and 114 at its upper and lower ends, respectively, which, in conjunction with the hollow cylinderical barrel 110; define a closed chamber 116 within which particulate material M is introduced. The barrel 110 at the upper end is provided with an annular collar 118 welded thereto and cap 120 is detachably secured to the collar by bolts 122. Similarly, the barrel at the lower end is provided by a collar 124 and a cap 126 is secured by bolts 128. Centrally of the cap 120, there is provided an opening 130 and centrally of the cap 126, there is provided an opening 132 in alignment with the opening 130. The caps 120 and 126 are provided with recesses 134 and 136 concentric with the openings 130 and 132. An elongate plunger (spindle) 138 with a cylinder 139 coupled thereto is mounted within the column 110 with the opposite ends of the plunger 138 extending, respectively, through the openings 130 and 132 and is axially supported by glands comprising a packing 140 e.g., teflon gasket disposed in recess 134 and held therein by a threaded nut 142 and a packing e.g., of teflon 144 held in recess 136 by nut 146. The cylindrical portion (segment) 139 is fit with guide rings 139a and 139b e.g., teflon O-rings and a piston seal 139c eg., Bal-Seal brand seal made by Bal-Seal Engineering of Santa Ana, Calif. Sealing gaskets are disposed between the respective collars and caps.
The lower cap 126 is provided with an outlet passage 154, the inner end of which is closely adjacent the axis of the plunger. The outlet cap 126 is also provided with a recess to accept a porous scintered element 127 and a support plate 128 to provide containment of the packed bed and uniform exit of solvent. Further, scintered element 127 is provided with a hole fit with a teflon-graphite "Hat" seal 127a which effectively prevents leakage of packing media and solvent around the plunger portion 156c.
In accordance with the invention, the spindle (plunger) 138 is composed of four separate segments: a cylindrical portion 156a which extends through the cap 120 and provides an inlet; a tapered portion 156b e.g., conically shaped; a cylindrical portion 156c of smaller diameter than the cylindrical portion 156d extending the remainder of the way through the chamber and through the cap 126; and cylindrical portion 139 providing containment of the packed bed e.g., of silicia chromotography media and means 160 for uniform distribution of the solvent finally through a scintered element 139d which is a part of the cylindrical portion 13. The spindle portion comprised of segments 156b and 156c is provided with a means e.g., threaded portion to attach tightly to segment 156a passing through the center of cylinder 139 holding it secure with all of its elements and providing a means to 156a-1 to introduce the solvent to the distribution portion of cylinder 139. Gasketing is provided to insure a liquid tight seal between the segment 156a, cylinder 139 and segment 156b. The tapered or conically-shaped portion 156b is located centrally of the barrel along with the cylindrical portion 139. When adjusted axially within the column, the plunger portion 156b and the cylinder 139 for applying pressure to the particulate medium both radially and axially and has for its purpose to achieve a tightly packed bed i.e., packing of the particulate material. To effect longitudinal movement of the plunger 138 and, hence, adjustment of the packing pressure, the plunger has at its lower end, externally of the barrel, a threaded portion 156 about which there is disposed a hollow cylinder 158, one end of which bears against the nut 146 and other end through which the threaded portion 156 extends and to which a nut 160 is applied. By rotating the nut 160, the spindle may be drawn downwardly within the barrel to exert both radial and axial forces on the particulate material within the barrel.
With the column in an inverted postion and inlet end cap 120 and plunger (spindle) 138 secure, the particulate material is introduced into the barrel about the spindle. The outlet end cap 126, along with all other elements, is secured and the particulate material slowly wetted with a solvent appropriate to the type of packing, whereupon the nut 160 is tightened to a torque value such that the pressure on the packing media does not exceed 300 pounds per square inch or other predetermined value to prevent crushing of the particulate material. The forces created by the cylinder which applies a force vertically through the scintered plate as it is moved downwardly with the spindle to which it is coupled to movement therewith and by the plunger which applies both vertical and horizontal force components results in a very uniform and reproducible packed bed.
In FIGS. 13, 14 15 and 16 there is shown the means 160 for distribution of fluid from the channel 156-2a and channel 156-2b onto the media bed M. The fluid from channel 156-2b passes into the channel 160-1b and then through holes 160-1a of the head 160-1. Thereafter the fluid to be separated by the bed is directed against the plate 160-2 and moves through holes 160-2a thereof into the cylinder 139 channels 160-1b onto the scintered porous plate 139d and then onto the bed M. See FIGS. 5 to 7 for more detail of a plate. At the outlet end of the frit or scintered disc is shown at 127 and the support plate is shown at 128 and is of the same type as disclosed in FIGS. 1 to 10. Fluid passes through holes 128-1 on the top and then into channels 128-2 which communicate with circumferential channel 154-1 of outlet 154. A suitable taper or the conical portion 156-b of the plunger is about 2.20°.
It should be understood that the present disclosure is for the purpose of illustration only and includes all modifications or improvements which fall within the scope of the appended claims. | This invention relates to a column for use in preparative HPLC so structured as to insure a reproducible packing bed uniformity regardless of the particle size of the medium used. | 1 |
BACKGROUND OF THE INVENTION
As is well known, insects and like small animal life are often very difficult to capture, especially with safety to the persons involved as well as to the animal life being obtained. Heretofore nets have been the primary means for capturing insects, and these are subject to serious drawbacks, including the lack of positive retention, need for handling in withdrawal, likelihood of injury to the captured insect, the need for agility, speed and skill, among many other reasons.
SUMMARY OF THE INVENTION
It is, therefore, an important object of the present invention to provide a unique and extremely simple insect capturing device which overcomes the above mentioned difficulties, is capable of highly effective use without special training, agility or skill, substantially assures capture without injury to the insect, permitting withdrawal of the insect in a proper container without handling by the operator or posing any hazard to the operator's safety.
It is another object of the present invention to provide an insect capturing device having the advantageous characteristics mentioned in the preceding paragraph which is extremely simple in construction for economical manufacture and sale in mass markets as a toy, while being of sturdy construction and reliability in operation throughout a long useful life for utilization by scientists and other animal life collectors.
Other objects of the present invention will become apparent upon reading the following specification and referring to the accompanying drawings, which form a material part of this disclosure.
The invention accordingly consists in the features of construction, combinations of elements, and arrangements of parts, which will be exemplified in the construction hereinafter described, and of which the scope will be indicated by the appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view showing an insect capturing device constructed in accordance with the teachings of the present invention and in an open, set or cocked condition.
FIG. 2 is a longitudinal sectional view taken generally along the line 2--2 of FIG. 1, enlarged for clarity and broken away to conserve drawing space.
FIG. 3 is a transverse sectional view taken generally along the line 3--3 of FIG. 2.
FIG. 4 is a partial transverse sectional view taken generally along the line 4--4 of FIG. 2.
FIG. 5 is a partial perspective view of the handle of the instant device, broken away to conserve drawing space, and enlarge for clarity.
FIG. 6 is a partial transverse sectional view taken generally along the line 6--6 of FIG. 2.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now more particularly to the drawings, and specifically to FIG. 1 thereof, the insect capturing device is there illustrated in toto and generally designated 10. Broadly, the insect capturing device includes a longitudinally elongate handle 11 having at one end insect receiving means 12. Mounting means 13 is longitudinally extensile and retractile with respect to the handle 11 and carries on its outer end an insect catcher 14. As will appear more fully hereinafter, the insect catcher 14, being generally hollow in the direction toward the receiver 12 catches an insect and conveys the same to the receiver for retention thereby.
Considering now the enlarged sectional view of FIG. 2, the handle 11 may be seen as defined by an elongate hollow open ended tube 20, say fabricated of plastic or other suitable material. The inner end region of tube 20, rightward as seen in the drawings, may be externally threaded, as at 21, and spaced adjacent to but inwardly of the threaded region 21 there may be provided a series of longitudinally spaced groups of annularly arranged through openings or holes 22, 23 and 24. The annular array of through holes 22 may be adjacent to the end of handle tube 20, and the annular arrays or groups of holes 23 and 24 may be successively spaced inwardly from the holes 22 and 23, respectively. The other or outer end region of handle tube 20 may be externally threaded, as at 25, and an intermediate region of tube 20 may be provided with an arcuate partially circumferential slot 26, and adjacent thereto and spaced inwardly therefrom a longitudinal cutout or opening 27. As best seen in FIG. 5, the longitudinal handle opening 27 extends along a longitudinal axis generally bisecting the arc of partial circumferential slot 26. Further, opposite end edges of longitudinal opening 27 are beveled or inclined to face upwardly and outwardly.
Provided on the inner end of handle tube 20 may be a closure or cap 30, say internally threaded for removable engagement with external tube threads 21. Interiorly of the end closure or cap 30 is a pad, cushion or bumper 31 of suitable resilient material, such as rubber, or the like, and facing into the inner end of tube 20.
On the outer end of the handle tube 20 is the receiver 12 which may include a holder or retaining member 32 carrying a plurality of cups or receptacles 33. More specifically, the holder or retaining member 32 may include a cylindrically hollow central part or hub 35 having internal screw threads and circumposed in threaded engagement about the external screw threads 25 of the handle tube 20. Just outward of the outer end of handle tube 20, the holder 32 may include a generally circular plate or disc 36 having a central through opening or hole 37 communicating with the interior of handle tube 20 and extending radially outwardly therefrom to a generally circular periphery 38 substantially concentric with the tube 20. The plate or disc 36 may be formed with a plurality of through openings or holes 40, which may be four in number, as illustrated, or otherwise, and which are each provided at spaced locations thereabout a plurality of yieldable internal projections or nubs 41. Carried by the plate or disc 36, extending circumferentially about each opening or hole 40 is a tubular retaining ring or loop 42. The retaining loops 42 may extend from the plate 36 longitudinally inwardly of and parallel to the handle tube 20.
A plurality of generally cylindrical receptacles or cups 45, each having one end open and one end closed, are respectively snugly engaged in the several retaining loops 42. For example, as seen in FIG. 2 the lower retaining loop 42 receives a receptacle 45 with the closed receptacle end proximate to and in closing relation with the lower opening 40. The upper receptacle or cup 45 is arranged with its open end adjacent to and opening through the adjacent opening 40, its closed end being spaced inwardly from the plate 36. Provided removably in a storage position over the inner end of each receptacle or cup 45 is a receptacle closure or cap 46. That is, the upper receptacle closure or cap 46 is removably engaged over the inner closed end of upper receptacle 45, and the lower receptacle closure or cap 46 is removably engaged over and in closing relation with the inner open end of the lower receptacle 45. The caps 46 may be frictionally or otherwise removably engaged on respective receptacles 45. For reasons which will become apparent hereinafter, the receptacles 45 are selectively carried by respective retaining members or loops 42 with their open ends proximate to and opening through the plate opening 40 (as is shown in FIG. 2), or remote from the plate with the closed receptacle end closing the respective plate opening (not shown).
Adjacent to and spaced from the open end of each receptacle 45, there is provided in the receptacle side wall a generally semi-circular slit or slot 52. The outer side of each receptacle closure or cap 46 is provided with a circumferential rim or flange 47 having a gap or opening 48 and combining with the cap wall to define a pocket 49. The pocket 49 is adapted to snugly and removably receive a generally flat partition member or disc 50 having a generally coplanar finger pull or tab 51 extending radially outwardly through and beyond the rim opening 48.
In the condition shown in FIG. 2, the lower receptacle cap 46 has its pocket 49 provided therein with a partition 50 frictionally retained therein and manually removable therefrom by deliberate pull on the tab 51. In the pocket 49 of upper receptacle cap 46 there is no partition 50. However, such partition is shown inserted through slot 52 to extend in closing relation across the upper receptacle 45, for purposes appearing presently in greater detail.
The mounting member 13 may be comprised of an elongate rod 55 extending spacedly through the central plate opening 37 and having an enlargement 56, in the nature of a piston, on its inner end slidably received in the handle tube 20. The enlargement or piston 56 may be formed with a circumferential groove 57, and a coil compression spring 58 is circumposed about the rod within the tube 20 havings its opposite ends in bearing engagement with the enlargement or piston 56 and a bearing engagement washer 59 between the spring and the plate 36 to urge the mounting rod 55 toward its longitudinally retracted position.
Carried on the outer end of the mounting rod 55 is the catcher 14, which may be of a hollow open-work or reticulate configuration, say frusto-conical as illustrated, or other suitable configuration with its interior hollow facing toward the receiver 21. The catcher 14 may advantageously fabricated of soft resiliently flexible material, such as plastic, or the like to avoid injury to insects being captured. The smaller, outer closed end of the catcher 14 may be provided with an enlargement, finger-grip part or knob 15 to facilitate manual grasping and opening or recocking, as will appear presently. The open larger diameter of the conical frustum configuration of catcher 14 may be provided with a plurality of reasonably flexible extensions or fingers, as at 56, extending obliquely toward the receiver 12, for gently guiding an insect toward the interior hollow of the catcher.
Exteriorly along an inner region of the handle 11 is provided an operating member or lever 60. The lever may be of elongate strip-like construction including an elongate inwardly extending handle portion 61 which terminates at its inner end in an enlarged finger press 62. Spaced from the finger press 62, the lever 60 is provided with an inwardly extending bight 63 entering into the longitudinal tube opening 27 and rockable therein for swinging movement of the arm 61. The bight region 27 thereby defines a fulcrum mounting the arm 61, and opposite to the arm the strip or lever extends from the bight region 27 to an outwardly projecting arcuate portion 64, thence to a flat portion 65 extending longitudinally closely along the tube 20, and finally to an outwardly projecting bight portion 66 terminating in an end portion or pawl 67 engagable through slot 26. A resilient member or band 68 may be circumposed about the flat strip portion 65 and adjacent region of tube 20, to yieldably urge the lever 60 toward its position illustrated in FIG. 2. However, the lever 60 is swingable about its fulcrum 63 upon depression of arm 61 and thumb press 62 against the resilient restoring force of band 68 to swing end portion or pawl 67 outwardly with respect to slot 26. In the condition shown in FIG. 2 it will be observed that lever end or pawl 67 engages in the slot 57 of piston 56 to retain the latter in position, the extended position of mounting rod 56 and catcher 14. Upon depression of lever finger press 62, lever end or pawl 67 is withdrawn from groove 57 to release rod 55 and catcher 14 for retractile movement under the force of spring 58. The piston 56 retracts toward and into resilient impact with pad 31. Circumposed about the handle tube 20, in the region of openings 22, 23 and 24, is a closure sleeve or tube 70 slidable to close one or more of the groups of apertures. By closure of one or more groups of apertures 22, 23 and 24 by closure sleeve 70, pneumatic or fluid pressure interiorly of handle tube 20 is built up upon release of piston 56 for movement toward closure cap 30. Thus, the groups of apertures 22, 23 and 24 provide fluid escape or vent means, and the more apertures uncovered or open, the less resistance to retractile movement of piston 56 and rod 55. The closure sleeve 70 thereby serves to selectively retard and determine the speed of retraction of rod 55 and catcher 14.
The rod 55 may be extended, as by manually grasping and withdrawing the knob 15 of catcher 14, during which the pawl 67 rides outwardly on the sloped or conical portion 54 of piston 56 and snaps into the slot 57 to retain the catcher in open or cocked position.
In the open or cocked condition shown in FIGS. 1 and 2, with the catcher 14 properly positioned to catch a desired insect, the lever 60 may be manually depressed to retract the catcher and thereby catch the insect. With the insect thereby caught in the hollow catcher and transported therefrom into a receptcle 45, the disc 50 may then be removed from pocket 49 and inserted into slot 52 so that disc 50 may prevent said insect from escaping, as by flying or crawling, from the receptacle when the latter is in or removed from retaining loop 42.
The receptacle or cup 45 may then be withdrawn from its retaining loop 42 and the closure cap 46 removed from the closed receptacle end and placed on the open receptacle end, after which the disc or trap partition 50 may be withdrawn and engaged in pocket 49 of the closure 46. The closed end of the receptacle 45 may then be inserted outwardly into retention loop or ring 42 into engagement with limiting nubs 41, the condition of the lower receptacle 45. This procedure may be repeated until all receptacles contain insects. Of course, the insect containing receptacles need not be carried by the retaining loops 42, but may be placed in storage and empty receptacles employed.
From the foregoing it is seen that the present invention provides an insect capturing device which is extremely simple and entirely safe in operation, of durable and reliable structure, and otherwise fully accomplishes its intended purposes.
Although the present invention has been described in some detail by way of illustration and example for purposes of clarity of understanding, it is understood that certain changes and modifications may be made within the spirit of the invention. | An insect capturing device including a handle carrying an outwardly facing receiver and a catcher shiftable toward and away from the receiver for catching an insect and depositing it in the receiver. | 0 |
FIELD OF THE INVENTION
[0001] The present invention relates to an apparatus for transfer or dissipation of heat from heat-generating components, and more particularly to a heat spreader having a vapor chamber defined therein and a method of manufacturing the heat spreader.
DESCRIPTION OF RELATED ART
[0002] It is well known that heat is generated during normal operations of a variety of electronic components, such as integrated circuit chips of computers. To ensure normal and safe operations, cooling devices such as heat sinks plus electric fans are often employed to dissipate the generated heat away from these electronic components.
[0003] As progress continues to be made in electronic industries, integrated circuit chips of computers are made to be more powerful while maintaining an unchanged size or even a smaller size. As a result, the amount of heat generated by these chips is commensurately increased. The heat sinks used to cool these chips are accordingly made larger in order to possess a higher heat removal capacity, which causes the heat sinks to have a much larger footprint than the chips. Generally speaking, a heat sink is most effective when there is a uniform heat flux applied over an entire base of the heat sink. When a heat sink with a large base is attached to an integrated circuit chip with a much smaller contact area, there is significant resistance to the flow of heat to the other portions of the heat sink base which are not in direct contact with the chip.
[0004] Currently, an advantageous mechanism for overcoming the resistance to heat flow in a heat sink base is to attach a heat spreader to the heat sink base or directly make the heat sink base as a heat spreader. In this situation, the heat spreader is configured to have a flat type configuration. Typically, the heat spreader includes a vacuum vessel defining therein a vapor chamber, and a working fluid contained in the chamber. In most cases, a wick structure is provided in the chamber, lining an inside wall of the vessel. As an integrated circuit chip is maintained in thermal contact with and transfers heat to the heat spreader, the working fluid contained in the chamber corresponding to the hot contacting location vaporizes into vapor. The vapor then runs quickly to be full of the chamber, and wherever the vapor comes into contact with a cooler wall surface of the vessel, it releases its latent heat of vaporization and thereafter turns into condensate. The condensate then returns back to the hot contacting location via a capillary force generated by the wick structure, to thereby remove the heat generated by the chip. In the chamber of the heat spreader, the thermal resistance associated with the vapor spreading is negligible, thus providing an effective means of spreading the heat from a concentrated source to a large heat transfer surface.
[0005] Conventionally, this flat type heat spreader is typically made by connecting two discrete metal plates together. Soldering process is such a method that is widely used to connect the two discrete plates together. However, the heat spreader made by this method is sometimes a little heavier than what is expected, since in the soldering process each of the metal plates is required, in view of the soldering requirements thereof, to have a minimum wall thickness which in some cases may be thicker than normally required. In addition, the reliability of the heat spreader made by the soldering process is also a problem. If the heat spreader is in fact not hermetically sealed in the soldering process, the chamber of the heat spreader will gradually lose its vacuum condition.
[0006] On the other hand, if the heat spreader is configured to have an elongated configuration, the heat spreader can be used as a heat pipe for spreading heat from one location to another remote location. For example, a first end of the heat pipe is thermally connected to a heat source while a second end of the heat pipe is thermally connected to a plurality of metal fins, thus transferring the heat generated by the heat source to the metal fins where the heat is dissipated. In this situation, the condensate resulted in the second end of the heat pipe has to travel a long distance from the second end to the first end of the heat pipe. The wick structure provided in the heat pipe is expected to provide a high capillary force and meanwhile produce a low flow resistance for the condensate so as to draw the condensate back timely. However, the wick structure provided in the conventional heat pipe generally has a uniform pore size distribution over its entire length. This uniform-type wick structure cannot satisfy this requirement. If the condensate is not timely brought back from the second end, the heat pipe will suffer dry-out problem at the first end thereof.
[0007] Therefore, it is desirable to provide a method of manufacturing a vapor chamber-based heat spreader which overcomes the foregoing disadvantages of the conventional soldering process. What is also desirable is to provide a vapor chamber-based heat spreader which can draw the condensate back effectively and timely.
SUMMARY OF INVENTION
[0008] The present invention relates, in one aspect, to a method for manufacturing a heat spreader. The method includes the following steps: (1) providing a metal foam framework, the metal foam framework having a plurality of pores and defining therein a major space; (2) filling a material into the pores and the major space of the metal foam framework and solidifying the material in the metal foam framework; (3) electrodepositing a layer of metal coating on an outer surface of the metal foam framework; (4) removing the material from the metal foam framework; and (5) filling a working fluid into the major space in the coating layer and hermetically sealing the coating layer to thereby obtain the heat spreader. The heat spreader has therein a wick structure formed of the metal foam framework and a vapor chamber formed of the major space. By this method, the heat spreader is integrally formed and therefore the reliability thereof improved. Also, the wall thickness of the heat spreader can be easily controlled by regulating the time period and the voltage associated with the electrodeposition step.
[0009] The present invention relates, in another aspect, to a heat spreader applicable for removing heat from a heat-generating component. The heat spreader includes a metal casing and a wick structure lines an inner surface of the metal casing. The metal casing defines therein a chamber and the wick structure occupies a portion of the chamber. The metal casing includes an evaporating section and a condensing section. The wick structure is in the form of a metal foam and has a pore size gradually increasing from the evaporating section towards the condensing section of the metal casing. Thus, a first section of the wick structure in conformity with the condensing section of the metal casing has a larger pore size and produces a relatively low resistance for the condensate in the condensing section. A second section of the wick structure in conformity with the evaporating section of the metal casing has a smaller pore size and is still capable of maintaining a relatively high capillary force for drawing the condensate back to the evaporating section. As a result, the flow resistance to the condensate is reduced as a whole and the condensate is thereby drawn back to the evaporating section effectively and timely.
[0010] Other advantages and novel features of the present invention will become more apparent from the following detailed description of preferred embodiments when taken in conjunction with the accompanying drawings, in which:
BRIEF DESCRIPTION OF DRAWINGS
[0011] FIG. 1 is a top plan view of a heat spreader in accordance with one embodiment of the present invention;
[0012] FIG. 2 is a cross-sectional view of the heat spreader of FIG. 1 , taken along line II-II thereof;
[0013] FIG. 3 is a cross-sectional view of the heat spreader of FIG. 1 , taken along line III-III thereof;
[0014] FIG. 4 is a flow chart showing a preferred method of the present invention for manufacturing the heat spreader of FIG. 1 ;
[0015] FIG. 5 is a cross-sectional view of a wick structure of the heat spreader of FIG. 1 ;
[0016] FIG. 6 is a schematic, cross-sectional view of a device applied for filling a filling material into the wick structure of FIG. 5 ;
[0017] FIG. 7 is a cross-sectional view of the wick structure of FIG. 5 after being filled with the filling material;
[0018] FIG. 8 is a schematic, cross-sectional view of an electrodeposition bath for electrodepositing a layer of metal coating on an outer surface of the wick structure of FIG. 7 ;
[0019] FIG. 9 is a view similar to FIG. 7 , but an outer surface of the wick structure is electrodeposited with the layer of metal coating;
[0020] FIG. 10 is a radial cross-sectional view of a heat spreader in accordance with an alternative embodiment of the present invention; and
[0021] FIG. 11 is a longitudinal cross-sectional view of the heat spreader of FIG. 10 .
DETAILED DESCRIPTION
[0022] FIGS. 1-3 illustrate a heat spreader 10 formed in accordance with a method of the present invention. The heat spreader 10 is integrally formed and has a flat type configuration. The heat spreader 10 includes a metal casing 12 with a chamber 14 defined therein. A wick structure 16 is arranged in the chamber 14 , lining an inner surface of the metal casing 12 and occupying a portion of the chamber 14 . The other portion of the chamber 14 , which is not occupied by the wick structure 16 functions as a vapor-gathering region. The wick structure 16 is a porous structure and is in the form of a metal foam. The metal casing 12 is made of high thermally conductive material such as copper or aluminum. The heat spreader 10 has two open distal ends 121 extending from two opposite sides thereof, respectively. A working fluid (not shown) is injected into the chamber 14 through the two open distal ends 121 and then the heat spreader 10 is evacuated and the two distal ends 121 are hermetically sealed. The working fluid filled into the chamber 14 is saturated in the wick structure 16 and is usually selected from a liquid such as water or alcohol which has a low boiling point and is compatible with the wick structure 16 .
[0023] In operation, the heat spreader 10 may function as an effective mechanism for spreading heat coming from a concentrated heat source (not shown) evenly to a large heat-dissipating surface. For example, a top wall 123 of the heat spreader 10 may be directly attached to a heat sink base (not shown) having a much larger footprint than the heat source in order to spread the heat of the heat source uniformly to the entire heat sink base. Alternatively, a plurality of metal fins may also be directly attached to the top wall 123 of the heat spreader 10 . As a bottom wall 124 of the heat spreader 10 is maintained in thermal contact with the heat source, the working fluid contained in the chamber 14 of the heat spreader 10 evaporates into vapor upon receiving the heat generated by the heat source. The generated vapor enters into the vapor-gathering region of the chamber 14 . Since the thermal resistance associated with the vapor spreading in the chamber 14 is negligible, the vapor then quickly moves towards the cooler top wall 123 of the heat spreader 10 through which the heat carried by the vapor is conducted to the entire heat sink base or the metal fins attached to the heat spreader 10 . Thus, the heat coming from the concentrated heat source is transferred to and uniformly distributed over the large heat-dissipating surface (e.g., the heat sink base or the fins). After the vapor releases the heat, it turns into condensate. In order to bring the condensate back to the bottom wall timely, the wick structure 16 has a plurality of upright ribs 161 connecting the top and bottom walls 123 , 124 of the heat spreader 10 , for transporting the condensate from the top wall 123 towards the bottom wall 124 where it is again available for evaporation, as particular shown in FIG. 2 . Also, these ribs 161 provide support for the heat sink attached to the heat spreader 10 and thus improve the mechanical performance of the heat spreader 10 .
[0024] On the other hand, if the flat type heat spreader 10 is designed to also have an elongated configuration, the heat spreader 10 may function as a plate-type heat pipe for conveying heat from one location to another distant location. For example, if an evaporating section 126 of the elongated heat spreader 10 is thermally attached to a heat source and a cooling device such as a plurality of metal fins is thermally connected to a condensing section 127 of the heat spreader 10 , then the generated vapor in the evaporating section 126 will move toward the condensing section 127 for heat dissipation and the condensate resulting from the vapor in the condensing section 127 will be brought back to the evaporating section 126 via the wick structure 16 . In this situation, the condensate has to travel a long distance as it flows from the condensing section 127 to the evaporating section 126 of the heat spreader 10 . In order to reduce the flow resistance to the condensate, the wick structure 16 is configured to have a pore size that gradually increases from the evaporating section 126 towards the condensing section 127 , as particular shown in FIG. 3 . Thus, the capillary forces and the flow resistances generated by different sections of the wick structure 16 are different. The general rule is that the larger a pore size a wick structure has, the smaller a capillary force and the lower a flow resistance it provides. Under this rule, a first section of the wick structure 16 in conformity with the condensing section 127 of the heat spreader 10 has a pore size larger than that of a second section of the wick structure 16 in conformity with the evaporating section 126 of the heat spreader 10 . Thus, the first section of the wick structure 16 produces a relatively low resistance for the condensate as it flows in the condensing section 127 , and the second section of the wick structure 16 is still capable of maintaining a relatively high capillary force for drawing the condensate back from the condensing section 127 to the evaporating section 126 . As a result, the flow resistance to the condensate is reduced as a whole and the condensate is drawn back to the evaporating section 126 effectively and timely, thus preventing the potential dry-out problem occurring at the evaporating section 126 .
[0025] As shown in FIG. 4 , a method is proposed to manufacture the heat spreader 10 . More details about the method can be easily understood with reference to FIGS. 5-9 . Firstly, a metal foam framework 20 is provided with a hollow space 22 defined therein, as shown in FIG. 5 . The metal foam framework 20 is to be formed as the wick structure 16 of the heat spreader 10 and has a configuration substantially the same as that of the wick structure 16 .
[0026] The metal foam framework 20 may be made of such materials as stainless steel, copper, copper alloy, aluminum alloy and silver. Typically, the metal foam framework 20 is fabricated by expanding and solidifying a pool of liquid metal saturated with an inert gas under pressure. Electroforming is also a typical method for fabricating the metal foam framework 20 , which generally involves steps of providing one kind of porous material such as polyurethane foam, then electrodepositing a layer of metal over the surface of the polyurethane foam and finally heating the resulting product at a high temperature to get rid of the polyurethane foam to thereby obtain a porous metal foam. Another fabrication method for the metal foam, called die-casting process, is also widely used, which generally includes steps of providing one kind of porous material such as polyurethane foam, filling ceramic slurry into the pores of the porous polyurethane foam and then solidifying the ceramic slurry therein, then heating the resulting product at a high temperature to get rid of the polyurethane foam to obtain a matrix of porous ceramic, then filling metal slurry into the pores of the ceramic matrix and finally, getting rid of the ceramic material after solidification of the metal slurry to thereby obtain a porous metal foam. In addition, there are still some other methods suitable for fabrication of metal foam. Fox example, the metal foam can be made by steps of filling a kind of bubble-generating material such as metallic hydride into a metal slurry to generate a large number of bubbles distributing randomly throughout the metal slurry and then solidifying the metal slurry to thereby obtain a metal foam with a plurality of pores therein. The size of the pores of the metal foam framework 20 may be in a wide range, subject to the levels of pressure applied during the fabrication process. If different pressures are applied to different sections of the metal foam framework 20 during the fabrication process, then a metal foam with different pore sizes will be obtained. In the present invention, the pressure is gradually increased along a direction from one end of the metal foam framework 20 toward an opposite end thereof; thus, the pore size is gradually decreased along the direction. Referring to FIG. 3 , the wick structure 16 formed by the metal foam framework 20 has a pore size gradually decreased from the end neighboring the condensing section 127 towards the end neighboring the evaporating section 126 .
[0027] Then, a mold 30 with a cavity therein is provided and the metal foam framework 20 is fittingly placed and received in the cavity of the mold 30 , as shown in FIG. 6 . The cavity of the mold 30 has a configuration substantially the same as that of the chamber 14 of the heat spreader 10 to be formed. A filling material 40 then is filled into the mold 30 via filling tubes 31 connecting to the cavity of the mold 30 . The filling material 40 is selected from such materials that can be easily removed after the heat spreader 10 is formed. For example, the filling material 40 may be paraffin or some kind of plastic or polymeric material that is liquefied when heated. The filling material 40 is filled into the mold 30 when it is at a molten state. The filling material 40 solidifies in the mold 30 when it is cooled. After the filling material 40 in the mold 30 is solidified, the mold 30 is removed. As a result, the pores in the metal foam framework 20 and the space 22 defined by the metal foam framework 20 are filled with the filling material 40 , as shown in FIG. 7 .
[0028] Thereafter, the method, as shown in FIG. 4 , includes an electrodeposition step in order to form the metal casing 12 of the heat spreader 10 . In order to proceed with the electrodeposition, an electrically conductive layer 50 is coated on an outer surface of the metal foam framework 20 filled with the filling material 40 , whereby the outer surface of the metal foam framework 20 is conductive. Then, the metal foam framework 20 with the filling material 40 contained therein is disposed into an electrodeposition bath 60 which contains an electrolyte 61 , as shown in FIG. 8 . The electrodeposition bath 60 includes a cathode electrode 62 and an anode electrode 63 , both of which are immersed in the electrolyte 61 and are located at opposite sides of the metal foam framework 20 , respectively. After electrodepositing for a specific period of time, the metal foam framework 20 is taken out of the electrodeposition bath 60 and a layer of metal coating 70 is accordingly formed on the outer surface of the metal foam framework 20 , as shown in FIG. 9 . Then, the filling material 40 in the metal foam framework 20 is removed away from the coating layer 70 by heating the filing material 40 at a temperature above a melting temperature of the filing material 40 . Although it is not shown in FIG. 9 , it should be recognized that two open ends as illustrated in FIGS. 1 and 3 are also formed by the coating layer 70 after the electrodeposition step so that the filling material 40 is able to be discharged from the metal foam framework 20 and the coating layer 70 . After the filling material 40 is completely removed, the wick structure 16 , the casing 12 and the heat spreader 10 as shown in FIGS. 1-3 are obtained. Thereafter, the working fluid is injected into the casing 12 to be saturated in the wick structure 16 . Finally, the casing 12 is vacuumed and the two open ends are sealed.
[0029] According to the method, the wall thickness of the heat spreader 10 can be easily controlled by regulating the time period and voltage involved in the electrodeposition step. Compared with the conventional soldering method, the reliability of the heat spreader 10 made by the method is also improved since the heat spreader 10 is integrally formed.
[0030] FIGS. 10-11 show a heat spreader 80 in accordance with an alternative embodiment of the present invention. The heat spreader 80 is elongated and is in the form of a round heat pipe. Similarly, the heat spreader 80 may be made by the foregoing method as shown in FIG. 4 . The heat spreader 80 includes an elongated metal casing 81 and a wick structure 82 lining an inner surface of the metal casing 81 . The wick structure 82 is in the form of a metal foam and has a pore size gradually increased from an evaporating section 811 towards a condensing section 812 of the heat spreader 80 .
[0031] It is to be understood, however, that even though numerous characteristics and advantages of the present invention have been set forth in the foregoing description, together with details of the structure and function of the invention, the disclosure is illustrative only, and changes may be made in detail, especially in matters of shape, size, and arrangement of parts within the principles of the invention to the full extent indicated by the broad general meaning of the terms in which the appended claims are expressed. | A heat spreader ( 10 ) and a method for manufacturing the heat spreader are disclosed. The heat spreader includes a metal casing ( 12 ) and a wick structure ( 16 ) lines an inner surface of the metal casing. The metal casing defines therein a chamber ( 14 ) and includes an evaporating section ( 126 ) and a condensing section ( 127 ). The wick structure is in the form of metal foam and occupies a portion of the chamber. In one embodiment, the wick structure has a pore size gradually increasing from the evaporating section towards the condensing section of the metal casing. The heat spreader is manufactured by electrodepositing a layer of metal coating ( 70 ) on an outer surface of a metal foam framework ( 20 ). The metal coating becomes the metal casing and the metal foam framework becomes the wick structure. | 2 |
BACKGROUND OF THE PRESENT INVENTION
[0001] 1. Field of the Present Invention
[0002] The present invention relates to hexahydrophthalate based compound and a process for producing the same. More particularly, the present invention relates to hexahydrophthalate based compound adapted to use as a plasticizer that contains no phthalic acid and benzoic acid, possess physical properties superior to DEHA and DINA in transparency and adhesion and is friendly to organisms and the environment, and a process for producing the same.
[0003] 2. Description of Prior Art
[0004] As known in the art, plasticizers provide capability of being processed, flexibility, and electrical insulation property to resins, such as PVC resin, during finishing thereof. Besides, plasticizers present swelling effect and are dissolvable in resins to form even films. As compared with resins without plasticizers, resins with plasticizers are advantageous to lower thermoplastic temperature, improve flowing and forming ability when heated up, enhance elasticity and reduce hardness.
[0005] Presently, the most popular plasticizers are those made of phthalic anhydride, such as Di-2-ethylhexyl phthalate (DOP) and Di-iso-nonyl phthalate (DINP). However, according to researches and reports, such plasticizers can bring environmental hormone-related problems and therefore are ecologically adverse. On the other hand, plasticizers referred to Di(2-ethylhexyl)adipate (DEHA) made of adipic acid are suspected to be harmful to human liver.
[0006] As to food packing materials, adhesion and transparency of PVC films are highly required. Food packing materials added with DEHA plasticizers are officially banned for being suspected to be harmful to human health. Food-packing materials added with DINA plasticizers feature improved migration of plasticizers due to increased molecular weight, and yet are flawed by deteriorated adhesion.
[0007] In the known prior art, U.S. Pat. No. 3,110,603 discloses polyalkylene glycol dibenzoate highly miscible with PVC resin but inefficient in plasticizing due to benzene rings structurally existing therein. In Publication No. WO2005023926, a diethyleneglycol ester based plasticizer is proposed, wherein the compound is produced from benzoic acid with excessive acidity. However, the compound contains benzene rings and has a relatively low molecular weight, tending to be volatile during a finishing process.
SUMMARY OF THE INVENTION
[0008] One objective of the present invention is to provide a hexahydrophthalate based compound without phthalates and benzoic acids that contain benzene rings.
[0009] The proposed hexahydrophthalate based compound of the invention is selected from the group consisting of the formula
[0000]
[0000] wherein n=2, 3, 4, 5 or 6, and R is alkyl of C 3 -C 11 .
[0010] The proposed hexahydrophthalate based compound is adapted to act as a plasticizer for use in a finishing process of resins, such as polyvinyl chloride (PVC) resin, wherein the plasticizer has improved quality and processing physical property as compared with DEHA plasticizers while being friendly to organisms and the environment.
[0011] Another objective of the present invention is to provide a PVC film for food packing using the aforementioned hexahydrophthalate based compound as a plasticizer. Since the hexahydrophthalate based compound structurally contains relatively higher concentration of ester groups and ether groups, it is highly miscible with PVC resin to contribute desired adhesion to the PVC packing film while being environment-friendly for containing no benzene ring therein.
[0012] Further objective of the present invention is to provide a process for producing the hexahydrophthalate based compound, comprising steps of:
[0000] (a) providing C 4 -C 12 diol and hexahydrophthalic anhydride as materials of a reactant, placing the reactant into a reactor in presence of a catalyst for esterification, introducing gaseous N 2 into the reactor before performing esterification, and performing esterification at 150° C.-260° C. for 3-10 hours until an acidity of the reactant becomes less than 3.0 mgKOH/g to obtain hexahydrophthalic alcohol; wherein the C 4 -C 12 diol is one of C 4 -C 12 straight-chain diols, C 4 -C 12 side-chain diols, C 4 -C 12 diol compounds having ether groups, PEG-200 and PEG-400;
(b) adding C 4 -C 12 monoacid into the reactor for further esterification with the hexahydrophthalic alcohol obtained in the Step (a), wherein a molar ratio of the monoacid to the hexahydrophthalic alcohol is 99.5:100-80:100, introducing gaseous N 2 into the reactor before performing esterification, and performing esterification at 150° C.-260° C. for 3-10 hours until the acidity of the reactant becomes less than 5.0 mgKOH/g to finalize esterification; and
(c) neutralizing the reactant obtained in the Step (b) with an aqueous alkali metal hydroxide solution, and then distilling, dehydrating, drying, filtering and purifying the neutralized reactant successively to obtain the hexahydrophthalate based compound with desired color and purity.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0013] The present invention proposes a hexahydrophthalate based compound without phthalates and benzoic acids that contain benzene rings. The proposed hexahydrophthalate based compound of the invention is selected from the group consisting of the formula
[0000]
[0000] wherein n=2, 3, 4, 5 or 6, and R is alkyl of C 3 -C 11 .
[0014] The proposed hexahydrophthalate based compound is configured to act as a plasticizer for use in a finishing process of resins, such as polyvinyl chloride (PVC) resin.
[0015] A process for producing hexahydrophthalate based compound comprises a first-stage esterification, a second-stage esterification, a neutralization and rinsing, a distillation, a dehydration and a filtration, which will be described in detail below.
First-Stage Esterification:
[0016] To optimize the plasticizing effect of a product, during the first-stage esterification, C 4 -C 12 diol and hexahydrophthalic anhydride are received in a reactor equipped with stir bars and a condenser in presence of a catalyst for esterification. Therein, the diol is overproduced by 0.1%-20% in mole. The catalyst accounts for 0.1 wt %-3.0 wt % of the total weight of the reactant and may be, but not limited to, an acid, such as toluene sulfonic acid, or an organic metal, such as tetraisopropyl titanate. An azeotrope solvent, such as xylene, is added. The azeotrope solvent accounts for 1.0 wt %-15.0 wt % of the total weight of the reactant.
[0017] Gaseous N 2 is introduced into the reactor before esterification, and then esterification is performed at 150° C.-260° C. for 3-10 hours until the acidity of the reactant becomes less than 3.0 mgKOH/g. The reaction yields hexahydrophthalic alcohol before proceeding to the second-stage esterification.
Second-Stage Esterification:
[0018] C 4 -C 12 monoacid is added into the reactor for the second-stage esterification. The molar ratio of the monoacid to the hexahydrophthalic alcohol is 99.5:100-80:100. Gaseous N 2 is introduced into the reactor before esterification, and then esterification is performed at 150° C.-260° C. for 3-10 hours until the acidity of the reactant becomes less than 5.0 mgKOH/g so as to finalize esterification.
Neutralization and Rinsing:
[0019] After the two stages of esterification, the reactant is treated by neutralization and rinsing processes. An aqueous alkali metal hydroxide solution is prepared as a neutralization agent for reacting with residual acid left behind after esterification to form salts. The concentration of alkali metal hydroxide in the solution is 3-20 wt %, preferably 5-15 wt %. After neutralization, the reactant is well rinsed to remove the salts generated as products of the neutralization.
Distillation:
[0020] After rinsing, the reactant is distilled to remove the aqueous solution to obtain anhydrous particles of the reactant.
Dehydration and Filtration:
[0021] The dehydration may, or may not, involve introducing an inert gas, as long as redundant water can be removed from the reactant. The dehydrated reactant is then filtered for removal of impurities to obtain the hexahydrophthalate based compound with desired color and purity.
[0022] The filtration may be conducted at room temperature or higher temperature and may use any known filter, such as cellulose, kieselguhr or wood flour.
[0023] When used as a plasticizer for PVC resin finishing, the disclosed hexahydrophthalate based compound possesses the quality and processing physical properties equivalent to those of normal phthalic acid-based plasticizers, such as DOP and DINP, and DEHA plasticizers and DINA plasticizers. Thus, the plasticizer of the disclosed hexahydrophthalate based compound can be widely used in manufacturing of a variety of plastic products, such as stationery, food packing materials, toys, appliances for children, waterbeds, inflatable products, food containers, baby carriages, bottle caps, household gloves, medical articles, packing for cosmetics, and so on.
[0024] While some embodiments and comparative embodiments will be given below for illustrating the effects of the present invention, it is to be understood that the scope of the present is not limited to the recited embodiments.
Method for Measuring Physical Properties of PVC Film
Transparency Test
[0025] Ten pieces of PVC film each being 0.4 mm thick, 2.5 cm wide, and 5 cm long are piled up and pressed in a pressing machine at 165° C. for 3.5 minutes to obtain a PVC lamination 3 mm thick. After being cooled, the PVC film is measured for transparency thereof.
Hardness Test
[0026] Three pieces of PVC film each being 0.4 mm thick are stacked and pressed into a PVC lamination 1.0 mm thick. Then, the PVC lamination is divided into segments each being 1.0 mm thick, 2.0 cm wide, and 3.0 cm long.
[0027] Six said segments are packed and stacked up to 6 mm in thickness and laid rested at 23° C. for 24 hours. Afterward, the stacked segments are measured at five different positions thereon by a hardness measurement device whose readings are taken after 15 seconds from the beginning of each measurement. Three of the readings are used to determine an average hardness of the stacked segments.
Adhesion Test
[0028] Two pieces of PVC film each being 0.1 mm thick, 3.0 cm wide, and 30 cm long are stacked up and then compressed to expel air that may otherwise exist therebetween. Then, adhesion between the two pieces of PVC film is measured.
Embodiment 1
[0029] Hexahydrophthalic anhydride of 0.5 mole, diethylene glycol of 1.15 moles, catalyst TIPT (Tetraisopropyl titanate) of 1.0 g and xylene of 34.0 g are received in a four-neck flask equipped with magnetic stir bars and a condenser for reaction at 160° C.-180° C. for 5 hours while the reactant is dehydrated during esterification. Esterification lasts until the acidity of the reactant becomes less than 3 mgKOH/g. Afterward, 0.96 mole of 2-EHA is added and esterification continues at 160° C.-230° C. for 5 hours until the acidity of the reactant becomes less than 5 mgKOH/g to finalize esterification.
[0030] After esterification, the reactant is treated by an aqueous alkali metal hydroxide solution, and then rinsed by water, distilled, dehydrated, and filtered to obtain the hexahydrophthalate based compound with desired color.
[0031] The obtained hexahydrophthalate based compound is used as a plasticizer for a finishing process of PVC resin. Two shares of powder samples are prepared, each containing polyvinyl chloride resin (available from Formosa Petrochemical Co., Taiwan, S-65 branded) of 100 g, the hexahydrophthalate based compound of 40 g, and barium-zinc stabilizer (available from Nan Ya plastics Corporation, Taiwan, LQX19T) of 2 g. Both samples are respectively mixed by a roller at 170□ for 5 minutes to form PVC films having thickness of 0.4 mm and thickness of 0.1 mm, respectively. The transparency and hardness of the PVC film having thickness of 0.4 mm are measured. The adhesion of the PVC film having thickness of 0.1 mm is measured. The measured results are shown in Table 1.
Embodiment 2
[0032] Hexahydrophthalic anhydride of 0.5 mole, triethylene glycol of 1.05 moles, catalyst TIPT (Tetraisopropyl titanate) of 1.0 g and xylene of 34.0 g are received in a four-neck flask equipped with magnetic stir bars and a condenser for reaction at 160° C.-180° C. for 5 hours while the reactant is dehydrated during esterification. Esterification lasts until the acidity of the reactant becomes less than 3 mgKOH/g. Afterward, 0.97 mole of 2-EHA is added and esterification continues at 160° C.-230° C. for 5 hours until the acidity of the reactant becomes less than 5 mgKOH/g to finalize esterification.
[0033] After esterification, the reactant is treated by an aqueous alkali metal hydroxide solution, and then rinsed by water, distilled, dehydrated, and filtered to obtain the hexahydrophthalate based compound with desired color.
[0034] The obtained hexahydrophthalate based compound is used as a plasticizer for a finishing process of PVC resin. Two PVC films having thickness of 0.4 mm and thickness of 0.1 mm, respectively, are formed as described in Embodiment 1.
[0035] The transparency and hardness of the PVC film having thickness of 0.4 mm are measured. The adhesion of the PVC film having thickness of 0.1 mm is measured. The measured results are shown in Table 1.
Embodiment 3
[0036] Hexahydrophthalic anhydride of 0.5 mole, PEG-200 of 1.03 moles, catalyst TIPT (tetraisopropyl titanate) of 1.0 g and xylene of 34.0 g are received by a four-neck flask equipped with magnetic stir bars and a condenser to undergo reaction at 160° C.-180° C. for 5 hours while the reactant is dehydrated during esterification. Esterification lasts until the acidity of the reactant becomes less than 3 mgKOH/g. Afterward, 0.95 mole of 2-EHA is added and esterification continues at 160° C.-230° C. for 5 hours until the acidity of the reactant becomes less than 5 mgKOH/g to finalize esterification.
[0037] After esterification, the reactant is treated by an aqueous alkali metal hydroxide solution, and then rinsed by water, distilled, dehydrated, and filtered to obtain the hexahydrophthalate based compound with desired color.
[0038] The obtained hexahydrophthalate based compound is used as a plasticizer for a finishing process of PVC resin. Two PVC films having thickness of 0.4 mm and thickness of 0.1 mm, respectively, are formed as described in Embodiment 1.
[0039] The transparency and hardness of the PVC film having thickness of 0.4 mm are measured. The adhesion of the PVC film having thickness of 0.1 mm is measured. The measured results are shown in Table 1.
Comparative Embodiment 1
[0040] Di(2-ethylhexyl)adipate (DEHA) is used as a plasticizer for finishing PVC resin. Two PVC films having thickness of 0.4 mm and thickness of 0.1 mm, respectively, are formed in the manner as described in Embodiment 1.
[0041] The transparency and hardness of the PVC film having thickness of 0.4 mm are measured. The adhesion of the PVC film having thickness of 0.1 mm is measured. The measured results are shown in Table 1.
Comparative Embodiment 2
[0042] Di-isononyl adipate (DINA) is used as a plasticizer for finishing PVC resin. Two PVC films having thickness of 0.4 mm and thickness of 0.1 mm, respectively, are formed in the manner as described in Embodiment 1.
[0043] The transparency and hardness of the PVC film having thickness of 0.4 mm are measured. The adhesion of the PVC film having thickness of 0.1 mm is measured. The measured results are shown in Table 1.
[0000]
TABLE 1
Transparency
Hardness
Adhesion
Embodiment 1
excellent
good
outstanding
Embodiment 2
excellent
good
outstanding
Embodiment 3
excellent
good
good
Comparative Embodiment 1
good
good
good
Comparative Embodiment 2
good
good
acceptable
Results
[0044] From the Table 1, the results of the measurements indicate that the hexahydrophthalate based compounds obtained from Embodiments 1-3 possess physical properties superior to DEHA and DINA in transparency and adhesion and also equivalent to DEHA or DINA plasticizers in hardness (plasticizing effect). | A hexahydrophthalate based compound is adapted to use as a plasticizer that contains no phthalic acid and benzoic acid, possess physical properties superior to DEHA and DINA in transparency and adhesion and is friendly to organisms and the environment; and a process for producing the hexahydrophthalate based compound includes esterifying hexahydrophthalic anhydride, a diol, and a catalyst for decarboxylation to get hexahydrophthalic alcohol, and adding a monoacid into the hexahydrophthalic alcohol for further esterification, thereby obtaining the hexahydrophthalate based compound. | 2 |
BACKGROUND OF THE INVENTION
The invention relates to a drawbar arrangement by which a drawn implement is coupled to a vehicle such as an agricultural tractor or utility vehicle, and more particularly, to a drawbar which has an adjustable length. It is well known to pivotally mount a drawbar at the rear of a tractor so that implements, such as a trailer or a mower can be coupled to the tractor. For example, a pivoted drawbar is shown in DE-PS-492 300. This pivoted drawbar is provided with spaced apart bores which can be aligned selectively with bores in transverse straps that are attached to the vehicle chassis. The length to which this pivoted drawbar extends beyond the rear end of the vehicle can be selected by inserting a locking pin through the aligned bores.
This type of adjustable length drawbar cannot be used in many cases due to the extent of the longitudinal supports and transverse straps. For example, the rear region of an agricultural tractor is occupied generally by a multitude of towing, mounting and hitch structures which limit the available space. In the design shown in DE-PS-492 300 the longitudinal supports and transverse straps restrict or make impossible the operation of the towing and mounting arrangements.
In many agricultural tractors an adjustable length pivoted drawbar is provided in order to comply with the requirements of various coupled implements. This is necessary since the distance between the coupling point and the end of the power take-off shaft may be different for the different implements that can be coupled to the tractor. The differing operating lengths are standardized by ISO or SAE.
Due to the limited space available it is common practice to attach the pivoted drawbar to the vehicle from underneath, for example, to the differential housing. If the distance between the coupling point and the end of a power take-off shaft is changed, then the operator must adjust the drawbar from the underside of the tractor. This may be accomplished by releasing a locking pin and moving the pivoted drawbar into the desired position and then manually securing the desired operating length by inserting the locking pin into an appropriate hole in the pivoted drawbar. This work is uncomfortable and requires a relatively large amount of time. The coupling process, in which the operator backs the tractor to the implement to be coupled, is difficult if the coupling point of the pivoted drawbar is very close to the rear of the tractor and cannot be visually inspected from the operator's seat.
SUMMARY OF THE INVENTION
Accordingly, an object of this invention is to provide a drawbar of the aforementioned type which can overcome the problems noted and which can be easily adjusted.
A further object of the invention is to provide such a drawbar which has coupling point which is easily visible from the operator's seat during the coupling process.
A further object of the invention is to provide such a drawbar which has locking means which is operable automatically as the drawbar is moved lengthwise to its desired position.
These and other objects are achieved by the present invention wherein an adjustable length drawbar assembly includes a cage which is pivotally attached to the rear of a vehicle and a drawbar which slides in the cage. A plurality of spaced apart bores extend laterally through the drawbar. A pair of claws are mounted to a selected one of the bores by a pin and a pair of springs urge the claws towards the drawbar. A pair of recesses are formed at the rear end of the cage adjacent to a pair of ramp surfaces. The claws are spread apart as they slide over the ramp surfaces, and the claws have tabs which are received by the recesses to releasably lock the drawbar into the desired position with respect to the cage. The claws may be pulled away from each other and out of the recesses, and then rotated on the pins 90° to disable the locking mechanism.
BRIEF DESCRIPTION OF THE DRAWINGS
The single FIGURE is a perspective view that shows in its upper area a partial view of the rear of a tractor and shows a adjustable length drawbar assembly according to the present invention.
DETAILED DESCRIPTION
Referring now to the single FIGURE, there is shown a partial view of the rear of a tractor 10 with axle housing 12, gearbox housing 14, lower steering arms 16, power take-off shaft stub 18 and power take-off shaft protective casing 20. A cage 22 is positioned below the rear of the tractor 10 and includes a lower bracket 24, an upper bracket 26 and four connecting links 28, 30. The links 28, 30 are welded in the rear and front region to the lower and upper bracket 24, 26, resulting in a largely open cage into which the drawbar 32 can be inserted to slide in its longitudinal direction. The largely open configuration avoids problems of dirt accumulation.
The front end of the cage 22 is supported by a generally U-shaped support 34 which can be attached to the lower part of the gearbox housing 14 by four bolts 36, of which only one is shown. In this region the cage 22 carries a pin or shank 38 which extends vertically, and which engages corresponding recesses in the gearbox housing 14 and in the support 34 and thereby provides a pivot axis about which the cage 22 may pivot. The recess in the gearbox housing 14 is formed by a sleeve 40 which is press fitted into the gearbox housing 14. The other recess 42 is formed in the base strap of the U-shaped support 34.
The rear part of the cage 22 is supported by a support 52 which permits sideways pivoting of the cage. The support 52 is attached to the underside of the gearbox housing 14 with spacers 54 by four bolts 56, only one of which is shown. The spacers 54 are simultaneously used as stops which limit sideways pivoting of the cage 22. For a closer limitation of the sideways movement of the cage 22, two further bolts 58, of which only one is shown, can be inserted into intermediate bores 60 in the support 52 and screwed into the gearbox housing 14.
The drawbar 32 is shown in the drawing broken along a line aligned with the cage 22. The front part 44 of the drawbar 32 is provided with a laterally extending bore 46 into which a stop pin 48 can be inserted and which protrudes to both sides. To secure the stop pin 48, a bolt 50 can be inserted from below through a bore in the front part 44 of the drawbar 32 and can be screwed into a threaded hole in the stop pin 48. The stop pin 48 prevents the drawbar 32 from being pulled out of the cage 22 towards the rear of the vehicle. This means that the drawbar 32 can be extended to the rear only up to a maximum length.
The main part of the drawbar 32 carries at its rear end a coupling socket 62. To form the coupling socket 62, a spacer 64 and a bracket 66 are attached to the rear end of the drawbar 32 with two bolts 68 and nuts 70. In order to couple to the coupling eye (not shown) of an implement to be towed (not shown), the coupling eye (not shown) is brought into the region of the coupling socket 62 and secured there with a pin 76 that can be inserted through vertical bores 72,74.
The drawbar 32 is provided with four horizontal laterally extending bores 78, 80, 82 and 84. The plurality of bores 78, 80, 82 and 84 correspond to the different desired operating lengths, which preferably are prescribed by standards. Locking claws 86, 88 can be mounted at one of the bores 78, 80, 82, 84. The claws 86, 88 are attached to both sides of the drawbar 32 by a pin 90 which is inserted through a central bore in each of the claws 86, 88 and a selected one of the bores 78, 80, 82, 84. The pin 90 can be secured by a snap-on plug 92.
In the assembled condition, springs 94, 96 force the claws 86, 88 against the drawbar 32, but the claws may be forced away from the drawbar 32 by hand. Each of the springs 94, 96 is provided with a loop which is used to fasten it to the associated claw 86, 88 with a bolt 98, 100. This attachment simplifies the assembly of the locking means since the springs 94, 96 are securely connected to the claws 86, 88.
Each of the claws 86, 88 is provided with upper and lower tabs 102, 104 which project from the claws 86, 88 towards the drawbar 32. The springs 94, 96 are biassed to urge the claws 86, 88 towards each other and against the side surfaces of the drawbar 32.
The rearward ends of the upper and lower cage brackets 24, 26 are each provided with inclined ramps 106. The ramps 106 blend into parallel surfaces 108 which terminate at rectangular grooves 110 which extend laterally into both sides of the brackets 24, 26. The brackets 24, 26 are narrower in the region of surfaces 108 than in the main body thereof on the other side of the grooves 110, so that shoulders 112 at the forward end of the grooves 110 forms stop surfaces.
MODE OF OPERATION
The length of the drawbar 32 may be adjusted as follows. Initially, the drawbar 32 is pulled out of the cage 22 until the stop pin 48 engages the front end of the cage 22 and limits further movement. With the drawbar 32 pulled out to its maximum, the coupling point at the coupling socket 62 is observable without any difficulty from the operator's cab. Now the desired operating length of the drawbar 32 is determined and the claws 86, 88 are secured with the pin 90 to the desired one of the bores 78, 80, 82, 84. To readjust the claws 86, 88, the snap-on plug 92 is removed from the pin 90, the pin 90 is removed from the spring 94, from the claw 86 and from the selected one the bores 78, 80, 82, 84. The claws 86, 88 are then reattached to the drawbar 32 at another one of the bores 78, 80, 82, 84.
The drawbar 32 may be pulled out of the cage 22 without resetting its length by pulling the two claws 86, 88 apart against the force of the spring 94 with both hands to thereby bring them out of the grooves 110 to release the lock, and by simultaneously pulling the two claws 86, 88 and the drawbar 32 to the rear. Alternatively, one of the claws 86, 88 may be pulled away from the drawbar 32 against the force of the spring 94 and then rotated 90° to bring its tab 104 to rest on the side surface of the drawbar 32. The same is then done to the other claw 88. This releases the locking mechanism so that the drawbar 32 may be adjusted lengthwise at a later time.
After setting a position for the drawbar 32, the operator can back up the vehicle while observing the coupling point, until the coupling socket 62 is brought into alignment with the coupling eye of the implement to be coupled, to enable coupling by inserting the pin 76. By backing the tractor further, the drawbar 32 will be pushed into the cage 22 until the ramps 106 will engage the tabs 102, 104 and move the claws 86, 88 away from each other against the force of the springs 94, 96. When the tabs 102, 104 reach the grooves 110, the claws 86, 88 will move towards each other and the tabs 102, 104 will move into the grooves 110 due to the force of the springs 94, 96. If the tabs 102, 104 do not snap into the grooves 110 rapidly enough, the tabs 102, 104 engage the stops 112 and further movement of the drawbar 32 into the cage 22 is stopped.
The claws 86, 88 can be retracted by hand against the spring force and rotated 90° from the position shown in the FIGURE. If the claws 86, 88 are then released, they will be supported on the side surfaces of the drawbar 32 by their tabs 102, 104 and the claws will not perform their locking function.
In order to securely hold the claws 86, 88 in the grooves 110, it may be appropriate and even required for safety reasons, to lock or latch the claws 86, 88 in place and prevent them from disengaging from the grooves 110. This can be accomplished by an additional snap-on plug, not shown, or a clamping arrangement or the like.
Thus, the drawbar of this invention may be initially pulled out beyond the rear of the tractor so that it is easily visible from the operator's seat. Then the claws are attached to the drawbar in a position that corresponds to a desired operating length. The operator can now take his seat and back the tractor towards the implement to be coupled while observing the coupling point. After the drawbar is coupled, the tractor is backed further until the claws automatically lock into the recesses in the cage. Now the drawbar has the desired operating length. If necessary, the claws can be unloaded by inserting a safety locking pin or another added positive locking device (not shown).
The drawbar of this invention may be handled easily and quickly coupled to implements, and its operating length may be easily adjusted to set the desired distance between the coupling point and the end of the power take-off shaft for different implements. The operator can comfortably perform the adjustment of the operating length at the rear of the tractor. This is done by simply moving the claws on the drawbar from one hole to another.
While the present invention has been described in conjunction with a specific embodiment, it is understood that many alternatives, modifications and variations will be apparent to those skilled in the art in light of the foregoing description. Accordingly, this invention is intended to embrace all such alternatives, modifications and variations which fall within the spirit and scope of the appended claims. | An adjustable length drawbar assembly includes a cage which is pivotally attached to the rear of a vehicle and a drawbar which slides in the cage. A plurality of spaced apart bores extending laterally through the drawbar. A pair of claws are mounted to a selected one of the bores by a pin and springs bias the claws towards the drawbar. A pair of recesses are formed at the rear end of the cage adjacent to a pair of ramp surfaces. The claws are spread apart as they slide over the ramp surfaces, and the claws have tabs which are received by the recesses to releasably lock the drawbar into the desired position with respect to the cage. The claws may be pulled away from each other and out of the recesses, and then rotated on the pins 90° to disable the locking mechanism. | 1 |
RELATED U.S. APPLICATIONS
This application supplements and completes PCT Provisional Application PCT/US2004/009124, filed Mar. 24, 2004.
BACKGROUND OF THE INVENTION
Racks are commonly used for securing objects for transportation, storage, and/or display reasons. It is also desirable to provide a mechanism for locking objects within these racks, thereby preventing any unauthorized removal of the objects from the racks.
One common use of a rack is to bind sporting equipment to an object such as a vehicle, a wall in a house or garage, or a store display rack. When a rack is used in conjunction with a vehicle, the main purpose is transportation of said object, whereas, when a rack is attached to a wall or display structure, the main purpose is storage and/or display. In either instance, the goal of the rack is to firmly support the object in a desired position.
Various forms of vehicle carriers heretofore have been provided for supporting and carrying objects on a vehicle. The typical method for supporting sporting equipment such as surfboards, sailboards, kayaks and the like, involves using canvas or rubber straps. For example, U.S. Pat. No. 4,007,862 issued to Heftmann and entitled Car Rack for Holding Surfboards and the Like, and U.S. Pat. No. 6,199,412 issued to Kennedy and entitled Lockable Tie Down Strap, both disclose a rack utilizing straps which are placed across the object to be supported within the rack. The straps are pulled tight, thereby securing the object within the rack. The straps may then be locked to prevent any unauthorized removal of the object from the rack. Although this is the most typical method of securing an object within a rack, there are obvious drawbacks. The flexible properties of strap-based systems are subject to wear and tear and weathering, which in time will result in the breaking of the straps. In addition, straps are easily unhooked, resulting in theft of the object. Even with a lock incorporated into the strap system, the straps are easily cut and the object removed.
More secure strap based systems have been disclosed. For example, in U.S. Patent Application No. 2001/0031588 A1 entitled Board Securing Device, the inventor discloses a device comprising a flexible cable loop strap that is engage able using a key or combination operated lock. The loop is placed around the circumference of a surfboard at a location proximate a rack mounting bar. The loop is then secured to the rack mounting bar, thus securing the board to the rack mounting bar. The disclosed loop offers a locking mechanism that is neither subject to the same degree of deterioration as are standard straps nor easily cut. However, the loop straps do not form part of the rack system. Instead, the loop straps are a time consuming addition to an existing rack system, offering no legitimate support between the object and the rack.
U.S. Pat. No. 5,582,044, issued to Bolich and entitled Adjustable Surfboard Clamp and Method, discloses a method for locking a surfboard to a roof rack crossbar using a series of adjustable mount block assemblies affixed to the rack crossbars at a lateral position of contact with the sides of a surfboard placed horizontally on top of the crossbars. The mount block assemblies utilize a metal clamp that is vertically adjusted to the thickness of the surfboard at the lateral position of contact. An internal axle connects two side cams vertically adjacent to a center mount block with the clamp affixed within the side cams. An axle allows for the clamp assemblies to open and close by means of rotation of the side cams relative to the position of the mount block. The mount block assemblies utilize a lock pin that inserts through an alignment of holes in the mount block assembly to a position of engagement with a cam lock assembly. Utility of the cam lock serves to prevent or allow removal of the lock pin. This clamping method prevents movement of a surfboard on the crossbar and deters theft.
While the mounting block based assembly of U.S. Pat. No. 5,582,044 forms an integral part of the rack assembly, use of the disclosed mounting block is complex. A user must determine through tedious trial and error, the optimal setting of the clamp with respect to the side cams for each board secured within the rack. Readjustment of the clamp requires that the user rotate the side cams, release an internal set screw, guestimate a proper setting of the clamp, and return the side cam to the “secure” position. If the clamp has been adjusted too short, the clamp will not fit over the board. If the clamp has been adjusted too high, there will be excess space between the board and the clamp. Neither are desirable settings, thus requiring a repeat of the process until an “optimal fit” is achieved. Furthermore, the clamp mechanism is designed such that the clamp face runs parallel with the longitudinal centerline of the vehicle, to which it is attached. Surfboards, as is the case with most sporting equipment, have a nonlinear outline. This being the case, the face of the clamp is not able to form full contact with the surfboard. Contact is limited to point contact between a corner of the clamp, which is a small surface area, and the surfboard rail. Such contact on the fragile rails of a surfboard will damage the rails. This damage is exacerbated by vibration of the surfboard in transit when the “optimal fit” is not a snug fit between the clamp and surfboard.
Thus there is a need in the art for a locking rack that will securely and snugly hold a variety of sized objects without using fragile straps, without requiring complex adjustments of the rack members and without damaging the objects at the point of contact.
BRIEF SUMMARY OF THE INVENTION
The current disclosure relates to a vice system useful for holding a variety of sized objects without adjusting the contact surface area. The vice face, when placed in contact with an object, forms snug, flush, secure and releasably lockable contact with an object. Said vices are applicable to vehicle transportation racks, storage racks and display racks.
Thus, one objective of the current invention is to provide a durable, simple and highly versatile rack system that fits a variety of sized objects without requiring a user to perform adjustments to a clamping mechanism while fitting said various sized objects.
A further objective of the current invention is to provide a rack system that avoids damaging objects held within the vice faces by providing flush contact between the vice face and the sides of the object via rotation of the vice faces along an axis.
A further objective of the current invention is to provide a vice system that is useful for transporting objects on the roof of a vehicle.
A further objective of the current invention is to provide a vice system that is useful for transporting objects on the sides or rear of a vehicle or on the sides of a motorcycle, bicycle or other similar transportation means.
A further objective of the current invention is to provide a vice system that is useful for storing or displaying objects on a wall of a house, garage or other similar structure.
A further objective of the current invention is to provide a vice system that is useful for displaying objects on a display rack such as those used in stores or used at trade shows.
Towards these and other ends, the vice comprises at least a pivoting vice face and a means of attaching said vice face to a structure such as a vehicle rack system, a wall mounting system or a display rack system. By way of the design of the vice face, a variety of objects will easily and snugly fit within the vice face without requiring user adjustment of the vice faces. When secured, said objects will not be able to move horizontally, diagonally nor vertically with respect to the vice faces. The vice faces are further provided with a locking means for preventing unauthorized removal of an object secured within the faces. Said means may be a padlock, keyed cam-lock, or other locking mechanism well known in the art.
BRIEF DESCRIPTION OF THE FIGURES
FIG. 1 is a side view of a mounting assembly.
FIG. 2 is an isometric view of a vice highlighting the vice face.
FIG. 3 is an isometric view of the slide block and vice comprising a tongue and groove pivoting means.
FIG. 4 is an isometric view of an alternative embodiment of the slide block and vice comprising a ball and socket pivoting means.
FIG. 5 is a view of an alternative embodiment of the slide block comprising a tongue member and vice comprising a platform member, both said members having a pivot shaft accepting a pivot pin to form a pivot means.
FIG. 6 is a cross section view highlighting the mounting bar, threaded rod, slide block and lock-nut.
FIG. 7 is a cross section view of an alternative embodiment for a mounting bar, slide block and lock-nut.
FIG. 8 is an alternative embodiment of the current invention comprising a means for adapting to a variety of commercial and custom rack devices.
FIG. 9 is an example of the current invention employed as a roof top rack useful for transporting a surfboard on a vehicle.
FIG. 10 is an example of the current invention employed as a wall mounted storage rack for storing a surfboard in a garage.
DETAILED DESCRIPTION OF THE INVENTION
Referring now to the drawings in greater detail, the invention vices 14 are shown in FIG. 1 in a preferred embodiment as used with a vehicle rack system 2 to support a surfboard or sailboard. Rack system 2 further comprises end supports 4 for attachment of the rack system to a surface, mounting bar 6 , slide block 8 , pivot pin 10 , lock-nut 12 , and vice 14 .
In the preferred embodiment, vice 14 , shown in greater detail in FIG. 2 , comprises a vice face 16 , a vice body 18 , a tongue 20 and vice pivot shaft 22 . Vice face 16 is preferably a curved shape with a radius from about 1-inch to about 18-inches. More preferably, the radius of vice face 16 is about 2-inches to about 10-inches. Most preferably, the radius of vice face 16 is about 3-inches to about 5-inches. In addition, the curve of vice face 16 measures preferably less than about 180 degrees. More preferably, the curve of vice face 16 measures less than about 90 degrees. Even more preferably, the curve of vice face 16 measures less than about 86 degrees. Most preferably, the curve of vice face 16 measures 85 degrees. Alternatively, the vice face 16 may be an ellipse preferably with a major axis ranging from about 18-inches to about 1-inch and a minor axis ranging from about 11.9-inches to about 0.6-inches; more preferably with a major axis ranging from about 10-inches to about 2-inches and a minor axis ranging from about 6.6-inches to about 1.5-inches; and most preferably with a major axis ranging from about 5-inches to about 3-inches and a minor axis ranging from about 3.3-inches to about 1.8-inches. One of ordinary skill in the art will readily employ a variety of shapes to achieve the spirit of the current invention.
The design of vice face 16 offers a structure that, when placed in direct contact with the sides of an object, such as the rails of a surfboard, will concomitantly provide sufficient contact with the rails and with the upper surface of the object preventing horizontal, diagonal and vertical movement of the object. By way of the design of the vice face 16 , the contact point between said vice face 16 and the object is subject to a diagonal pressure, sufficient to prevent diagonal, vertical and horizontal movement with respect to the vice face 16 .
Alternatively, the embodiment of the vice faces may have a non-curved design and still employ the principles of the current invention, such as but not limited to an angular shape. Furthermore, the size, radius, radians and/or angle of the vice 14 may change to accommodate the larger profiles seen in kayaks, canoes, travel mates, stacks of surfboards, snowboards, wind surfers or other objects. It is obvious to those of skill in the art to employ a variety of shapes and dimensions to a vice or other securing object to achieve the spirit of this disclosure.
In a still further embodiment, vice 14 is easily adjusted by the user to accommodate various sized objects. Because the current invention's design holds object in place using a single point contact, a wide range of sized objects are secured using a vice face of a single dimension. For example, a vice face 16 of the current invention designed with a radius of 4 inches readily secures objects as small as ½-inch (1.3 centimeters), as is common for snow boards and skim boards, all the way to 3½ inches, such as the standard surfboard on the market. By way of a telescoping or segmented vice body 18 , the current invention can adjust linearly to bring the curved vice face in proximity to the contact point for a larger object, such as a wind surfer, generally having a 6 to 10 inch profile, or a kayak, generally having an 18 inch profile. By providing for a means to adjust linearly, the current invention is applicable to a wide range of sized objects without requiring a user to purchase a variety of vice faces. It is obvious to those of skill in the art to employ a variety of shapes and dimensions to a vice or other securing object to achieve the spirit of this disclosure. Those of ordinary skill in the art will readily provide means for relocating the vice faces of the current invention to meet the contact point of various sized objects.
Vice face 16 is preferably integrated into vice body 18 . Vice body 18 further comprises tongue 20 which in turn further comprises vice pivot shaft 22 . In this embodiment, and as seen in FIG. 3 , the vice 14 is such that it can form a pivoting tongue and groove relationship with a structure having arms 24 forming said groove and further comprising pivot shafts 28 within the arms. Preferably, slide block 8 is such a structure and in this embodiment comprises arms 24 extending from slide block body 26 to form a groove and further comprising arm pivot shafts 28 . Alternatively, end support 4 may be such a structure, comprising arms 24 forming a groove and having pivot shafts 28 . In a further embodiment, a fixed block forms such a structure wherein the fixed block is fixedly and permanently attached to mounting bar 6 , and wherein the fixed block further comprises arms 24 to form a groove, said arms having pivot shafts 28 . When used in conjunction with vice 14 , tongue 20 fits between arms 24 , and thus vice pivot shaft 22 aligns with arm pivot shafts 28 . Pivot pin 10 is then inserted through vice pivot shaft 22 and arm pivot shafts 28 forming a pivoting point between the vice 14 and the slide block 8 .
In an alternative embodiment, seen in FIG. 4 , the pivot point between vice 14 and sliding block 8 are formed using a ball and socket arrangement. In such an embodiment an arm 30 and ball 32 extend from vice 14 and further fit into socket 34 housed within slide block 8 forming a pivot point between the vice 14 and the slide block 8 .
In a further alternative embodiment, as seen in FIG. 5 , vice body 18 further comprises tongue 20 which in turn further comprises vice pivot shaft 22 . A structure such as slide block 8 , end support 4 or similar structure comprises pivot shaft 28 . Pivot shaft 22 and pivot shaft 28 are aligned and pivot pin 10 is securely inserted through said pivot shafts thereby creating a pivot point between vice body 18 and the structure such as slide block 8 , end support 4 or similar structure.
It is obvious to one of ordinary skill in the art to employ a variety of pivoting means to achieve the spirit of the above disclosure. Without being exhaustive, such means include but are not limited to hinges, ball bearings, and other obvious pivoting means. In addition, those of ordinary skill in the art will readily invert the placement of the pivoting means, for example, coupling the tongue or other structure with the slide mechanism and the groove or complementary structure with the vice.
In the preferred embodiment, slide block 8 is further coupled to a stable object, such as a vehicle rack mounting bar 6 , as detailed in FIG. 6 . Preferably, the mounting bar 6 is a hollow structure, comprising a longitudinal slot 36 and housing a threaded rod 38 . It is obvious to those of ordinary skill in the art that the mounting bar 6 can be of any shape and design, including but not limited to round, square, and/or hexagonal. Slide block body 26 traverses longitudinal slot 36 and further comprises rod shaft 40 . Threaded rod 38 runs through rod shaft 40 , which is of a diameter sufficient to allow smooth passage of threaded rod 38 through rod shaft 40 . Also on side block 8 and traversing longitudinal slot 36 is lock-nut 12 . Lock-nut 12 further comprises push structure 42 coupled to push rod 44 coupled to half-nut 46 . Half-nut 46 releasably engages with threaded rod 38 through the application of force to push structure 42 . When engaged with threaded rod 38 , half-nut 46 prevents any longitudinal movement of slide block 8 thus securely affixing slide block 8 in a user defined position along mounting bar 6 . In addition, lock-nut 12 may further comprise a locking means 48 to prevent unauthorized release of half-nut 46 from threaded rod 38 . Such locking means 48 are well known in the art to include but not be limited to, keyed cam-locks and pad locks.
In an alternative embodiment, shown in FIG. 7 , mounting bar 6 comprises a channel 50 having a serrated channel surface 52 . It is obvious to those of ordinary skill in the art that mounting bar 6 can comprise any rail-like shape and design without loosing the spirit of this disclosure. Slide block body 26 traverses the plane of the channel and comprises an optimally shaped foot 54 within the channel to provide and a means for securely affixing slide block 8 in a user defined position along mounting bar 6 . Foot 54 , further comprising a serrated surface, is similarly coupled to a push structure 42 and to a push rod 44 , as described in the preferred embodiment. Foot 54 releasably engages with serrated channel surface 52 through the application of force to push structure 42 . Engaging serrated channel surface 52 with the serrated surface of foot 54 prevents any longitudinal movement of slide block 8 , thus securely affixing slide block 8 in a user defined position along mounting bar 6 . In addition, slide block body 26 may further comprise a locking means 48 to prevent unauthorized release of foot 54 from serrated channel 52 . Such locking means 48 are well known in the art to include but not be limited to, keyed cam-locks and pad locks.
In a further example embodiment shown in FIG. 8 , slide body block 26 comprises a mounting bar attachment member 56 that is adaptable to a variety of standard member bars 6 . In this embodiment, member bar 6 is any shape member bar, including those forming parts of racks systems currently available in the art, as well as those custom built by users. Here, slide body block 26 has an adaptable attachment member 56 that is preferably made of a material that is just malleable enough to form to a variety of shaped member bars 6 ; however, said material is rigid enough to not allow the slide body block 26 to slide along member bar 6 when the slide body block is configured to securely attach or clamp with member bar 6 . Additionally, a locking means may be provided to lock slide body block 26 on to member bar 6 . In a further example of this embodiment, the attachment member 56 can be an exchangeable piece having a custom cut out for attachment to a variety of commercial and custom racks' member bars.
It is obvious to those of ordinary skill in the art that a variety of means for securing a sliding member at a user defined position along a mounting bar are anticipated by this disclosure and will fall well within the spirit of this disclosure. It is also obvious to those of skill in the art, that the disclosed shape of said vice faces and the rotational aspect of the vice face to form full and flush contact with an object is applicable to numerous devices and is in no way limited to racks.
FIG. 9 is a preferred embodiment for use of the current invention. The invention is horizontally mounted atop a vehicle for the purpose of transporting a surfboard. In this example, two mounting bars 6 are placed on the roof of a car sufficiently spaced apart along the longitudinal axis of the car. Each mounting bar further connects with two slide blocks 8 wherein the vices 14 of each slide block are positioned such that the vice faces 16 are capable of facing each other.
A user will select a position along the mounting bar for securely affixing one of the two slide blocks (first set) on each of said mounting bars. Ideally, but not necessarily, the each affixed slide block is fixed at a position on the respective mounting bar wherein the two slide blocks form a line running parallel with the vehicle's longitudinal center axis.
The slide blocks are then secured at a user defined position by engaging the slide blocks' lock-nut assembly with the threaded rod of the mounting bar. By applying pressure to the push structure located on the slide block, the half-nut forms contact with the threaded rod and the threads of both the inner surface of the half-nut and the threaded rod are interlaced. Interlacing said threads prevents further movement of the slide block along the threaded rod. The half-nut assembly is then locked into position using a keyed cam-lock, thereby preventing the unauthorized release of the slide blocks from its defined position along the mounting assembly.
Next, the user places the surfboard in contact with the vice faces associated with the affixed slide blocks. The slightest of pressure from the rails of the surfboard when in contact with the vice faces will cause the vices to pivot along the axis formed at the pivot point. Such rotation is in a plane parallel to the surface of the vehicle's roof, and places the entire vice faces in flush contact with the rails. Such full and flush contact is beneficial for avoiding damage caused by point contact on a rail.
The remaining two slide blocks (second set), one on each mounting bar, are relocated along their respective mounting bars until forming contact with the surfboard rail opposite the rail in contact with the first set. Again, the slightest pressure against the vice faces by the rails will rotate the vices along a plane parallel to the vehicle's roof surface placing the entire face of said vices in full and flush contact with the surfboard's rail. A user will then secure and the second set of slide blocks to the mounting bar by following the same procedure as stated for slide blocks set one.
When a surfboard is secured within a full set of vice assemblies according to this disclosed example, all horizontal, diagonal and vertical movement of the board is restricted. Horizontal movement traversing the longitudinal axis of the vehicle is prevented by the vices contacting the surfboard rails. Horizontal movement parallel to the longitudinal axis of the vehicle is prevented via the thickness of the board's beam. Vertical movement of the surfboard is prevented by the curve of the vice face.
It is obvious to those of ordinary skill in the art that such an application as disclosed in this example is generally applicable to any horizontal surface, and would fall well within the spirit of this invention.
In another preferred embodiment, seen in FIG. 10 , the disclosed invention is vertically mounted on a wall in a garage for the purpose of storing a surfboard. However, such an application is equally applicable to the vertical back end of a motor home, to the side of a motorcycle, or to any other vertical surface. Additionally, such an embodiment is applicable to diagonal and horizontal mounting, such as would be useful with a display rack, or from ceiling rafters. Those of skill in the art will readily apply the current invention to numerous surfaces for a variety of reasons, all within the spirit of the current invention. In this example, the alternative embodiment of the invention is disclosed wherein each mounting bar has a sliding block and a fixed block.
Two mounting bars, each containing a slide block and a fixed block wherein the vice faces are capable of facing each other, are placed vertically on a wall such that the mounting bars run parallel to the floor. Preferably, but not necessarily, the fixed blocks are in a position on the mounting bar closer the floor than are the slide blocks.
A surfboard is then placed on the rack with the rails contacting the vice faces associated with the fixed blocks. Such contact will rotate the vices along a plane parallel to the wall surface, placing the entire face of said vices in full and flush contact with the surfboard's rail. As mentioned above, such full and flush contact is beneficial to prevent the damage encountered through point contact.
The sliding blocks on each mounting bar are then relocated along the mounting bar to a location proximate the rail opposite that in contact with the fixed blocks' vice faces. Again, such contact will rotate the vices along a plane parallel to the wall surface, placing the entire face of said vices in full and flush contact with the surfboard's rail. A user will then secure the slide blocks to the mounting bar by following the same procedure as stated herein above.
When a surfboard is held within a full set of vice assemblies according to this disclosed example, all horizontal, diagonal and vertical movement of the board is restricted. Horizontal movement parallel the wall is prevented via the thickness of the board's beam. Horizontal movement perpendicular the wall is prevented by the curve of the vice face. Vertical movement is prevented by the vices contacting the surfboard rails. | This invention relates to racks for securely holding a variety of objects. The racks are easily mounted in the horizontal, vertical and/or diagonal positions. Moreover, the racks will rigidly hold objects of varying thickness without complicated adjustments of the contact surface area. | 1 |
FIELD OF THE INVENTION
The present invention relates to a marker that is useful in combination with all manners of vaccines, implants or treatment drugs, applied either topically or orally, in either animals or humans. The invention particularly relates to a combined medicament/marker having a controlled clearing time.
BACKGROUND OF THE INVENTION
In the treatment of both animals and humans, it is often useful to provide a means for marking the site where a medicament is injected, inserted or otherwise applied.
More specifically, when dealing with animals which are being raised for food, it is often required that the animals be inoculated with a variety of materials in order to insure that the food harvested therefrom is wholesome. Furthermore, certain medicaments, albeit useful during the animal's growth phase, are nevertheless prohibited at the time of harvest. Regulations prescribe time limits regarding the use of such medicaments to insure a sufficient time period for clearing via natural biodegradation prior to harvest.
Industry compliance with the stated guidelines is a particularly vexing problem, which the industry has been recalcitrant in monitoring. For example, although feedlot attendants may be supplied with the required immunization or medicament, they may be derelict in their responsibilities and fail to apply the material to the animal.
Alternatively, a particular material might need to be given a clearing time period, for example 30 days prior to harvest, thereby allowing a safe clearing time from the animal's flesh. If the feed lot attendant is tardy in making the application, or simply becomes confused about the dates or inoculates a group of animals in error, harmful concentrations of the prohibited materials may find their way into the food supply.
With regard to human applications, there are instances where certain inoculations or tests are initiated and follow-up must occur at a prescribed time interval. In other instances, medicaments are provided in the form insertable implants which reside within the body for extended periods. Furthermore, in a military or possibly a hospital or nursing care environment, it might be beneficial to include a visual confirmation that an individual has received an inoculation.
In all of the above noted circumstances, the inclusion of a marking ingredient or tell-tale which has a controlled biodegradability can act as either evidence of instillation or evidence that a particular period of time has elapsed subsequent to instillation or application of the medicament.
DESCRIPTION OF THE PRIOR ART
U.S. Pat. No. 6,013,122 discloses tattoo inks which can be designed to degrade after a predetermined time. However, there is no disclosure that these inks can be used as indicators to show how long ago a medication was administered.
U.S. Pat. No. 3,416,530 discloses a tablet-like body for insertion along the scleral radius. The tablet is designed to dispense medication to the eye at a predetermined and continuous rate, and utilizes a dye, such as methylene blue, to provide a visual indication that the tablet continues to dispense the medicament. The reference fails to provide a marking device capable of providing a residual marker subsequent to medicament dosage or one that remains visible for a predetermined clearing time.
U.S. Pat. No.3,427,377 proposes a composition of penicillin and a dye of 2,4-disulfo-5-hydroxy-4′, 4″-bis-(diethylamino)-triphenyl-carbinol calcium salt, for administration to the udders of dairy animals. This formulation indicates the presence of penicillin in milk as long as the antibiotic is excreted by the udders.
U.S. Pat. No. 4,572,831 teaches a combination of flourescamine or other furanones and a visible, fugitive dye or pigment. Said composition is useful in marking skin for radiological purposes without leaving visible markings on a patient for an extended period of time.
U.S. Pat. No. 4,152,412 to Brewer discusses an injectable marking vaccine carried on a physiologically acceptable colored particle (e.g., activated charcoal) so as to provide a clearly visible mark evidencing the administration of the desired vaccine.
What is lacking in the art is a cutaneously applied biodegradable tell-tale composition, which composition includes an effective amount of a marker formulation having a pigment or dye in combination with a suitable carrier therefore, and further containing a therapeutically effective amount of one or more medicaments having a controllable period of efficacy or clearing time, and including one or more of a variety of compatible medicaments, vaccines or combinations thereof; wherein instillation/application of the tell-tale marker formulation/medicament combination provide visual evidence for gauging both the application, per se, and time since application of said medicament.
SUMMARY OF THE INVENTION
The instant invention provides a biodegradable tell-tale composition which is applied cutaneously or subcutaneously to a human or animal subject for aiding in the determination of instillation of medicament and furthermore for providing, via the biodegradable functionality, a useful tool for measuring the period of time passed since the most recent inoculation.
It is envisioned that the tell-tale composition of the instant invention will have a plurality of utilities. For example:
1) the tell-tale composition can be given by itself (single injection);
2) the tell-tale composition can be used in or as a carrier agent in a vaccine;
3) the tell-tale composition can be added in small amounts to a vaccine thereby converting it to a marker vaccine;
4) the tell-tale composition can be used in combination with a pour on medicament;
5) the tell-tale composition can be used as an added ingredient in a topdress product (dry product).
Accordingly, it is an objective of the instant invention to provide a tell-tale composition comprising one or more biodegradable tell-tale materials, in combination with a chemical agent, e.g. a medicament, thereby providing a biodegradable marker.
It is a further objective of the instant invention to teach a method wherein the tell-tale composition is utilized In the food and health industry, such that inspectors in the meat processing industries are provided with a tool for ascertaining the safety of any harvestable animal for inclusion within the human food chain.
DETAILED DESCRIPTION OF THE INVENTION
Now with reference to the instillation/application of medicaments, inclusion of a marker as taught by the instant invention will provide the harvester (packer) with a tool for identifying any animals that pass through their plants. The instant invention particularly sets forth a tell-tale or marking composition which includes a plurality of diverse medicaments, vaccines, or the like. Illustrative of those diverse medicaments, vaccines, or the like contemplated by the invention are those incorporated in Tables 1-9, which are appended hereto. In practice, one or more of said medicaments, vaccines or combinations thereof, which are exemplified by, but not limited to materials selected from the group consisting of steroidal anti-inflammatory agents, non-steroidal anti-inflammatory agents, hormones, nutrient supplements, antibiotics, medicated premixes and feeds, mammary gland antibiotics, bovine vaccines, ovine vaccines, porcine vaccines and mixtures thereof, are included in therapeutically effective amounts. This invention has utility in treating both humans or animals. The tell-tale marker composition can be formulated in any color, and can be visible under a variety of lighting conditions, e.g. full-spectrum visible light, infra-red light, ultra-violet light, monochromatic light or the like.
In a particularly preferred embodiment, the tell-tale marker color will appear under the hide, in the mouth or on the surface of the skin and also can be seen on the outer layer of the hide, skin or hair.
The marker formulation can exhibit a particular initial coloration and subsequently transform to another visually distinct coloration. It also can be injected or given orally at a given day and appear at a later date or appear in a few hours depending on the type and the purpose of the vaccine and how the marker and vaccine are designed to interact. The tell-tale is constructed and arranged to disintegrate or wear away after a given period of time has elapsed, again depending on the use of the marker.
As an example of a desired utility, in the case of swine, if a market animal is vaccinated today and it is desired that the animal be harvested in 30 days, then the marker will be designed to disintegrate in 30 days. If the animal were to be harvested prior to the expiration of the 30 day time period, the harvester will then see the marker on the carcass at the injection site and will thus be warned that the animal has been vaccinated within 30 days prior to harvest. Alternatively, absence of a visible marker at the injection site can serve as an indicator that the animal is clear of any remaining drug residue.
This invention provides the manager of an animal processing facility, e.g. a swine or beef processing facility, with a valuable safety and management tool. The visibility of the marker provides an evidentiary tool as to instillation of the medicament, thereby acting as an aid in managing feedlot personnel to insure compliance with regard to initial application. The feedlot manager can visually inspect the animals after the inoculation should have been given and confirm that instructions have been complied with by virtue of the appearance of a visible marker on the surface of the hide. It will be expected that the marker will mark the underside of the hide, the hide itself or the fat at the injection site on a particular vaccinated animal. For convenience, the injection site on an animal should always be on one particular side of the neck or behind the ear area, thus making the marker easily discoverable. If that marker was set to disintegrate after 30 days and the harvester sees no marker then he knows that animal has not been vaccinated in the last 30 days, however if the marker shows up, then it will be apparent to the harvester that a particular animal has been vaccinated with some kind of vaccine in the last 30 days or any given number of days that the marker is set for. If the marker is used in or with an implant in the ear, for example, it can change color to let the producer know that the implant is running out and needs to be replaced.
Now with reference to human use, this marker can be used in many areas of human treatment wherein vaccines or implants are used. The marker can be useful in functioning as a reactor to the presence of a disease or a reminder of an implant that needs to be replaced. It can be used to see how long the body uses the vaccine, so the marker would disintegrate after a given time period.
EXAMPLE 1
A study was conducted utilizing a marker on fat tissue that was 2.5″ thick. A 1″×16 gauge needle was utilized for instillation of the medicament. The test was done with fat tissue maintained at room temperature, e.g. approximately 78 degrees Fahrenheit.
An injection of the marker was made having a volume of about 2 mL. After one hour, the marker was approximately the size of a dime and the marker went more up and down than to the side or it followed the needle path. A second test was conducted with about 10 mL of marking agent. After one hour has elapsed, the marked area was essentially elliptical in shape and approximately 2.5 inches long. Both marks appeared to follow the needle path and were elliptical or egg shaped.
The particular marker composition can be in the form of one or more types of pigment within an acceptable vehicle or carrier which, because of their physical characteristics, can be readily eliminated from the tissue of an animal or human being. It is within the purview of the instant invention to eliminate the pigment(s) passively via absorption or dissolution into the interstitial fluid or alternatively by active degradation driven by interaction with the hosts immune system. By entrapping, encasing, incorporating, complexing, encapsulating, or otherwise associating these pigments (which are otherwise readily eliminated if placed in the tissue themselves) with an acceptable vehicle or carrier, the marker/vehicle complex so produced possesses a visible color, as well as the necessary physical characteristics to remain within the tissue for a particularly defined time period. In order to provide a controlled visual tool for determining residence time, it is contemplated to provide markers which remain in the tissue for a predetermined period of time (such as several hours, or any number of days, for example 10 days, 30 days, 3, 6, or 9 months, 1,2,5 or 10 years, etc.) and then spontaneously disappear.
These “semi-permanent” or “temporary” tell-tale compositions are formulated by a process which may include one or more of the following mechanisms, such as entrapping, encasing, completing, incorporating, or encapsulating the appropriate markers, which markers are readily eliminated from the tissue, into an appropriate vehicle in combination with one or more medicaments, vaccines or the like. The pigments are designed to slowly bioabsorb, bioerode, or biodegrade over a predetermined period of time. For example, as an aid to serving as a reminder device for an implanted birth control device having up to a five year life span, the pigment will begin to disappear during the fourth and fifth years.
When it is desirable for degradation of the tell-tale marker composition to occur within a relatively short period of time, bioabsorbable microcapsules or microflakes may be utilized. In the case of microcapsules, pigment/vehicle complexes comprise a core of pigment surrounded by the pigment vehicle, which is capable of maintaining its structural integrity until a particular threshold percentage of the pigment vehicle is dissolved, bioeroded, or bioabsorbed. At this point, the pigment vehicle no longer provides protection from elimination. The pigment is then released into the tissue, where it is eliminated over a relatively short period of time.
Alternatively, microflakes made of pigment and pigment vehicle, in which the pigment is mixed throughout the microflakes, maintain a relatively consistent pigmented surface area during the process of bioabsorption. Over a predetermined period of time, the visible pigmented surface dissolves.
The pigment vehicle for the pigment or dye comprises any biologically tolerated material that retains the pigment or dye in the tissue, for whatever time or under whatever conditions are desired. In any of these cases, the pigment vehicle carries a colored pigment or dye suitable for administration into the dermis, or subcutaneous tissue, e.g., the fatty layer underlying the dermis. The pigment vehicle is sufficiently transparent or translucent so as to permit the color of the pigment or dye to show through and be visible. Preferably, the pigment or dye comprises particles smaller than 1 micron. For producing semi-permanent tell-tales, the pigments or dyes are entrapped, encased, complexed, incorporated, encapsulated, or otherwise associated in or with pigment vehicles composed of bioabsorbable, bioerodable, or biodegradable material. The material is designed to bioabsorb, bioerode, or biodegrade over a predetermined period of time so that the pigmented material, when administered into the tissue, creates a marker which lasts only until the pigment vehicle bioabsorbs. Upon partial or complete bioabsorption of the pigment vehicle, the pigment or dye is released, allowing its elimination from the tissue.
A great many biodegradable polymers exist, and the length of time which the pigment lasts in a visible state in the tissue is determined by controlling the type of material and composition of the pigment vehicle. Among the bioabsorbable, bioerodable, or biodegradable polymers which can be used are those disclosed in Higuchi et al., U.S. Pat. Nos. 3,981,303, 3,986,510, and 3,995,635, including zinc alginate poly(lactic acid), poly(vinyl alcohol), polyanhydrides, and poly(glycolic acid). Alternatively, microporous polymers are suitable, including those disclosed in Wong, U.S. Pat. No. 4,853,224, such as polyesters and polyethers, and Kaufman, U.S. Pat. Nos. 4,765,846 and 4,882,150.
Other polymers which degrade slowly in vivo are disclosed in Davis et al., U.S. Pat. No. 5,384,333, which are biodegradable polymers which are solid at 20-37° C. and are flowable, e.g., a liquid, in the temperature range of 38-52° C. Preparation of the tell-tale entails incorporation of the dye or pigment in the polymer matrix, subsequent to which the system may be warmed to approximately 50° C., where it liquifies. The tell-tale composition may then be injected into the tissue, where it cools and resolidifies.
For this type of semi-permanent pigment vehicle, any biodegradable polymer system which has the following characteristics can be used, including homopolymers, copolymers, block copolymers, waxes and gels, as well as mixtures thereof. A preferred polymer system is a triblock copolymer of the general formula A-B-A where A represents a hydrophobic polymer block, and B represents a hydrophilic polymer. The monomers and polymers are preferably linked through ester groups. Preferred hydrophobic polymers and oligomers include, but are not limited to, units selected from polyglycolic acid, polyethylene terephthalate, polybutyl lactone, polycaprolactone, D-polylactic acid, polytetrafluoroethylene, polyolefins, polyethylene oxide, polylactic acid, polyglutamic acid, poly-L-lysine, and poly-L-aspartic acid. Preferred hydrophilic polymers include polyethylene glycol, polypropylene glycol, and poly(vinyl alcohol).
Hydrogel matrices or pigment vehicles for preparing semi-permanent tell-tale markers may be formed by crosslinking a polysaccharide or a mucopolysaccharide with a protein and loading the dye or pigment into the hydrogel matrices. Proteins include both full-length proteins and polypeptide fragments, which in either case may be native, recombinantly produced, or chemically synthesized. Polysaccharides include both polysaccharides and mucopolysaccharides.
A hydrogel in which the tell-tale pigment or dye can be incorporated to a suitable carrier is disclosed in Feijen, U.S. Pat. No. 5,041,292. This hydrogel comprises a protein, a polysaccharide, and a cross-linking agent providing network linkages therebetween wherein the weight ratio of polysaccharide to protein in the matrix is in the range of about 10:90 to about 90:10. The pigment or dye is mixed into this matrix in an amount sufficient to provide color when the hydrogel matrix is administered to the tissue. Examples of suitable polysaccharides include heparin, fractionated heparins, heparan, heparan sulfate, chondroitin sulfate, and dextran, including compounds described in U.S. Pat. No. 4,060,081 to Yannas et al. Using heparin or heparin analogs is preferred because there appears to be reduced immunogenicity. The protein component of the hydrogel may be either a full-length protein or a polypeptide fragment. The protein may be in native form, recombinantly produced, or chemically synthesized. The protein composition may also be a mixture of full-length proteins and/or fragments.
Typically, the protein is selected from the group consisting of albumin, casein, fibrinogen, gamma-globulin, hemoglobin, ferritin and elastin. The protein component may also be a synthetic polypeptide, such as poly-alpha-amino acid. polyaspartic acid or polyglutamic acid. Albumin is the preferred protein component of the matrix, as it is an endogenous material which is biodegradable in blood and tissue by proteolytic enzymes. Furthermore, albumin prevents adhesion of thrombocytes and is nontoxic and nonpyrogenic.
In forming hydrogels containing pigments or dyes; the polysaccharide or mucopolysaccharide and the protein are dissolved in an aqueous medium, followed by addition of an amide bond-forming cross-linking agent. A preferred cross-linking agent for this process is a carbodiimide, preferably the water-soluble diimide N-(3-dimethyl-aminopropyl)-N-ethylcarbodiimide. In this method, the cross-linking agent is added to an aqueous solution of the polysaccharide and protein at an acidic pH and a temperature of about 0 to 50° C., preferably from about 4 to about 37° C., and allowed to react for up to about 48 hours. The hydrogel so formed is then isolated, typically by centrifugation, and washed with a suitable solvent to remove uncoupled material.
Alternatively, a mixture of the selected polysaccharide or mucopolysaccharide and protein is treated with a cross-linking agent having at least two aldehyde groups to form Schiff-base bonds between the components. These bonds are then reduced with an appropriate reducing agent to give stable carbon-nitrogen bonds.
Once the hydrogel is formed, it is loaded with the pigment or dye by immersing the hydrogel in a solution or dispersion of the pigments or dye. The solvent is then evaporated. After equilibration, the loaded hydrogels are dried in vacuo under ambient conditions and stored.
Virtually any pigment or dye may be loaded into the hydrogel vehicles, providing that surface considerations, such as surface charge, size, geometry and hydrophilicity, are taken into account. For example, incorporation and release of a high-molecular weight dye will typically require a hydrogel having a generally lower degree of cross-linking. The release of a charged pigment or dye will be strongly influenced by the charge and charge density available in the hydrogel, as well as by the ionic strength of the surrounding media.
The rate of pigment or dye release from the vehicles can also be influenced by post-treatment of the hydrogel formulations. For example, heparin concentration at the hydrogel surface can be increased by reaction of the formulated hydrogels with activated heparin (i.e., heparin reacted with carbonyldiimidazole and saccharine) or with heparin containing one aldehyde group per molecule. A high concentration of heparin at the hydrogel surface will form an extra “barrier” for positively charged dyes or pigments at physiological pH values. Another way of accomplishing the same result is to treat the hydrogels with positively charged macromolecular compounds like protamine sulfate, polylysine, or like polymers. Another way of varying hydrogel permeability is to treat the surfaces with biodegradable block copolymers containing both hydrophilic and hydrophobic blocks. The hydrophilic block can be a positively charged polymer, like polylysine, while the hydrophilic block can be a biodegradable poly(a-amino acid), such as poly(L-alanine), poly(L-leucine), or similar polymers.
Another slow-release system useful as a marker pigment vehicle for pigments or dyes to form a semi-permanent tell-tale is a dye or pigment and an enzyme encapsulated within a microcapsule having a core formed of a polymer which is specifically degraded by the enzyme and a rate controlling skin. The integrity of the shell is lost when the core is degraded, causing a sudden release of pigment or dye from the capsule. In this type of system, the microcapsule consists of a core made up of a polymer around which there is an ionically-bound skin or shell. The integrity of the skin or shell depends on the structure of the core. An enzyme is encapsulated with the biologically-active substance to be released during manufacture of the core of the microcapsule. The enzyme is selected to degrade the core to a point at which the core can no longer maintain the integrity of the skin, so that the capsule falls apart. An example of such a system consists of an ionically cross-linked polysaccharide, calcium alginate, which is ionically coated with a polycationic skin of poly-L-lysine. The enzyme used to degrade the calcium-alginate coated with poly-L-lysine microcapsules is an alginase from the bacteria Beneckea pelagio or Pseudomonas putida . Enzymes exist that degrade most naturally-occurring polymers. For example, the capsule core may be formed of chitin for degradation with chitinase. Other natural or synthetic polymers may also be used and degraded with the appropriate enzyme, usually a hydrogenase.
A particularly preferred bioabsorbable polymer vehicle is a triblock copolymer of poly caprolactone-polyethylene glycol-poly caprolactone. This polymer contains ester bonds which hydrolyze in a hydrophilic environment. The biodegradable polymer matrix should comprise about 30-99% of the tell-tale carrier.
Several mechanisms are involved in the rate and extent of dye or pigment release. In the case of very high molecular weight pigments, the rate of release is more dependent upon the rate of pigment vehicle bioabsorption. With lower molecular weight pigments, the rate of pigment release is more dominated by diffusion. In either case, depending on the particular pigment vehicle composition selected, ionic exchange can also play a major role in the overall release profile.
All references cited herein are hereby incorporated herein in their entirety.
It is to be understood that while a certain form of the invention is illustrated, it is not to be limited to the specific form or arrangement of parts herein described and shown. It will be apparent to those skilled in the art that various changes may be made without departing from the scope of the invention and the invention is not to be considered limited to what is shown and described in the specification and drawings.
TABLE 1
ANTI-INFLAMMATORY
Steroidal Anti-Inflammatory Agents
Betamethasone
Dexamethasone
Flumethasone
Methylprednisolone
Prednisolone
Hydrocortisone
Triamcinolone
Isoflupredone
Prednisolone, Pheniramine and Vitamins
Prednisolone, Chlorpheniramine
Prednisolone, Trimeprazine
Non-Steroidal Anti-Inflammatory Agents
Phenylbutazone
Dipyrone
Flunixine
Ketoprofene
Orgotein
Tolfenamiuc Acid
TABLE 2
HORMONES
Anabolic Agents
Other Pituitary or Hypotalamic
Testosterone
Hormones
Fluoxymesterone
ACTH
Boldenone
Osytocine
Stanozolol
Cosyntropin
Testosterone and
Hyperadrenocorticism Treatment
Estradiol
Selegiline
Melengestrol
Insulin
Gonadotropine Hormones &
Beef/Pork Insulins
Releasing Factors
Pork Insulin
FSH (Folliculo-
Human Biosynthetic
Stimulating Hormone
Insulin
LH (Luteinizing
Thyroid Hormones & Anti-Thyroid
Hormone)
Products
Gonadoreline
Levothyroxine (T-4)
PMSG and HCG
Levothyroxine (T-4)
Mixture
Methinazole
Deslorelin
Adrenocortical Hormones
Progestagenes
Flurocortisone
Progesterone
Desoxycorticosterone
Medroxyprogesterone
Hormone Mixtures, Vitamines,
Megestrol
Minerals, etc.
Altrenogest
Methyltestosterone,
Estrogens
Estradiol, Thyroxine,
Diethylstilbestrol
Vitamines ADEB
Conjugated Estrogens
Antihistamines
Luteolytic Products
Dimenhydrinate
Dinoprost
Diphenhydramine
Cloprostenol
Tripelennamine
Hydroxyzine
Chlorpheniramine
TABLE 3
NUTRIENT SUPPLEMENTS
VITAMINS ONLY
VITAMIN D
VITAMIN K1
B COMPLEX VITAMINS
VITAMIN C
COMBINED VITAMINS
COMBINED B COMPLEX
COMBINATIONS OF A AND D
COMBINATIONS OF A, D AND E
VITAMINS AND MINERALS
B COMPLEX VITAMINS WITH
IRON, COPPER AND COBALT
VITAMINS (B COMPLEX) IRON,
COBALT AND CHOLINE
VITAMIN D WITH PHOSPHORUS
VITAMIN E WITH SELENIUM
VITAMINS WITH AMINO-ACIDS
B COMPLEX VITAMINS WITH
AMINO-ACIDS AND CHOLINE
VITAMINS (B COMPLEX),
AMINO-ACIDS, FE, CO, CU
VITAMINS, AMINO-ACIDS,
MINERALS, CLUCIDS
TABLE 4
ANTIBIOTICS
NATURAL PENICILLINS
QUINOLONES
COMBINED SULFONAMIDES
PENICILLIN G POTASSIUM
CIPROFLOXACIN
SULFAMETHAZINE AND
PENICILLIN G SODIUM
ORBIFLOXACIN
SULFATHIAZOLE
PENICILLIN G PROCAINE
ENROFLOXACIN
QUINOLONES
SEMISYNTHETIC
MACROLIDES
CIPROFLOXACIN
PENICILLINES
RIFAMPIN
ORBIFLOXACIN
PENICILLIN V
ERYTHROMYCIN
ENROFLOXACIN
AMPICILLIN
TYLOSIN
MACROLIDES
CLOXACILLIN
TIMICOSIN
RIFAMPIN
AMOXICILLIN
ERYTHROMYCIN
TYLOSIN
TICARCILLIN
LINCOMYCINES
TIMICOSIN
CEPHALOSPORI
CLINDAMYCINE
CLINDAMYCINE
CEPHALOTHIN
LINCOMYCINE
LINCOMYCINES
CEFAZOLIN
ANTIFUNGAL
CLINDAMYCINE
CEFTIOFURE
NYSTATIN
LINCOMYCINE
AMINOCYCLITOLS
GRISEOFULVIN
ANTIFUNGAL
STREPTOMYCINE
KETOCONAZOLE
NYSTATIN
GENTAMYCINE
SULFONAMIDES
GRISEOFULVIN
SPECTINOMYCINE
SULFADIMETHOXINE
KETOCONAZOLE
TETRACYCLINES
SULFAMETHAZINE
SULFONAMIDES
TETRACYCLINES
SALICYLAZOSULFAPYRIDINE
SULFADIMETHOXINE
DOXYCYCLINE
SULFAQUINOXALINE
SULFAMETHAZINE
OXYTETRACYCLINE
NITROFURANS
SALICYLAZOSULFAPYRIDINE
CHLORAMPHENICOLS
FUMAGILLINE
SULFAQUINOXALINE
CHLORAMPHENICOLS
COMBINED PENICILLINES
NITROFURANS
FLORFENICOL
PENICILLINE G, PROCAINE AND
FUMAGILLINE
QUINOLONES
BENZATHINE
ANTIBIOTICS AND
CIPROFLOXACIN
COMBINED SULFONAMIDES
VITAMINS
ORBIFLOXACIN
SULFAMETHAZINE AND
PEN-STREP, VITAMINS
ENROFLOXACIN
SULFATHIAZOLE
(A, D, E, K,
MACROLIDES
SULFONAMIDES COMBINED
B COMPLEX)
RIFAMPIN
WITH OTHER ANTIBIOTICS
TRIPLE SULFAS, VITAMINS
ERYTHROMYCIN
SULFAQUINOXALINE AND
(AD3,
TYLOSIN
PYRIMETHAMINE
B COMPLEX) AND MINERALS
TIMICOSIN
SULFADIAZINE AND
NEOMYCINE,
LINCOMYCINES
TRIMETHOPRIME
SULFAMETHAZINE, K,
CLINDAMYCINE
SULFAMETHOXAZOLE AND
MG, CA, NA, CL,
LINCOMYCINE
TRIMETHOPRIME
ACETATE
ANTIFUNGAL
SULFADOXINE AND TRIMETHOPRIME
ANTIBIOTICS AND BETA-
NYSTATIN
LINCOMYCINE AND
LACTAMASE INHIBITORS
GRISEOFULVIN
SPECTINOMYCINE
AMPICILLINE AND
KETOCONAZOLE
LINCOMYCINE AND
SULBACTAM
SULFONAMIDES
SPECTINOMYCINE
AMOXCILLINE AND
SULFADIMETHOXINE
TETRACYCLINES AND
CLAVULINIC ACID
SULFAMETHAZINE
NEOMYCINES
TICARCILLIN AND
SALICYLAZOSULFAPYRIDINE
TETRACYCLINES AND NEOMYCINE
CLAVULINIC ACID
SULFAQUINOXALINE
OXYTETRACYCLINE AND NEOMYCINE
NITROFURANS
ANTIBIOTICS AND ANTI-
FUMAGILLINE
INFLAMMATORY AGENTS
COMBINED PENICILLINES
TETRACYCLINE, NOVOBIOCINE AND
PENICILLINE G, PROCAINE
PREDNISOLONE
AND
BENZATHINE
TABLE 5
MEDICATED PREMIXES &
FEEDS
ANTIBIOTICS ONLY
TYLOSINE
LINCOMYCINE
PROCAINE PENICILLINE G
TIAMULIN
CHLORTETRACYCLINE
OXYTETRACYCLINE
FLORFENICOL
COMBINED ANTIBIOTICS
LASALOCIDE
AMPROLIUM WITH, OR WITHOUT
ETHOPABATE
DECOQUINATE
MEDICATED FEEDS
LEVAMISOLE
FENBENDAZOLE
TABLE 6
MAMMORY GLAND ANTIBIOTICS
ANTIBIOTICS ONLY
CEPHAPIRINE
ERYTHROMYCINE
CLOXACILLINE
OXYTETRACYCLINE
NOVOBIOCIN
PIRLIMYCINE
COMBINED ANTIBIOTICS
PENICILLINE G, PROCAINE AND
NOVOBIOCINE
PENICILLINE G, PROCAINE AND
DIHYDROSTREPTOMYCINE
PEN G POT, STREPTOMYCINE,
NEOMYCINE AND POLYMYXINE
FOUR ANTIBIOTICS AND
HYDROCORTISONE
TABLE 7
BOVINE VACCINES
BOVINE VACCINES: IBRM-PIM
BOVINE VACCINES: BVDK
BOVINE VACCINES: IBRK-PIK-BVDK
BOVINE VACCINES: IBRM-PIM-BVDM
BOVINE VACCINES: IBRM-BVDM-PIM-CFK-LPK
BOVINE VACCINES: IBEM-PIM-BVDK
BOVINE VACCINES: SVM
BOVINE VACCINES: IBRM-PIM-SVM
INTRAMUSCULAR
BOVINE VACCINES: IBRK-PIK-BVDK-SVK
BOVINE VACCINES: IBRM-PIM-BVDM-SVM
BOVINE VACCINES: IBRM-PIM-BVDK-SVM
BOVINE VACCINES: IBRM-PIM-BVDM-SVK
BOVINE VACCINES: IBRM-PIM-BVDK-SVM
BOVINE VACINES: HSK
BOVINE VACCINES; HSK-PHK BVDM-SVM-HSK
BOVINE VACCINES: IBRM-PIM-BVDK-SVM-LPK
BOVINE VACCINES: IBRK-PIM-BVDK-SVM-LPK
BOVINE VACCINES: IBRK-PIK-BVDK-SVK-LPK
BOVINE VACCINES: IBRM-BVDM-PIM-HSK-LPK-CFK
BOVINE VACCINES: IBRM-PIM-BVDK-SVM-LPK-CFK
BOVINE VACCINES: IBRK-PIK-BVDK-SVK-LPK-HSK
BOVINE VACCINES: RCM
BOVINE VACCINES: CFK
BOVINE VACCINES: CFK-LPK
BOVINE VACCINES: ECK (MASTITIS)
BOVINE VACCINES: SAK
BOVINE VACCINES: PPK
BOVINE VACCINES: BAM
BOVINE VACCINES: TVM
BOVINE VACCINES: MOK
BOVINE VACCINES: 4CLOSTRIDIUM-K - ENTK
BOVINE VACCINES: 4CLOSTRIDIUM-K - ENTK-HSK
TABLE 8
OVINE VACCINES
OVINE VACCINES: ENTK-PSTK-TTK
OVINE VACCINES: ENTK-PSTK-TTK-3 CLOSTRIDIUM-K
OVINE VACCINES: CHK
OVINE VACCINES: CFK-CHK
OVINE VACCINES: ENTK-4CLOSTRIDIUM-K
OVINE VACCINES: ENTK-TTK-3 CLOSTRIDIUM-K
OVINE VACCINES: ENTK-5 CLOSTRIDIUM-K
OVINE VACCINES: FNK
TABLE 9
PORCINE VACCINES
PROCINE VACCINES: BOK
RABIES
PORCINE VACCINES: BOK-PAK
PORCINE VACCINES: ERK
BOVINE, OVINE
PORCINE VACCINES: ERM
PORCINE VACCINES: BOK-PAK-
TETNUS
ERK
PORCINE VACCINES: ECK
BOVINE, OVINE
PORCINE VACCINES: ENTK-ECK
PORCINE VACCINES: BOK-PAK-
LEPTOSPIRA
ECK
PORCINE VACCINES: LPK
BOVINE AND PORCINE
PORCINE VACCINES: BOK-PAK-
ERK-ECK
PORCINE VACCINES: PVK
PORCINE VACCINES: ERK-PVK
PORCINE VACCINES: ERK-LPK-
PVK
PORCINE VACCINES: TGEM
PORCINE VACCINES: TGEK
PORCINE VACCINES: ROM
PORCINE VACCINES: TGEM-ROM
PORCINE VACCINES: TGEK-ROM
PORCINE VACCINES: ECK-TGEM-
ROM
PORCINE VACCINES: APK
PORCINE VACCINES: BOK-PAK-
ERK-APK
PORCINE VACCINES: ECK-TGEM-
ROM-ENTK
PORCINE VACCINES: BOK-PAK-
ENTK-ECK-ERK-ROM-TGEM
PORCINE VACCINES: BOK-PAK-
MHK
PORCINE VACCINES: STK
PORCINE VACCINES: MHK
PORCINE VACCINES: HPK
PORCINE VACCINES: HPK-MHK
PORCINE VACCINES: ERK-HPK
PORCINE VACCINES: RRSM
PORCINE VACCINES: INK | The instant invention provides a biodegradable tell-tale composition which is applied cutaneously or subcutaneously to a human or animal subject for aiding in the determination of instillation or application of a medicament, vaccine or the like; and furthermore for providing, via the biodegradable functionality, a useful tool for measuring the period of time which has passed since the most recent inoculation. | 2 |
REFERENCE TO RELATED APPLICATIONS
The present invention claims the benefit of German Patent Application No. 102 53 401.2, filed Nov. 15, 2002.
TECHNICAL FIELD
The present invention relates to a cover for a sliding roof system having at least two guide elements that are movably arranged on two opposite sides of the cover, such that the distance between them is variable. The present invention also relates to a sliding roof system having two guide tracks and to a cover of this type.
BACKGROUND OF THE INVENTION
German Laid-Open Document DE 100 02 457 describes a sliding roof system that employs two straight guide tracks extending roughly in the longitudinal direction of a vehicle along the roof. The distance between the guide tracks decreases from front to back. To guide the cover in the tracks, two guide elements are provided, each of which is contained in one of the guide tracks and connected to the cover by a parallelogram guide. This makes it possible for the distance between the two guide elements to change as the distance between the guide tracks changes.
In theory, the two parallelogram guides would also prevent the cover from twisting about its vertical axis or from being laterally displaced. In practice, however, the cover is prevented from twisting and displacement due to the guide elements precisely guided in the guide tracks and due to the cover being prevented from tilting. In other words, every force acting upon the cover to displace it laterally or to twist it about its vertical axis leads, as a result of the parallelogram guides, to rotational forces being applied to the two guide elements in the guide tracks. As a result, the entire sliding roof system is relatively hard to move and tends to jam. In addition, the parallelogram guide is only suitable for straight-line guide tracks that lie parallel to each other, not guide tracks whose distance from each other varies along the length of the track.
There is a desire to refine a sliding roof system to support the cover in a centered position relative to the guide tracks without risking the possibility that the guide elements may jam in the guide tracks or that the entire system may be subjected to undue strain.
SUMMARY OF THE INVENTION
One embodiment of the invention is directed to a cover for a sliding roof system having at least two guide elements that are movably arranged on two opposite sides of the cover so that the distance between them is variable. The two guide elements are each attached in a sliding guide, which predefines a displacement direction for the guide elements that differs from the displacement direction of the cover such that the cover is centered with regard to the two guide elements. The sliding guide in the invention greatly reduces the risk that the components will tilt relative to each other, thus assuring ease of motion in the system.
According to one embodiment of the present invention, each guide element is connected in an articulated fashion to a guide bar, which is received in the sliding guide. The articulated joint between the guide bar, which is movably guided on the cover, and the guide element ensures that no torque can be transmitted from the cover to the guide element, preventing the guide element from being jammed in the guide track in which it is contained. The articulated joints attaching the guide elements also makes it possible to use curved guide tracks while preserving smooth sliding performance.
According to one embodiment of the present invention, each guide bar is connected in an articulated fashion to a lever, and a coupling lever is supported on the cover so that it is able to swivel about a swivel axis. The levers are both connected in an articulated fashion to the coupling lever on each side of the swivel axis. In this manner, the cover can reliably be centered with respect to the two guide elements with minimal production expense.
According to another embodiment of the present invention, each guide bar is connected to a toothed rack that may be designed as an integral part of the guide bar. A gear wheel is rotatably supported on the cover with both toothed racks meshing in the gear wheel. This embodiment employs constrained guidance of the cover to ensuring centering of the cover with respect to the two guide bars with minimal production expense.
According to a further embodiment of the present invention, a second, supplemental pair of guide elements is provided with guide bars, each of which is supported on the cover in a sliding guide. The displacement direction of the first pair of guide elements is in a mirror-symmetrical fashion and obliquely oriented with respect to the displacement direction of the cover, and the displacement direction of the second pair of guide elements is perpendicular to the displacement direction of the cover. In this embodiment, no coupling between the guide bars of the guide elements is necessary because the spatial orientation of the displacement direction of the guide elements alone assures that the cover will remain centered between the two guide tracks in which the guide elements are movably contained.
The above-mentioned object of the present invention is also achieved by a sliding roof system having two guide tracks that extend along the roof of a motor vehicle at a changing distance and a cover as described above. Regarding the advantages of a sliding roof system of this type, reference is made to the above explanations.
BRIEF DESCRIPTION OF THE DRAWINGS
The present invention is described below on the basis of various embodiments, which are depicted in the attached drawings in which
FIG. 1 depicts a schematic top view of a sliding roof system according to the invention in accordance with a first embodiment;
FIG. 2 depicts a schematic top view of a sliding roof system according to the invention in accordance with a second embodiment;
FIG. 3 depicts a schematic top view of a sliding roof system according to the invention in accordance with a third embodiment;
FIG. 4 depicts a schematic top view of a sliding roof system according to the invention in accordance with a fourth embodiment; and
FIG. 5 depicts a schematic top view of a sliding roof system according to the invention wherein the guide tracks are substantially straight.
DETAILED DESCRIPTION OF THE EMBODIMENTS
FIG. 1 illustrates a sliding roof system having two guide tracks 10 and a cover 12 . Both guide tracks 10 extend roughly in the longitudinal direction of a vehicle roof (not shown). In the illustrated embodiment, both guide tracks 10 are designed to be curved in two planes, specifically about one axis parallel to a vertical axis of the vehicle and about another axis that is parallel to a transverse axis of the vehicle. In this manner, both guide tracks 10 can follow the shape of the side edges of the vehicle roof, particularly because modern vehicle roofs are usually curved and have a width that changes from front to back. Accordingly, the distance of the guide tracks from each other may also change as a function of the position that is being observed along the vehicle's longitudinal axis.
The cover 12 is displaceable in the guide tracks in a basically familiar manner. The cover position can be changed from a closed position, in which the cover 12 closes an opening in the roof of the vehicle, into an open position, in which the opening in the roof is exposed, by a drive mechanism (not shown). For the present invention, no emphasis is placed on the details of the displacement mechanism for the cover 12 or on the materials used for the cover 12 ; the present invention encompasses covers made of any material and having any position (e.g., covers made of metal, plastic, transparent material, etc.; covers that are moved outside the roof, covers that are moved inside the roof, etc.).
A guide element 14 is arranged in each guide track 10 . In the illustrated embodiment, the guide element 14 is designed as a slider. The drive mechanism (not shown) for the cover 12 engages the guide elements 14 . A guide bar 18 is mounted on each guide element 14 via an articulated joint 16 , which in each case is movably contained in a sliding guide 20 . Each sliding guide 20 is fixedly attached to the cover 12 . A lever 24 is attached at the end of each guide bar 18 that is facing away from guide element 14 via another articulated joint 22 . The lever 24 is also connected to one end of a coupling lever 28 via a further articulated joint 26 . The coupling lever 28 is rotatably supported on the cover 12 by a swivel axle 30 that is arranged centrally between both articulated joints 26 .
By rotating the coupling lever 28 , about a swivel axis of the swivel axle 30 , the distance of the guide elements 14 from each other can be varied via the levers 24 and the guide bars 18 and can therefore be adjusted to adapt to the specific distance between guide tracks 10 at any given point. Because the coupling lever 28 is fixedly mounted on the cover 12 via the swivel axle 30 , the cover 12 is centered between both guide elements 14 . Due to the displacement direction predefined by both sliding guides 20 , which is perpendicular to the displacement direction P of the cover 12 , the mechanism for moving the guide elements 14 cannot jam. This eliminates the need for an additional guide. However, a second guide having guide elements, guide bars, sliding guide, and coupling lever may be provided, if desired, to guide the cover in an even more stable fashion.
FIG. 2 illustrates another embodiment of the inventive sliding roof system. For the components that are common with the first embodiment, the same reference numerals are used, and in this respect reference is made to the above explanations.
In the second embodiment, the guide bars 18 are each equipped with a toothed rack 32 , which is designed as an integral part of the guide bars 18 in the illustrated embodiment. Alternatively, the toothed racks 32 may be separate components attached to their respective guide bars 18 via any known mechanism. A gear wheel 34 is rotatably mounted on a swivel axle 30 and attached to the cover 12 . The toothed racks 32 are disposed so that the sides opposite each other mesh in the gear wheel 34 .
A coupling mechanism configured in this manner makes it possible to adjust the distance of guide elements 14 from each other while at the same time keeping the cover 12 centered by about the swivel axis of the swivel axle 30 with respect to the guide elements 14 .
FIG. 3 illustrates a third embodiment of the invention. For the components that are the same as the preceding embodiments, the same reference numerals are used, and reference is made to the above explanations.
In this embodiment, the guide bars 18 of the guide elements 14 are not coupled to each other at all. Instead, the guide bars 18 can be moved freely in the sliding guides 20 attached to the cover 12 . Additionally, the displacement direction V of the guide bars 18 , which is predefined by the sliding guides 20 , is oriented to be oblique with regard to the displacement direction P (i.e., at an angle α that is not 90°). The angle α in this example is identical for both guide bars 18 ; the guide bars are therefore mirror symmetrical with regard to a central axis of cover 12 that runs parallel to the displacement direction P. Alternatively, the angle α may be different for different guide bars 18 , if desired.
In addition to the first pair of sliding guides and guide elements, a second, supplemental pair of guide elements 40 is provided, which are mounted on a second, supplemental pair of guide bars 42 in an articulated fashion, the guide bars in turn being movably contained in supplemental sliding guides 44 , which are fixedly mounted on the cover 12 . Both of the supplemental sliding guides 44 define a displacement direction for both of the supplemental guide bars 42 that is perpendicular to displacement direction P of the cover 12 and therefore also perpendicular to the central axis of the cover 12 .
Due to the different orientations of the sliding guides 20 and the supplemental sliding guides 44 , this embodiment ensures that the cover 12 is centered between the guide elements 14 and also between the second pair of guide elements 40 . In addition, because all of the guide elements 14 , 40 are attached by articulated joints to the guide bars 18 , 42 and because the sliding guides 20 furnish a friction-free guide for the guide bars 18 , 42 , the cover 12 is reliably prevented from being tilted relative to the guide tracks 10 , thus assuring ease of action of the sliding roof system.
FIG. 4 illustrates a fourth embodiment of the invention. Here, too, for the components that are the same as in the preceding embodiments, the same reference numerals are used, and reference is also made to the above explanations.
In this embodiment, two sliding guides 20 are disposed perpendicular to the displacement direction P of the cover. Each guide bar 18 arranged in the sliding guides 20 is supported by a resilient member, such as a spring 46 , on a limit stop 48 . The resilient member 46 is mounted in the center of the cover 12 . In this way, the cover 12 is centered in the middle between the two guide tracks 10 .
It should be understood that various alternatives to the embodiments of the invention described herein may be employed in practicing the invention. It is intended that the following claims define the scope of the invention and that the method and apparatus within the scope of these claims and their equivalents be covered thereby. | The present invention relates to a cover for a sliding roof system having at least two guide elements, which are movably arranged on two opposite sides of the cover such that the distance between them is variable. The two guide elements are each attached in a sliding guide, which predefines a displacement direction for the guide elements that differs from the displacement direction of the cover, such that the cover is centered with regard to the two guide elements. The invention also relates to a sliding roof system having two guide tracks, which extend along a roof of a motor vehicle at a changing distance, and a cover. | 1 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation application of U.S. NonProvisional Appn. No. 11/041,498, filed Jan. 24, 2005, which is a divisional application of U.S. NonProvisional Appn. No. 09/651,290 filed Aug. 30, 2000, now issued as U.S. Pat. No. 6,991,786, both of which are hereby incorporated by reference herein for all purposes
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH
[0002] This invention was made with government support under GM40314 awarded by the National Institutes of Health. The government has certain rights in the invention.
FIELD OF THE INVENTION
[0003] The present invention relates to the field of bacteriology. In particular, the invention relates to novel antimicrobial agents comprising transmissible plasmids that kill targeted recipient bacteria, but are not harmful to donor bacteria.
BACKGROUND OF THE INVENTION
[0004] Various scientific and scholarly articles are referenced in parentheses throughout the specification. These articles are incorporated by reference herein to describe the state of the art to which this invention pertains.
[0005] As the use of conventional pharmaceutical antibiotics (herein referred to as antibiotics) increases for medical, veterinary and agricultural purposes, the increasing emergence of antibiotic-resistant strains of pathogenic bacteria is an unwelcome consequence. This has become of major concern inasmuch as drug resistance of bacterial pathogens is presently the major cause of failure in the treatment of infectious diseases. Indeed, people now die of certain bacterial infections that previously could have been easily treated with existing antibiotics. Such infections include, for instance, Staphylococcus pneumoniae , causing meningitis; Enterobacter sp., causing pneumonia; Enterococcus sp., causing endocarditis, and Mycobacterium tuberculosis , causing tuberculosis.
[0006] The emergence of single- or multi-drug resistant bacteria results from a gene mobilization that responds quickly to the strong selective pressure that is a consequence of antibiotic uses. Over the last several decades, the increasingly frequent usage of antibiotics has acted in concert with spontaneous mutations arising in the bacterial gene pool to produce antibiotic resistance in certain strains. This gene pool is continually utilized by previously sensitive strains capable of accessing it by various means including the transfer of extrachromosomal elements (plasmids) by conjugation. As a result, single- and multi-drug resistance mutations are commonly found in a large variety of bacterial plasmids.
[0007] Presently there is no known method by which to avoid the selection of antibiotic resistant bacterial mutants that arise as a result of the many standard applications of antibiotics in the modem world. Accordingly, a need exists to develop alternative strategies of antibacterial treatment.
[0008] Interest in the use of bacteriophages to treat infectious bacterial diseases developed early in the twentieth century, and has undergone a resurgence in recent years. For instance, bacteriophages have been shown effective in the treatment of certain pathogenic E. coli species in laboratory and farm animals, and have been proposed as a viable alternative to the use of antibiotics (Smith & Huggins, J. Gen. Microbial. 128: 307-318, 1981; Smith & Huggins, J. Gen. Microbial. 129: 2659-2675, 1983; Smith et al., J. Gen. Microbial. 133: 1111-1126, 1986; Kuvda et al., Appl. Env. Microbial. 65: 3767-3773, 1999). However, the use of bacteriophages as antimicrobial agents has certain limitations. First, the relationship between a phage and its host bacterial cell is typically very specific, such that a broad host-range phage agent generally is unavailable. Second, the specificity of interaction usually arises at the point of the recognition and binding of phage to the host cell. This often occurs through the expression of surface receptors on the host cell to which a phage specifically binds. Inasmuch as such receptors are usually encoded by a single gene, mutations in the host bacterial cell to alter the surface receptor, thereby escaping detection by the phage, can occur with a frequency equivalent to or higher than, the mutation rate to acquire antibiotic resistance. As a result, if phage were utilized as commonly as antibiotics, resistance of pathogenic bacteria to phages could become as common a problem as antibiotic resistance.
[0009] Another approach to controlling pathogenic bacteria has been proposed, which relies on using molecular biological techniques to prevent the expression of antibiotic resistance genes in pathogenic bacteria (U.S. Pat. No. 5,976,864 to Altman et al.). In this method, a nucleic acid construct encoding an “external guide sequence” specific for the targeted antibiotic resistance gene is introduced into the pathogenic bacterial cells. The sequence is expressed, hybridizes with messenger RNA (mRNA) encoding the antibiotic resistance gene product, and renders such mRNA sensitive to cleavage by the enzyme RNAse P. Such a system also has limited utility, since it is targeted to specific antibiotic resistance genes. While the system may be effective in overcoming resistance based on expression of those specific genes, continued use of the antibiotics places selective pressure on the bacteria to mutate other genes and develop resistance to the antibiotic by another mechanism.
[0010] It is clear from the foregoing discussion that current alternatives to antibiotic use are limited and suffer many of the same drawbacks as antibiotic use itself. Thus, a need exists for a method of controlling pathogenic bacteria that is flexible in range and that cannot be overcome by the bacteria by a single small number of mutations.
SUMMARY OF THE INVENTION
[0011] The present invention provides novel antibacterial agents that are efficiently transferred to pathogenic bacteria, which have a flexible range, and to which the target bacteria have difficulty developing resistance. These antibacterial agents offer an effective alternative to the use of conventional antibiotics.
[0012] According to one aspect of the invention, an antibacterial agent is provided which comprises a non-pathogenic donor bacterial cell harboring at least one transmissible plasmid having the following features: (a) an origin of replication for synthesizing the plasmid's DNA in a bacterial cell, wherein initiation of replication at the origin of replication is negatively controlled by a plasmid replication repressor; (b) an origin of transfer to provide the initiation site for conjugative transfer of the transmissible plasmid from the donor cell to at least one recipient cell; and (c) at least one selectable marker gene. The donor bacterial cell further comprises one or more conjugative transfer genes conferring upon the donor cell the ability to conjugatively transfer the transmissible plasmid to the recipient cell. The donor cell also produces the plasmid replication repressor. The recipient cell is a pathogenic bacterium that does not produce the plasmid replication repressor.
[0013] According to another aspect of the invention, a different antibacterial agent is provided which comprises a non-pathogenic donor bacterial cell harboring at least one transmissible plasmid having these following features: (a) an origin of replication for synthesizing the plasmid's DNA in a bacterial cell; (b) an origin of transfer to provide the start site for conjugative transfer of the transmissible plasmid from the donor cell to at least one recipient cell; and (c) at least one killer gene that, upon expression in a bacterial cell, produces a product that kills the cell. The donor cell again comprises one or more transfer genes conferring upon the donor cell the ability to conjugatively transfer the transmissible plasmid to the recipient cell, and is modified so as to be unaffected by the product of the killer gene. The recipient cell is a pathogenic bacterium that has not been modified so as to be unaffected by the product of the killer gene.
[0014] The present invention also provides methods of treating a patient for a pathogenic bacterial infection which comprises administering to the patient one of the aforementioned antibacterial agents. The mode of administration is selected to ensure that the donor cells of the antibacterial agent come into conjugative proximity to the pathogenic bacterial cells, such that the transmissible plasmids of the donor cells are conjugatively transferred from the donors to the pathogenic cells. Following conjugation and dependent upon the nature of the plasmid, it either undergoes unchecked replication or the at least one killer gene is expressed to produce a gene product that is detrimental or lethal to the pathogenic bacterial cells.
[0015] The present invention also provides pharmaceutical preparations for treating a patient for a bacterial infection. These preparations comprise one of the aforementioned antibacterial agents, formulated for a pre-determined route of administration to the patient.
[0016] Other features and advantages of the present invention will be understood by reference to the drawings, detailed description and examples that follow.
BRIEF DESCRIPTION OF THE DRAWINGS
[0017] FIG. 1 . Schematic diagram showing process of killing pathogenic bacteria by conjugative transfer of plasmids that engage in runaway replication in the recipient cells.
[0018] FIG. 2A . Schematic diagram of a non-self-transmissible, runaway replication plasmid system using a helper plasmid and a transmissible runaway replication plasmid.
[0019] FIG. 2B . Schematic diagram of a self-transmissible, runaway replication plasmid system.
DETAILED DESCRIPTION OF THE INVENTION
[0020] The present invention provides novel antibacterial strategies that utilize the highly efficient bacterial conjugation system to transfer a “killer” plasmid from a donor cell that is engineered to be immune to the killer plasmid, to a target bacterial cell that is not.
[0021] In one aspect of the invention, the “killer plasmid” is one that undergoes runaway replication in the recipient cells, ultimately killing the cells. The basic principles underlying the mechanism by which runaway plasmid replication kills cells are outlined below.
[0022] Plasmids are dispensable DNA molecules that are stably maintained in bacterial populations. Plasmids replicate extra-chromosomally inside the bacterium and can transfer their DNA from one cell to another by a variety of mechanisms. DNA sequences controlling extra-chromosomal replication (ori) and transfer (tra) are distinct from one another; i.e., a replication sequence cannot control plasmid transfer, and vice-versa. Replication and transfer are both complex molecular processes that require plasmid- and host-encoded functions.
[0023] Bacterial conjugation is the unidirectional and horizontal transmission of information from one bacterium to another. The genetic material transferred may be a plasmid or it may be part of a chromosome. Bacterial cells possessing a conjugative plasmid contain a surface structure (the sex pilus) that is involved in the coupling of donor and recipient cells, and the transfer of the genetic information. Conjugation requires contact between cells, and it is clear that the transfer of genetic traits can be mediated by many plasmids in a process which involves the physical transfer of DNA from a donor to a recipient cell.
[0024] Among all natural transfer mechanisms, conjugation is the most efficient. The conjugative process permits the protection of plasmid DNA against environmental nucleases, and the very efficient delivery of plasmid DNA into a recipient cell.
[0025] Conjugation functions are plasmid encoded. Numerous conjugative plasmids (and transposons) are known, which can transfer associated genes within one species (narrow host range) or between many species (broad host range). Transmissible plasmids have been reported in numerous Gram-positive genera including pathogenic strains of Streptococcus, Staphylococcus, Bacillus, Clostridium and Nocardia . The early stages of conjugation differ in Gram-negative and Gram-positive bacteria. As mentioned, the role of some of the transfer genes in conjugative plasmids from Gram-negative bacteria is to provide pilus-mediated cell-to-cell contact, formation of a conjugation pore and related morphological functions. The pili do not appear to be involved in initiating conjugation in Gram-positive bacteria. The feature best understood in the enterococci is the involvement of pheromones. Pheromones are hydrophobic polypeptides of 7:8 amino acids produced by potential recipient cells. Pheromones invite attention of potential donor cells containing conjugative plasmids. PAD I is one of the best studied pheromone-induced plasmids which can replicate in 50 different bacterial hosts in addition to Enterococcus faecelis strains from which it was initially isolated (Clewel, D. B. 1999. Sex pheromone systems in Enterococci, In: Cell-Cell Signaling in Bacteria, Ed. G. M. Dunny, S. C. Winans; ASM, Washington D.C. pp 47-65). Moreover, conjugation can occur between genera as widely diverse as anaerobes and aerobes.
[0026] Naturally occurring plasmids are present within host cells at a characteristic concentration (referred to herein as a particular plasmid's “copy number”). Of great significance to the present invention is the fact that plasmid copy number is negatively controlled. Thus, mutations that destroy the elements of the negative control cause an over-replication phenotype that manifests itself by an increase in the plasmid's copy number (“copy-up” phenotype). In extreme cases of copy-up mutations, plasmid replication is completely unchecked due to the loss of copy control mechanisms. This is referred to as “runaway plasmid replication” or simply “runaway replication.”
[0027] Runaway plasmid replication is lethal for the host cell. This is because, although the plasmid encodes the replication (Rep) protein that controls its copy number, all other replication proteins are encoded by chromosomal genes. These chromosomally encoded proteins assemble into a complex called a replisome. A typical bacterial cell possesses a small, fixed number of replisomes. Because both the chromosome and the plasmids require the same replisomes for DNA synthesis, an excess of plasmids acts like a trap to occupy all of the cell's replisomes. This results in the inability of the cell's chromosome to replicate, ultimately leading to the death of the host cell.
[0028] The use of runaway replication plasmids as a means to kill recipient cells has a number of advantages over conventional antibiotic methodologies. One significant advantage is that, since the entire host replication machinery is targeted, multiple mutations would be required to avoid death by elevating the expression or activity of the replisome sub-assemblies. For instance, mutations in ten genes would be required just to increase the amount or activity of DNA polymerase III holoenzyme (composed of ten different subunits), and this polymerase is just one of the replisome's sub-assemblies. Thus, there is little or no chance of a bacterium acquiring resistance to being killed by over-replicating plasmids. In contrast, conventional antibiotics typically inhibit only a single enzymatic activity that is essential for the cell's survival. A single-target strategy unavoidably leads to the quick acquisition of resistance to such drugs, caused by the relatively high spontaneous mutation frequency for one gene (10 −6 to 10 −8 ).
[0029] Because runaway replication mutations are lethal to the host cell, donor cells that maintain such plasmids must be engineered so that replication control is restored. This is accomplished by providing the wild-type Rep protein to the host cell, either on another plasmid or by integration into the bacterial chromosome using standard homologous recombination techniques.
[0030] Thus, the runaway replication plasmid, antibacterial strategy of the invention comprises the following basic components:
[0031] (1) a plasmid that, alone or with the assistance of a helper plasmid, comprises the genes necessary to effect conjugative transfer of the plasmid from a donor cell to a recipient cell; the replication of the plasmid is negatively controlled by a gene that can be de-activated (via mutation) so as to release the negative control on plasmid replication (referred to as a “runaway replication plasmid”);
[0032] (2) optionally, a helper plasmid with the requisite transfer genes; and
[0033] (3) a donor cell for maintaining the runaway replication plasmid in a replication-suppressed state, so as not to be killed by the plasmid.
[0034] A number of conjugative plasmids have been well characterized, and can serve as subjects for mutagenesis to create runaway mutants, which may be used in embodiments of the present invention. Such mutants contain all components needed for conjugative self-transfer from donor to recipient cells but are defective in their replicative repressor (Rep) function. Examples of such mutants, both broad-range and narrow-range, are known in the art (Haugan et al., Plasmid 33: 27-39, 1995; Molin et al., J. Bacterial. 143: 1046-1048, 1980; Toukdarian & Helinski, Gene 223: 205-211, 1998). A particularly preferred plasmid of this type is a mutant of plasmid R6K, as described in detail in Examples 1 and 2. Other examples include, but are not limited to, RK2, pCU1, pl5A, pIP501, pAMβt and pCRG1600.
[0035] As an alternative to the use of mutants, it may sometimes be preferable to use various components of conjugative plasmids whose features are well understood, to create plasmids having all necessary features. Features required on runaway replication plasmids or helper plasmids include (I) an origin of replication (oriT herein), the sequence from which replication of the plasmid originates and the sequence that is negatively regulated by a Rep protein; (2) an origin of transfer (or therein); the sequence from which the conjugal plasmid transfer originates; (3) the transfer (tra) genes required in trans to effect conjugation; and (4) a screenable marker gene that would function in a donor but not in the recipient cells. The donor cell containing the runaway replication plasmid is engineered to contain a functional repressor (Rep) of replication at oriV, thereby controlling replication of the runaway replication plasmid while it is still in the donor.
[0036] Two basic systems are contemplated: a non-self-transmissible plasmid system and a self-transmissible plasmid system. These are shown schematically in FIGS. 2A and 2B .
[0037] In the non-self-transmissible system ( FIG. 2A ), the runaway replication plasmid contains an oriT, an oriV and a screenable marker gene. The helper plasmid contains the additional tra genes, along with its own origin of replication and a selective marker. Thus, the helper plasmid enables conjugative transfer of the runaway replication plasmid, but is itself confined to the donor cell due to its lack of an oriT. Since the runaway replication plasmid lacks the necessary tra genes to convert the recipient cell into a donor cell, the cycle of conjugation ends with the original recipient cell. It cannot transfer its runaway replication plasmid to a second recipient before it dies.
[0038] In the self-transmissible system (FIG. 2 B}, the runaway replication plasmid contains an oriT, an oriV and a screenable marker gene. It also contains the additional tra genes needed for conjugative transfer. Thus, unlike the non-self-transmissible plasmid described above, once this plasmid has been transmitted from the original donor to a first recipient, it is capable of transmitting itself again to subsequent recipients before the first recipient cell is killed by runaway replication. A plasmid of this type has the capability of much faster dissemination among recipient cells than the non-self-transmissible type, resulting in faster and more widespread killing of those cells.
[0039] In either the self-transmissible or the self-non-transmissible system, the donor cells must contain a gene encoding a functional Rep protein that represses plasmid replication initiated at oriV. The Rep-encoding gene is typically integrated into the donor genomic DNA. Plasmid DNA comprising the Rep-encoding gene is introduced into bacterial cells by any commonly known technique (e.g., transformation). The Rep-encoding gene can be integrated into the host genome by a site-specific recombination, according to standard methods (Li-Ch Huang, E. Wood and M. Cox; J. Bacterial. 179:6076-6083, 1997).
[0040] A number of bacterial oriV's and the Rep proteins that negatively control them have been characterized. Each of these is contemplated for use in the present invention. Examples of suitable oriV/Rep systems for use in the invention include, but are not limited to: RK2, R6K, rts 1, pl5A, RSF100, F and Pl.
[0041] The selection of oriV will confer on the system its range of potential recipients for runaway replicating plasmids. In most instances it may be preferable to target a specific pathogen as recipient of the runaway replication plasmid. Such instances include, but are not limited to using the conjugative runaway plasmids for combating Enterobacteria, Enterococci, Staphylococci and non-sporulating Gram-positive pathogens such as Nocardia and Mycobacterium sp. Examples of selective host range plasmids from which such oriV's may be obtained include, but are not limited to, P1 and F.
[0042] In instances where it is desirable to affect a wide variety of pathogenic recipients, a broad range oriV is employed. Examples of broad range (“promiscuous”) plasmids from which oriV's may be obtained include, but are not limited to: R6K, RK2, pl5A and RSF100.
[0043] As used herein, the term “range” (or “host range”) refers generally to parameters of both the number and diversity of different bacterial species in which a particular plasmid (natural or recombinant) can replicate. Of these two parameters, one skilled in the art would consider diversity of organisms as generally more defining of host range. For instance, if a plasmid replicates in many species of one group, e.g., Enterobacteriaceae, it may be considered to be of narrow host range. By comparison, if a plasmid is reported to replicate in only a few species, but those species are from phylogenetically diverse groups, that plasmid may be considered of broad host range. As discussed above, both types of plasmids (or components thereof) will find utility in the present invention.
[0044] Conjugative transfer (tra) genes also have been characterized in many conjugative bacterial plasmids. The interchangeability between the gene modules conferring the ranges of hosts susceptible for conjugal transfer and vegetative replication include Gram-positive and Gram-negative species. Examples of characterized tra genes that are suitable for use in the present invention are the tra genes from: (I) F (Firth, N., Ippen-Ihler, K. and Skurray, R. A. 1996, Structure and function of F factor and mechanism of conjugation. In: Escherichia coli and Salmonella , Neidhard et al., eds., ASM Press, Washington D.C.); (2) R6K (Nunez, B., Avila, P. and de la Cruz, 1997, Genes involved in conjugative DNA processing. Mol. Microbial. 24: 1157-1168); and (3) Ti (Ferrand, S. K., Hwang, I. and Cook, D. M. 1996, The tra region of Nopaline type Ti plasmid is a chimera with elements related to the transfer systems of RSF1010, RP4 and F. J. Bacteriol. 178: 4233-4247).
[0045] According to another aspect of the invention, the bacterial conjugation system is again utilized, this time to efficiently deliver a variety of “killer genes” to target bacterial cells. The delivery of various killer genes to bacterial cells occurs in nature, upon infection of bacteria with bacteriophages. Bacteriophages utilize a number of different mechanisms to maintain their own replication cycles, generally resulting in lysis of the host bacterial cells. Indeed, bacteriophages have been proposed and used as alternatives to antibiotics, as discussed above in the Background of the Invention. One serious drawback to the use of bacteriophages for this purpose is that they are oft n extremely host-specific, binding only to cell surfaces possessing specific receptors. As a result, bacteria quickly develop resistance mutations in the receptor, thereby escaping recognition by the phage. The present invention circumvents that drawback by placing the killer genes (from a phage or other source) on a conjugative plasmid. The conjugative plasmid containing the killer gene, like the conjugative runaway replication plasmids described above, is thereafter efficiently distributed to recipient cells.
[0046] Bacteriophages kill host cells by a variety of mechanisms, many of which are encoded by a discrete set of genes in the phage genome. For instance, bacteriophage MS2 contains a gene encoding a bacterial lysis protein (Coleman et al. 1983. J. Bacterial. 153: 1098-1100). Phage T4D contains genes encoding proteins that degrade cytosine-containing DNA in bacterial host cells (Kutter, E. and Wilberg, J. 1968. J. Mol. Biol. 38: 395-411). Other T4 phage encode gene products that interfere with transcription of cytosine-containing DNA (Drivdahl, R. and Kutter, E. 1990. J. Bacterial. 172: 2716-2727). Yet other T4 gene products are responsible for the disruption of the bacterial nucleoid (Bouet, J., Woszczuk, J., Repoila, F., Francois, V., Jouam, J. and Krisch, H. 1994. Gene 141: 9-16). Genes such as these can be inserted into a conjugative plasmid such as those described above, for efficient distribution to target recipient cells.
[0047] In addition, other types of killer genes may be utilized similarly. These include naturally-occurring or synthetic genes. A nonlimiting example of a naturally-occurring gene that is suitable for use in the invention is the hok gene product described by Gerdes et al. (Gerdes et al. 1986. EMBO J. 5: 2023-2029). Examples of man-made nucleic acid molecules that may be used in this aspect of the invention include: (1) sequences encoding non-hemolytic-amino acid oligomers, which are a new class of molecules based on inhibitors of Sigma-Core RNA polymerase interaction; (2) sequences encoding peptides with bactericidal activity and endotoxin-neutralizing activity for Gram-negative bacteria as described in U.S. Pat. No. 5,830,860; (3) sequences encoding RNA molecules with binding affinity to critical bacterial cellular targets (e.g., Chen, H., Gold, L. 1994. Biochemistry 33:8746-8756); and (4) oligonucleotides generated by the SELEX method for the in vitro evolution of nucleic acid molecules with highly specific binding to target molecules as described in U.S. Pat. No. 5,475,096 and U.S. Pat. No. 5,270,163.
[0048] In these systems, death of the donor plasmid must be considered. It can be prevented by employing a synthetic promoter-operator system whose expression is prevented by the repressor made only in the donor cells.
[0049] Regardless of the type of killer plasmid that is utilized, the plasmid must contain a screenable marker gene. In traditional molecular biological manipulations of recombinant bacteria, the screenable marker gene is an antibiotic resistance gene. Since the present invention is designed to avoid further spread of antibiotic resistance, an alternative screenable marker system is preferred for use in the present invention. Accordingly, though antibiotic resistance markers can be used, preferred screenable markers are nutritional markers, i.e., any auxotrophic strain (e.g., Trp − , Leu − , Pro − .) containing a plasmid that carries a complementing gene (e.g., trp + , leu + , pro + ). The donor bacterial strain for any of the above-described killer plasmids can be any one of thousands of non-pathogenic bacteria associated with the body of warm-blooded animals, including humans. Preferably, non-pathogenic bacteria that colonize the non-sterile parts of the body (e.g., skin, digestive tract, urogenital region, mouth, nasal passages, throat and upper airway, ears and eyes) are utilized as donor cells, and the methodology of the invention is used to combat bacterial infections of these parts of the body. In another embodiment, safe donors of these plasmids are developed for combating systemic infection. Examples of particularly preferred donor bacterial species include, but are not limited to: (1) non-pathogenic strains of Escherichia coli ( E. coli F18 and E. coli strain Nissle 1917), (2) various species of Lactobacillus (such as L. casei, L. plantarum, L. paracasei, L. acidophilus, L. fermentu m, L. zeae and L. gasseri ), (3) other nonpathogenic or probiotic skin-or GI colonizing bacteria such as Lactococcus, Bi. fidobacteria, Eubacteria , and (4) bacterial mini-cells, which are anucleoid cells destined to die but still capable of transferring plasmids (see; e.g., Adler et al (1970) Proc. Nat. Acad, Sci USA 57; 321-326; Frazer et al. (1975) Current Topics in Microbiology and Immunology 69: 1-84; U.S. Pat. No. 4,968,619 to Curtiss III).
[0050] As mentioned, the target recipient cells are pathogenic bacteria dispersed throughout the body, but particularly on the skin or in the digestive tract, urogenital region, mouth, nasal passages, throat and upper airways, eyes and ears. Of particular interest for targeting and eradication are pathogenic strains of Pseudomonas aeruginosa, Escherichia coli, Staphylococcus pneumoniae and other species, Enterobacter spp., Enterococcus spp. and Mycobacterium tuberculosis . Others are also discussed herein, and still others will be readily apparent to those of skill in the art.
[0051] It is clear from the foregoing discussion that numerous types of killer plasmids (e.g., runaway replication plasmids, plasmids carrying lethal phage genes, etc.) are suitable for use in the present invention. In view of this, one of skill in the art will appreciate that a single donor bacterial strain might harbor more than one type of killer plasmid. Such multiple plasmid systems can contain a plurality of plasmids targeted to different recipient cells. Further, two or more donor bacterial strains, each containing one or more killer plasmids, may be combined for a similar multi-target effect.
[0052] Once the recombinant donor bacteria comprising the killer plasmid(s) are produced, they are used to protect against one or more selected pathogens in individuals requiring such treatment. Depending on the cell population or tissue targeted for protection, the following modes of administration of the bacteria of the invention are contemplated: topical, oral, nasal, pulmonary/bronchial (e.g., via an inhaler), ophthalmic, rectal, urogenital, subcutaneous, intraperitoneal and intravenous. The bacteria preferably are supplied as a pharmaceutical preparation, in a delivery vehicle suitable for the mode of administration selected for the patient being treated. The term “patient” or “subject” as used herein refers to humans or animals (animals being particularly useful as models for clinical efficacy of a particular donor strain).
[0053] For instance, to deliver the bacteria to the gastrointestinal tract or to the nasal passages, the preferred mode of administration is by oral ingestion or nasal aerosol, or by feeding (alone or incorporated into the subject's feed or food). In this regard, it should be noted that probiotic bacteria, such as Lactobacillus acidophilus , are sold as gel capsules containing a lyophilized mixture of bacterial cells and a solid support such as mannitol. When the gel capsule is ingested with liquid, the lyophilized cells are re-hydrated and become viable, colonogenic bacteria. Thus, in a similar fashion, donor bacterial cells of the present invention can be supplied as a powdered, lyophilized preparation in a gel capsule, or in bulk for sprinkling into food or beverages. The re-hydrated, viable bacterial cells will then populate and/or colonize sites throughout the upper and lower gastrointestinal system, and thereafter come into contact with the target pathogenic bacteria. For topical applications, the bacteria may be formulated as an ointment or cream to be spread on the affected skin surface. Ointment or cream formulations are also suitable for rectal or vaginal delivery, along with other standard formulations, such as suppositories. The appropriate formulations for topical, vaginal or rectal administration are well known to medicinal chemists.
[0054] The present invention will be of particular utility for topical or mucosal administrations to treat a variety of bacterial infections or bacterially related undesirable conditions. Some representative examples of these uses include treatment of (1) conjunctivitis, caused by Haemophilus sp., and corneal ulcers, caused by Pseudo17Jonas aeruginosa; (2) otititis extema, caused by Pseudomonas aeruginosa ; (3) chronic sinusitis, caused by many Gram-positive cocci and Gram-negative rods; (4) cystic fibrosis, associated with Pseudomonas aeruginosa ; (5) Enteritis, caused by Helicobacter pylori (ulcers), Escherichia coli, Salmonella typhimurium, Campylobacter and Shigella sp.; (6) open wounds, both surgical and non-surgical, as a prophylactic measure for many species; (7) burns to eliminate Pseudomonas aeruginosa or other Gram-negative pathogens; (8) acne, caused by Propionobacter acnes ; (9) nose and skin infections caused by methicillin resistant Staphylococcus aureus (MSRA); (10) body odor caused mainly by Gram-positive anaerobic bacteria (i.e., use in deodorants); (11) bacterial vaginosis associated with Gardnerella vaginalis and other anaerobes; and (12) gingivitis and/or tooth decay caused by various organisms.
[0055] Pharmaceutical preparations comprising the donor bacteria are formulated in dosage unit form for ease of administration and uniformity of dosage. Dosage unit form, as used herein, refers to a physically discrete unit of the pharmaceutical preparation appropriate for the patient undergoing treatment. Each dosage should contain a quantity of the donor bacteria calculated to produce the desired antibacterial effect in association with the selected pharmaceutical carrier. Procedures for determining the appropriate dosage unit are well known to those skilled in the art.
[0056] Dosage units may be proportionately increased or decreased based on the weight of the patient. Appropriate concentrations for achieving eradication of pathogenic bacteria in a target cell population or tissue may be determined by dosage concentration curve calculations, as known in the art.
[0057] Other uses for the donor bacteria of the invention are also contemplated. These include agricultural and horticultural applications, such as: (1) use on meat or other foods to eliminate pathogenic bacteri; (2) use in animal feed (chickens, cattle) to reduce bio-burden or to reduce or eliminate particular pathogenic organisms (e.g., Salmonella ); (3) use on fish to prevent “fishy odor” caused by Proteus and other organisms; and (4) use on cut flowers to prevent wilting.
[0058] The following examples are set forth to describe the invention in greater detail. They are intended to illustrate, not to limit, the invention. Unless otherwise specified, general cloning, microbiological, biochemical and molecular biological procedures such as those set forth in Sambrook et al., Molecular Cloning, Cold Spring Harbor Laboratory (1989) (“Sambrook et al.”) or Ausubel et al. (eds) Current Protocols in Molecular Biology, John Wiley & Sons (2000) (“Ausubel et al.”) are used.
Example 1
[0059] Preparation of Runaway Replication Plasmid from Plasmid R6K. Plasmid R6K is an Escherichia coli conjugative plasmid. Replication of R6K derivatives containing its oriV called γ on requires a Rep protein, π, which is encoded by the plasmid's pir gene. The π protein is bifunctional in replication; it acts as an activator of replication at low cellular levels and an inhibitor of replication at elevated levels. For a review of R6K replication and its control by the π protein, see Filutowicz & Rakowski (1998) Gene 223, 195-204.
[0060] Using site-directed mutagenesis, the inventor has obtained the following three types of mutations within the pir gene:
[0061] (1) double amino acid substitution: pro106leu, phe107ser (numbering of residues according to Stalker et al. (1982) J. Mol. Biol. 161: 33-43)
[0062] (2) deletion of codons 106 and 107; and
[0063] (3) deletion of codons 105, 106 and 107.
[0064] The mutated pir genes were combined with the γ on in two locations. In one location, the mutant gene was contained on a plasmid different from the plasmid containing the γ ori, thus providing π protein in trans. In another location, the mutant pir gene was contained on the same plasmid with γ ori, thus providing its function in cis.
Example 2
[0065] Bacterial Cells Transformed with Plasmids Containing Mutated pir and γ on in cis are Killed. Escherichia coli cells were transformed with either (1) the plasmids containing a mutated pir gene and the γ on in trans; or (2) a plasmid containing a mutated pir gene and the γ on in cis.
[0066] In transformed cells containing the mutant pir and the γ on in trans, the copy number of the γ 0 on plasmid was increased 20- to 25-fold in comparison to wild-type pir controls. Cells transformed with the mutant pir and the γ on in cis were killed by the runaway replication of γ ori. The occurrence of the runaway phenotype when mutant pir is in cis to the on but not in trans is believed to be caused by the enhanced effect of the origin activation and translation of nascent π protein occurring next to each other.
[0067] The present invention is not limited to the embodiments described and exemplified above, but is capable of variation and modification without departure from the scope of the appended claims. | Novel antimicrobial agents that can serve as replacements to conventional pharmaceutical antibiotics are disclosed. The antimicrobial agents comprise conjugatively transmissible plasmids that kill targeted pathogenic bacteria, but are not harmful to donor bacteria. Two types of lethal transmissible plasmids are disclosed. One type kills recipient bacteria by unchecked (“runaway”) replication in the recipient cells and is prevented from occurring in donor cells. Another type kills recipient bacteria by expressing a gene that produces a product detrimental or lethal to recipient bacterial cells, that gene being prevented from expression in donor cells. | 2 |
DESCRIPTION
The present invention refers to a labelling machine.
In the case of labelling machines, e.g. for bottles, glass jars and vessels, receptacles etc., it is common practice to subject, with the aid of a control means, the plates to specific rotary motions and rotary positions in the course of the labelling process, said rotary motions and positions being transmitted by frictional or positive engagement to the objects to be labelled, which are pressed onto the plates by the plungers and which, in turn, entrain said plungers which are supported in a freely rotatable manner. In cases of use in which the angular position of the plunger does not have any influence on the labelling process, this is absolutely unproblematic.
There are, however, also cases of use in which the angular position of the plunger during the labelling process has to be defined precisely. This is, for example, necessary when the plunger has on one side thereof a flattened contact surface for a label end projecting upwards beyond the object to be labelled, or is equipped with a controllable gripping finger for a label, or is provided with an opening permitting a label to be applied to the upper side of an object to be labelled, or when the surface of the object to be labelled which is seized by the plunger is eccentric with respect to the axis of rotation of the plate. In such cases, it is known to provide the plunger with a rotating means of its own. Such a labelling machine is described in German-Offenlegungsschrift 38 23 471.
The present invention deals with the problem of constructing in the case of a labelling machine according to the generic clause the rotating means, which is used for rotating the plungers, in a particularly simple and economy-priced manner.
In the case of a labelling machine according to the present invention, direct control of the plungers by the rotating means is only effected if said plungers are raised from the objects to be labelled, whereas indirect control of the plungers by means of the plates is effected if said plungers are pressed onto an object to be labelled. This permits a particularly simple and economy-priced structural design of the rotating means, and it is also easily possible to equip labelling machines which have already been delivered, subsequently with such a rotating means. Resetting of the rotating means will, in most cases, not be necessary, when the rotary program for the plates is changed; the rotating means mainly has to guarantee that the plunger will occupy a predetermined starting position, when it is applied to the vessel or the like. Complicated cam paths, which directly influence the plungers during the whole labelling process, can be dispensed with.
There are many possibilities of constructing the rotating means. The necessary starting position or neutral position of a plunger can, for example, be defined by two cooperating stop means in a very simple manner, one of said stop means being connected to the plunger and the other to the stationary part of the labelling machine. By means of a torsion spring acting on the plunger, the stop means are caused to engage as soon as the plunger has been raised from the object to be labelled. After having been applied to an object to be labelled, the plunger will then be entrained by said object against the force exerted by the torsion spring. In this case, the torsion spring of the rotating means will also be effective when the plunger has been applied to the object to be labelled, but a sufficiently weak dimensioning of said spring will guarantee that its force will easily be exceeded.
It will, however, be particularly expedient, when, in accordance with the further development of the invention, the rotating means is only effective as long as the plunger is not in contact with an object to be labelled. In this case, the plunger can rotate in the labelling area together with the object to be labelled completely unhindered without being obstructed by a torsion spring or the like.
On the basis of a further development, the necessary torque for returning the plunger to the neutral position defined by the recess can be adjusted by simple adaptation of the oblique ramp and of the force of the spring.
Further developments result in a rotating means having a particularly simple structural design and functioning in a reliable manner, said rotating means influencing the plunger only if said plunger is not in contact with the object to be labelled.
In order to guarantee that the plunger will be entrained by the object to be labelled, it will be expedient, when, in accordance with a further development of the invention, the plunger is provided with a friction facing acting on the object to be labelled.
In the following, an embodiment of the present invention will be described in detail on the basis of the drawings, in which:
FIG. 1 shows a vertical fragmentary section through a labelling machine in the area of an object to be labelled, which has a plunger applied thereto,
FIG. 2 shows the fragmentary section according to FIG. 1 in a condition in which the plunger has been raised from the object to be labelled,
FIG. 3 shows the view Y according to FIG. 2,
FIG. 4 shows the view X according to FIG. 2.
The labelling machine, only part of which is shown in FIG. 1 to 4, is equipped such that it can apply various labels to objects, in the form of bottles 24, which are to be provided with a label. The labelling machine includes a rotary table 20, which rotates about a vertical axis and in which a plurality of plates 1 having a vertical axis of rotation is supported, said plates 1 being uniformly distributed over the circumference of said rotary table 20. The plates 1 communicate via a pinion 21 with a toothed segment 22, which is pivotably supported on said rotary table 20 and which, in turn, engages via a cam roller 17 a closed groove path 23 formed in a stationary cam ring 16. On the basis of this arrangement, all plates 1 are subjected to programmed rotation and positioning, as required by the labelling operation, when the rotary table 20 is being rotated. In order to guarantee a reliable transmission of the rotation of the plate 1 to the bottle 24, a friction facing 19 is provided on the upper surface of the table 1.
A rotary head 14 is provided concentrically with and in spaced relationship with the rotary table 20, said rotary head 14 being connected to the rotary table 20 such that it is secured against rotation relative thereto and, consequently, it will rotate together with said rotary table 20. Pillow blocks 13 are secured to the rotary head 14, said pillow blocks being uniformly distributed over the circumference of said rotary head, one above each plate 1. Each pillow block 13 accommodates therein a cylindrical sleeve 9, which is closed at its upper end face and open at its lower end face and which is adapted to be vertically moved within said pillow block. A sliding block 25 and a rotatable cam roller 12 are secured to the inner side of the sleeve 9 facing the axis of the rotary head 14. In order to secure the sleeve 9 against rotation, the sliding block 25 is guided in a vertical slotted link 26 of the pillow block 13, whereas the cam roller 12 engages a closed, groove-shaped lifting cam path 11, which is formed in a stationary cam barrel 27. By means of said lifting cam path 11 and the cam rollers 12 following said lifting cam path, a control means is defined for controlling the lifting movement and the vertical level, respectively, of the sleeves 9.
A vertically extending rod 15 is supported in each sleeve 9 such that it is vertically movable therein, the upper end face of said rod 15 and the closed upper end face of the sleeve 9 having inserted between them a spring element 10 in the form of a biased pressure spring. This biased pressure spring tries to force the rod 15 downwards towards the plate 1 or rather a bottle 24 supported by said plate.
On the lower end of the rod 15 projecting beyond the sleeve 9, which, in turn, projects downwards beyond the rotary head 14, a plunger 2 is rotatably supported by means of a vertical, cylindrical bearing bore, a hardened ball being arranged between said lower end of the rod 15 and said plunger 2. The cylindrical upper part of the plunger 2 is provided with a cross hole in which a pin 28 is releasably held by means of a clamping spring. The pin 28 engages a complementary annular groove in the rod 15 with a certain amount of play, whereby said plunger 2 is releasably held on said rod 15. In the central portion of the plunger 2, a disklike cam path 4 is formed, which has a cylindrical circumferential surface and which will be described in detail hereinbelow. The lower part of the plunger 2 is constructed after the fashion of a centering bell and, on one side thereof, it is provided with a vertical, knurled flattened portion 29. The lower surface of the plunger 2 has secured thereto a friction facing 18 in the area which comes into contact with the bottle 24 or rather with the bottle cap. This will improve the transmission of the rotary movement from the bottle 24 to the plunger 2.
At the lower end of each sleeve 9, a holder 8 is adjustably clamped in position, which, in the upper portion thereof is constructed after the fashion of a horizontal, slotted clamp with an attachment screw 30 and which includes an arm projecting vertically downwards from said clamp up to and beyond the cam path 4. At the lower end of this arm, a rotatable roller 5 is arranged, which is located on a level between the cam path 4 and the plate 1. The roller 5, whose axis of rotation extends radially to the axis of rotation of the plunger 2, is arranged such that it can touch the outer rim of the lower end face of the cam path 4. This rim of the cam path 4 is constructed after the fashion of a one-sided lifting cam path and is provided with a recess 7 defining a preferred neutral position of the plunger 2, when it is in contact with said roller 5. This recess 7 is followed at both sides thereof by downwardly sloping ramps 6, which, defining a tip, meet at the opposite side of the cam path 4. Cooperating with the roller 5, the two ramps 6 guarantee that the plunger 2 will return to its neutral position.
The downwardly projecting arm of the holder 8 is arranged on the inner side of the sleeve 9 which faces the axis of rotation of the rotary table 20 so that the application of the lables, which is carried out from outside by labelling cylinders or the like (not shown), is not obstructed. In the case of the embodiment shown, the labels in question are a body label, a rear label and a neck label, which includes a strip 31 projecting upwards beyond the head of the bottle 24. When the label is being affixed to the bottle 24, this strip 31 is first positioned in contact with the flattened portion 29 of the plunger 2. In a discharge star, which is provided subsequent to the rotary table 20 and which is not shown, said strip 31 is then turned down by means of rollers or the like and pressed onto the upper side of the bottle cap.
In order to guarantee that the strip 31 will exactly be positioned on the knurled flattened portion 29, each plunger 2 has associated therewith a rotating means 3, which is essentially defined by the cam path 4, the roller 5 and the spring element 10. The function of this rotating means 3 is the following one:
In the bottle-free area of rotation of the rotary table 20 between the inlet station (not shown) and the discharging station (not shown either), the sleeve 9 with the holder 8 and the roller 5 is guided by means of the lifting cam path 11 in its upper end position shown in FIG. 2. In this position, the rod 15 with the plunger 2 is, unhindered, pressed downwards by means of the spring element 10 to such an extent that the lower rim of the cam path 4 will be in spring-loaded contact with the roller 5. If the roller 5 first comes into contact with one of the two oblique ramps 6, it will roll along said ramp until it comes into engagement with the recess 7. In the course of this process, the plunger 2 will be rotated clockwise or anticlockwise until it has reached its neutral position, the plunger being slightly lowered at the same time. If the roller 5 first comes into contact with the recess 7, no rotation of the plunger 2 will take place, said plunger 2 being then immediately fixed in its neutral position.
The above-described rotation and fixing of the plungers 2 is completely independent of the rotation of the plates 1, which stand still in the bottle-free area of rotation or which can also carry out a reverse rotation.
In the area of the inlet station, the sleeve 9 plus all the parts which are secured thereto or supported thereon is moved downwards by means of an adequate descent in the lifting cam path 11, the relative position shown in FIG. 2 being first maintained in the course of said downward movement, until the friction facing 18 of the plunger 2 comes into contact with the cap of the bottle 24. This will stop the vertical movement of the plunger. The lowering movement of the sleeve 9 is continued still further, whereby the spring element 10 will be compressed. This will have the effect that, on the one hand, a sufficiently large clamping force between the plate 1 and the plunger 2 will be produced even in the case of tolerances in the height of the bottles 24 and that, on the other hand, the roller 5 will be moved downwards and completely out of the range of action of the cam path 4 until the lower end position of the sleeve 9 with the holder 8 and the roller 5 has been reached, said lower end position being shown in FIG. 1. The plunger 2 will thus first remain in its neutral position and the bottle 24 will be clamped firmly between the plate 1 and the plunger 2. When the plate 1 now carries out its various rotations and positioning movements under the influence of the groove path 23 in the course of the labelling process, these rotations and positioning movements will be transmitted exactly to the bottle 24 and from said bottle to the plunger 2 with the aid of the friction facings 18 and 19. This will have the effect that, when the neck label is being applied, the strip 31 will be placed precisely onto the flattened portion 29 of the plunger 2 due to an adequate selection of the neutral position of said plunger. The rotary means 3 for the plunger 2 is ineffective as long as the plunger 2 is fixed on the level, which is shown in FIG. 1, by a bottle 24.
If a bottle 24 supported by a plate 1 breaks, the respective plunger 2 will move down immediately under the influence of the spring element 10 until the cam path 4 strikes against the roller 5, which is still held in the same position, whereby the plunger 2 will immediately be adjusted to its neutral position in the manner described hereinbefore. If a rotary plate 1 has not placed thereon any bottle 24 at all, the plunger 2 will remain fixed in its neutral position throughout its whole revolution through the labelling area.
In the area of the discharge station, the sleeves 9 are gradually raised, by means of an ascent in the lifting cam path 11, from the lower end position shown in FIG. 1 to the upper end position shown in FIG. 2. In the course of this movement, the plunger 2 will first remain on the bottle 24 under the influence of the spring element 10 until the roller 5 strikes against the lower rim of the cam path 4, whereupon also the plunger 2 will participate in the lifting motion. The possibly necessary rotation of the plunger 2 can now already begin, if the roller 5 first strikes against one of the two oblique ramps 6. It is thus guaranteed that, even in the case of high labelling machine throughputs, the plungers 2 certainly will have reached their neutral position, when they are placed onto a bottle 24 again. It is, of course, also possible to construct the groove path 23 in such a way that the plungers 2 will, normally, already occupy their neutral position, when they are raised from the bottles 24. In this case, the rotating means 3 will only become effective if bottles 24 break.
An adjustment of the neutral position of the plungers 2 can easily be effected by adjusting the holders 8 with the aid of the attachment screw 30. If the labelling machine is changed over for processing a different type of bottles, in the case of which normal normal, rotationally symmetrical plungers or centering bells are required, the holders 8 can perhaps be removed. | In a labelling machine comprising at least one plate (1), which is adapted to carry out controlled rotations, and a plunger (2), which is adapted to carry out controlled upward and downward movements, the object to be labelled, e.g. a bottle (24), being fixed between said plate and said plunger such that it is secured against rotation relative thereto, the plunger has associated therewith a rotating means (3), which will rotate said plunger to a specific angular position and/or fix it in said angular position, if the plunger is not in contact with the object to be labelled. However, if the plunger is in contact with the object to be labelled, it will be decoupled from said rotating means, whereupon it can rotate freely together with the object to be labelled, which is driven by the plate. Such a rotating means can be established with the aid of simple structural means and permits a manifold use of asymmetric plungers having a preferred position. This is the case e.g. with plungers having contact surfaces for projecting labels, plungers having recesses for turning down projecting label ends, and plungers equipped with gripping fingers for the labels etc. | 1 |
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 the payment of any royalties thereon or therefor.
BACKGROUND OF THE INVENTION
(1) Field of the Invention
The present invention generally relates to a system for reducing acoustic and visible signatures generated when a submarine countermeasure is launched. More particularly a submarine countermeasure launcher that generates gas to launch a countermeasure has the capacity to capture the gas and therefore reduce the signatures that could be used by an enemy for detection purposes. Countermeasure devices are used to protect submarines from attacking platforms by providing decoys.
(2) Description of the Prior Art
Ballistic missile submarines currently have eight countermeasure launch device ports positioned outside the submarine's pressure hull. They are located within the outer hull superstructure forward of the sail. These launch devices are each loaded with an individual countermeasure or another underwater instrument while the submarine is in port. The individual countermeasure or underwater instrument is launched at sea from the submarine's control room. The launch devices are expendable and cannot be reloaded while the submarine is at sea.
Prior to the present invention, the gas generated when firing a countermeasure puts large amounts of acoustic energy and gas bubbles into the water creating a significant detection risk from the resultant acoustic and visual observables.
SUMMARY OF THE INVENTION
Accordingly, it is a general purpose and object of the present invention to provide a system for making a countermeasure launcher more covert at time of launching. It is a further object to achieve this by inhibiting the gas generated during the firing from escaping the launch tube.
These objectives are accomplished with the present invention by providing a countermeasure launcher system design centered around capturing the launch tube ram piston at the end of its stroke in such a way that the bubbles produced by a gas generator are contained within the countermeasure launcher's launch tube. The captured bubbles can be released slowly with reduced acoustic effect.
BRIEF DESCRIPTION OF THE DRAWINGS
For a more complete understanding of the present invention and the advantages thereof, reference is now made to the following description of the preferred embodiment taken in conjunction with the accompanying drawings in which:
FIG. 1 is a partially cutaway pictorial representation of a countermeasure launcher in accordance with the present invention; and
FIG. 2 shows a partial sectional view of the launcher tube of FIG. 1 and the components within it prior to launch.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Refer now to the FIG. 1 for a description of the operation of the system and the components required to carry out its operation. A countermeasure launcher 10 comprises a cylinder 12 with a gas generator 14 at the back end of the launcher device 10 . An electrical connector 15 feeds into the back end of the gas generator 14 . A ram plate 16 is disposed in front of the gas generator 14 . The electrical connector 15 provides firing voltage to the gas generator 14 . The edges of the ram plate 16 are sealed by an O-ring 18 . A countermeasure 20 is disposed in launch cylinder 12 forward of ram plate 16 . The rear of the countermeasure 20 is nested in a thrust plate 22 to protect countermeasure 20 from ram plate 16 upon firing. Countermeasure launcher 10 is sealed against the ocean by an end cap 24 held in place by one or more shear pins 26 .
Upon issuance of a firing command, an electrical signal is sent to the countermeasure launcher 10 , via electrical connector 15 . This causes gas generator 14 in countermeasure launcher 10 to discharge a large quantity of gas, which creates a high pressure behind ram plate 16 , thereby causing the ram plate 16 to move forward down launch cylinder 12 while pushing countermeasure 20 and thrust plate 22 before it. When countermeasure 20 contacts end cap 24 , the one or more shear pins 26 break, and cap 24 is pushed away enabling countermeasure 20 to exit launch cylinder 12 .
In the prior art, after discharge of the countermeasure 20 , thrust plate 22 and ram plate 16 also exit launch cylinder 12 . This causes the gas behind ram plate 16 to rapidly follow through the opening and to disperse into the seawater. This sudden gas discharge causes a great deal of both acoustic energy and visible turbulence. It is audible and visible to any enemy craft monitoring the area in which it occurs, and it compromises the position of a submarine discharging the countermeasure 20 .
The present invention provides a countermeasure launcher with a greatly reduced acoustic and visual signature. It achieves this by blocking the escape route of the gasses and then discharging these gasses slowly over a period of time.
In order to achieve this a stop ring 28 is added to the launch device 10 . Stop ring 28 is disposed near the outer end of the launch cylinder 12 . A pressure relief valve 30 is positioned behind stop ring 28 . The pressure relief valve 30 can be a disk valve or another valve having quiet operation. A spring plunger 32 retains the ram plate 16 and the thrust plate 22 forward of the pressure relief valve 30 after firing so that neither the ram plate 16 nor the thrust plate 22 inhibits the operation of the pressure relief valve 30 . Spring plunger 32 also minimizes thrust plate 22 oscillations thereby reducing transmitted acoustic energy. Stop ring 28 is positioned in launch cylinder 12 so as to allow the external end of countermeasure 20 to be resting inside of the stop ring 28 prior to firing and to guide countermeasure 20 while exiting from launch cylinder 12 upon firing. Countermeasure 20 has a slightly smaller outer diameter than the inner diameter of stop ring 28 allowing countermeasure 20 to exit upon launch. Thrust plate 22 has a diameter larger than the inner diameter of stop ring 28 so that it is prevented from exiting upon launch.
Refer now to FIG. 2 for a further description of many of the components of FIG. 1 . FIG. 2 shows a partial sectional view of launch cylinder 12 and the components within it. End cap 24 , shear pins 26 , gas generator 14 , and electrical connector 15 have been removed from the launch cylinder 12 and are not shown in this view.
At the forward end of the launch cylinder 12 is shown the stop ring 28 that is comprised of a spiral retaining ring 34 inserted in a launch cylinder annular groove 36 . In addition the stop ring 28 is made up of a stop/guide ring assembly 38 , having a metallic stop ring 40 and a urethane guide ring 42 bonded together. The guide ring 42 has the countermeasure 20 resting inside it prior to launch and assists in guiding the countermeasure 20 during launch. The stop ring 40 stops the thrust plate 22 and the ram plate 16 upon launching the countermeasure 20 . During launch, thrust plate 22 and ram plate 16 move past spring plunger 32 by causing plunger 32 to depress. Once thrust plate 22 and ram plate 16 move past plunger 32 , plunger 32 returns to its initial position preventing plates 16 and 22 from vibrating because of recoil off of stop ring 28 . This enables the pressure relief valve 30 to be clear of internal components when slowly discharging the contained gas.
The gas generator 14 of FIG. 1 is attached to threads 44 positioned on the outer side of the aft end of the launch cylinder 12 . The inner portion of the aft end of the launch cylinder 12 , shown prior to launch, has the ram plate 16 and thrust plate 22 . The ram plate 16 has an annular groove 46 holding the O-ring 18 . The thrust plate 22 is an assembly made up of a urethane guide ring 48 bonded to a thrust plate stop ring 50 . Four equally spaced cap screws 52 connect the thrust plate 22 to the ram plate 16 forming a ram/thrust plate assembly 54 .
The launching operation of the inventive device differs from that of the prior art in the following manner. Instead of leaving the launch cylinder 12 , as in the prior art, the ram plate 16 and thrust plate 22 are retained by stop ring 28 . In addition the ram plate 16 and the thrust plate 22 are held between the stop ring 28 and the spring plunger 32 . The pressure relief valve 30 opens due to the pressure contained within the cylinder 12 . Upon opening pressure relief valve 30 slowly bleeds the trapped, compressed gas into the surrounding ocean.
There has therefore been described a system for launching a countermeasure with considerably less noise than the former embodiment due to the elimination of suddenly discharged gasses that create noise.
Valve 30 can be positioned at any location having access to the high pressure gasses contained within the cylinder. For example, valve 30 can be embodied in the ram portion of the countermeasure. This alternative allows the improved countermeasure launcher to be installed in existing submarines and prevents the necessity of aligning the pressure relief valve with a submarine pressure exit port upon installation aboard the submarine. The valve also can embodied anywhere along the length of the cylinder.
Different types of valves can also be used for valve 30 in place of the pressure activated disk valve of the preferred embodiment. Valve 30 can be an electrically actuated valve that will allow release of the high pressure gasses on command rather than automatically as in the preferred embodiment.
Alternate means of retaining the ram also exist. One possible retaining means is by use of a retaining cable attached to the back end of the launch tube and the back end of the ram. This alternative also prevents the ram from exiting the launch tube.
It will be understood that various changes in the details, materials, steps and arrangement of parts, which have been herein described and illustrated in order to explain the nature of the invention, may be made by those skilled in the art within the principle and scope of the invention as expressed in the appended claims. | A countermeasure launcher system, for use by a submarine, reducing any detectable signature by preventing the escape of pressurized gas into seawater at the forward end of the system's launch tube upon launching a countermeasure. The pressurized gas that is used in launching the countermeasure is trapped within the launch tube by a unique arrangement of specific components. The pressurized gas is then permitted to slowly exit at a later time via a pressure relief valve in the launch tube's wall. | 1 |
BACKGROUND OF THE INVENTION
This application is a continuation of prior U.S. application Ser. No. 337,116 filed Jan. 5, 1982 which is a continuation of application Ser. No. 106,920 filed Dec. 26, 1979, both now abandoned.
This invention relates to water soluble polyether copolymers, and, more particularly, to novel high viscosity, liquid water soluble polyoxyalkylene glycolpolyurethane copolymers suitable for use as functional fluids and to the method of preparing the same.
Water soluble poly(alkylene oxide) polymers have achieved wide scale commercial acceptance as functional fluids for a broad spectrum of applications such as lubricating fluids, hydraulic fluids, metal working lubricants, heat transfer fluids and metal-quenching medium. As functional fluids, the poly(alkylene oxide) polymers can be used in either their substantially 100% concentrated form, or, most widely, in aqueous compositions thereof where the polymer serves as both lubricant and thickening agent or viscosity builder.
Poly(alkylene oxide) polymers which are most widely used as functional fluids are, in general, copolymers that will contain both oxyethylene groups and higher oxyalkylene groups, such as oxypropylene and oxybutylene groups. The amount of oxyethylene groups in the molecule is such that the polymers are soluble in water at ordinary temperatures and the amount of oxypropylene or higher oxyalkylene groups is such that the polymers remain liquid at ordinary temperatures up to molecular weights of 40,000 and higher.
The poly(alkylene oxide) polymers can be prepared as disclosed, for example, in U.S. Pat. No. 2,425,845 to Toussaint et al., under conditions permitting control over such important parameters as molecular weight, composition, and molecular structure. Thus, for example, by appropriate selection of initiator, epoxide ratio (ethylene oxidepropylene oxide ratio), and mode of feed (mixed, sequential, gradient, etc.); poly(alkylene oxide) polymers can be prepared with generally precise controlled viscosity, solubility, cloud point, surface tension, and the like characteristics which are critical to the performance of a functional fluid.
Notwithstanding the versatility and desirability of poly(alkylene oxide) polymers as a class of functional fluids, the polymers do have some limitations such as being generally more expensive than alternate petroleum derived materials. To offset these economic limitations a combination of superior performance characteristics must be relied on. For example, in water-based systems, poly(alkylene oxide) polymers of high viscosity are required so that lower concentrations of polymer can be employed. Known, conventional poly(alkylene oxide) polymers, exhibit viscosities which are directly related to their molecular weight. However, molecular weights much greater than 20,000 are difficult to obtain from ethylene oxide-propylene oxide copolymers because of undesirable side reactions involving the propylene oxide moiety, and the costs attendant with overcoming the process difficulties of preparing high molecular weight polymers, which includes carrying out the reaction in multiple stages, further increases the costs and economic disadvantages thereof. At the same time, lower molecular weight polymers, which may be prepared in a single stage reaction, are inefficient as thickening agents and must be used at economically, prohibitive concentrations.
It would be highly desirable, therefore, to develop water soluble poly(alkylene oxide) polymers of very high molecular weights and/or viscosities that exhibit effective functional fluid characteristics and are highly efficient thickening agents for water-based systems. Moreover, the development of such polymers which could be readily and economically prepared would certainly be highly advantageous.
Within the past few years other chemical methods have been suggested for preparing high molecular weight poly(alklyene oxide) polyols such as, for example, disclosed in U.S. Pat. No. 2,990,396 to Clark et al and U.S. Pat. No. 4,113,785 to Helfert et al wherein polyoxyalkylene polyols are reacted with polyepoxides or diepoxy compounds in various ratios to prepare a variety of high molecular weight polymers that may be water insoluble and cross-linked or may be water soluble. However, in the case where water-soluble polymers are produced, the processes disclosed generally require several reaction steps and the use of molar, as compared to small catalytic quantities, of alkali metal catalysts; consequently development of a process which would be even more direct would offer some further technical as well as economic advantages.
SUMMARY OF THE INVENTION
In accordance with the present invention there are provided high molecular weight, high viscosity, primarily straight chain, liquid, water soluble, polyoxyalkylene glycol block copolymers that are suitable for use as functional fluids comprising polyoxyalkylene glycol block copolymers having the general formula: ##STR2## wherein Q is the organic residue from an aliphatic or aromatic diisocyanate including thoe diisocyanates of the oligomeric or prepolymer types derived from the reaction of an excess of diisocyanate with a short chain diol which contain urethane linkages; x is an integer representing the average number of polyurethane blocks in the copolymer and is in the range of 1 to 10; R 1 and R 2 , which can be the same or different, are hydrogen, methyl, ethyl or mixtures thereof with the proviso that the overall content of species wherein R 1 and R 2 is hydrogen must be at least 50 percent by weight; R 3 and R 4 , which can be the same or different, are organic residues resulting from the removal of terminal hydrogen atoms from difunctional polyols and may be alkylene, arylene, alkarylene, aralkylene, cycloalkylene, heterocycloalkylene radicals or mixtures thereof; y and z are integers representing the average number of polyether blocks in the copolymer with the proviso that the sum of y and z must be from 1.05 to 2.0 times the value of x; and n, m, r, and s, which may be the same or different, are integers wherein n=m and r=s and the sums of n+m and r+s, which may be the same or different, are each in the range of about 8 to 250.
The novel copolymeric compositions of the invention are water soluble materials that have utility in a wide spectrum of functional fluid applications, either in concentrated form or in water-based systems. Moreover the copolymeric compositions have been found to be highly efficient thickening agents for water-based systems, having a significantly higher viscosity than found for conventional poly(alkylene oxide) polymers of similar molecular weight.
In accordance with the invention there is also provided a process for preparing water soluble, high molecular weight poly(alkylene oxide) block copolymers which are suitable for use as functional fluids which comprises reacting, with vigorous agitation, a stoichiometric excess of a polyoxyalkylene diol containing at least 50 percent by weight of oxyethylene groups with an organic diisocyanate wherein the total equivalent of hydroxyl functionality of said diol exceeds the equivalents of isocyanate functionality by a factor in the range of from about 1.05 to 1 to 2.0 to 1 for the time necessary to prepare a hydroxyl terminated copolymer condensation product. The condensation reaction can be carried out at elevated temperatures of from about 40° C. to about 175° C. with or without a catalyst being present.
DESCRIPTION OF THE INVENTION
The polyoxyalkylene glycols suitable for use in preparing the polyoxyalkylene copolymers of the present invention are diols having the formula:
R[O(CH.sub.2 CHR.sup.1 O).sub.n H].sub.2
wherein R is an organic residue resulting from the removal of terminal hydrogen atoms from diols and may be alkylene, arylene, alkarylene, aralkylene, cycloalkylene, heterocycloarylene and the like radicals or mixtures thereof, R 1 is hydrogen, methyl, ethyl or mixtures thereof, and n is an integer in the range of 4 to about 125.
The suitable diols are polyoxyalkylene glycols which have a molecular weight from about 600 to about 12,500, and preferably from about 1500 to about 6,000, and contain both oxyethylene groups and higher oxyalkylene groups, such as oxypropylene and oxybutylene groups in the molecule. The amount of oxyethylene groups in the molecule is such that the polyoxyalkylene glycols are water soluble at ordinary temperatures and the amount of oxypropylene or higher oxyalkylene group is such that the polyoxyalkylene glycols remain liquid at ordinary temperatures. The oxyethyleneoxypropylene ratio may vary, but compounds suitable for use in accordance with the practice of the invention should have at least 50 percent by weight of oxyethylene groups, with a ratio of from about 60-40 to about 90-10 being preferred.
These polyoxyalkylene glycols are known in the art and are commonly produced by reacting a mixture of ethylene oxide and other alkylene oxides, such as propylene oxide, with a short chain compound having two active hydrogen atoms including, for example, dihydric alcohols, such as ethylene glycol, 1,2-propylene glycol, 1,3-propylene glycol, butylene glycols, diethylene glycol, dipropylene glycol, triethylene glycol, as well as other such aliphatic dihydroxy compounds; aromatic dihydroxy compounds such as bisphenol A; cycloaliphatic dihydroxy compounds and the like.
The polyoxyalkylene glycols can have a variety of molecular structures such as random, block, heteric (both random and block structure together), gradient (as for example, from a continuously varying programmed feed), and various other combinations. The products of reaction will have generally linear oxyalkylene chains and such chains will terminate with hydroxyl groups. Exemplary suitable polyoxyalkylene glycols are available commercially under the trademark designation UCON fluids and CARBOWAX polyethylene glycols from Union Carbide Corporation, and the trademark designations Pluronics from BASF Wyandotte.
Diisocyanates suitable for use in preparing the polyoxyalkylene copolymers of the present invention may be any of the known aromatic or aliphatic diisocyanates provided that these are clearly difunctional, i.e., they should be free of any functionality greater than 2 and essentially free of monofunctional species to avoid crosslinking and chain growth termination reactions. These isocyanates are well known to those skilled in the polyurethane art and illustrative thereof can be mentioned aromatic diisocyanates such as 4,4'-methylenebis(4-phenylisocyanate) tolylene diisocyanate, and phenylene diisocyanate which are preferred because of their high reactivities and low equivalent weights; aliphatic diisocyanates, such as 4,4'-methylenebis (cyclohexylisocyanate), and trimethylhexamethylene diisocyanate and the like, and mixtures of such diisocyanates.
Also suitable are oligomeric diisocyanates, known as prepolymers, which result from reacting a short chain glycol with substantial excess of diisocyanate to form a low to moderate molecular weight (molecular weight up to about 1500) linear urethane prepolymer terminated with --NCO groups. The choice of glycols employed in the preparation of urethane prepolymers for use in compositions of the invention should be made so that the polyoxyalkylene copolymer prepared therefrom will be water soluble.
In producing the polyoxyalkylene copolymers of the invention a stoichiometric excess of the polyoxyalkylene glycol is reacted with the diisocyanate. The copolymers of the invention must be prepared under conditions wherein the total equivalents of hydroxyl functionality exceeds the total equivalent of isocyanate functionality. The OH/NCO ratio can vary from about 1.05:1.0 and 2.0:1.0, and preferably is in the range from about 1.15:1.0 and 1.50:1.0. This stoichiometry assures the production of a copolymer terminated with hydroxyl groups which, hence, is unreactive towards water, alcohol, amines, etc. which may be used in formulating functional fluids with the copolymers of the invention.
The molecular weights of the polyoxyalkylene block copolymer compositions of the invention that are produced are less than that which may be theoretically calculated but, in general, can be varied by the choice of reactants employed. For example, the use of lower molecular weight, high oxyethylene content polyoxyalkylene glycols provides copolymers more closely approaching their theoretical molecular weights than does the use of high molecular weight polyoxyalkylene glycols of lower oxyethylene content.
The viscosities of the polyoxyalkylene copolymers of the invention are governed both by their molecular weight and by their urethane moiety content. With any given combination of reactants, the copolymer viscosity will increase with decreasing OH/NCO ratio and at a given OH/NCO ratio, the product viscosity will increase with increasing urethane moiety content. In any case, the copolymers of this invention will exhibit viscosities of from about 2 to about 5 times that of a conventional polyoxyalkylene glycol of comparable molecular weight. This is an important and surprising feature of the compositions of the present invention since the thickening efficiency of the copolymer in water-based systems is an important factor in determining the concentration of the polymer that must be used to achieve desired results from a given functional fluid formulation.
The polyoxyalkylene block copolymers of the invention can be produced by reacting one or more polyoxyalkylene glycols with one or more diisocyanates in stoichiometric proportions wherein, as hereinabove discribed, the total equivalent of hydroxyl functionality of the polyoxyalkylene glycol reactant exceeds the total equivalents of isocyanate functionality of the diisocyanate reactant by a factor of from about 1.05:1 to 2.0:1.
To be suitable for use in preparing the block copolymer compositions of the invention, the polyoxyalkylene glycols must be free from residual basic catalyst used in their preparation. If the residual catalyst is not removed, the ensuing condensation reaction with a diisocyanate will lead to the formation of gels. The polyoxalkylene glycol may be neutralized by any suitable method known in the art such as by ion-exchange techniques or treating the glycol under heat with a solid magnesium silicate. For example, in the ion-exchange procedure, an aqueous alcoholic solution of the basic catalyst containing polyglycol is first passed through a bed of an acidic (H-form) ion-exchange resin and the effluent is then stripped of water and alcohol diluents. In the alternate procedure, the base-containing polyglycol is first heated with magnesium silicate neutralizer for one to several hours at 50° C. to 100° C. and then recovered by filtration to remove the solid neutralizer. Regardless of the neutralizing procedure used, the hydroxyl number molecular weight of the neutralized polyoxyalkylene glycol should be determined so that the amount of diisocyanate reactant to be used in the condensation reaction can be established.
Another important factor that must be taken into account concerning the polyoxyalkylene glycol reactant to be used in accordance with the practice of the invention is the water content thereof. The glycol reactant should be essentially free of water, that is, it should contain less than 0.1%, and preferably, 0.02% or less of water. The polyglycol may be treated by vacuum stripping or azeotropic distillation to remove undesirable amounts of water. A low water content in the glycol reactant is required because water is reactive with isocyanates and the presence thereof in any significant quantity will upset the OH/NCO stoichiometry of the ensuing condensation reaction.
As pointed out hereinabove, in polyoxyalkylene glycols suitable for use in preparing polyoxyalkylene glycol block copolymers of the invention at least 50 percent by weight of the oxyalkylene groups in the chain must be oxyethylene groups, and preferably, should be from about 65 to 85 percent by weight of the total weight.
Suitable diisocyanates as hereinabove described for use in preparing the polyoxyalkylene glycol block copolymers of the invention may be any aromatic or aliphatic difunctional diisocyanates having a molecular weight of up to about 1500; or mixtures thereof.
Regardless of the type or types of diisocyanate used, the equivalent weight or free NCO content must be determined before using it as a reactant in the condensation reaction of the invention.
The condensation is preferably carried out in bulk without the use of solvents or diluents, though if desired, a solvent can be used which is nonreactive and inert to the reactants. In a preferred embodiment, the polyoxyalkylene glycol reactant, and catalyst, if one is desired, are charged to a heated reactor and the diisocyanate reactant is fed to the heated reactor. The time of addition is not critical and is generally chosen so that the exotherm does not exceed the cooling capabilities of the reactor. It is desirable to blanket the reaction charge with an inert gas such as nitrogen to prevent color buildup due to oxidation.
After completion of the condensation reaction, the high viscosity products formed are preferably removed from the reactor while still hot in order to facilitate the material transfer. Alternatively, a preferred procedure may involve converting the bulk reaction product directly to an aqueous concentrate, e.g. a 50% aqueous solution, by adding the required amount of water directly into the reaction product after completion of the condensation reaction and using the reactor agitator to form a solution at a temperature of 50° C. to 100° C.
Efficient agitation of the reaction mixture is an important factor in the process because of the high viscosity of the reaction product, and suitable agitation means must be provided.
The temperature at which the condensation reaction can be carried out is not narrowly critical but will generally range from about 40° C. to about 175° C., and preferably, from about 50° C. to about 125° C. The pressure used is, also, not critical and may be varied widely, though atmospheric pressure is generally preferred.
The condensation reaction can be effected with or without a catalyst being present, but generally, it is preferred that a catalyst is employed. From about 0.01 percent to about 0.1 percent, based on the weight of polyoxyalkylene glycol, of a catalyst typically employed in the preferation of polyurethanes, such as DABCO, stannous octoate, dibutyltin dilaurate, and the like, can be advantageously employed. When carried out in the presence of a catalyst, the reaction proceeds rapidly and as little as 10 minutes may be satisfactory though about 1 hour is generally preferred.
The invention is further described in the Examples which follow. All parts and percentages are by weight unless otherwise specified.
EXAMPLE I
A quantity of a diethylene glycol started ethylene oxide/propylene oxide (75/25 by weight) polyoxyalkylene glycol having a nominal viscosity of 5000 SUS (approx 1000-1400 centistokes) and a molecular weight of 4000-5000 was neutralized by heating for one hour at 100° C. with 2 percent by weight of magnesium silicate purchased under the trademark designation Magnesol. The polyglycol was then filtered and vacuum stripped.
The neutralized polyglycol was analyzed and determined to have a molecular weight of 4924, a water content of 0.04 percent, a viscosity of 976 centistokes at 100° F. and no alkalinity.
A 1-liter glass resin kettle fitted with an agitator (4-bladed, pitched blade types operated at 300 rpm), temperature recording thermocouple, feed tank, and an inert gas inlet tube was used in carrying out the condensation reaction experiments of this Example.
A series of four reaction experiments was run using the proportion of reactants summarized in Table I and the following procedures:
The neutralized polyoxyalkylene glycol and the catalyst were charged to the reaction vessel and a nitrogen blanket was then fed into the reactor. The reactants were heated to 55° C.-60° C. with agitation. Molten 4,4'-methylenebis (phenylisocyanate) (MDI) was then fed into the reactant charge through the feed tank, using a total feed time of about 10 minutes. The temperature was allowed to rise as the reaction exothermed and the charge built viscosity. Following addition of all the MDI, the temperature was increased to about 100° C. and maintained there for about one hour. The viscous copolymer was then discharged from the reactor while hot and then analyzed. The characterization data determined for each of the reaction products prepared in this Example are also summarized in Table I, below.
TABLE I______________________________________ EXPERIMENTAL REACTION A B C D______________________________________ReactantsCharge (grams)Polyglycol 492.4 300.36 300.36 300.36Catalyst 0.246 0.15 0.15 0.15MDI 17.91 10.56 10.16 9.62OH/NCO RatioOverall Basis 1.549 1.604 1.666 1.761Isocyanate Moiety 3.51 3.40 3.27 3.10(wt. % of reactants)Product Molecular WeightBy OH Number 13,256 12,174 11.648 9,906By GPC 12,460 13,210 13,300 11,380(Gel PermeationChromatography)Actual Degree of 4.85 4.29 4.00 3.39Polymerization(From OH NumberMolecular Weight)Product Viscosity(CKS at 100° F.)Bulk Fluid 137,300 100,800 77,100 48,90050% Aqueous Sol'n 1,740 1,355 1,123 810Product Cloud Point, °C.50% Aqueous Sol'n 83 83 84 841% Aqueous Sol'n 58 60 61 62______________________________________
The catalyst used in this example was dibutyltin dilaurate and the OH number and Gel Permeation Chromatography are standard techniques for determining the molcular weight of polymers.
It is apparent that high molecular weight, water soluble polymers were prepared which exhibit extremely high viscosities.
EXAMPLE 2
Using the procedure and apparatus of Example 1, a series of 5 reaction experiments was run to study the relationship of isocyanate moiety content of the copolymer prepared and viscosity. The proportions of reactants are summarized in Table II.
In this Example a diethylene glycol started ethylene oxide/propylene oxide (75/25 by weight) having a nominal viscosity of 5000 SUS at 100° F. (1000-1400 cks) and a molecular weight of 4000-5000 was used after neutralizing by the technique of Example 1. After neutralization, the polyoxyalkylene glycol was determined to have a molecular weight of 4,170, a water content of 0.016 percent, a viscosity of 1,134 centistokes (cks) at 100° F. and a nil alkalinity. The diisocyanate and catalyst of Example 1 were used in the experiments of this Example.
After completion of the reaction in each of the experiments of this example, the reaction product was discharged from the reactor while hot. An analysis of the properties determined for the reaction products of each of the experiments is summarized in Table II.
It is apparent from the data that high molecular weight, high viscosity, water soluble copolymers are prepared in each of the reaction experiments of the Example. It is also shown that increasing the isocyanate moiety content of the copolymer results in a product that exhibits a higher viscosity.
TABLE II______________________________________ Reaction Experiment______________________________________ReactantWeights (grams)Polyglycol 333.6 834 333.6 333.6 333.6Catalyst 0.167 0.411 0.167 0.167 0.167MDI (diisocyanate) 15.99 39.27 15.39 14.29 13.33OH/NCO RatioOverall basis 1.298 1.321 1.348 1.454 1.557Weight % Isocyanate 4.57 4.50 4.41 4.10 3.84MoietyReaction ProductPropertiesMolecular Weight 13,438 12,940 12,759 12,287 11,315By OH NumberGel Permeation 15,760 15,270 14,130 15,400 14,240Chromatography(GPC)Actual Degree of 5.65 5.40 5.29 4.95 4.45Polymerization(From OH NumberMolecular Weight)Viscosity(CKS. at 100° F.)Bulk Fluid 255,590 204,142 165,696 134,770 77,64050% Aqueous Sol'n 2,888 2,584 2,196 1,797 1,209Cloud Point °C.1% Aqueous Solution 52.5 51.5 52 54 56______________________________________
EXAMPLE 3
Using the procedure and apparatus of Example 1, a condensation reaction was carried out using the following proportion of ingredients.
______________________________________Polyglycol 333.6 gramsCatalyst 0.167 gramsToluene Diisocyanate 10.92 grams(TDI)______________________________________
The polyglycol used was the neutralized polyglycol of Example 2 which after neutralization had a molecular weight of 4,170, a water content of 0.016%, viscosity at 100° F. of 1,134 centistokes and a nil alkalinity. The catalyst used was the catalyst of Example 1.
After completion of the condensation reaction, the reaction products were removed while hot from the reactor and an analysis thereof made. In Table III, below, are summarized the results of the analysis.
TABLE III______________________________________Reactant ParametersPolyglycol Molecular Weight 4,170Viscosity, cks. 1,134OH/NCO Ratio (Polyol basis) 1.276Weight % Isocyanate Moiety 3.17Reaction Product PropertiesMolecular WeightBy OH Number 11,214By GPC 13,600Actual Degree of Polymerization 4.58(From OH Number Mol. Wt.)Viscosity, cks, at 100° F.Bulk Fluid 110,82650% Aqueous Solution 1,057Cloud Point, °C.50% Aqueous Solution 841% Aqueous Solution 63______________________________________
As is apparent from the data, a high molecular weight, high viscosity, water soluble copolymer was prepared.
EXAMPLE 4
A polyoxyalkylene glycol which was a random structure ethylene oxide/propylene oxide copolymer (77/23 by weight) prepared by reacting a stream of 75/25 ethylene oxide-propylene oxide with an initiator which was the reaction product of bisphenol A and 6 moles of ethylene oxide was used in this experiment. The polyoxyalkylene glycol, which was neutralized by ion-exchange techniques and vacuum stripped, had a number average molecular weight of 5,095 and a viscosity at 100° F. of 1420 cks (6565 SUS).
Using the procedure and apparatus of Example 1 a condensation reaction was carried out using the following proportion of ingredients.
______________________________________Polyglycol 305.7 gramsCatalyst 0.158 gramsMDI 10.17 gramsOH/NCO ratio (polyol basis) 1.485Weight % Isocyanate Moiety 3.20______________________________________
The reaction product was removed hot from the reactor and analyzed. A summary of the properties determined for the reaction product are reported in Table IV, below.
TABLE IV______________________________________Polyglycol ReactantMolecular Weight 5095Viscosity @ 100° F., cks. 1420Reaction ProductMolecular WeightBy OH Number 11,702By GPC 13,480Viscosity @ 100° F., cks.Bulk Fluid 93,39750% Aqueous Solution 1,672Cloud Point, °C.50% Aqueous Solution 73.51% Aqueous Solution 40.5______________________________________
From the data, it is apparent that a high molecular weight, high viscosity, water soluble copolymer was produced.
EXAMPLE 5
Using the procedure and apparatus of Example 1, a series of three experimental reactions were carried out using the following properties of ingredients:
______________________________________ A B C______________________________________Polyglycol (grams) 236.95 236.95 236.95Catalyst (grams) 0.118 0.118 0.118MDI (grams) 8.32 8.94 10.0OH/NCO Ratio 1.539 1.432 1.280(overall basis)Weight % Isocyanate 3.39 3.64 4.05Moiety______________________________________
The polyoxyalkylene glycol used in this Example was the same as the polyglycol used in Example 2, except that it was neutralized by ion-exchanging and then vacuum stripped. The polyglycol had a molecular weight of 4,739, a water content of 0.0088%, a viscosity at 100° F. of 1,179 cks., and a nil alkalinity. The catalyst and isocyanate used here were the same as that used in Examples 1 and 2.
A summary of the analysis of the reaction products from each of the experimental reactions is reported in Table V. It is apparent from the data that high molecular weight, high viscosity, copolymers were prepared by each experimental reaction.
TABLE V______________________________________ Experimental Reaction A B C______________________________________Polyglycol ReactantMolecular Weight 4,739 4,739 4,739Viscosity @ 100° F., CKS. 1,179 1,179 1,179OH/NCO Ratio 1.539 1.432 1.280Reaction ProductsMolecular WeightBy OH Number 9,170 10,200 11,030By GPC 11,290 12,710 13,840Viscosity, Cks. @ 100° F.Bulk Fluid 43,555 63,711 98,97350% Aqueous Solution 832 1,047 1,474Cloud Points, °C.50% Aqueous Solution 82 82 80.51% Aqueous Solution 57.5 57 54.5______________________________________
EXAMPLE 6
Using the procedure and apparatus of Example 1, a series of four experimental reactions were carried out using the following proportion of ingredients:
______________________________________Polyglycol (grams) 384.2 384.2 384.2 384.2Catalyst (grams) 0.192 0.192 0.192 0.192Diisocyanate (grams) 34.12 33.52 32.74 31.93OH/NCO Ratio 1.102 1.132 1.159 1.189(overall basis)Weight % Isocyanate 8.26 8.03 7.85 7.67______________________________________
The polyoxyalkylene glycol used was diethylene glycol started ethylene oxide/propylene oxide (75/25 by weight) random copolymer. The polyoxyalkylene glycol did not require neutralization but was vacuum stripped prior to use. The material had a molecular weight of 2,561, a water content of 0.0082 percent, a viscosity at 100° F. of 347 centistokes and a nil alkalinity. The catalyst and diisocyanate of Example 1 were used in this Example.
The reaction products prepared during each experimental reaction were analyzed and the properties determined are summarized in Table VI. It is apparent from the data that a high molecular weight, high viscosity, water soluble copolymer was produced.
TABLE VI______________________________________ Experimental Reaction A B C D______________________________________Polyglycol ReactantMolecular Weight 2,561 2,561 2,561 2,561Viscosity @ 100° F., cks. 347 347 347 347OH/NCO Ratio 1,102 1.132 1.159 1.189Reaction ProductsMolecular WeightBy OH Number 12,021 10,896 9,766 8,459Viscosity, cks, 100° F.Bulk Fluid 304,529 249,710 174,454 124,89950% Aqueous Solution 2,656 2,508 2,024 1,538Cloud Point, °C.50% Aqueous Solution 61 62.5 63.5 641% Aqueous Solution 29.5 30.5 32.5 34.5______________________________________
EXAMPLE 7
Using the procedure and apparatus of Example 1, two experimental reactions were run using a 40/60 mole percent and 30/70 mole percent mixture of the polyoxyalkylene glycol used in Example 5 (75/25 by weight random EO/PO copolymer) and a diethylene glycol started ethylene oxide propylene oxide (85/15 by weight) random copolymer polyoxyalkylene glycol. Each of the polyglycols was neutralized by ion-exchanging and then vacuum stripped. The 75/25 copolymer had a molecular weight of 4,739 and a viscosity of 1,179 cks at 100° F. while the 85/15 copolymer had a molecular weight of 1389 and a viscosity of 178 cks at 100° F. The proportion of ingredients in each of the two experimental reactions were as follows:
______________________________________ A B______________________________________75/25 Polyglycol (grams) 223.56 158.9985/15 Polyglycol (grams) 96.67 106.95Catalyst (grams) 0.16 0.133Diisocyanate (grams) 25.14 25.0OH/NCO Ratio (polyol 1.153 1.095basis)Weight % Isocyanate 7.3 11.15______________________________________
The catalyst and diisocyanate reactants used in this Example were the same as were used in Example 1.
The reaction products obtained from each of the two experimental reactions were analyzed and the results determined are summarized in Table VII. The data shows that high molecular weight, high viscosity, water soluble copolymers were produced during each of the experimental reactions of this Example.
TABLE VII______________________________________Reactants75/25 Polyglycol mole % 40 30Molecular Weight 4,739 4,739Viscosity at 100° F., cks 1,179 1,17985/15 Polyglycol mole % 60 70Molecular Weight 1,389 1,389Viscosity at 100° F., cks 178 178OH/NCO Ratio (polyol basis) 1.153 1.095Reaction ProductsMolecular Weight 12,023 11,968By OH NumberViscositv, cks, 100° F.Bulk Fluid 303,098 552,52550% Aqueous Solution 2,519 4,163Cloud Point, °C.50% Aqueous Solution 77 731% Aqueous Solution 47.5 39.5______________________________________
EXAMPLE 8
Using the apparatus and procedure of Example 1, 864.5 grams of a polyoxyalkylene glycol having a molecular weight of 2,561 and a 75/25 ethylene oxide/propylene oxide random composition is reacted with 51.39 grams of toluene diisocyanate (80/20 2,4/2,6 type) at 100° C. in the absence of any added catalysts. The reaction mixture is periodically examined by Infra-Red Spectroscopy to monitor the presence of unreacted --NCO functionality which absorbs at 4.42μ in the Infra-Red. When such instrumental analysis shows no --NCO functionality to be present, a wet chemical analysis for --NCO, using the standard method employing reaction with excess di-n-butylamine followed by back-titration of excess amine with hydrochloric acid, is run to confirm completion of the reaction. The reaction product is discharged while hot and a high viscosity, water soluble fluid copolymer is obtained. | A high molecular weight, high viscosity liquid, water soluble polyoxyalkylene block copolymer suitable as a functional fluid is provided having the formula ##STR1## wherein Q is the organic residue from an organic diisocyanate; x is an integer in the range of about 1 to 10; R 1 and R 2 are hydrogen, methyl, ethyl, or mixtures thereof with the proviso that the overall content of species wherein R 1 and R 2 are hydrogen must be at least 50 percent by weight; R 3 and R 4 are organic residues resulting from the removal of terminal hydrogen atoms from difunctional polyols; y and z are integers representing the polyether blocks in said copolymer and the sum of which must be from about 1.05 to 2.0 times the value of x; and n, m, r, and s are integers wherein n=m and r=s and the sums n+m and r+s are each in the range of 8 to 250. | 2 |
RELATED APPLICATION
This is a continuation-in-part of application Ser. No. 09/087,657, filed May 30, 1995, now abandoned.
FEDERALLY SPONSORED RESEARCH/DEVELOPMENT PROGRAM
This invention was made with government support under Grants DAAH-04-93-G-0328 and DAAG55-97-C-0036 awarded by the United States Army Research Office. The government has certain rights in the invention.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention is broadly concerned with pelletized finely divided adsorbents selected from the group consisting of metal oxides, metal hydroxides, and mixtures thereof, and methods of forming such pellets. The pellets are preferably formed by pressing the finely divided metal adsorbents at pressures of from about 50 psi to about 6000 psi to yield self-sustaining bodies which retain at least about 25% of the surface area/unit mass and total pore volume of the starting mewl adsorbents prior to pressing thereof. In use, target compound(s) are contacted with adsorbent pellets of the invention to destructively adsorb or chemisorb the target compound(s).
2. Description of the Prior Art
There is mounting concern about air quality, particularly the quality of indoor air. In most cases, indoor air is of worse quality than outdoor air. The removal of gaseous contaminants from air can be achieved by the application of a variety of principles. These include adsorption, catalytic transformation, and absorption. Among these adsorption is the most widely applied method. In adsorption, gases, vapors, or liquids come into contact with the surface of the adsorbent and adhere to it to some degree. This adsorption can be the result of residual physical forces (Van der Waal's forces) or chemical binding to the surface where the adsorbed molecule binds stronger to the adsorbing surface. Although adsorption can occur on a variety of solid surfaces, only a few materials have adsorptive characteristics sufficiently favorable for air cleaning. These include activated carbons, zeolites, molecular sieves, silica gel, and activated alumina.
Activated carbon has been the most commonly used is dealing with purification of air. The highest quality activated carbon is made from coconut shells and has a surface area/unit mass of about 600-900 m 2 /g. However, activated carbon does not strongly adsorb air pollutants and the adsorbed material an be released over time with confirmed air flow. Moreover, activated carbon is difficult to clean up.
Another tool for indoor air purification is as electrostatic filter. Electrostatic filters work well at removing particulates from the indoor air. However, electrostatic filters are inadequate at removing many chemical vapors from the air, and there are numerous chemical vapor air pollutants which are of concern. The most prevalent of these include formaldehyde, acetaldehyde, methanol, methylene chloride, carbon tetrachloride, arbors monoxide, dimethyl amine, toluene, benzene, sulfur dioxide, acetonitrile, nitrosoamine, and nitrogen dioxide.
Nanocrystals make up a high surface area form of matter that can serve as another adsorbent which can be used for removing pollutants such as chlorocarbons, acid gases, military warfare agents, and insecticides from the air. The unique chemical reactivity of nanocrystals allows the destructive adsorption and chemisorption of toxic substances and are a substantial advance in air purification. However, nanocrystals are a very fine dust which take up large volumes of space and are conducive to electrostaticity, thus making them difficult to handle and at times inconvenient.
There is a need for an adsorbent compound capable of strongly adsorbing air pollutants which does not release those pollutants over time. Furthermore, this absorbent compound must be easy to handle and be of decreased volume compared to nanocrystal adsorbents.
SUMMARY OF THE INVENTION
The present invention overcomes these problems and provides adsorbent pellet bodies and methods for adsorbing a wide variety of target compounds using such pellet bodies. To this end, the invention contemplates the use of adsorbent pellets which are formed by pressing lively divided adsorbents. Adsorbent reactions using the inventions can be carried out over a wide range of temperatures, but preferably the temperature is such that the target compounds are in gaseous form.
In more detail, the adsorbent pellets of the invention are formed by pressing or agglomerating a quantity of finely divided adsorbent powder selected from the group consisting of metal hydroxides, metal oxides, and mixtures thereof. More preferably, the powder is an oxide or hydroxide of Mg, Ca, Ti, Zr, Fe, V, Mn, Ni, Cu, Al, or Zn. Metal oxides are the most preferred adsorbent powder with MgO and CaO being particularly preferred. While conventionally prepared powders can be used to form the pellets, the preferred powders are prepared by aerogel techniques from Utamapanya et al., Chem. Mater., 3:175-181 (1991). The starting powders should advantageously have an average crystallite size of up to about 20 nm, and more preferably from about 3 to 9 nm. The pellets of this invention are formed by pressing the adsorbent powder at a pressure of from about 50 psi to about 6000 psi, more preferably from about 500 psi to about 5000 psi, and most preferably at about 2000 psi. While pressures are typically applied to the powder by way of an automatic or hydraulic press, one skilled in the art will appreciate that the pellets can be formed by any pressure-applying or other agglomerating means (e.g., centrifugal or vibratory agglomerators). Furthermore, a binder or filler can be mixed with the adsorbent powder and the pellets can be formed by pressing the mixture by hand. Agglomerating of agglomerated as used hereinafter includes pressing together of the adsorbent powder as well as pressed together adsorbent powder. Agglomerating also includes the spraying, adhering, centrifugation, vibration or pressing of the adsorbent powder (either alone or in a mixture) to form a body, which may optionally be famed around a cue material other than the adsorbent powder. To give but out example, the adsorbent powders of the invention can be embedded in or supported on a porous substrate such as a filtration media.
If a metal oxide pellet is desired, the corresponding metal hydroxide should be thermally converted (i.e., “activated” at 500° C., overnight is a vacuum) to the metal oxide form. Activation can be carried out either on the metal hydroxide powder or on the finished metal hydroxide pellet. However, it is preferred that the metal hydroxide first be pressed into a pellet followed by thermal conversion to a metal oxide pellet.
The pellets of the invention should retain at least about 23% of the multi-point surface area/unit mass of the metal hydroxide or metal oxide (whichever was used to form the pellet) particles prior to pressing together thereof. More preferably, the multi-point surface area/unit mass of the pellets will be at least about 50%, and most preferably at least about 90%, of the multi-point surface area/unit mass of the starting metal oxide or metal hydroxide particles prior to pressing. In another embodiment, the pellets retain at least about 25% of the total pore volume of the metal hydroxide or metal oxide particles prior to pressing thereof, more preferably, at least about 50%, and most preferably at least about 90% thereof. In the most preferred forms, the pellets of ibis invention will retain the above percentages of both the multi-point surface area/unit mass and the total pore volume.
In terms of pore radius, the preferred pelletized adsorbents should have an average pore radius of at least about 45 Å, more preferably from about 50 Å to about 100 Å, and most preferably from about 60 Å to about 75 Å. The pellets of this invention normally have a density of from about 0.2 to about 2.0 g/cm 3 , more preferably from about 0.3 to about 1.0 g/cm 3 , and most preferably from about 0.4 to about 0.7 g/cm 3 . The minimum surface-to-surface dimension of the pellets (e.g., diameter in the case of spherical or elongated pellet bodies) of this invention is at least about 1 mm, more preferably from about 10-20 mm.
Broadly speaking, the use of the pelletized adsorbents in accordance with the invention is carried out by contacting the adsorbent powders with a target compound in fluid (i.e., liquid or gaseous) form. Preferable contacting systems include any type of flow reactor which allows a fluid stream containing the target compound to be circulated through a mass of pellets. Another suitable contacting system includes forming a membrane which contains the pelletized adsorbents and using the membrane to filter the target compound from a gas or liquid. The contacting step can take place over a wide range of temperatures and pressures; however, it is preferable that the temperature be such that the conveying stream and target compound are in a gaseous form.
A wide variety of target compounds can be adsorbed using the techniques of the invention. These target compounds broadly include any compounds which can be adsorbed, either destructively adsorbed or chemisorbed, by the starting metal hydroxide or metal oxide powder. More particularly, these target compounds may be selected from the group consisting of acids, alcohols, aldehydes, compounds containing an atom of P, S, N, Se or Te, hydrocarbon compounds (e.g., both halogenated and non-halogenated hydrocarbons), and toxic metal compounds.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a graph depicting the adsorption of acetaldehyde on pelletized AP—MgO compared to adsorption of acetaldehydes on powder AP—MgO;
FIG. 2 is a graph illustrating the adsorption of acetaldehyde onto powder AP—MgO in comparison to the adsorption of acetaldehyde onto activated carbon;
FIG. 3 is a graph illustrating the adsorption of acetaldehyde onto powder AP—MgO, powder CP—MgO, and powder CM—MgO;
FIG. 4 is a graph depicting the adsorption of acetaldehyde onto powder AP—MgO after exposure to air for varying lengths of time versus the adsorption of acetaldehyde onto activated carbon exposed to air for varying lengths of time:
FIG. 5 is a graph comparing the adsorption of propionaldehyde onto powder AP—MgO under atmospheric pressure of air with the adsorption of propionaldehyde onto commercial samples of activated carbon under atmospheric pressure of air;
FIG. 6 is a graph comparing the adsorption of dimethylamine onto powder AP—MgO under atmospheric pressure of air with the adsorption of dimethylamine onto activated carbon under atmospheric pressure of air;
FIG. 7 is a graph illustrating the adsorption of ammonia onto powder AP—MgO both with and without exposure to air and comparing this adsorption to adsorption of ammonia onto activated carbon both with and without exposure to air, and
FIG. 8 is a graph which depicts the adsorption of methanol onto powder AP—MgO under one atmosphere pressure of air compared to the adsorption of methanol onto activated at one atmosphere pressure of air.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The following examples set forth preferred methods in accordance with the invention. It is to be understood, however, that these examples are provided by way of illustration and nothing therein should be taken as a limitation upon the overall scope of the invention. In these examples, “AP—MgO” and “AP-CaO” refer to the respective aerogel (or autoclave) prepared oxides. “CP—MgO” and “CP—CaO” refer to the respective oxides produced by conventional techniques. “CM—MgO” and “CM—CaO” refer a the respective commercially available oxides.
EXAMPLE 1
In this example, adsorbent AP—Mg(OH) 2 pellets were prepared and their surface characteristics were determined. These characteristics were compared to the characteristics of AP—Mg(OH) 2 in its powder form.
Materials and Methods
1. Preparation of AP—Mg(OH) 2 Powder (no activation)
Highly divided nanocrystalline Mg(OH) 2 samples were prepared by the autoclave treatment described by Utamapanya et al., Chem. Mater., 3:175-181 (1991), incorporated by reference herein. In this procedure, 10% by weight magnesium methoxide is methanol solution was prepared and 83% by weight toluene solvent was added. The solution was then hydrolyzed by addition of 0.75% by weight water dropwise while the solution was stirred and covered with aluminum foil to avoid evaporation. To insure completion of the reaction, the mixture was stirred overnight. This produced a gel which was treated in an autoclave using a glass lined 600 ml capacity Parr miniature reactor. The gel solution was placed within the reactor and flushed for 10 minutes with nitrogen gas, whereupon the reactor was closed and pressurized to 100 psi using the nitrogen gas. The reactor was then heated up to 265° C. over a 4 hour period at a beating rate of 1° C./min. The temperature was then allowed to equilibrate at 265° C. for 10 minutes (final reactor pressure was about 700 psi). At this point, the reactor was vented to release the pressure and vent the solvent. Finally, the reactor was flushed with nitrogen gas for 10 minutes.
2. Preparation of AP—Mg(OH) 2 Pellets
The AP—Mg(OH) 2 powder prepared as set forth above was ground, using a mortar and pestle, to remove any clumped powder. A portion of the powder was then placed in a small hydraulic press to make spherical 12 mm diameter pellets. Pressures ranging from 1000 psi to 10,000 psi were applied to form the pellets. The resulting pellets were crushed through sieves to form smaller pellets in order to facilitate the measuring of the surface characteristics (the sieve size was 0.27-1.168 mm).
A second portion of the AP—Mg(OH) 2 powder was pelletized using a Stokes automatic press. The actual pressure applied is not known because the Stokes press did not have a gauge. However, the actual pressure applied to prepare the pellets is reproducible by controlling the movement of the upper punch on the pelletizer which has a scale. Low compression is just enough pressure to allow the sample to be handled without crumbling. High compression is the maximum compression that can be used without jamming the machine or causing pellets to crack as they are ejected. Medium is the setting approximately half way between low and high.
3. Determination of Surface area/unit mass of AP—Mg (OH) 2 Powder and Pellets
The surface area/unit mass and total pore volume were measured for the powder prepared above, as well as for the resultant pellets which were press-formed.
Similar surface area/unit mass measurements were performed using 70 mg samples of magnesium hydroxide from each preparative procedure. Specifically, the powder samples were heated to a temperature of 120° C. under dynamic vacuum (about 1×10 −2 Torr), held for 10 minutes, and then allowed to cool. Both the Brunauer-Emmett-Teller (BET) one-point and multi-point gas absorption methods were employed using N 2 adsorption at liquid N 2 temperature to measure the surface area/unit mass. The BET surface area measurement techniques are described in Introduction to Powder Surface Area, Lowell. S., John Wiley & Sons: New York (1979), incorporated by reference herein.
4. Determination of Total Pore Volume of AP—Mg(OH) 2
The total pore volume was determined by the Barrett, Joyner, and Halenda (BJH) method. Too sample was placed in a closed glass cell connected to a manifold filled with nitrogen gas. The sample cell was immersed in liquid nitrogen until the Pressure above the sample was the same as ambient pressure at which time the pores were assumed to be filled with liquid nitrogen. The pressure above the sample was then reduced to 95% of ambient pressure and the volume of nitrogen gas released from the sample was measured by the BET machine. This desorption process was carried out at 90%, 85%. 80%, and so on down to 5% of ambient pressure. At each interval, the volume of nitrogen gas released from the sample is measured and used to derive the total pore volume. The BET total pore volume measurement techniques are described in the Quantachrome NOVA 2200 Gas Sorption Analyzer's User's Manual (Version 4.01), incorporated by references herein.
Results and Discussion
1. Comparison of Characteristics of Powder AP—Mg(OH) 2 vs. Pelletized AP—Mg(OH)2
a. Pellets Formed by Small Hydraulic Press
The surface area/unit mass for the multiple BET decreased from 346 m 2 /g for the powder to 4.16 m 2 g for the 10,000 psi pellets. The same was seen for the single point BET surface area/unit mass, which went from 635 m 2 /g for the powder to 8.29 m 2 /g for the 10,000 psi pellets, the total pore volume also decreased from 0.956 cc/g for the powder to 0.01217 cc/g for the 10,000 psi pellets. The average pore radius was affected very little with change in the pressure. There was however a significant change in the isotherm curves, which indicates a change in pore shape. The powder sample (before pelletization) looked almost identical to the sample subjected to a pressure of 1,000 psi. The results are illustrated in Table 1.
TABLE 1
Surface area/unit mass and pore size distribution of magnesium hydroxide in
powder and pellet form, prepared using the hydraulic press.
Multi-
%
Avg.
Applied
point
Multi-
Single
Total pore
% Total
pore
Pore
Pressure
S.A.
point
point S.A.
volume
Pore
radius
Shape
Form
(psi)
(m 2 /g)
S.A. b
(m 2 /g)
(cc/g)
Volume c
(Å)
Type d
Powder
None
346
—
635
0.956
—
55.2
E
Pellet a
1,000
289
83.5
534
0.803
83.9
55.6
A, E
Pellet
2,000
235
67.9
458
0.629
65.8
53.5
A, E
Pellet
4,000
116
33.5
254
0.311
32.5
53.5
A
Pellet
5,000
80.3
23.2
165
0.216
22.6
53.8
A
Pellet
10,000
4.16
1.2
8.29
0.0122
1.3
58.4
D
a Pellet size is 0.250-1.168 mm.
b Percent of multi-point surface area/unit mass retained by pellet when compared to multi-point surface area/unit mass of the powder
c Percent of total pore volume retained by pellet when compared to total pore volume of the powder
d Pore shape type abbreviation are as follows: A—Cylindrical pores, open at both ends; B—Tapered or wedged-shaped pores with narrow necks open at one or both ends; and E—Bottleneck pores
Table 1 demonstrates that the surface characteristics change a great deal depending on formation pressure. It is noted that in going from the powder to the pellet compressed at 1,000 psi, the surface area/unit mass and pore size changed only a little; therefore, these pellets can be used in any type of flow reactor. In conclusion, it was found that the 1,000 psi pellets of AP—Mg(OH) 2 worked ideally by eliminating the problem caused by electrostatic forces, without losing a significant amount of surface area/unit mass or pore volume.
b. Pellets Formed by Stokes Automatic Press
Referring to Table 2, it can again be seen that pelletization did not significantly decrease the surface areas/unit mass and porosities of the AP—Mg(OH) 2 . In some instances the surface area/unit mass was even higher than that of the powder. The pellets made with low compression were very brittle and, after activation (heating at 500° C. under vacuum), they turned into powder. The medium compression pellets were much better, and only a small amount of powder was present after activation. The pellets formed by high compression were sturdy and did not break or form powder upon activation. Therefore, the medium and high compression pellets are ideal. Because the Stokes press did not include a pressure gauge, the exact value of the pressure used in the high compression test is not known. However, in comparing the pellet characteristics of Table 2 with those of Table 1, the high compression is likely around 2000 psi.
TABLE 2
Surface area/unit mass and pore size distribution of magnesium hydroxide in
a powder and pellet form, prepared using the Stokes press.
%
Single
Total
%
Average
Relative
Multi-
Multi-
point
pore
Total
pore
Pore
Com-
point S.A.
point
S.A.
volume
Pore
radius
Shape
Form
pression
(m 2 /g)
S.A. a
(m 2 /g)
(cc/g)
Volume b
(Å)
Type c
Powder
None
386
—
692
1.038
—
53.8
E
Pellet
Low
440
114.0
699
1.090
105.0
49.5
A, E
Pellet
Medium
346
89.6
679
0.944
90.9
54.6
A, E
Pellet
High
300
77.7
606
0.794
76.5
53.0
A, E
a Percent of multi-point surface area/unit mass retained by pellet when compared to multi-point surface area/unit mass of the powder.
b Percent of total pore volume retained by pellet when compared to a total pore volume of the powder.
c Pore shape type abbreviation are as follows: A—Cylindrical pores, open at both ends; D—Tapered or wedged-shaped pores with narrow necks opened at one or both ends; and E—Bottleneck pores
EXAMPLE 2
In this example, adsorbent AP—MgO pellets (one sample activated in its pellet form and one sample activated in its powder form) were prepared from AP—Mg(OH) 2 powder and their physical characteristics were determined. These characteristics were compared to the characteristics of AP—MgO in its powder form. The purpose of this test was to determine whether the AP—MgO pellets would maintain substantially the same surface characteristics when activated in its pellet form as when activated in the powder form. It is preferable to pelletize the hydroxide first, and then activate the pellets, which converts the pellets to the oxide.
Materials and Methods
1. Preparation of AP—Mg(OH) 2 Powder (no activation) and AP—MgO Powder (with activation)
Highly divided nanocrystalline Mg(OH) 2 samples were prepared by the autoclave treatment described by Utamapanya et al., Chem. Mater ., 3:175-181 (1991), incorporated by reference herein. In this procedure, 10% by weight magnesium methoxide in methanol solution was prepared and 83% by weight toluene solvent was added. The solution was then hydrolyzed by addition of 0.75% by weight water dropwise while the solution was stirred and covered with aluminum foil to avoid evaporation. To insure completion of the reaction, the mixture was stirred overnight. This produced a gel which was treated in as autoclave using a glass lined 600 ml capacity Parr miniature reactor. The gel solution was placed within the reactor and flushed for 10 minutes with nitrogen gas, whereupon the reactor was closed and pressurized to 100 psi using the nitrogen gas. The reactor was then heated up to 265° C. over a 4 hour period at a heating rate of 1° C./min. The temperature was then allowed to equilibrate at 265° C. for 10 minutes (final reactor pressure was about 700 psi). At this point, the reactor was vented to release the pressure and vent the solvent. Finally, the reactor was flushed with nitrogen gas for 10 minutes.
The Mg(OH) 2 powder was then divided into two parts—one part for pelletization followed by activation, and one part for activation followed by pelletization The Mg(OH) 2 particles of the latter sample was then thermally converted to MgO. This was accomplished by beating the Mg(OH) 2 under dynamic vacuum (10 −2 Torr) conditions at an ascending temperature rate to a maximum temperature of 500° C. which was held for 6 hours. Further details about the MgO preparation can be found in PCT Publication WO 95/27679, also incorporated by reference herein.
2. Preparation of AP—Mg(OH) 2 Pellets and AP—MgO Pellets
Magnesium hydroxide powder and magnesium oxide powder (as prepared above) were each separately ground, using a mortar and a pestle, to remove any clumped powder. A portion of each powder was separately pelletized using the Stokes automatic press resulting in AP—Mg(OH) 2 pellets and AP—MgO pellets. The actual pressure applied is unknown because the Stokes press did not have a gauge. However, the actual pressure applied to prepare the pellets is reproducible by controlling the movement of the upper punch on the pelletizer which has a sale. Low compression is just enough pressure to allow the sample to be handled without crumbling. High compression is the maximum compression that an be used without jamming the machine or causing pellets to crack as they are ejected. Medium is the setting approximately half way between low and high.
3. Activation of AP—Mg(OH), Pellets to AP—MgO Pellets
The AP—Mg(OH) 2 pellets were thermally converted to AP—MgO pellets in the same manner in which the AP—Mg (OH) 2 powder was activated as described above.
4. Determination of Surface area/unit mass and Total Pore Volume of AP—MgO
The surface area/unit mass and total pore volume were measured for the pellets which were activated after pelletization as well as for the pellets which were activated before pelletization. These measurements were made in the same manner as described in Example 1.
Results And Discussion
A. Comparison of characteristics or AP—MgO Pellets Activated Before Pelletization vs. AP—MgO Pellets Activated After Pelletization
The results of this test are set forth in Tables 3 and 4 below. In comparing the results, it is observed that the pellets made out of the magnesium hydroxide and subsequently activated possessed higher surface area/unit mass and larger porosity than the pellets which were activated as a powder and then pelletized.
TABLE 3
Surface area/unit mass and pore size distribution of magnesium oxide prepared
by activation of hydroxide pellets
%
Single
Total
%
Average
Relative
Multi-
Multi-
point
pore
Total
pore
Pore
Com-
point S.A.
point
S.A.
volume
Pore
radius
Shape
Form
pression
(m 2 /g)
S.A. a
(m 2 /g)
(cc/g)
Volume b
(Å)
Type c
Powder
None
221
—
334
0.682
—
61.9
E
Pellet
Low
222
100.0
340
0.715
104.8
64.5
A, E
Pellet
Medium
214
96.8
328
0.684
100.3
63.9
A, E
Pellet
High
214
96.8
330
0.677
99.3
63.4
A, E
a Percent of multi-point surface area/unit mass retained by pellet when compared to multi-point surface area/unit mass of the powder.
b Percent of total pore volume retained by pellet when compared to a total pore volume of the powder.
c Pore shape type abbreviation are as follows: A—Cylindrical pores, open at both ends; D—Tapered or wedged-shaped pores with narrow necks opened at one or both ends; and E—Bottleneck pores
TABLE 4
Surface area/unit mass and pore size distribution of magnesium oxide
activated as a powder and then pressed into pellets
%
Single
Total
%
Average
Relative
Multi-
Multi-
point
pore
Total
pore
Pore
Com-
point S.A.
point
S.A.
volume
Pore
radius
Shape
Form
pression
(m 2 /g)
S.A. a
(m 2 /g)
(cc/g)
Volume b
(Å)
Type c
Powder
None
221
—
334
0.682
—
61.9
E
Pellet
Low
210
95.0
324
0.676
99.1
64.3
A, E
Pellet
Medium
205
92.8
321
0.657
96.3
64.1
A, E
Pellet
High
199
90.0
316
0.613
89.9
61.6
A, E
a Percent of multi-point surface area/unit mass retained by pellet when compared to multi-point surface area/unit mass of the powder.
b Percent of total pore volume retained by pellet when compared to a total pore volume of the powder.
c Pore shape type abbreviation are as follows: A—Cylindrical pores, open at both ends; D—Tapered or wedged-shaped pores with narrow necks opened at one or both ends; and E—Bottleneck pores
EXAMPLE 3
In this test, surface and pore characteristics of conventionally prepared MgO and CaO and aerogel prepared MgO and CaO were compared. Some samples were pressed before activation (i.e., metal hydroxide was pressed into pellets and the pellets were activated) and some were pressed after activation (i.e., metal hydroxide powder was activated and the obtained oxide was pressed into pallet form). The samples were pressed with a Stokes press as described above. The aerogel powders were prepared as previously described The conventional powders were prepared by hydrating 99.99% ultrapure metal oxide with excess distilled deionized water, heating it under a nitrogen flow forming metal hydroxide, removing the excess of water in the microwave, and treating the metal hydroxide tinder dynamic vacuum at the same conditions used in preparing the aerogel metal oxide as in the previous examples. The surface characteristics were determined by the procedures described in Example 1. The results are illustrated in Table 5 below.
TABLE 5
Results of pelletization studies (Activation = 500° C. vacuum dehydration)
Multi-
Point
Surface
Single Point
Total Pore
Area
Surface Area
Volume
Sample Description
(m 2 /g)
(m 2 /g)
(cc/g)
CP-MgO Pressed Before Activation
Powder
235
241
0.438
Medium Compression
309
298
0.295
High Compression
275
271
0.275
CP-MgO Pressed After Activation
Powder
235
241
0.438
Medium Compression
255
251
0.287
High Compression
241
235
0.311
AP-MgO Pressed Before Activation
Powder
343
120
0.681
Low Compression
351
133
0.676
Medium Compression
337
135
0.657
High Compression
341
128
0.613
AP-MgO Pressed After Activation
Powder
343
120
0.681
Low Compression
335
137
0.676
Medium Compression
331
134
0.657
High Compression
326
141
0.613
CP-CaO Pressed Before Activation
Powder
133
128
0.233
Medium Compression
93
91
0.154
High Compression
80
77
0.144
CP-CaO Pressed After Activation
Powder
133
128
0.233
Medium Compression
105
102
0.173
High Compression
132
130
0.212
AP-CaO Pressed Before Activation
Powder
129
0.198
Low Compression
137
0.220
Medium Compression
144
0.231
High Compression
135
0.222
AP-CaO Pressed After Activation
Powder
129
0.198
Low Compression
141
0.234
Medium Compression
141
0.228
High Compression
146
0.244
The data from Table 5 provides further evidence that a higher surface area/unit mass is obtained when the hydroxide is activated in pellet form. This is beneficial, as storage of pelletized, rather than powder, hydroxide is more convenient due to its lower volume. The total pore volume shows the same trend for MgO; however, for CaO it is opposite. The difference is small, so most likely the shorter exposure time will be the main factor in choosing a preparation method. Overall the pelletizing is very beneficial as it preserves surface area/unit mass, decreases the volume, and minimizes the static nature of the powder, making it easier to handle the adsorbent.
EXAMPLE 4
1. Adsorption of Acetaldehyde by MgO pellets
In this test, the adsorptive abilities of MgO pellets were compared to that of MgO powder. AP—MS(OH) 2 powder was prepared and thermally activated to AP—MgO powder as described above. MgO pellets (pressed at 4000 psi and activated after pelletization) were also prepared as described above. The adsorption conditions and procedure followed were the same for the pellet as for the powder. Each sample was placed in the U-tube of a conventional Recirculating Reactor. The reactor contained a circulation pump which continually passed the gaseous acetaldehyde over and through the adsorbents. Samples were taken at set time intervals and the pollutant content was analyzed. The contacting step was carried out for about 24 hours. For some experiments, air was added to the acetaldehyde vapor.
2. Results and Conclusions
FIG. 1 graphically illustrates the adsorption of acetaldehyde on powder and pelletized samples of Ap—MgO. Over a period of twenty hours, the efficiency of adsorption on the two samples was very similar. The adsorption on the pelletized samples evolved considerable amounts of heat just as in the adsorption on the powder samples. Furthermore, the adsorption on both the pellets and the powder caused the sample color to change to dark orange. This further indicates that the pelletized AP—MgO has retained the surface characteristic and thus the adsorptive abilities of powder AP—MgO.
EXAMPLE 5
This test, in combination with the results from Example 4, illustrates the superior adsorptive abilities of AP—MgO pellets in comparison to activated carbon, a prior an adsorbent. As demonstrated in Example 4, pelletized AP—MgO has adsorptive abilities very similar to powder AP—MgO. This Example illustrates that powder AP—MgO is substantially superior to activated carbon in its adsorptive abilities. Therefore, pelletized AP—MgO is also substantially superior to activated carbon in its adsorptive abilities. The adsorption conditions and procedures followed were identical to those described in Example 4.
The results are shown graphically in FIG. 2 . The powder AP—MgO adsorbed substantially more acetaldehyde than the activated carbon, particularly at the twenty hour point. As already demonstrated, the pelletized AP—MgO has surface characteristics and adsorptive abilities comparable to the powder AP—MgO. Therefore, the pelletized AP—MgO has the adsorptive qualities of the powder AP—MgO as well as the reduced volume and greater ease of handling not found in the powder AP—MgO. It follows that the results of the following examples will be applicable to the AP—MgO pellets as well as to the AP—MgO powder.
EXAMPLE 6
The ability of powder AP—MgO, CP—MgO, and CM—MgO to adsorb acetaldehyde was analyzed in the absence of air. Each sample was placed in the U-tube of a conventional Recirculating Reactor. The reactor contained a circulation pump which continually passed the gaseous acetaldehyde over and through the adsorbents. Samples were taken at act time intervals and the pollutant content was analyzed. The contacting step was carried out for about 20 hours.
The results of this experiment are depicted in FIG. 3 . One mole of AP—MgO adsorbed one mole of acetaldehyde at room temperature over a start period of time. The adsorption was exothermic with a considerable amount of heat being evolved. The color of the solid sample changed dramatically from a whitish-gray before adsorption to a dark orange after adsorption. While adsorption was rapid and vigorous onto the AP—MgO and CP—MgO samples, it was barely observable on the CM—MgO sample where no beat or color changes were observed.
EXAMPLE 7
This series of tests was conducted to determine the effort of air exposure on the adsorptive abilities of powder AP—MSO in comparison to activated carbon. The following categories of samples were analyzed: fresh samples of AP—MgO and commercial activated carbon; AP—MgO and commercial activated carbon samples exposed to air for 24 hours; AP—MgO and commercial activated carbon samples exported to air for ten (10) days; and AP—MgO and commercial activated carbon stored in an oven under air (60° C.) for ten (10) days. The adsorptive procedure followed was identical to that set forth in Example 6.
The results ( FIG. 4 ) demonstrate that the different environments have only a slight effect on the adsorption process. Furthermore, in each instance, the AP—MgO adsorbed substantially more acetaldehyde than did the activated carbon.
EXAMPLE 8
An experiment was conducted to determine the ability of powder AP—MgO to adsorb organic species other than acetaldehyde. This ability was cot pared to the adsorptive ability of three commercially available samples of activated carbon. The molar ratio of adsorbent to propionaldehyde was 10:1. The adsorption conditions and procedures followed were as described in Example 4 except that gaseous propionaldehyde was recirculated over and through the adsorbents under atmospheric pressure of air for about 20 hours. As set forth in FIG. 5 , the AP—MgO adsorbed more propionaldehyde than any of the activated carbon samples. As shown is Example 4, pelletized AP—MgO will achieve substantially the same results.
EXAMPLE 9
An experiment was conducted to determine the ability of powder AP—MgO to adsorb dimethylamine compared with the ability of activated carbon to adsorb dimethylamine. The molar ratio of adsorbent to dimethylamine was 10:1. The adsorption conditions and procedures followed were as described in Example 8 except that gaseous dimethylamine was recirculated over and through the adsorbents under atmospheric pressure of air for about 20 hours. As set forth in FIG. 6 , the AP—MgO adsorbed more dimethylamine than the activated carbon samples. Pelletized AP—MgO will achieve substantially the same results as the powder AP—MgO.
EXAMPLE 10
An experiment was conducted to determine the ability of powder AP—MgO to adsorb ammonia compared with the ability of activated carbon to adsorb ammonia. The molar ratio of adsorbent to ammonia was 10:1. The adsorption conditions and procedures followed were as described in Example 8 except that gaseous ammonia was recirculated over and through the adsorbents for about 20 hours both under air and in the absence of air. Asset forth in FIG. 7 , the AP—MgO adsorbed more ammonia than the activated carbon samples. While the ammonia was adsorbed is lesser amounts than the aldehydes, it was adsorbed at a rapid rate. Pelletized AP—MgO will achieve substantially the same results as the powder AP—MgO.
EXAMPLE 11
An experiment was conducted to determine the ability of powder AP—MgO to adsorb methanol as compared to the ability of activated carbon to adsorb methanol. The molar ratio of adsorbent to methanol was 10:1. The adsorption conditions and procedures followed were as described in Example 8 except that gaseous methanol was recirculated over and through the adsorbents for about 20 hours under air. As set forth in FIG. 8 , the AP—MgO adsorbed substantially more methanol than the activated carbon samples adsorbed. While the methanol was adsorbed in teaser amounts than the aldehydes, it was adsorbed at a rapid ate. Pelletized AP—MgO will achieve substantially the same results as the powder AP—MSO.
EXAMPLE 12
Production of Pallet Using a Disk Granulator
The metal hydroxide powder is granulated in a Colton Model 561 Rotary Wet Granulator to generate spherical particles of about 10 mm in diameter. These particles are granulated through an addition of small amounts of water. The minimum amount of water is used to start the growth of granules.
Granules of the hydroxide after some drying in air or inert atmosphere are activated to oxides, which regenerates the high surface area. This is accomplished by heating the Mg(OH) 2 under dynamic vacuum (10 −2 Torr) conditions at an ascending temperature rate to a maximum temperature of 500° C. which is held for 6 hrs.
EXAMPLE 13
Production of Metal Oxide Powder-Enhanced HEPA Filter Using Spray Granulation
A mark 20 HEPA from Natural Solutions is impregnated using high surface area metal oxides. Metal oxides an be applied to the filter substrate by spraying metal oxide or hydroxide mixed with water, or other solvent. In this technique, water or solvent droplets adhere to the filter substrate, forming a porous layer of powder bound to the filter. In case water is used and there is significant conversion from oxide so hydroxide, the Sitar has to be activated. Processing under vacuum to reactivate the oxide may be used. | Pelletized adsorbent compositions and methods of adsorbing toxic target compounds are provided for the destructive adsorption or chemisorption of toxic or undesired compounds. The pelletized adsorbents are formed by pressing together powder nanocrystalline particles comprising a metal hydroxide or a metal oxide at pressures of from about 50 psi to about 6000 psi to form discrete self-sustaining bodies. The pelletized bodies should retain at least about 25% of the surface area/unit mass and total pore volume of the starting metal particles. | 1 |
DESCRIPTION
1. Technical Field
The invention relates generally to shutters for opening and closing light paths and more specifically to an optical shutter for use in a laser system associated with a slit lamp or an operating microscope for ophthalmic procedures to protect the user's eyes from harmful laser light.
2. Background Art
Laser systems associated with a slit lamp for ophthalmic procedures carried out in a doctor's office or associated with an operating microscope for ophthalmic procedures carried out in hospital surgery are known. As part of such procedures, the doctor typically views the operating site through binoculars while using a relatively low power laser aiming beam. At the time the laser is actually employed for the operating procedure at a higher power, it is necessary to protect the doctor's eyes from the laser beam. Therefore, various types of optical shutters have been devised for this purpose. Typically, the shutter is positioned by a solenoid drive mechanism which has the disadvantage of relatively slow speed and the further disadvantage of requiring substantial power relative to the power required by a motor drive as with the present invention. In other respects, the conventional optical shutters have employed plural lenses and mechanism for positioning such plural lenses between shielding and non-shielding positions.
With the mentioned prior art practices in mind, the object of the present invention is to provide an optical shutter mechanism employing a relatively fast motor drive, a self-latching mechaism and a single shutter lens for uncovering and covering dual light paths associated with binoculars and means for operating the lens with the motor so as to minimize the power required during the shutter operation. Other objects will become apparent as the description proceeds.
DESCRIPTION OF THE INVENTION
The invention is directed to providing a shutter mechanism comprising an assembly adapted to be installed between binoculars and either a slit lamp or operating microscope used in conjunction with a laser for ophthalmic procedures. Two light paths through the shutter mechanism correspond to the viewing paths of the binocular eye pieces. A single lens member is operatively associated with a motor-driven crank arm such that when the motor is energized, the lens can be quickly positioned to block both lights paths immediately prior to use of a high power laser beam and to assume a self-latching mode. Binoculars are secured on one side of the invention assembly and a slit lamp or operating microscope is secured on the opposite side of the invention assembly. The drive motor is powered through a foot switch such that when the foot switch is operated, the shutter moves into position to block both light paths and thereby protect the eyes of the operator, i.e., the doctor or surgeon performing the ophthalmic procedure. As the shutter rotates to its shielding position, a position sensitive switch is actuated which enables laser power to be applied to the operation site at a selected high level and for a brief interval of time. Release of the foot switch serves to reverse the direction of operation of the motor and to restore the shutter to its non-blocking position prior to which the laser power level will have been restored to a level that will not be harmful to the operator or patient.
DESCRIPTION OF DRAWINGS
FIG. 1 is a cross section of the invention shutter mechanism assembly and illustrating how the slit lamp or operating microscope fitting and the binoculars are clamped to opposite ends of the invention assembly.
FIG. 2 is a left end view of the assembly of FIG. 1.
FIG. 3 is a right end view of the assembly of FIG. 1.
FIG. 4 is a section view taken along line 4--4 of FIG. 1.
FIG. 5 is a section view taken along line 5--5 of FIG. 1.
FIG. 6 is a left end view of the shutter core.
FIG. 7 is a right end view of the shutter core.
FIG. 8 is a section view taken along line 8--8 of FIG. 6.
FIG. 9 is an end view of a core cover.
FIG. 10 is a side view of a core cover.
FIG. 11 is a left end view of the shutter mounting shaft.
FIG. 12 is a right end view of the shutter mounting shaft.
FIG. 13 is a cross section of the shutter mounting shaft.
FIG. 14 is a side view of the filter crank.
FIG. 15 is an end view of the filter crank.
FIG. 16 is an outer end view of the male shutter flange which is adapted to fit a slit lamp or operating microscope fitting.
FIG. 17 is a section view taken along line 17--17 of FIG. 16 of the male shutter flange.
FIG. 18 is a side view of the shutter housing.
FIG. 19 is a left end view of the shutter housing.
FIG. 20 is a section view taken along line 20--20 of FIG. 19.
FIG. 21 is a right end view of the shutter housing.
FIG. 22 is a side view of the shutter filter.
FIG. 23 is a section view taken along line 23--23 of FIG. 22.
FIG. 24 is an outer end view of the female shutter flange which is adapted to accept the binoculars.
FIG. 25 is a section view taken along line 24--24 of FIG. 24.
FIG. 26 is a simplified schematic diagram of a system incorporating the shutter mechanism of the invention.
BEST MODE FOR CARRYING OUT THE INVENTION
Referring initially to FIG. 1, the shutter mechanism 35 of the invention is adapted to be installed in an ophthalmic laser system between binoculars 36 and a slit lamp or operating microscope fitting 37 as indicated in FIG. 1. The description will first describe the electromechanical construction of the invention shutter mechanism 35 and will then discuss its operating features.
As seen in FIG. 1, the shutter mechanism 35 comprises the shutter core 38 formed of black coated aluminum and as best seen in FIGS. 6, 7 and 8 includes a pair of laterally-spaced, horizontally-oriented apertures or bores 40, 42 which align with the binocular sight paths, an aperture-recess formation 44 for mounting the filter drive motor 45 (FIGS. 1 and 4), a hole 46 between and on the horizontal centerline of holes 40, 42 for mounting the shutter mounting shaft taken along line 13--13 of FIG. 11 48 and a rib portion 50. Motor 45 drives the end 53 of filter crank 52 through gear 54 on the motor shaft and gear 58 on crank end 53. The outer crank end 55 slides in a slot 56 formed in the shutter filter 60. Filter 60 is formed of thin, e.g. 0.125 inch, amber-tinted, transparent "Plexiglas" sheet material. Filter 60 is in turn secured by bolt 62 on one end of mounting shaft 48 and is formed with outwardly-extending filter lens sections 65, 66 which can be brought into the binocular sight paths, i.e., to cover holes 40, 42, as in the dashed line position of FIG. 4 or in a position to uncover such light paths as in the solid line position of FIG. 4. Radially-oriented slot 56 is formed alongside section 66. Adjustable stops 70, 72 are utilized to respectively limit the counterclockwise and clockwise directions of travel of the shutter filter 60 as viewed in FIG. 4.
Core 38 mounts in the aluminum-formed shutter housing 75 which provides a hollow interior and wire entryway 74 and is secured by set screw 76. An aluminum-formed male shutter flange 77 retains a thin, metal plate core cover 82 with holes 40', 42' aligned with holes 40, 42. Flange 77 is secured by screws 78 to one side of housing 75 for receiving the previously-mentioned slit lamp or operating microscope fitting 37 utilizing thumb screw 73. An aluminum-formed female shutter flange 80 retains another core cover 82 and is secured by screw 81 to the opposite end of housing 75. The female shutter flange 80 is adapted to receive the binoculars 36 and secure such binoculars by means of a thumb screw 83 inserted in the threaded hole 84 (FIG. 1). Flanges 77 and 80 may, if desired, be formed integrally with respective core covers 82.
Drive motor 45 comprises a microsize, reversible DC motor energized through a pair of leads 79 which in turn are fed from the shutter mechanism 35 through a grommet 85 (FIG. 5) which also receives another pair of leads 86 connected to a microswitch 88. Contacts 90, 92 are opened and closed by means of a cam 94 which contacts switch actuator 96 (FIG. 5). Cam 94 on the end of the shutter mounting shaft 48 engages switch actuator 96 whenever the shutter filter 60 is in the shielding position as indicated in dashed lines in FIG. 4. Thus, switch 88 is normally employed as a means to signal and allow the laser source to produce a laser pulse and to deenergize drive motor 45 through appropriate control circuitry when the filter shutter 60 is in the filtering position. Also, through appropriate controls the laser is then pulsed at selected power without danger to the operator's eyes.
In the general system diagram illustrated in FIG. 26, operation of foot switch 90 is coordinated with the application of the briefly pulsed laser beam under selected operating power such that when the foot switch 90 is depressed, a pulse of power is applied to drive motor 45 to move the shutter filter 60 to the closed or filtering position and when the operator removes his foot from the foot switch 90, a pulse of power is applied to drive motor 45 so as to cause the filter crank 52 to rotate the shutter filter 60 to the nonfiltering position as indicated in the solid line position of filter 60 in FIG. 4. Appropriate controls apply such power pulses and in correct polarity relation for the desired direction of rotation. The foot switch 90 as indicated in FIG. 26 is linked electrically to the laser source and thus the selected pulse of laser power can be applied after the usual preliminary aiming and aligning procedure has been accomplished. The adjustable stops 70, 72 limit the travel of shutter filter 60. A cylindrical rubber bumper 57 secured to filter 60 extends into slot 56 of shutter filter 60 to absorb any shock induced by crank overtravel. Also to be noted is that crank 52 and slot 56 are oriented operationally such that when filter crank 52 drives the shutter filter 60 into either the nonfiltering position as in solid lines in FIG. 4 or in the filtering position as in dashed lines in FIG. 4, the filter crank 52 assumes a self-latching position. By this is meant that when the shutter filter 60 is in either the nonfiltering or filtering position, it cannot be rotated from such position except by energizing drive motor 45 by a short power pulse of suitable duration and polarity for the appropriate direction of rotation to drive filter crank 52 accordingly.
Of particular significance is the relation of the filter crank 52 to the shutter filter 60. In this regard, slot 56 (FIG. 4) is oriented with respect to filter crank 52 such that when motor 45 is initially energized by a power pulse to move shutter filter 60 to the blocking position, indicated in dashed lines in FIG. 4, filter crank 52 can actually rotate and move approximately 15° to 20° before any load is transferred to drive motor 45. Thus, when a load is initially placed on motor 45, the motor is operating at near maximum power output and is thus at or near-peak efficiency. This allows the shutter filter to be moved to blocking position very rapidly, e.g., in 40 to 50 milliseconds and with minimum power requirement. In one embodiment an extremely small Micromo Series 1516 motor was employed with satisfactory results.
Since shutter filter 60 is of a single-piece, thin, plastic plate construction and includes slot 56, filter crank 52 can be connected directly to shutter filter 60 without intermediate linkage. Further, the described tinted, Plexiglas thin-plate filter construction eliminates the need for plural ground glass blocking lenses as in prior art devices and provides an extremely lightweight and easily rotated filtering lens. | A shutter mechanism for employment in an ophthalmic laser treatment system mounts between the binoculars and a slit lamp or operating microscope. The shutter mechanism provides a filter movable into the optical viewing path when the laser is under selected power during treatment to prevent damage to the operator's eyes from the laser beam and uncovers the viewing paths when said treatment site is being viewed in conjunction with laser beam alignment and similar pre-operational procedures. | 0 |
FIELD OF INVENTION
[0001] The present invention releates to a novel 3-aryl-2-hydroxypropionic acid derivative, to a process and intermediate for preparing such a compound, having the utility in clinical conditions associated with insulin resistance, to methods for its therapeutic use and to pharmaceutical compositions containing it.
BACKGROUND OF THE INVENTION
[0002] Insulin resistance, defined as reduced sensitivity to the actions of insulin in the whole body or individual tissues such as skeletal muscle, myocardium, fat and liver prevail in many individuals with or without diabetes mellitus. The insulin resistance syndrome, IRS, refers to a cluster of manifestations including insulin resistance with accompanying hyperinsulinemia, possibly non insulin dependent diabetes mellitus (NIDDM); arterial hypertension; central (visceral) obesity; dyslipidemia observed as deranged lipoprotein levels typically characterized by elevated VLDL (very low density lipoproteins) and reduced HDL (high density lipoproteins) concentrations and reduced fibrinolysis.
[0003] Recent epidemiological research has documented that individuals with insulin resistance run a greatly increased risk of cardiovascular morbidity and mortality, notably suffering from myocardial infarction and stroke. In non-insulin dependent diabetes mellitus these atherosclerosis related conditions cause up to 80% of all deaths.
[0004] In clinical medicine there is at present only limited awareness of the need to increase the insulin sensitivity in IRS and thus to correct the dyslipidemia which is considered to cause the accelerated progress of atherosclerosis.
[0005] Furthermore there is at present no pharmacotherapy available to adequately correct the metabolic derangements associated with IRS. To date, the treatment of NIDDM has been focused on correction of the deranged control of carbohydrate metabolism associated with the disease. Stimulation of endogenous insulin secretion by means of secretagogues, like sulphonylureas, and if necessary administration of exogenous insulin are methods frequently used to normalize blood sugar but that will, if anything, further enhance insulin resistance and will not correct the other manifestations of IRS nor reduce cardiovascular morbidity and mortality. In addition such treatment involves a significant risk of hypoglycemia with associated complications.
[0006] Other therapeutic strategies have focused on aberrations in glucose metabolism or absorption, including biguanides, such as methformin, or glucosidase inhibitors, such as acarbose. Although these agents have been efficacious to a degree, their limited clinical effect is associated with side effects.
[0007] A novel therapeutic strategy involves the use of insulin sensitizing agents, such as the thiazolidinediones, which, at least in part, mediate their effects via an agonistic action on nuclear receptors. Ciglitazone is the prototype in this class. In animal models of IRS these compounds seem to correct insulin resistance and the associated hypertriglyceridaemia and hyperinsulinemia, as well as hyperglycemia in diabetes, by improving insulin sensitivity via an effect on lipid transport and handling, leading to enhanced insulin action in skeletal muscle, liver and adipose tissue.
[0008] Ciglitazone as well as later described thiazolidinediones in clinical development either have been discontinued reportedly due to unacceptable toxicity or show inadequate potency. Therefore there is a need for new and better compounds with insulin sensitizing properties.
PRIOR ART
[0009] [0009]
[0010] and certain derivatives thereof disclosed in U.S. Pat. No. 5,306,726 and WO 91/19702 are said to be useful as hypoglycemic and hypocholesterolemic agents, and in U.S. Pat. No. 5,232,945 said to be useful in the treatment of hypertension.
[0011] AU 650 429 discloses structurally related compounds, but claimed to have different properties: diuretic, antihypertensive, platelets anti-aggregating and anti-lipoxygenase properties.
[0012] EP 139 421 discloses compounds having the ability to lower blood lipid and blood sugar levels. Among these compounds is troglitazone, a compound that has reached the market for treatment of NIDDM or decreased glucose tolerance.
DESCRIPTION OF THE INVENTION
[0013] It has now surprisingly been found that the novel compound (S)-2-ethoxy-3-[4-(2-{4-methanesulfonyloxyphenyl}ethoxy)phenyl]propanoic acid having the formula I
[0014] is effective in conditions associated with insulin resistance.
[0015] The invention also relates to pharmaceutically acceptable salts, solvates, such as hydrates, and crystalline forms of the compound of the formula I.
[0016] In the present specification the expression “pharmaceutically acceptable salts” is intended to define but is not limited to such salts as the alkali metal salts (e.g. sodium, lithium and potassium), alkaline earth metal salts (e.g. calcium, barium and magnesium), aluminium, zinc and bismuth salts, ammonium salts, salts with basic amino acids, such as arginine, lysine, and salts with organic amines such as ethanolamine, ethylenediamine, triethanoleamine, benzylphenethylamine, diethylamine, tromethamine, benzathine, chloroprocaine, choline, meglumine, procaine, clernizole and piperazine.
[0017] Throughout the specification and the appended claims, a given chemical formula or name shall encompass all pharmaceutically acceptable salts thereof, crystalline forms and solvates thereof such as for instance hydrates.
METHODS OF PREPARATION
[0018] The compound of the invention may be prepared as outlined below according to any of methods A—H. However, the invention is not limited to these methods, the compounds may also be prepared as described for structurally related compounds in the prior art.
[0019] A. The compound of the invention of the formula I, can be prepared by converting a compound of formula II
[0020] wherein A is —OR p , wherein R p is a protective group, e.g. ethyl, or A is a chiral auxiliary group, such as a chiral amine, e.g. (R)-fenylalycinol, a chiral alcohol, such as menthol or a chiral oxazolidinone, such as (S)-4-benzyl-2-oxazolidinone. The convertion can be performed as a hydrolysis which can be either acidic or basic and performed according to standard methods known to anyone skilled in the art or as described in the experimental part.
[0021] B. The compound of the formula I or the formula II, wherein A is a chiral auxiliary group or —OR p and R p is as defined above, can be prepared by reacting a compound of the formula III
[0022] wherein X is OH or a leaving group such as a sulfonate or a halogen, with a compound of the formula IV
[0023] wherein Q is H and A is a chiral auxiliary group, —OH or —OR p , and R p is as defined above. The reaction can be performed either by an alkylation reaction or a Mitsunobu reaction.
[0024] In an alkylation reaction the leaving group X can be a sulfonate such as mesylate, nosylate, tosylate, or a halogen, such as bromine or iodine. The compounds of formula III and IV, in approximately equimolar amounts or with an excess of either compound, are heated to reflux temperature in an inert solvent, such as isopropanol or acetonitrile, in the presence of a base, such as potassium carbonate or cesium carbonate.
[0025] The mixture is refluxed for the necessary time, typically between 0.5 h to 24 h, the work up procedure usually includes filtration, for removal of solid salt, evaporation, neutralisation (when A═OH) and extraction with water and an organic solvent such as dichloromethane, 20 ethyl acetate, or diethyl ether.
[0026] The crude product is purified if desired e.g. by recrystallization or by standard chromatographic methods.
[0027] The Mitsunobu reaction can be carried out according to standard methods or as described in for example Tsunoda T., Yamamiaya Y., Ito S., Tetrahedron Letters, 34, 1639-1642 (1993) or O. Mitsunobu, Synthesis, 1981, p.1. When using a Mitsunobu reaction A can not be —OH.
[0028] In a typical Mitsunobu reaction a compound of formula III, wherein the group X is a hydroxyl group, and a compound of formula IV are mixed, in approximately equimolar amounts or with an excess of either compound, in an inert solvent, such as chloroform, dichloromethane, or tetrahydrofuran. A slight molar excess, 1-4 equivalents, of an azodicarboxylate, such as DEAD or ADDP and a phosphine (1-4 equivalents), such as tributylphosphine or triphenylphosphine are added and the reaction is stirred at a temperature high enough—for example room temperature—and a time long enough (1-24 hours) to obtain product, which can be worked up with standard literature methods and if desired purified, e.g. by standard chromatographic methods.
[0029] The compound of formula III can be prepared by standard procedures known to anyone skilled in the art, from commercially available starting materials or as described in the experimental section.
[0030] The compound of formula IV wherein Q is H and A is a chiral auxiliary group, —OH or —OR p , wherein R p is as defined above, can be prepared as described below in the experimental part or by converting a compound of formula IV
[0031] wherein Q is R q , wherein R q is a protective group, e.g. benzyl, and A is a chiral auxiliary group, —OH or —OR p wherein R p is as defined above,
[0032] C. The compound of formula II, wherein A is a chiral auxiliary group, and the compound of formula IV, wherein A is a chiral auxiliary group and Q is hydrogen or R q , wherein R q is as defined above and, can be prepared by diastereoisomeric separation of the compound of the formula V
[0033] wherein A is a chiral auxiliary group, Q is hydrogen, —CH 2 CH 2 Ph—4—OSO 2 CH 3 or R q , wherein R q is as defined above. The separation of the diastereomers can be performed either by crystallization or by chromatography. The chromatographic separation can be performed as described in the experimental part.
[0034] The compound of formula V wherein A is a chiral auxiliary group, Q is hydrogen, —CH 2 CH 2 Ph—4—OSO 2 CH 3 or R q , wherein R q is as defined above, can be prepared by converting a compound of formula VI
[0035] wherein Q is hydrogen, —CH 2 CH 2 Ph—4—OSO 2 CH 3 or R q , and R x is hydrogen or R p , wherein R q and R p are as defined above, for example by reacting it with a chiral amine or a chiral alcohol.
[0036] The compound of formula V when A is a chiral amine can be prepared by reacting a compound of formula VI with a chiral amine such as (R)-phenyl glycinol for example in the presence of a peptide coupling system (e.g. EDC, DCC, HBTU, TBTU, PyBop or oxalylchloride in DMF), an appropriate base (e.g. pyridine, DMAP, TEA or DiPEA) and a suitable organic solvent (e.g. dichloromethane, acetonitrile or DMF) in accordance to methods well known to those skilled in the art or as described in the examples.
[0037] The compound of formula V when A is a chiral alcohol can be prepared in the same way using a chiral alcohol, such as menthol, instead of a chiral amine, or by the mix-anhydride method with pivaloyl chloride and the lithium salt of the chiral alcohol.
[0038] The compound of formula V wherein A is a chiral auxiliary group and Q is hydrogen, —CH 2 CH 2 Ph—4—OSO 2 CH 3 or R q , wherein R q is as defined above, and the compound of formula VI, wherein Q is hydrogen, —CH 2 CH 2 Ph—4—OSO 2 CH 3 or R q and R x is hydrogen or R p , wherein R q and R p are as defined above, can be prepared by reduction of a compound of formula VII
[0039] wherein A is a chiral auxiliary group, —OH, or —OR p wherein R p is as defined above and Q is hydrogen, —CH 2 CH 2 Ph—4—OSO 2 CH 3 or R q , wherein R q is as defined above, and if desired followed by removal of protecting groups.
[0040] The reduction of the olefin may be carried out by using a wide variety of reducing methods known to reduce carbon-carbon double bonds, such as catalytic hydrogenation in the presence of an appropriate catalyst or hydrogen transfer reagents such as diethyl-2,5-dimethyl-1,4-dihydropyridine-3,5-dicarboxylate.
[0041] The catalytic hydrogenation can be performed in alcohol, cellosolves, protic polar organic solvents, ethers, lower alifatic acids, and particularly in methanol, ethanol, methoxyethanol, dimethylformamide, tetrahydrofuran, dioxane, dimetoxyethane, ethyl acetate or acetic acid either used alone or in mixture. Examples of the catalysts used include palladium black, palladium on charcoal, platinum oxide or Wilkinson's catalyst. This reaction can be performed at different temperatures and pressures depending on the reactivity of the aimed reaction.
[0042] In case of hydrogen transfer reaction with diethyl-2,5-dimethyl-1,4-dihydropyridine-3,5-dicarboxylate the reaction can be conducted by mixing equimolar amounts of reactants and warming the mixture to melting (140-250° C.) in inert atmosphere or in vacuum.
[0043] The compound of formula VII wherein A is a chiral auxiliary group, —OH, or —OR p , wherein R p is as defined above and Q is hydrogen, —CH 2 CH 2 Ph—4—OSO 2 CH 3 − or R q , wherein R q is as defined above, can be prepared by a condensation reaction, such as a Knoevenagel or Wittig type reaction, of a carbonyl compound of the formula VIII
[0044] wherein Q is hydrogen, —CH 2 CH 2 Ph—4—OSO 2 CH 3 or R q , wherein R q is as defined above, with a compound of the formula IX
[0045] in which formula A is a chiral auxiliary group, —OH or —OR p , wherein R p is as defined above, or a compound of the formula X
[0046] in which formula A is a chiral auxiliary group or —OR p , wherein R p is as defined above, L 1 =L 2 =L 3 are phenyl or L 1 =L 2 are —Oalkyl and L 3 is ═O, and, if desired, followed by removal of protecting groups or by an arylation reaction as described in for example Cacchi S., Ciattini P. G., Morera E., Ortar G., Tetrahedron Letters, 28 (28) 1987, pp 3039-3042.
[0047] In the condensation step, approximately equimolar amounts of reactants are mixed in the presence of a base, to provide the olefin compound. This step may be carried out in the presence of an inert solvent or in the absence of a solvent at a temperature between −20° C. and the melting point for the mixture. It might be necessary to add a dehydrating agent in order to achieve the olefinic compound.
[0048] In a typical such reaction the compounds of formula VIII and formula IX are mixed in a solvent such as tetrahydrofuran. Anhydrous potassium tert-butoxide is slowly added at low temperature i.e. −20° C. The reaction is quenched with acetic acid. The crude product is isolated, redissolved in toulene and refluxed with p-toluene sulfonic acid in a Dean-Stark apparatus. The solution is cooled and the product is isolated and purified according to standard methods (see Groger T., Waldmann E., Monatsh Chem 89, 1958, p 370).
[0049] The condensation step could also be performed as a Wittig-type reaction (see for example Comprehensive Organic Synthesis vol. 1 p. 755-781 Pergamon Press) or as described in the experimental part.
[0050] In a typical such reaction, approximately equimolar amounts of reactants of formula VIII and formula X are stirred in the presence of a base such as tetramethylguanidine or potassium carbonate in a 1-5 fold molar excess. This step may be carried out in the presence of an inert solvent such as dichloromethane or acetonitrile and at a suitable temperature (−10° C.+60° C.) and at a time long enough.
[0051] The compound of the formula VIII when Q is —CH 2 CH 2 Ph—4—OSO 2 CH 3 can be prepared by coupling a compound of the formula III wherein X is —OH or a leaving group such as a sulfonate or a halogen, with a compound of the formula XI
[0052] When X is a leaving group such as a sulfonate or a halogen, the reaction may be performed as an alkylation reaction and when X is —OH, as a Mitsunobu reaction as described above.
[0053] D. The compound of formula I or formula II wherein A is —OR p and R p is as defined above and the compound of formula IV wherein A is OH or —OR p and Q is H or R q wherein R p and R q are as defined above can be prepared by enantiomeric separation, such as chiral chromatography of the compound of the formula V
[0054] wherein A is —OH or —OR p , Q is H, —CH 2 CH 2 Ph—4—OSO 2 CH 3 or R q wherein R p and R q are as defined above.
[0055] E. The compound of the formula I or the formula II wherein A is a chiral auxiliary group or —OR p , wherein R p is as defined above, and the compound of formula IV wherein A is a chiral auxiliary group, —OH, or —OR p , wherein R p is as defined above and Q is hydrogen or R q , wherein R q is as defined above and, can be prepared by asymmetric reduction of a compound of the formula VII
[0056] wherein A is a chiral auxiliary group, —OH, or —OR p , wherein R p is as defined above and Q is hydrogen, —CH 2 CH 2 Ph—4—OSO 2 CH 3 or R q , wherein R q is as defined above. The asymmetric reduction can be carried out using a wide variety of reducing methods known to reduce carbon-carbon double bonds such as catalytic hydrogenation in the presence of an appropriate chiral catalyst such as Rh-BINAP or [Et-DuPHOS-Rh(COD)] or catalytic hydrogenation with an appropriate catalyst, such as palladium on charcoal using the chiral auxiliary group to induce the asymmetry.
[0057] The catalytic hydrogenation can be carried out in a wide variety of solvents, such as alcohol, cellosolves, protic polar organic solvents, ethers, lower alifatic acids, and particularly in methanol, ethanol, methoxyethanol, dimethylformamide, tetrahydrofuran, dioxane, dimetoxyethane, ethyl acetate or acetic acid, either used alone or in a mixture. The reaction can proceed at different temperatures and pressures depending on the reactivity of the aimed reaction.
[0058] F. The compound of the formula I or the formula II, wherein A is a chiral auxiliary group, or —OR p , wherein R p is as defined above, and the compound of formula IV wherein A is a chiral auxiliary group, —OH, or —OR p , wherein R p is as defined above and Q is hydrogen or R q , wherein R q is as defined above, can be prepared by alkylating a compound of the formula XII
[0059] wherein A is a chiral auxiliary group, —OH, or —OR p , wherein R p is as defined above, and Q is hydrogen, —CH 2 CH 2 Ph—4—OSO 2 CH 3 or R q , wherein R q is as defined above, with the required stereochemistry dependent on the reaction conditions used.
[0060] The alkylation may be carried out using a variety of alkylating agents, such as ethyl halide or diethyl sulfate (see for example Benedict D. R., Bianchi T. A., Cate L. A., Synthesis (1979), pp. 428-429, Barluenga J., Alonso-Cires L., Campos P. J., Asensio G., Synthesis, 1983, p. 53-55, Bull Chem Soc Jpn, 1986, 59, 2481, S. Patai, The Chemistry of the Ether Linkage, Wiley-Interscience N.Y., 1967, 445-498 or Survey of Organic Synthesis vol 1, Wiley-Interscience 1970, N.Y., p. 285-328).
[0061] The compound of formula XII wherein A is a chiral auxiliary group, —OH, or —OR p , wherein R p is as defined above, and Q is hydrogen, —CH 2 CH 2 Ph—4—OSO 2 CH 3 or R q , wherein R q is as defined above, can be prepared by asymmetric reduction of a compound of the formula XIII
[0062] wherein A is a chiral auxiliary group, —OH, or —OR p , wherein R p is as defined above, and Q is hydrogen, —CH 2 CH 2 Ph—4—OSO 2 CH 3 or R q , wherein R q is as defined above.
[0063] The asymmetric reduction may be performed by using a wide variety of reducing methods which are known to reduce ketones enantioselectively (see Flynn G. A., Beight D. W., Tetrahedron Letters, 29(4), 1988, pp. 423-426).
[0064] The compound of formula XII wherein A is a chiral auxiliary group and Q is hydrogen, —CH 2 CH 2 Ph—4—OSO 2 CH 3 or R q , wherein R q is as defined above, may also be prepared by induced chiral reduction of a compound of formula XII, wherein A is a chiral auxiliary group and Q is hydrogen, —CH 2 CH 2 Ph—4—OSO 2 CH 3 or R q , wherein R q is as defined above (see Xiang Y. B., Snow K., Belley M., J. Org. Chem., 1993, 58, pp 993-994).
[0065] The compound of formula XII, wherein A is a chiral auxiliary group, —OH or —OR p , wherein R p is as defined above, and Q is hydrogen, —CH 2 CH 2 Ph—4—OSO 2 CH 3 or R q , wherein R q is as defined above, can be prepared by converting a compound of the formula XIV
[0066] wherein A is a chiral auxiliary group, —OH or —OR p , wherein R p is as defined above, and Q is hydrogen, —CH 2 CH 2 Ph—4—OSO 2 CH 3 or R q , wherein R q is as defined above, with the required stereochemistry, dependent on the reaction conditions used ( see for example K. Koga, C. C. Wu and S. Yamada, Tetrahedron Letters, no. 25, 1971, p 2283-2286, Kunz H., Lerchen H-G., Tetrahedron Letters, 28 (17) 1987, pp.1873-1876).
[0067] G. The compound of formula II, wherein A is a chiral auxiliary group, and the compound of formula IV wherein A is a chiral auxiliary group and Q is R q , wherein R q is as defined above, can be prepared by reacting a compound of formula XV
[0068] wherein X is a leaving group, such as a halogen or a sulfonate, and Q is —CH 2 CH 2 Ph—4—OSO 2 CH 3 or R q , wherein R q is as defined above, with a compound of the formula IX
[0069] wherein A is a chiral auxiliary group.
[0070] In the alkylation step the compound of formula XV is reacted with a compound of formula IX in the presence of one or more bases such as potassium carbonate, triethylbenzylammonium chloride, sodium hydride, LDA, butyllithium or LHMDS in an inert solvent such as acetonitrile, DMF or dichloromethane at a suitable temperature and time. The reaction can be carried out using standard methods known in the litterature. (see for example Pearsson W. H., Cheng M. C., J. Org. Chem., 51 (19) 1986, 3746-3748, Myers A. G., Yang B. H., Gleason J. L., J. Am. Chem. Soc. 1994, 116, pp 9361-9362, Negrete G. R., Konopelski J. P., Tetrahedron Assymetry, 2, 2, pp. 105-108, 1991, Davies S. G., Sanganee H. J., Tetrahedron Assymetry, 6, 3, pp. 671-674, 1995, Hulin B., Newton L. S., Lewis D. M., Genereux P. E., Gibbs E. M., Clark D. A. J. Med.Chem. 39, 3897-3907 (1996) and Savignac M., Durand J-O, Genet J-P, Tetrahedron Assymetry, 5, 4, pp.717-722, 1994).
[0071] The compound of formula XV wherein X is a leaving group, such as a halogen or a sulfonate, and Q is —CH 2 CH 2 Ph—4—OSO 2 CH 3 or R q , wherein R q is as defined above, can be prepared from a compound of formula XVI
[0072] wherein Q is —CH 2 CH 2 Ph—4—OSO 2 CH 3 or R q , wherein R q is as defined above, using standard methods known to anyone skilled in the art.
[0073] The compound of formula XVI wherein Q is —CH 2 CH 2 Ph—4—OSO 2 CH 3 or , wherein R q is as defined above, can be prepared by reduction of a compound of formula VIII, wherein Q is —CH 2 CH 2 Ph—4—OSO 2 CH 3 or R q , wherein R q is as defined above, by standard methods known to anyone skilled in the art.
[0074] H. The compound of the invention of formula I and the compound of formula IV, wherein A is —OH and Q is hydrogen or R q , wherein R q is as defined above, can be prepared by resolution of the racemate thereof and, if desired, followed by neutralization. The resolution can be performed by separative crystallization of a salt consisting of the racemate of, either the compound of the invention of formula I, or the compound of formula IV, and a chiral base, such as quinine, in an inert solvent such as ethyl acetate or toluene (see for example Duhamel P., Duhamel L., Danvy D., Plaquevent J. C., Giros B., Gros C., Schwartz J. C., Lecomte J. M., U.S. Pat. No. 5,136,076, Stephani R., Cesare V., J. Chem. Ed., 10, 1997, p. 1226 and Yamamoto M., Hayashi M., Masaki M., Nohira H., Tetrahedron Assymetry, 2, 6, pp. 403-406, 1991).
[0075] The compounds of the invention may be isolated from their reaction mixtures using conventional techniques.
[0076] Persons skilled in the art will appreciate that, in order to obtain the compounds of the invention in an alternative and in some occasions, more convenient manner, the individual process steps mentioned hereinbefore may be performed in different order, and/or the individual reactions may be performed at different stage in the overall route (i.e. chemical transformations may be performed upon different intermediates to those associated hereinbefore with a particular reaction).
[0077] In any of the preceeding methods of preparation A—H, where necessary, hydroxy, amino or other reactive groups may be protected using a protecting group, R p or R q as described in the standard text “Protective groups in Organic Synthesis”, 2 nd Edition (1991) by Greene and Wuts. The protecting group R p or R q may also be a resin, such as Wang resin or 2-chlorotrityl chloride resin. The protection and deprotection of functional groups may take place before or after any of the reaction steps described hereinbefore. Protecting groups may be removed in accordance to techniques which are well known to those skilled in the art.
[0078] The expression “inert solvent” refers to a solvent which does not react with the starting materials, reagents, intermediates or products in a manner which adversely affects the yield of the desired product.
[0079] Unless otherwise stated or indicated the term chiral auxiliary group denotes a chiral group, such as a chiral alcohol or amine, for instance (−)-menthol, (+)-isomenthol, (−)-norneol, (R)-2-phenyl glycinol, (S)-2-phenyl glycinol, (R)-4-phenyl-2-oxazolidinone or (S)-4-benzyl-2-oxazolidinone, which when connected to a carbonyl group easily can be cleaved to the corresponding acid.
[0080] Intermediates
[0081] When preparing the compound of formula I of the invention an intermediate of the formula IV
[0082] wherein Q is hydrogen and A is —OH or —OR p , wherein R p is a protective group, e.g. ethyl, or A is a chiral auxiliary group, such as a chiral amine, e.g. (R)-fenylglycinol, or a chiral alcohol, such as menthol or a chiral oxazolidinone, such as (S)-4-benzyl-2-oxazolidineone, is particularly useful. It is prepared as described above. Under the same heading its use as intermediate for the preparation of the end compound of the invention is described.
[0083] Pharmaceutical Preparations
[0084] The compound of the invention will normally be administered via the oral, parenteral, intravenous, buccal, rectal, vaginal, transdemal and/or nasal route and/or via inhalation, in the form of pharmaceutical preparations comprising the active ingredient either as a free acid, or a pharmaceutical acceptable organic or inorganic base addition salt, in a pharmaceutically acceptable dosage form. Depending upon the disorder and patient to be treated and the route of administration, the compositions may be administered at varying doses.
[0085] The compound of the invention may also be combined with other therapeutic agents which are useful in the treatment of disorders associated with the development and progress of atherosclerosis such as hypertension, hyperlipidemias, dyslipidemias, diabetes and obesity.
[0086] Suitable daily doses of the compound of the invention in therapeutical treatment of humans are about 0.005-5 mg/kg body weight, preferably 0.01-0.5 mg/kg body weight.
[0087] According to a further aspect of the invention there is thus provided a pharmaceutical formulation including the compound of the invention, or pharmaceutically acceptable derivatives thereof, in optional admixture with pharmaceutically acceptable adjuvants, diluents and/or carriers.
[0088] Pharmacological Properties
[0089] The present compound of formula (I) will be adapted for prophylaxis and/or treatment of clinical conditions associated with reduced sensitivity to insulin (insulin resistance) and associated metabolic disorders. These clinical conditions will include, but will not be limited to, abdominal obesity, arterial hypertension, hyperinsulinaemia, hyperglycaemia (non insulin dependent diabetes mellitus (NIDDM)) and the dyslipidaemia (plasma lipoprotein disturbances) characteristically appearing with insulin resistance. This dyslipidaemia, also known as the atherogenic lipoprotein profile of phenotype B, is characterised by moderately elevated non-esterified fatty acids, elevated very low density lipoproteins (VLDL) triglycerides, low high density lipoproteins (HDL) cholesterol and the presence of small, dense, low density lipoproteins (LDL). Treatment with the present compound is expected to lower the cardiovascular morbidity and mortality associated with atherosclerosis. These cardiovascular disease conditions include macro-angiophaties causing myocardial infarction, cerebrovascular disease and peripheral arterial insufficiency of the lower extremities. Because of their insulin sensitizing effect the compound of formula (I) is also expected to reduce the progress of clinical conditions associated with chronic hyperglycaemia in diabetes like the micro-angiophaties causing renal disease and retinal damage. Furthermore the compound may be useful in treatment of various conditions outside the cardiovascular system associated with insulin resistance like the polycystic ovarian syndrome. The compound of the invention is a non-toxic insulin sensitizing agent with surprisingly good therapeutic effect and pharmacokinetic properties and without undesirable weight gain.
[0090] General Experimental Procedures
[0091] [0091] 1 H NMR and 13 C NMR measurements were performed on a BRUKER ACP 300 and Varian UNITY plus 400 and 500 spectrometers, operating at 1 H frequencies of 300, 400 and 500 MHz respectively, and at 13 C frequencies of 75, 100 and 125 MHz respectively.
[0092] Unless otherwise stated, chemical shifts are given in ppm with the solvent as internal standard.
WORKING EXAMPLES
Example 1
[0093] (S)-2-Ethoxy-3-[4-(2-{4-methanesulfonyloxyphenyl}ethoxy)phenyl]propanoic acid
[0094] a) 2-(4-Methanesulfonyloxyphenyl)ethylmethanesulfonate
[0095] p-Hydroxyphenethylalcohole (15 g; 0.108 mole) was dissolved in dichloromethane. Triethylamine (27.3 g; 0.27 mole) was added followed by addition of a solution of methanesulfonyl chloride (27.2 g; 0.239 mole) in dichloromethane at 0° C. The reaction mixture was allowed to reach room temperature, then stirred at room temperature and followed by TLC. The reaction mixture was filtered and the filtrate was washed with water. The organic phase was dried with sodium sulfate and then evaporated in vacuo to give 28 g (yield 88%) of 2-(4-methanesulfonyloxyphenyl)ethylmethanesulfonate.
[0096] [0096] 1 H-NMR (400 MHz; CDCl 3 ): δ 2.85 (s, 3H), 3.05 (t, 2H), 3.15 (s, 3H), 4.35 (s, 2H), 7.2 (dm, 2H), 7.25 (dm, 2H).
[0097] [0097] 13 C-NMR (100 MHz; CDCl 3 ): δ 34.8, 37, 27, 37, 31, 69.6, 122.2, 130.5, 135.8, 148.1.
[0098] b) 4-[2-(4-Formylphenoxy)ethyl]phenylnethanesulfonate
[0099] 2-(4-Methanesulfonyloxyphenyl)ethylmethanesulfonate (30 g; 0.102 mole) was dissolved in acetonitrile and slowly added to a mixture of p-hydroxybenzaldehyde (31.1 g; 0.255 mole) and potassium carbonate (41.46 g; 0.3 mole) in acetonitrile. The resulting mixture was refluxed until 2-(4-methanesulfonyloxyphenyl)ethylmethanesulfonate was consumed. The salts were filtered off, the solvent evaporated in vacuo, dichloromethane was added and the organic phase was washed with water. After evaporation of the solvent, purification by chromatography on silica gel using dichloromethane as eluant gave 21.6 g (yield 66%) of 4-[2-(4-formylphenoxy)ethyl]phenylmethanesulfonate.
[0100] [0100] 1 H-NMR (400 MHz; CDCl 3 ): δ 3.05-3.15 (t, 2H+s, 3H), 4.2 (t, 2H), 6.95 (dm, 2H), 7.2 (dm, 2H), 7.3 (dm, 2H), 7.8 (dm, 2H), 9.8 (s, 1H).
[0101] [0101] 13 C-NMR (100 MHz; CDCl 3 ): δ 37.3, 38.3, 63.4, 116.1, 122.1, 129.2, 130.6, 132.6, 138.1, 147.7, 162.6, 191.7.
[0102] c) 2-Ethoxy-3-{4-[2-(4-methanesulfonyloxyphenyl)ethoxy]phenyl}acrylic acid ethyl ester
[0103] Tetramethylguanidine (9 g; 78 mmole) was slowly added to a solution of 4-[2-(4-formylphenoxy) ethyl]phenylmethanesulfonate (27 g; 84.2 mmole) and (1,2-diethoxy-2-oxyethyl) triphenylphosphonium chloride (30 g; 72 mmole) in chloroform (300 ml) at 0° C. After stirring at room temperature over night the solvent was evaporated in vacuo. Diethyl ether was added to the residue and insoluble material was filtered off. More diethyl ether was added and the mixture was filtered again. The filtrate was washed with sodium hydrogen carbonate solution. The organic phase was dried (magnesium sulfate) and the solvent was evaporated. Recrystallization of the residue in ethanol gave 20.2 g (yield 64.6%) of 2-ethoxy-3-{4-[2-(4-methanesulfonyloxyphenyl)-ethoxy]phenyl}acrylic acid ethyl ester.
[0104] [0104] 1 H-NMR (500 MHz; CDCl 3 ): δ 1.34-1.38 (2t, 2×6H, J=7 Hz for both), 3.11 (t, 2H, J=6 Hz), 3.13 (s, 3H), 3.98 (q, 2H, J=7 Hz), 4. 2 (t, 2H, J=6.8 Hz), 4.28 (q, 2H, J=7 Hz), 6.87 (dm, 2H, J=9 Hz, unresolved), 6.95 (s, 1H), 7.23 (dm, 2H, J=9 Hz, unresolved), 7.33 (dm, 2H, J=9 Hz, unresolved), 7.73 (dm, 2H, J=9 Hz, unresolved).
[0105] [0105] 13 C-NMR (125 MHz; CDCl 3 ): δ 14.3, 15.5, 35.0, 37.3, 61.0, 67.5, 68.1, 114.4, 122.0, 123.8, 126.6, 130.5, 131.7, 137.7, 143.1, 147.9, 159.0, 164.9.
[0106] d) 2-Ethoxy-3-[4-(2-{4-methanesulfonyloxyphenyl}ethoxy)phenyl]propanoic acid ethyl ester
[0107] 2-Ethoxy-3-{4-[2-(4-methanesulfonyloxyphenyl)ethoxy]phenyl}acrylic acid ethyl ester (1.47 g; 3.38 mmole) was hydrogenated for 3 hours at atmospheric pressure in ethyl acetate (50 ml) using Pd/C (5%; 0.75 g) as catalyst. The reaction mixture was filtered through celite and dried (magnesium sulfate). The solvent was evaporated in vacuo to give (1.44 g; yield 98%) of 2-ethoxy-3-[4-(2-{4-methanesulfonyloxyphenyl}-ethoxy) phenyl]propanoic acid ethyl ester.
[0108] [0108] 1 H-NMR (500 MHz; CDCl 3 ): δ 1.16 (t, 3H, J=7 Hz), 1.23 (t, 3H, J=7 Hz), 2.92-2.96 (m, 2H), 3.09 (t, 2H, J=6.6), 3.13 (s, 3H), 3.31-3.38 (m, 1H), 3.56-3.63 (m, 1H), 3.94-3.98 (m, 1H), 4.12-4.19 (m, 4H), 6.8 (dm, 2H, J=8.8 Hz, unresolved), 7.14 (dm, 2H, J=8.9 Hz, unresolved), 7.22 (dm, 2H, J=8.9 Hz, unresolved), 7.33 (dm, 2H, J=8.6 Hz, unresolved).
[0109] [0109] 13 C-NMR (125 MHz; CDCl 3 ): δ 14.2, 15.0, 35.1, 37.2, 38.4, 60.7, 66.1, 68.1, 80.3, 114.3, 121.9, 129.5, 130.4, 130.5, 138.0, 147.8, 157.4, 172.5.
[0110] e) 2-Ethoxy-3-[4-(2-{4-methanesulfonyloxyphenyl}ethoxy)phenyl]propanoic acid
[0111] Lithium hydroxide hydrate (0.12 g; 2.82 mmole) dissolved in water (10 ml) was slowly added to a solution of 2-ethoxy-3-[4-(2-{4-methanesulfonyloxyphenyl}ethoxy) phenyl]propanoic acid ethyl ester (1.12 g; 2.56 mmole) in tetrahydrofuran (30 ml). After stirring at room temperature for 3 hours, water (50 ml) was added and tetrahydrofuran was removed by evaporation in vacuo. The water residue was acidified with hydrochloric acid (2M) and extracted three times with ethyl acetate. The organic phase was dried (magnesium sulfate), filtered and the solvent was evaporated in vacuo to give 1 g (yield 96%) of 2-ethoxy-3-[4-(2-{4-methanesulfonyloxyphenyl}ethoxy)-phenyl]propanoic acid.
[0112] [0112] 1 H-NMR (500 MHz; CDCl 3 ): δ 1.17 (t, 3H, J=7 Hz), 2.91-2.99 (m, 1H), 3.03-3.11 (m, 3H), 3.12 (s, 3H), 3.39-3.47 (m, 1H), 3.57-3.64 (m, 1H), 4.01-4.06 (m, 1H), 4.14 (t, 2H, J=6.7 Hz), 6.81 (dm, 2H, J=8.6 Hz, unresolved), 7.15 (dm, 2H, J=8.6 Hz, unresolved), 7.22 (dm, 2H, J=8.6 Hz, unresolved), 7.33 (dm, 2H, J=8.6 Hz, unresolved).
[0113] [0113] 13 C-NMR (125 MHz; CDCl 3 ): δ 15.0, 35.1, 37.2, 37.8, 66.8, 68.1, 79.7, 114.4, 121.9, 128.8, 130.49, 130.52, 137.9, 147.8, 157.5, 169.1.
[0114] f) (S)-2-ethoxy-N-(2-hydroxy-(R)-1-phenylethyl)-3-[4-(2-{4-methanesulfonyloxyphenyl}-ethoxy)phenyl]propanoic amide.
[0115] A solution of 2-ethoxy-3-[4-(2-{4-methanesulfonyloxyphenyl}ethoxy)phenyl]propanoic acid (10.5 g; 25.7 mmole) in dry dichloromethane (150 ml) was cooled on an ice-bath and EDC (5.42 g; 28.3 mmole), diisopropylethylamine (4.8 ml; 28.3 mmole) and HOBtxH 2 O (3.82 g; 28.3 mmole) were added. After 20 minutes the ice-bath was removed and (R)-phenylglycinol (3.88 g; 28.3 mmole) was added. After stirring at room temperature over night dichloromethane (100 ml), citric acid (60 ml, 10%) and ethyl acetate were added and the phases were separated. The organic phase was washed with citric acid (60 ml), sodium bicarbonate (2×60 ml) and brine (60 ml), dried (sodium sulfate), filtered and the solvent evaporated in vacuo. The crude product was crystallized twice in ethyl acetate/heptan to give 4.43 g of (R)-2-ethoxy-N-(2-hydroxy-(R)-1-phenylethyl)-3-[4-(2-{4-methanesulfonyloxyphenyl}ethoxy) phenyl]propanoic amide. The mother liquids were combined, the solvent was evaporated in vacuo and the residue was purified by chromatography on silica gel using ethyl acetate:heptan (gradient 25 to 100% ethyl acetate) to give 5.14 g (yield 38%) of (S)-2-ethoxy-N-(2-hydroxy-(R)-1-phenylethyl)-3-[4-(2-{4-methanesulfonyloxyphenyl}ethoxy)-phenyl]propanoic amide and 0.51 g (totally 4.94 g, yield 36%) of (R)-2-ethoxy-N-(2-hydroxy-(R)-1-phenylethyl)-3-[4-(2-{4-methanesulfonyloxyphenyl}-ethoxy) phenyl]propanoic amide.
[0116] [0116] 1 H-NMR (600 MHz; DMSO-d 6 ): δ 1.04 (t, 3H, J=7.0 Hz), 2.74 (dd, 1H, J=13.9 and 7.6 Hz), 2.84 (dd, 1H, J=13.9 and 5.3 Hz), 3.05 (t, 2H, J=6.7 Hz), 3.30 (m, 1H), 3.34 (s, 3H), 3.44 (m, 1H), 3.55 (t, 2H, J=5.8 Hz), 3.88 (dd, 1H, J=7.3 and 5.5 Hz), 4.15 (t, 2H, J=6.7 Hz), 4.83 (m, 1H), 4.85 (t, 1 OH, J=5.4 Hz), 6.80 (d, 2H, J=8.4 Hz), 7.09 (d, 2H, J=8.4 Hz), 7.17 (m, 3H), 7.23 (m, 2H), 7.28 (d, 2H, J=8.3 Hz), 7.43 (d, 2H, J=8.3 Hz), 8.06 (d, 1 NH, J=8.2 Hz).
[0117] [0117] 13 C-NMR (150 MHz; DMSO-d 6 ): δ 15.2, 34.4, 37.5, 38.0, 54.6, 64.5, 65.1, 67.9, 81.1, 114.2, 122.2, 126.8, 127.0, 128.1, 129.8, 130.4, 130.7, 138.1, 141.2, 147.8, 157.0, 171.1.
[0118] g) (S)-2-Ethoxy-3-[4-(2-{4-methanesulfonyloxyphenyl}ethoxy)phenyl]propanoic acid
[0119] (S)-2-Ethoxy-N-(2-hydroxy-(R)-1-phenylethyl)-3-[4-(2-{4-methanesulfonyloxyphenyl}ethoxy) phenyl]propanoic amide (4.49 g; 8.59 mmole), concentrated sulfuric acid (12.5 ml), dioxan (50 ml) and water (50 ml) were stirred at 80° C. for 6 hours. After cooling, water (100 ml) was added and the product was extracted with dichloromethane (2×100 ml). The organic phases were combined and washed with brine (60 ml), dried (sodium sulfate), filtered and evaporated in vacuo. Purification by chromatography on silica gel using heptan:ethyl acetate:acetic acid (10:10:1) as gradient and azeotropic destillation with toluen gave 2.78 g (yield 79%) of (S)-2-ethoxy-3-[4-(2-{4-methanesulfonyloxyphenyl}ethoxy) phenyl]propanoic acid.
[0120] [0120] 1 H-NMR (600 MHz; DMSO-d 6 ): δ 1.02 (t, 3H, J=7.0 Hz), 2.78 (dd, 1H, J=13.9 and 8.0 Hz), 2.86 (dd, 1H, J=13.9 and 5.2 Hz), 3.04 (t, 2H, J=6.8 Hz), 3.28 (dq, 1H, J=9.1 and 7.0 Hz), 3.35 (s, 3H), 3.49 (dq, 1H, J=9.1 and 7.0 Hz), 3.92 (dd, 1H, J=5.2 and 7.7 Hz), 4.15 (t, 2H, J=6.8 Hz), 6.82 (d, 2H, J=8.7 Hz), 7.11 (d, 2H, J=8.7 Hz), 7.27 (d, 2H, J=8.5 Hz), 7.42 (d, 2H, J=8.5 Hz), 12.59 (s, br, 1 OH).
[0121] [0121] 13 C-NMR (150 MHz; DMSO-d 6 ): δ 15.2, 34.4, 37.5, 37.7, 65.0, 67.9, 79.4, 114.2, 122.2, 129.6, 130.4, 130.7, 138.0, 147.8, 157.1, 173.4.
Example 2
[0122] (S)-2-Ethoxy-3 -[4-(2-{4-methanesulfonyloxyphenyl}ethoxy)phenyl]propanoic acid
[0123] a) 3-(4-Benzyloxyphenyl)-2-ethoxyacrylic acid ethyl ester
[0124] Tetramethylguanidine (33 g; 0.286 mole) was added to a solution of 4-benzyloxybenzaldehyde (59.1 g; 0.278 mole) and (1,2-diethoxy-2-oxyethyl) (triphenyl) phosphonium chloride (101.8 g; 0.237 mole) in dichloromethane (600 ml) at 0° C. After stirring at room temperature over night, the solvent was evaporated in vacuo. The residue was dissolved in diethyl ether, insoluble material was filtered off and the filtrate was evaporated. The residue was stirred over night with sodium bisulfite (saturated water solution) and diethyl ether. The solid material was filtered off, the filtrate was extracted with diethyl ether, dried (magnesium sulfate) and the solvent was evaporated in vacuo. Purification of the crude product by flash chromatography and crystallization in isopropanol gave 66.8 g (yield 86.3%) of 3-(4-benzyloxyphenyl)-2-ethoxyacrylic acid ethyl ester.
[0125] [0125] 13 C-NMR (125 MHz; CDCl 3 ): δ 14.4, 15.6, 61.0, 67.5, 70.0, 114.8, 124.0, 126.7, 127.5, 128.1, 128.6, 131.7, 136.7, 143.1, 159.2, 165.0.
[0126] b) 3-(4-Benzyloxyphenyl)-2-ethoxypropanoic acid ethyl ester
[0127] 3-(4-Benzyloxyphenyl)-2-ethoxyacrylic acid ethyl ester (0.5 g; 1.5 mmole) was hydrogenated at atmospheric pressure using rhodium on charcoal as catalyst (5%, 50 mg) in methanol (20 ml). The crude product was purified by chromatography using heptane:ethyl acetate (5:1) as eluant to give 50 mg (yield 10%) of 3-(4-benzyloxyphenyl)-2-ethoxypropanoic acid ethyl ester.
[0128] [0128] 1 H NMR (300 MHz; CDCl 3 ): δ 7.47-7.30 (m, 5H), 7.17 (d, J=8.8, 2H), 6.91 (d, J=8.8 Hz, 2H), 5.06 (s, 2H), 4.17 (q, J=7.2 Hz, 2H), 3.98 (t, J=6.6 Hz, 1H), 3.61 (dq, J=8.9 and 6.8 Hz, 1H), 3.36 (dq, J=8.9 and 6.8 Hz, 1H), 2.97 (d, J=6.6 Hz, 2H), 1.22 (t, J=7.2 Hz, 3H), 1.18 (t, J=6.8 Hz, 3H).
[0129] [0129] 13 C NMR (75 MHz; CDCl 3 ): δ 172.6, 157.6, 137.1, 130.4, 129.5, 128.6, 127.9, 127.5, 114.6, 80.4, 70.0, 66.2, 60.8, 38.5, 15.1, 14.2.
[0130] c) 3-(4-Benzyloxyphenyl)-2-ethoxypropanoic acid
[0131] Lithium hydroxide hydrate (7.4 g; 177 mmole) dissolved in water (150 ml) was added to a solution of 3-(4-benzyloxyphenyl)-2-ethoxypropanoic acid ethyl ester (23.25 g; 70.8 mmole) in dioxan (150 ml). After stirring at room temperature over night dioxan was evaporated in vacuo, water was added and the mixture was washed with diethyl ether. The water phase was acidified with hydrochloric acid (1 M) and extracted with ethyl acetate. The organic phase was washed with water and brine, dried and the solvent was evaporated in vacuo to give 21.1 g (yield 99.2%) of 3-(4-benzyloxyphenyl)-2-ethoxypropanoic acid.
[0132] [0132] 1 H NMR (300 MHz; CDCl 3 ): 67 1.15 (t, 3H), 2.9-3.1 (m, 2H), 3.35-3.45 (m, 1H), 3.6-3.7 (m, 1H), 3.95-3.41 (m, 1H), 5.05 (s, 2H), 6.95 (d, 2H), 7.2 (d, 2H), 7.25-7.5 (m, 5H).
[0133] [0133] 13 C NMR (75 MHz; CDCl 3 ): δ 15.0, 38.1, 66.6, 70.0, 79.9, 114.7, 127.5, 128.0, 128.6, 129.3, 130.5, 137.1, 157.7, 176.3.
[0134] d) 3-(4-Benzyloxyphenyl)-(S)-2-ethoxy-N-(2-hydroxy-(R)-1-phenylethyl)propanoic amide
[0135] A solution of 3-(4-benzyloxyphenyl)-2-ethoxypropanoic acid (2.92 g, 9.74 mmole) in dry dichloromethane (30 ml) was cooled on an ice-bath and EDC (2.03 g; 10.61 mmole), diisopropylethylamine (1.84 ml, 10.61 mmole) and HOBtxH 2 O ( 1.43 g; 10.61 mmole) were added. After 30 minutes the ice-bath was removed and (R)-phenylglycinol (1.46 g, 10.61 mmole) was added. After stirring at room temperature over night ethyl acetate (100 ml) was added and the mixture was washed with potassium hydrogensulfate (1 M), saturated sodium bicarbonate solution, sodium carbonate solution and brine. The organic phase was dried (sodium sulfate), filtered and the solvent was evaporated in vacuo. The crude product was purified by chromatography on silica gel using ethyl acetate:heptan to give 1.5 g (yield 37%) of 3-(4-benzyloxyphenyl)-(S)-2-ethoxy-N-(2-hydroxy-(R)-1-phenylethyl)propanoic amide and 1.25 g (yield 31%) of 3-(4-benzyloxyphenyl)-(R)-2-ethoxy-N-(2-hydroxy-(R)-1-phenylethyl)propanoic amide.
[0136] [0136] 1 H NMR (400 MHz; CDCl 3 ): δ 7.43-7.27 (m, 8H), 7.22 (d, J=8.3 Hz, 4H), 7.13 (d, NH, J=7.8 Hz, 1H), 6.96 (d, J=8.3 Hz, 1H), 5.08 (s, 2H), 5.01 (m, IH), 3.99 (dd, J=6.8 and 3.9 Hz, 1 H), 3.69 (m, 2H), 3.50 (q, J=6.8 Hz, 2H), 3.15 (dd, J=14.2 and 3.9 Hz, 1H), 2.97 (dd, J=14.2 and 6.8 Hz, 1H), 2.94 (m, OH, 1H), 1.16 (t, J=6.8 Hz, 3H).
[0137] [0137] 13 C NMR (100 MHz; CDCl 3 ): δ 172.3, 157.5, 138.9, 137.0, 130.7, 129.4, 128.6, 128.4, 127.7, 127.6, 127.3, 126.5, 114.4, 81.0, 69.8, 66.3, 66.0, 55.3, 37.8, 15.1.
[0138] e) 3-(4-Benzyloxyphenyl)-(S)-2-ethoxypropanoic acid
[0139] 3-(4-Benzyloxyphenyl)-(S)-2-ethoxy-N-(2-hydroxy-(R)-1-phenylethyl)propanoic amide (8.9 g; 21.22 mmole) was hydrolyzed with concentrated sulfuric acid (27 ml) in water (104 ml) and dioxane (104 ml) at 90° C. for 5 hours. The reaction mixture was poured onto water (220 ml) and extracted with ethyl acetate. The organic phase was washed with brine, dried (sodium sulfate) and the solvent was evaporated in vacuo to give 6.85 g of a mixture of 3-(4-benzyloxyphenyl)-2-(S)-ethoxypropanoic acid and (S)-2-ethoxy-3-(4-hydroxyphenyl)-propanoic acid, which was used without further purification.
[0140] [0140] 1 H NMR (400 MHz; CDCl 3 ): δ 7.47-7.30 (m, 5H), 7.19 (d, J=8.8, 2H), 6.93 (d, J=8.8 Hz, 2H), 5.10 (s, 2H), 4.06 (dd, J=7.8 and 4.4 Hz, 1H), 3.64 (dq, J=9.8 and 6.8 Hz, 1H), 3.44 (dq, J=9.8 and 6.8 Hz, 1H), 3.09 (dd, J=14.2 and 4.4 Hz, 1H), 2.98 (dd, J=14.2 and 7.8 Hz, 1H), 1.19 (t, J=6.8 Hz, 3H).
[0141] f) 3-(4-Benzyloxyphenyl)-(S)-2-ethoxypropanoic acid ethyl ester
[0142] Hydrogen chloride (g) was bubbled through a solution of 3-(4-benzyloxyphenyl)-2-(S)-ethoxypropanoic acid (6.85 g) in ethanol (400 ml). Thionyl chloride (2 ml, 27.4 mmole) was slowly added and the reaction mixture was refluxed for 2 hours. The solvent was evaporated in vacuo to give 8 g of a mixture of 3-(4-benyloxyphenyl)-(S)-2-ethoxypropanoic acid ethyl ester and (S)-2-ethoxy-3-(4-hydroxyphenyl)propanoic acid ethyl ester which was used without further purification.
[0143] [0143] 1 H NMR (300 MHz; CDCl 3 ): δ 7.47-7.30 (m, 5H), 7.17 (d, J=8.8, 2H), 6.91 (d, J=8.8 Hz, 2H), 5.06 (s, 2H), 4.17 (q, J=7.2 Hz, 2H), 3.98 (t, J=6.6 Hz, 1H), 3.61 (dq, J=8.9 and 6.8 Hz, 1H), 3.36 (dq, J=8.9 and 6.8 Hz, 1H), 2.97 (d, J=6.6 Hz, 2H), 1.22 (t, J=7.2 Hz, 3H), 1.18 (t, J=6.8 Hz, 3H).
[0144] [0144] 13 C NMR (75 MHz; CDCl 3 ): δ 172.6, 157.6, 137.1, 130.4, 129.5, 128.6, 127.9, 127.5, 114.6, 80.4, 70.0, 66.2, 60.8, 38.5, 15.1, 14.2.
[0145] g) (S)-2-Ethoxy-3-(4-hydroxyphenyl)propanoic acid ethyl ester
[0146] 3-(4-Benzyloxyphenyl)-(S)-2-ethoxypropanoic acid ethyl ester was hydrogenated at atmospheric pressure for 2 hours in ethyl acetate using Pd/C as catalyst. Purification by chromatography on silica gel using toluen:ethyl acetate as eluant gave 3.83 g (yield in 3 steps 76%) of (S)-2-ethoxy-3-(4-hydroxyphenyl)propanoic acid ethyl ester.
[0147] [0147] 1 H-NMR (400 MHz; CDCl 3 ): δ 1.18 (t, 3H, J=6.8 Hz), 1.24 (t, 3H, J=7 Hz), 2.96 (d, 2H, J=6.5 Hz), 3.34-3.43 (m, 1H), 3.57-3.66 (m, 1H), 4.00 (t, 1H, 6.5 Hz), 4.18 (q, 2H, J=7 Hz), 5.30 (s, 1 OH), 6.74 (dm, 2H, J=8.5 Hz, unresolved), 7.10 (dm, 2H, J=8.5 Hz, unresolved).
[0148] [0148] 13 C-NMR (100MHz; CDCl 3 ): δ 14.2, 15.0, 38.4, 60.9, 66.2, 80.4, 115.1, 129.0, 130.5, 154.5, 172.7.
[0149] h) (S)-2-Ethoxy-3-[4-(2-{4-methanesulfonyloxyphenyl}ethoxy)phenyl]propanoic acid ethyl ester
[0150] A solution of 2-(4-methanesulfonyloxyphenyl)ethylmethanesulfonate (described in Example 1a) (2.41 g; 8.14 mmole) in acetonitrile (11.8 ml) was added to a mixture of (S)-2-ethoxy-3-(4-hydroxyphenyl) propanoic acid ethyl ester (1.3 g; 5.46 mmole), potassium carbonate (2.26 g; 16.4 mmole) and magnesium sulfate (1 g) in acetonitrile (50 ml). The reaction mixture was refluxed for 19 hours. More of 2-(4-methanesulfonyloxyphenyl)ethyl-methanesulfonate (0.8 g; 2.73 mmole) was added and the reaction mixture was refluxed for another 25 hours. Solid material was filtered off and the solvent was evaporated in vacuo to give 3.6 g of (S)-2-ethoxy-3-[4-(2-{4-methanesulfonyloxyphenyl}ethoxy) phenyl]-propanoic acid ethyl ester.
[0151] i) (S)-2-Ethoxy-3-[4-(2-{4-methanesulfonyloxyphenyl}ethoxy)phenyl]propanoic acid
[0152] Lithium hydroxide hydrate (0.229 g; 5.45 mmole) dissolved in water (6 ml) was slowly added to a mixture of (S)-2-ethoxy-3-[4-(2-{4-methanesulfonyloxyphenyl}ethoxy)phenyl]-propanoic acid ethyl ester (2.29 g; 5.24 mmole) in tetrahydrofuran (50 ml) and water (10 ml) at 5° C. The reaction mixture was stirred at 5° C. for 2.5 hours, at 20° C. for 3 hours, at 0° C. for 15 hours and at 20° C. for 3,5 hours. More lithium hydroxide hydrate (44 mg, 1.05 mmole) dissolved in water (1 ml) was added at 10° C. After another 21.5 hours of stirring at 10° C., more lithium hydroxide hydrate (44 mg; 1.05 mmole) dissolved in water (1 ml) was added. The reaction mixture was stirred at 25° C. for 3 hours and then kept at 2° C. for 67 hours. Tetrahydrofuran was evaporated in vacuo and then water and ethyl acetate were added. Insoluble material was filtered off and the phases of the filtrate were separated. The water phase was washed twice with ethyl acetate, acidified with hydrochloric acid (2 M; 3.2 ml) and extracted with ethyl acetate (30 ml). The organic phase was washed twice with water, dried (magnesium sulfate), filtered and the solvent was evaporated in vacuo to give 1.9 g (yield 72% in 2 steps) of (S)-2-ethoxy-3-[4-(2-{4-methanesulfonyloxyphenyl}-ethoxy)phenyl]propanoic acid.
[0153] [0153] 1 H-NMR (600 MHz; DMSO-d 6 ): δ 1.02 (t, 3H, J=7.0 Hz), 2.78 (dd, 1H, J=13.9 and 8.0 Hz), 2.86 (dd, 1H, J=13.9 and 5.2 Hz), 3.04 (t, 2H, J=6.8 Hz), 3.28 (dq, 1H, J=9.1 and 7.0 Hz), 3.35 (s, 3H), 3.49 (dq, 1H, J=9.1 and 7.0 Hz), 3.92 (dd, 1H, J=5.2 and 7.7 Hz), 4.15 (t, 2H, J=6.8 Hz), 6.82 (d, 2H, J=8.7 Hz), 7.11 (d, 2H, J=8.7 Hz), 7.27 (d, 2H, J=8.5 Hz), 7.42 (d, 2H, J=8.5 Hz), 12.59 (s, br, 1 OH).
[0154] [0154] 13 C-NMR (150 MHz; DMSO-d 6 ): δ 15.2, 34.4, 37.5, 37.7, 65.0, 67.9, 79.4, 114.2, 122.2, 129.6, 130.4, 130.7, 138.0, 147.8, 157.1, 173.4.
[0155] Biological Activity
[0156] The biological activity of the compound of the invention was tested in obese diabetic mice of the Ume{dot over (a)} ob/ob strain. Groups of mice received the test compound by gavage once daily for 7 days. On the last day of the experiment the animals were anesthetized 2 h after dose in a non-fed state and blood was collected from an incised artery. Plasma was analyzed for concentration of glucose, insulin and triglycerides. A group of untreated obese diabetic mice of the same age served as control. The weight of the mice was measured before and after the experiment and the obtained weight gain was compared to the weight gain of the control animals. The individual values for glucose, insulin and triglyceride levels of the mice from the test group were expressed as the percent rage of the corresponding values from the control group.
[0157] The desired “therapeutic effect” was calculated as the average percent reduction of the three variables glucose, insulin and triglycerides below the levels in the control animals. The therapeutic effect of the tested compounds according to the invention was compared to the same effect in the prior art compound troglitazone, administrered by gavage in the oral dose of 100 μmol/kg for 7 days.
[0158] The superior effects of the tested compound according to the invention compared to that of troglitazone when given in the same oral dose demonstrate the increased potency and efficiacy of the claimed compound.
Abbreviations NIDDM non insulin dependent diabetes mellitus VLDL very low density lipoproteins HDL high density lipoproteins IRS insulin resistance syndrom PPAR peroxisome proliferator activated receptor DEAD diethyl azodicarboxylate ADDP azodicarbonyl dipiperidine EDC 1-(3-dimethylaminopropyl)-3-ethylcarbodiimide EDCxHCl 1-(3-dimethylaminopropyl)-3-ethylcarbodiimide hydro- chloride DCC dicyclohexylcarbodiimide HBTU O-benzotriazol-1-yl-N,N,N',N'-tetramethyluronium hexa- fluorophosphate TBTU O-benzotriazol-1-yl-N,N,N',N'-tetramethyluronium tetra- fluoroborate PyBop benzotriazole-1-yl-oxy-tris-pyrolidino-phosphonium hexa- fluorophosphate DMP dimethylformamide DMAP 4-dimethylaminopyridine TEA triethylamine DiPEA diisopropylethylamine BINAP 2,2'-bis(diphenylphosphino)-1,1'-binaphtyl COD cyclooctadiene LDA lithium diisopropylamide LHMDS lithium hexamethyldisilylamine TLC thin layer chromatography THF tetrahydrofuran Pd/C palladium on charcoal HOBt x H2O 1-hydroxybenzotriazole-hydrate m multiplet t triplet s singlet d doublet q quartet qvint quintet br broad dm multiplet of doublet rac racemate | A novel 3-aryl-2-hydroxypropionic acid derivative, a process and intermediate for its manufacture, pharmaceutical preparations containing it and the use of the compound in clinical conditions associated with insulin resistance. | 2 |
CROSS REFERENCE TO RELATED APPLICATIONS
This invention is related to the invention described in the provisional application Ser. No. 60/407,414 filed on Aug. 28, 2002 entitled, MINI-VALVE HEART VALVE REPLACEMENT, and claims priority therefrom.
BACKGROUND OF THE INVENTION
Blood vessel valves include flexible tissue leaflets that passively alternate between open and closed positions as the forces of a blood stream act upon them. As blood flows in a first direction, the leaflets are urged apart from each other, and allow the blood to pass. Between pulses, as the blood attempts to flow in a reverse direction, the blood acts upon upstream surfaces of the individual leaflets, causing the leaflets to move inwardly. As the leaflets move inwardly, the edges of the individual leaflets (two, in the case of bicuspid valves, and three in the case of tricuspid valves) abut against each other, effectively blocking the blood flow in the reverse direction.
Valves are also present within the heart. The heart contains four one-way valves that direct blood flow through the heart and into the arteries. Three of these valves, the aortic valve, the tricuspid valve, and the pulmonary valve, each have three leaflets. The fourth valve, the mitral valve, has two leaflets. By defining a direction in which blood can flow, these valves are responsible for the resulting pump effect a heart has on blood when the heart beats.
A number of diseases result in a thickening, and subsequent immobility or reduced mobility, of valve leaflets. Valve immobility leads to a narrowing, or stenosis, of the passageway through the valve. The increased resistance to blood flow that a stenosed valve presents eventually leads to heart failure and death.
Treating severe valve stenosis or regurgitation has heretofore involved complete removal of the existing native valve followed by the implantation of a prosthetic valve. Naturally, this is a heavily invasive procedure and inflicts great trauma on the body leading usually to great discomfort and considerable recovery time. It is also a sophisticated procedure that requires great expertise and talent to perform.
Historically, such valve replacement surgery has been performed using traditional open-heart surgery where the chest is opened, the heart stopped, the patient placed on cardiopulmonary bypass, the native valve excised and the replacement valve attached. More recently, it has been proposed to perform valve replacement surgery percutaneously, that is, through a catheter, so as to avoid opening the chest.
One such percutaneous valve replacement method is disclosed in U.S. Pat. No. 6,168,614 (the entire contents of which are hereby incorporated by reference) issued to Andersen et al. In this patent, the prosthetic valve is collapsed to a size that fits within a catheter. The catheter is then inserted into the patient's vasculature and moved so as to position the collapsed valve at the location of the native valve. A deployment mechanism is activated that expands the replacement valve against the walls of the body lumen. The expansion force pushes the leaflets of the existing native valve against the lumen wall thus essentially “excising” the native valve for all intents and purposes. The expanded structure, which includes a scaffold configured to have a valve shape with valve leaflet supports, is then released from the catheter and begins to take on the function of the native valve. As a result, a full valve replacement has been achieved but at a significantly reduced physical impact to the patient.
One particular drawback with the percutaneous approach disclosed in the Andersen '614 Patent is the difficulty in preventing leakage around the perimeter of the new valve after implantation. Since the tissue of the native valve remains within the lumen, there is a strong likelihood that the commissural junctions and fusion points of the valve tissue (as pushed against the lumen wall) will make sealing of the prosthetic valve around the interface between the lumen and the prosthetic valve difficult. Furthermore, in some patients, the deflection of the leaflets against the lumen walls could potentially obstruct the ostial openings of the lumen.
Although both the traditional open heart valve replacement surgery and the newer percutaneous valve replacement surgery replace a native valve in entirely different ways and both have their drawbacks, the paradigm of these two approaches is identical: Render the native valve useless, either through excision (open heart) or immobilization (percutaneous), and then implant a completely new replacement prosthetic valve to take over. In other words, both approaches rely entirely on the premise that the native valve must be entirely replaced (physically or functionally) by an entirely new prosthetic valve.
In contravention of the prior art, the present invention introduces an entirely different paradigm to valve replacement surgery, something neither taught nor contemplated by the open heart approach or the percutaneous approach (e.g., U.S. Pat. No. 6,168,614) and something that largely avoids the drawbacks associated with both. More specifically, the present invention is premised on leaving the native valve in place, not on its excision or immobilization, and then utilizing the native valve as a platform for actually treating the diseased valve. This is a wholly new approach to treating diseased valves.
For example, in one embodiment of the invention, the physician diagnoses that the patient has a stenotic valve and then percutaneously mounts a plurality of small “leaflet valves” or “mini-valves” on one or more of the diseased native valve leaflets. In other words the native valve and its leaflets are used as a planar surface or a type of “bulkhead” on which new mini leaflet valves are mounted. The native valve remains in place but valve disfunction is remedied due to the presence of these new leaflet valves. As a result, the diseased valve is successfully treated without the complication associated with removing the native valve.
This leads to a much simpler and safer approach as compared to the prior art. It avoids the invasive nature of the open heart approach and avoids the sealing and ostial blockage problems of the percutaneous approach.
BRIEF SUMMARY OF THE INVENTION
The present invention relates to the treating of narrowed, stiff or calcified heart valves. The aforementioned problems with present treatment methods are addressed by treating the targeted valve leaflets individually, rather than replacing the entire valve using an open-heart or a percutaneous procedure. That is, in the present method, the rigid heart valve leaflet is treated by introducing small prosthetic valves into the leaflet itself.
The present invention includes a method of treating the individual leaflets of a targeted heart valve that includes installing one or more small, one-way valves into the targeted leaflets. These smaller valves can be placed in the leaflet using catheter systems, obviating the need for opening the heart or great vessels, cardiopulmonary bypass, excision of the diseased valve, and a thoracotomy. Additionally, multiple small valve placements might reduce the long-term risks associated with a complete prosthetic valve, because failure of an individual valve will not necessarily lead to cardiac failure. The remaining small valves and remaining healthy native valves might be sufficient to sustain life.
One aspect of the present invention provides a method of placing small valves through a target valve that involves puncturing the target valve and pushing the miniature valve through the target valve tissue. The valve is then anchored in place using a variety of mechanisms including tabs, riveting of the valve housing, spines, friction placement or the use of a fixation cuff.
Another aspect of the present invention provides a variety of valve implant mechanisms constructed and arranged for placement in a target valve leaflet. The valve implant mechanisms include a valve housing that operably houses a valve mechanism such as a duckbill valve, a tilting check valve, a ball and cage valve, or a hinged leaflet valve or a valve using tissue leaflets. The valve implant may also include an anchoring mechanism such as tabs, spines, threads, shoulders, or a deformable housing.
The present invention also provides a device useable to remove a section of the target valve, without damaging the surrounding valve tissue, and inserting a valve implant into the void left in the target valve. The device is contained within a catheter such that a valve implant insertion procedure can be accomplished percutaneously. Preferably, this delivery system is constructed and arranged to be placed through a 14 French catheter, traverse the aorta, land on a targeted leaflet such as one of the leaflets of the aortic valve, puncture the leaflet at a predetermined spot, cut a hole on the order of 4 mm in diameter, capture and remove any cut tissue, place a radially compressed one-way valve including a Nitonol attachment cuff and a stainless steel sizing ring into the leaflet hole, securely attach the valve assembly to the leaflet, dilate the hole and the valve assembly to a precise final diameter, such as 8 mm, using a balloon, and be retracted leaving the valve assembly in place in the leaflet.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of three valve implants of the present invention installed in the leaflets of a tricuspid valve;
FIG. 2 is a side elevation of two valve implants of the present invention installed in a stenotic leaflet;
FIGS. 3 a–f are side elevations of various embodiments of the valve implant of the present invention;
FIG. 4 a is a detailed sectional view of a preferred embodiment of the valve implant of the present invention in a compressed or folded state;
FIG. 4 b is a detailed sectional view of the valve implant of FIG. 4 a in an expanded state;
FIGS. 4 c–f are sectional views of alternative configurations of the preferred valve implant of the present invention;
FIG. 5 a is a sectional view of an embodiment of the delivery system of the present invention;
FIG. 5 b is a detailed sectional view of the distal end of the delivery system of FIG. 5 a;
FIG. 6 is a sectional view of the leaflet capture catheter of the present invention;
FIG. 7 a is a sectional view of the delivery catheter of the present invention;
FIG. 7 b is a perspective view of an alternative cutter of the present invention;
FIG. 8 is a sectional view of the sheath catheter of the present invention;
FIG. 9 a is a detailed sectional view of the handle of the delivery system of the present invention;
FIG. 9 b is a side elevation of the handle of FIG. 9 a;
FIG. 10 a is a side elevation of the handle of the present invention in a “Deliver” position;
FIG. 10 b is a sectional view of the distal end of the delivery system of the present invention when the handle is in the “Deliver” position of FIG. 10 a;
FIG. 11 a is a side elevation of the handle of the present invention in an “Insert” position;
FIG. 11 b is a sectional view of the distal end of the delivery system of the present invention when the handle is in the “Insert” position of FIG. 11 a;
FIG. 12 a is a side elevation of the handle of the present invention in a “Cut” position;
FIG. 12 b is a sectional view of the distal end of the delivery system of the present invention when the handle is in the “Cut” position of FIG. 12 a;
FIGS. 13 a–e are an operational sequence of the capture device of FIG. 6 interacting with the cutting drum of FIG. 7 a to remove and capture a section of tissue from a target valve leaflet;
FIG. 14 a is a side elevation of the handle of the present invention in a “Distal” position;
FIG. 14 b is a sectional view of the distal end of the delivery system of the present invention when the handle is in the “Distal” position of FIG. 14 a;
FIG. 15 a is a side elevation of the handle of the present invention in a “Proximal” position;
FIG. 15 b is a sectional view of the distal end of the delivery system of the present invention when the handle is in the “Proximal” position of FIG. 15 a;
FIG. 16 a is a side elevation of the handle of the present invention in an “Inflate” position;
FIG. 16 b is a sectional view of the distal end of the delivery system of the present invention when the handle is in the “Inflate” position of FIG. 16 a and a balloon of the delivery system is inflated;
FIG. 17 a is a side elevation of the handle of the present invention in an “Inflate” position during a deflating procedure;
FIG. 17 b is a sectional view of the distal end of the delivery system of the present invention when the handle is in the “Inflate” position of FIG. 17 a and the balloon of the delivery system has been deflated;
FIG. 18 is a sectional view of a valve implant of the present invention in a deployed configuration;
FIGS. 19A and 19B are cross-sectional views of a valve implant of the present invention in a deployed configuration;
FIG. 20 is a cross-sectional view of a portion of a catheter delivery system in accordance with a preferred embodiment of the present invention;
FIG. 21 is a flow chart figure showing a tether retraction system for use in a catheter delivery system in accordance with the present invention;
FIGS. 22A and 22B are top views of a hinged valve in accordance with another preferred embodiment of the present invention;
FIGS. 23A , 23 B and 23 C are cross-sectional views of a hinged valve in accordance with the present invention; and,
FIGS. 24A and 24B are cross-sectional views of a hinged valve in accordance with the present invention.
DETAILED DESCRIPTION OF THE INVENTION
Referring now to the FIGS., and first to FIG. 1 , there is shown a native tricuspid valve 5 with a valve implant 10 of the present invention installed in each of the three leaflets 7 of the tricuspid valve 5 . The valve implants 10 are shown in an open position to demonstrate that blood is allowed to flow through the valve implants 10 , in one direction, even though the native tricuspid valve 5 remains closed. These valve implants 10 would similarly work with a native bicuspid valve, unicuspid valve or quadracuspid valve. Notably, each of the three leaflets shown in the tricusoid valve of FIG. 1 has a free edge that is coapting with the free edges of the other two leaflets. The valve implants 10 are implanted within the confines of each leaflet 7 , spaced apart from the free edge, such that the free edge of each leaflet remains undisturbed in that the degree to which the free edge is continual with the free edges of the other leaflets remains essentially unchanged.
FIG. 2 demonstrates the positioning of a valve implant 10 in a native leaflet 7 . The leaflet 7 is shown as having calcified tissue 9 , characteristic of a stenosed valve. Notably, the valve implants 10 have been inserted through the calcified tissue 7 . Also notable is that there may be more than one valve implant 10 inserted into a single leaflet 7 if additional flow capacity is desired. Alternatively, though not shown, the valve implant 10 may be installed between the leaflets 7 . This configuration is especially feasible in heavily stenosed valves that have relatively immovable leaflets. Such leaflets may be fully or partially fused together. The valve implants generally comprise an anchoring mechanism 12 and a valve mechanism 14 .
FIGS. 3–5 illustrate several embodiments of the valve implants 10 of the present invention. In FIGS. 3 a–f , a family of valve implants 10 is provided that are characterized by a rigid housing 16 with a self-tapping tip 18 . The valve implants 10 of FIGS. 3 a–f include a variety of valve mechanisms 14 and anchoring mechanisms 12 .
The valve implant 10 of FIG. 3 a , as well as those of FIGS. 3 c and 3 d , has a valve mechanism 14 that comprises a single flap 20 , hinged on one side, that acts against the rigid housing 16 to prevent flow in a reverse direction. A benefit of this valve design is ease of construction. The valve implant 10 of FIG. 3 a also uses the friction between the rigid housing 16 and the native heart leaflet 7 ( FIG. 2 ) as an anchoring mechanism to hold the valve implant 10 in place. The pointed tip 18 allows the valve implant 10 to be urged through, or twisted through, the native heart leaflet without the need for cutting a hole in the leaflet prior to installing the valve implant 10 . Thus, in certain cases, there is sufficient gripping power between the housing 16 and the leaflet 7 to hold the housing 16 in place. This holding power may be increased by providing a textured surface (not shown) on the housing 16 , or selecting a housing material, such as a mesh or stiff fabric, that allows a controlled amount of ingrowth, sufficient to secure the valve implant 10 , but not so much as to cause a flow hindrance within the valve implant 10 .
The valve implant 10 of FIG. 3 b has a valve mechanism 14 that comprises a pair of members constructed and arranged to form a duckbill valve 22 . The duckbill valve 22 operates in a similar way to a tricuspid or bicuspid valve. When fluid flows through the valve in a desired direction, each of the members of the duckbill valve 22 move apart from each other. When the flow reverses, such as during diastole, the fluid forces the members of the duckbill valve 22 together, closing the valve 10 .
Also included in the valve implant 10 of FIG. 3 b is an anchoring mechanism 12 . The anchoring mechanism 12 generally comprises a plurality of radially extending posts 24 . These posts 24 act against an upstream side 26 ( FIG. 2 ) of the leaflet 7 , thereby counteracting systolic pressure from the blood stream.
The valve implant 10 of FIG. 3 c includes a single flap 20 valve mechanism 14 and an anchoring mechanism 12 that includes a plurality of angled barbs 28 . The barbs 28 are located near the upstream side of the valve implant 10 and are angled back toward the downstream side. The angled barbs 28 may provide increased gripping power, especially if more than one row, such as shown in FIG. 3 c , are provided. Because one or more of the rows of barbs 28 will be located within the leaflet 7 when the valve implant is in place, the barbs 28 provide resistance to movement in both directions, and may stimulate ingrowth.
The valve implant 10 of FIG. 3 d provides a combination of many of the features already discussed. The valve 10 has an anchoring mechanism 12 that includes both posts 24 , on the downstream side to prevent valve movement in the upstream direction, and angled barbs 28 on the upstream side of the valve 10 . The valve mechanism 14 demonstrates another valve design. The valve mechanism is an outside-hinged dual flap valve 30 . The individual flap members rotate about their outer edges when influenced by fluid flow.
FIG. 3 e shows a valve implant 10 with a valve mechanism 14 that uses an inside-hinged dual flap valve 32 , with individual flap members when influenced by fluid flow. The valve implant 10 combines upstream posts 24 with upstream-angled barbs 28 on the downstream side of the valve implant 10 .
The valve implant 10 shown in FIG. 3 f combines a single flap 20 , as a valve mechanism 14 , with an anchoring mechanism 12 that uses an external helical thread 34 to anchor the valve implant 10 to a valve leaflet 7 . The helical thread 34 provides resistance to movement in both the upstream and downstream directions. The helical thread 34 also provides a self-tapping action when the valve implant 10 is being screwed into place in a leaflet 7 .
One skilled in the art will realize that any of the aforementioned anchoring mechanisms 12 and valve mechanisms 14 may be combined in a single valve implant 10 . For example, the valve implants 10 shown in FIG. 2 include upstream and downstream posts 24 as well as upstream and downstream angled barbs 28 .
A preferred embodiment of the valve implant 10 of the present invention is shown in FIGS. 4 a and 4 b . The valve implant 10 is expandable from the compressed configuration shown in FIG. 4 a , to the expanded configuration shown in FIG. 4 b . The valve implant 10 is constructed and arranged to fit within a catheter when in the compressed configuration. Compression may be accomplished radially, helically, longitudinally, or a combination thereof. Preferably, the compression of the valve implant 10 is radial.
Like the aforementioned embodiments of the valve implants 10 , the valve implant 10 of FIG. 4 generally includes an anchoring mechanism 12 and a valve mechanism 14 . The anchoring mechanism 12 generally comprises a cuff 36 and a sizing ring 38 . The cuff 36 is preferably constructed of Nitonol and has a middle portion 40 a set of radially expanding distal legs 42 and a set of radially expanding proximal legs 44 .
In the compressed state, the legs 42 and 44 are somewhat aligned with the middle portion 40 to allow the cuff 36 to be compressed into a catheter, preferably a 14 French catheter. The cuff 36 is either expandable or self-expanding. Upon release from the catheter, the legs 42 and 44 fold outwardly until they radiate from the middle portion 40 at approximately right angles to the longitudinal axis of the cuff 36 . The legs 42 and 44 are designed to act against the upstream and downstream sides, respectively, of a valve leaflet, sandwiching the leaflet therebetween and anchoring the cuff 36 to the leaflet.
The anchoring mechanism 12 of the valve implant 10 shown in FIGS. 4 a and 4 b also includes a sizing ring 38 . The sizing ring 38 is preferably a stainless steel stent that circumjacently surrounds the middle portion 40 of the cuff 36 . The sizing ring 38 is constructed and arranged to expand with the cuff 36 until a predetermined size is reached. Once the predetermined size is reached, the sizing ring 38 prevents further expansion by the cuff 36 . Over expansion of the cuff 36 could render the valve mechanism 14 inoperable, cause calcified tissue to break away from the stenosed valve and become released into the blood stream, tear the leaflet tissue, or weaken the cuff 36 .
The valve mechanism 14 includes a sleeve 46 and one or more valve members 48 . The sleeve 46 may be rigid or flexible, but it is preferably flexible. More preferably, the sleeve 46 is constructed of any sufficiently flexible material capable of withstanding the environment to which it will be subjected, including but not limited to, any mammalian tissue, including human or pig tissue, vertebrate tissue, or a polymer or other synthetic material. The valve members 48 are shown as being duckbill valves but may be any of the aforementioned discussed valve designs.
Most preferably, the valve mechanism 14 comprises an intact harvested valve from an animal, such as pig, and is taken from an appropriate location such that the expanded, original size is suitable for use in the leaflets of the stenotic valve being treated. The harvested valve is sutured or otherwise attached to the inside surface of the cuff 36 . In operation, the valve implant 10 is compressed such that it can be placed in a small catheter for percutaneous delivery. At the time of delivery, the valve implant 10 is attached to a stenotic leaflet and radially expanded to its functional diameter. Prior to, or during expansion, the distal and proximal legs 42 and 44 expand radially, allowing the cuff 36 to create a strong bulkhead-like fitting on both sides of the leaflet. After attachment is made to the leaflet, the cuff 36 , sizing ring 38 , and the valve mechanism 14 are radially expanded to the functional diameter of the valve implant 10 . During this expansion, the sizing ring 38 exhibits plastic deformation until it achieves the maximum diameter, at which point the sizing ring 38 resists further expansion.
FIGS. 4 c–f depict alternative configurations for the preferred valve implant 10 . The valve implant 10 in FIG. 4 c has a sleeve 46 attached to the anchoring mechanism 12 with two rows of sutures 166 and is configured so an upstream edge 168 of the sleeve 46 is roughly aligned with the distal legs 42 of the anchoring mechanism 12 . The valve implant 10 in FIG. 4 d has a sleeve 46 attached to the anchoring mechanism 12 with one row of sutures 166 and is configured so the upstream edge 168 of the sleeve 46 is roughly aligned with the proximal legs 44 of the anchoring mechanism 12 . The valve implant 10 in FIG. 4 e has a sleeve 46 attached to the anchoring mechanism 12 with two rows of sutures 166 and is configured so the downstream edge 170 of the sleeve 46 is roughly aligned with the proximal legs 44 of the anchoring mechanism 12 . The valve implant 10 in FIG. 4 f has a sleeve 46 attached to the anchoring mechanism 12 with one row of sutures 166 and is configured so the downstream edge 170 of the sleeve 46 is roughly aligned with the distal legs 42 of the anchoring mechanism 12 . The sleeve 46 may comprise a scaffold to which valve members 48 are attached, or the entire valve mechanism 14 may be a harvested tissue valve such as an aortic valve.
In one preferred embodiment, the valve implant 10 can be configured to include commissural support structure like a wireform stent as sometimes found in known standard sized prosthetic tissue valves. In such a configuration, the valve material will comprise a biologic tissue such as human pericardium or equine pericardium or small intestine submucousal tissue. In the present invention, the material must be thin enough to be compressed and perhaps folded so as to fit the valve implant 10 within the delivery system (described below). In a preferred embodiment, such tissue has a thickness of around 180 microns or less.
In another alternative embodiment, the cuff mechanism could be a torroidal shaped sack (not shown), similar in shape to a deflated inner tube, attached to the exterior surface of the base of the valve implant 10 and connected to a UV curable liquid polymer reservoir contained within the delivery catheter. The sack material is composed of an elastic material that can be radially expanded by a balloon angioplasty catheter or by the injection of the liquid polymer. The liquid adhesive contained within the sack can be transformed to a solid polymer through UV light activated cross-linking
This sack, essentially empty, can be manipulated by the delivery catheter to straddle both sides or surfaces around the hole cut in the leaflet for receiving the valve implant 10 . Once located, the sack can be enlarged by an underlying balloon catheter. Then, UV curable liquid polymer can be injected into the sack through the delivery catheter. Once filled with an adequate amount of a polymer and adjusted distally/proximally to form sufficient bulges on both sides of the valve leaflet, a UV light emission source, located within the delivery catheter near the bag is activated to wash the adhesive filled bag with UV curing light. Once hardened by the UV effect, the cuff maintains its enlarged size without balloon support.
Referring to FIGS. 22A–24B , yet another embodiment of a valve implant 10 of the present invention is shown, this embodiment being a hinged valve. In this embodiment, the valve implant 10 comprises a valve “poppet” 221 that is connected to a valve leaflet 7 by an attachment mechanism 220 that operates much like a hinge. The valve poppet 221 pivots between a sealed and an unsealed condition around the pivot point of the attachment mechanism 220 according to the flow of blood ( FIGS. 24A and 24B ).
The poppet 221 or “mini-leaflet” can be comprised of any material sufficiently flexible to allow for the described movement yet sufficiently durable to withstand the environment. For example, the poppet 221 may made from materials such as biologic tissue, a polymer or a carbon based material. Moreover, the poppet 221 could be coated with tissue prom the patient, e.g., tissue from a patient's vein wall. The poppet material may include supporting internal structure and/or an outer ring to ensure the structural integrity of the poppet 221 during operation. The poppet can have a curved in order to better conform the poppet 221 to the contour of the native leaflet 7 .
In this regard, after a hole is created in the leaflet 7 (discussed below), the poppet 221 is pushed or screwed into the leaflet. It may be retained there by barbs or screw threads or by hooks or other types of retaining mechanisms.
The attachment mechanism 220 ( FIGS. 22A–22B and 24 A– 24 B), in a preferred embodiment, is a hinge. The hinge may fabricated from such materials as a polymer strip, a biologic tissue strip, a metal (e.g., stainless steel) strip or a pryolytic carbon material. Referring to FIGS. 24A and 24B , the hinged mechanism may be attached to the leaflet 7 tissue using a barbed spike 240 .
In an optional embodiment of the invention shown in FIGS. 22A–24B , the valve implant 10 may also include a support ring 222 that is disposed around the inside perimeter of the hole that is cut in the leaflet 7 to receive the valve implant 10 . The support ring 222 may serve to limit embolization and to enhance leaflet integrity (thereby avoiding prolapse). The support ring 222 could be deployed into the hole either with an expanding balloon or it could be mechanically deployed using a mechanical spreader.
Referring to FIGS. 23A–24B , the optional support ring 222 may include struts 224 , 225 that serve to capture the edges of the leaflet 7 in the hole so as to support and retain the support ring 220 at the site.
Catheter Delivery System
Referring now to FIGS. 5 a and 5 b , there is shown a preferred embodiment of a catheter delivery system 50 of the present invention. The catheter delivery system 50 generally comprises a leaflet capture catheter 52 , a delivery catheter 54 , a catheter sheath 56 , and a handle 58 . The catheter delivery system 50 is preferably constructed and arranged for use with a guidewire 60 .
As best seen in FIG. 6 , the leaflet capture catheter 52 includes a cutter die 62 connected to a hemostatic hub 64 with a cannula 66 . The cutter die 62 may be of unitary construction and includes a conical distal end 68 that increases in radius proximally until a flat 70 is reached. Proceeding proximally, the flat 70 ends abruptly to form a capture groove 72 . At the proximal end of the capture groove 72 , the cutter die 62 returns to approximately the same diameter as the flat 70 . The purpose of the cutter die 62 is to “grab” tissue that resiliently “pops” into the capture groove 72 . Once in the capture groove 72 , the tissue is held in place as a cutter 90 (explained below) cuts through the tissue.
One skilled in the art will realize that alternatives could be used instead of a cutter die 62 . For example, the cutter die 62 could be replaced with a balloon, constructed and arranged to be inflated on the upstream side of the leaflet 7 (or both sides of the leaflet to capture the tissue) and sized to fit within the cutter 90 . A second balloon could also be arranged to be inflated on the downstream side of the leaflet, such that the leaflet is captured between the two balloons. The balloon concept, though arguably more complicated and expensive, may prove useful in situations where a cut needs to be made in tissue that has lost the resiliency needed to “pop” into the capture groove 72 of the cutter die 62 . Other devices, such as barbs and clamps, are also envisioned to act in this manner.
The cannula 66 connects with the cutter die 62 and the hemostatic hub 64 . At the distal end of the cannula 66 is a needle tip 74 . The needle tip 74 is angled to form a sharp point usable to puncture tissue. The cannula 66 includes a lumen 76 extending the length thereof. This lumen 76 is used to accommodate a guidewire 60 ( FIG. 5 ).
The hemostatic hub 64 allows the leaflet capture catheter 52 to be removably attached to the handle 58 . The hemostatic hub 64 includes a body 78 , a threaded knob 80 , and an elastomeric seal 82 . The body 78 defines an interior cavity 84 that is shaped to receive and hold a cannula hub 86 that is attached to a proximal end of the cannula 66 . The interior cavity 84 is also shaped to receive the elastomeric seal 82 , which is compressed between the threaded knob 80 and the body 78 . The interior cavity 84 is partially internally threaded to receive the external threads of the threaded knob 80 . The threaded knob 80 defines a guidewire port 88 that aligns with the interior cavity 84 and the lumen 76 of the cannula 66 so that a continuous port is available for the guidewire 60 to extend the length of the leaflet capture catheter 52 . When a guidewire 60 is inserted through the guidewire port 88 , the threaded knob 80 and the elastomeric seal 82 act together as a hemostatic valve. When the threaded knob 80 is rotated to compress the elastomeric seal 82 , the elastomeric seal 82 swells inwardly, until it forms a blood-tight seal around the guidewire 60 . The cannula 66 and the hub 64 are constructed and arranged to carry the tensile force generated during a hole cutting procedure, discussed in detail below.
The leaflet capture catheter 52 is slidingly and coaxially contained within the delivery catheter 54 . The delivery catheter 54 is best shown in FIG. 7 a , and includes a cutter 90 , a balloon catheter 92 , and a delivery catheter hub 94 . The cutter 90 is constructed and arranged to act with the cutter die 62 ( FIG. 6 ) to cut tissue. The cutter 90 includes a cutter drum 96 that is a sharpened cylindrical blade having a cutting tip 98 . The cutter tip 98 , as shown in FIG. 7 a , lies in a plane that is substantially perpendicular to a longitudinal axis of the delivery catheter. However, an alternative embodiment of the cutter drum 96 , shown in FIG. 7 b , may provide increased cutting power. The cutter drum 96 in FIG. 7 b has a curved, non-planar cutting tip 98 . Preferably, the cutter drum 96 is sized to cut a hole having a diameter of approximately 4 mm through a leaflet. The cutter drum 96 has a cutter bulkhead 100 at its proximal end that is attached to the balloon catheter 92 with an adhesive 102 . Other suitable attachment means for attaching the cutter drum 96 to the balloon catheter 92 include threads, welds, unitary construction and the like. To cut tissue, the cutter die 62 is pulled within the cutter drum 90 . Thus, the balloon catheter 92 , and the adhesive 102 fixing the bulkhead 100 to the balloon catheter 92 , must be able to carry the compressive force that results from opposing the equal and opposite tensile force applied to the leaflet capture catheter 52 .
The balloon catheter 92 generally includes an inner tube 104 extending distally and proximally from within an outer tube 106 . A balloon 108 is connected at a distal end to the outside of the inner tube 104 and at a proximal end to the outside of the outer tube 106 . The outside diameter of the inner tube 104 is smaller than the inside diameter of the outer tube 106 , such that a fluid passageway is formed therebetween for inflation of the balloon 108 . A flexible valve stop 110 is attached to the outer tube 106 just proximal of the proximal end of the balloon 108 . The valve stop 110 has a flexible sleeve 112 that extends distally over the proximal end of the balloon 108 . The function of the valve stop 110 is to prevent proximal movement of the valve implant 10 during delivery. The valve implant 10 , as will be seen below, will be placed over the balloon 108 , distal of the valve stop 110 . The flexible sleeve 112 allows the balloon to inflate while maintaining a desired positioning of the valve implant 10 . The inner tube 104 has an inner diameter large enough to accommodate the cannula 66 of the leaflet capture catheter 52 . A proximal end of the balloon catheter 92 is attached to the catheter hub 94 .
The catheter hub 94 includes a catheter hub body 114 that defines an inner cavity 116 and a balloon inflation port 118 . The proximal end of the inner cavity 116 has internal threads to receive an externally threaded knob 120 . An elastomeric seal 122 resides between the threaded knob 120 and the catheter hub body 114 . The threaded knob 120 defines a capture catheter port 124 that aligns with the interior cavity 116 of the body 114 and the interior of the balloon catheter 92 so that the leaflet capture catheter 52 may pass therethrough.
The balloon catheter 92 is attached to the catheter hub 94 in such a manner that fluid introduced into the balloon inflation port 118 will flow between the outer tube 106 and the inner tube 104 to inflate the balloon 108 . The outer tube 106 is attached at its proximal end to the distal end of the interior cavity 116 of the catheter hub body 114 . Preferably, an adhesive 126 is used to connect the outer tube 106 to the interior cavity 116 of the catheter hub body 114 at a position distal of the balloon inflation port 118 . The inner tube 104 extends proximally from the proximal end of the outer tube 108 . The proximal end of the inner tube 104 is also attached to the interior cavity 116 of the catheter hub body 114 . However, this connection is made at a position proximal of the balloon inflation port 118 , preferably with an adhesive 128 . Thus, fluid entering the balloon inflation port 118 is blocked from flowing in a proximal direction by the proximal adhesive 128 . It is also blocked from traveling in a distal direction on the outside of outer tube 106 by the distal adhesive 126 . Instead, the fluid is forced to flow between the inner tube 104 and the outer tube 106 in a distal direction toward the interior of the balloon 108 .
The leaflet capture catheter 52 and the delivery catheter 54 are slideably contained within the sheath catheter 56 . Referring now to FIG. 8 , it can be seen that the sheath catheter 56 includes a large diameter sheath 130 attached to a distal end of sheath tubing 132 , which is attached at a proximal end to a sheath hub 134 . The sheath hub 134 secures the sheath catheter 56 to the handle 58 . The sheath hub 134 includes a tab 154 , the function of which will be explained below. The sheath 130 , sheath tubing 132 , and the sheath hub 134 , all define a delivery catheter port 136 that extends throughout the length of the sheath catheter 56 . The large diameter sheath 130 , is preferably a 14 French catheter, and sized to accommodate the cutter drum 96 .
Referring now to FIGS. 9A and 9B , there is shown a preferred embodiment of the handle 58 of the present invention. The handle 58 includes a handle body 138 that defines at a bottom portion a figure grip 140 . An actuator 142 is pivotally attached to the handle body 138 with a pivot pin 164 . At the top of the actuator 142 , is a leaflet capture catheter bracket 144 . The leaflet capture catheter bracket 144 is constructed and arranged to hold the leaflet capture hemostatic hub 64 . At a top portion of the body 138 there is defined a slotted chamber 146 . The slotted chamber 146 is constructed and arranged to hold the delivery catheter hub 94 as well as the sheath hub 134 . The slotted chamber 146 includes external threads 148 around which the sheath retraction nut 150 rides. At the top of the slotted chamber 146 there is defined a slot 152 through which the balloon inflation port 118 of the delivery catheter hub 94 and a tab 154 of the sheath hub 134 extend. Below the slotted chamber 146 , a sheath retraction indicator 156 extends distally from the handle body 138 . Preferably, the handle 58 includes a safety button 158 that prevents a physician from unintentionally depressing the actuator 142 .
The handle 58 is thus constructed and arranged to slide the leaflet capture catheter 52 in a proximal direction relative to the sheath catheter 56 and the delivery catheter 54 when the actuator 142 is squeezed toward the finger grip 140 , thereby pulling the hemostatic hub 64 in a proximal direction. The handle 58 is also constructed and arranged to slide the sheath catheter 56 proximally over the leaflet capture catheter 52 and the delivery catheter 54 when the sheath retraction nut 150 is rotated proximally. The operation of the handle 58 and the rest of the delivery system 50 are explained in more detail below.
Referring to FIGS. 19A , 19 B and 20 , in one embodiment of the present invention, the catheter delivery system 50 includes a tether 190 looped around the proximal legs 44 of the valve implant 10 . The tether extends from the proximal legs 44 all the way through the catheter until both ends of the tether 190 are joined at a connector 192 that resides outside the catheter delivery system 50 near the handle. The tether 190 allows the user to retract the valve implant 10 from the valve placement site after it has been deployed from the catheter if it is determined that the deployment was improper or in the event a complication arises with after deployment.
For example, if after deployment, it is determined that placement of the valve implant 10 is incorrect, the physician can pull on the tether and retract the valve implant 10 as shown in FIG. 19B . If, on the other hand, it is determined that placement of the valve implant 10 has been successful, then the physician simply cuts the tether and pulls the free end out of from the proximal legs 44 and out of the delivery device as shown in FIG. 19A .
Operation
Referring now to FIGS. 10–19 , the operation of the present invention is explained. Each of the following figures will include two drawings, a drawing that shows the position of the handle 58 , and a drawing of the corresponding catheter configuration.
Referring now to FIG. 10 , the first step a physician takes in using the delivery device 50 to place a valve implant 10 in a leaflet of a native valve is to use a guidewire 60 to locate the site of the native valve. The guidewire 60 is thus threaded through the necessary blood vessels to the site of the native valve. For example, if it were desired to place the valve implant 10 in, or between, the leaflets of the aortic valve, the guidewire 60 would be placed percutaneously in the femoral artery, or other suitable arterial access, advanced up the aorta, around the arch, and placed above the target leaflet of the aortic valve. Once the guidewire 60 is in place, the catheter delivery system 50 is advanced along the guidewire 60 .
In FIG. 10 a , it can be seen that the target leaflet 7 has been located with the guidewire 60 and the catheter delivery system 50 has been advanced along the guidewire 60 the target leaflet 7 . Positioning the catheter delivery system 50 on the target leaflet 7 may be aided using imaging methods such as fluoroscopy and/or ultrasound. FIG. 10 a shows that when this step is performed, the sheath retraction nut 150 is in the “Deliver” position as shown on the sheath retraction indicator 156 . In the “Deliver” position, the sheath 130 covers the capture groove 72 of the cutter die 62 . The cutter 90 remains retracted proximal of the capture groove 72 . Also, the conical distal end 68 of the cutter die 62 extends from the distal end of the sheath 130 .
In this regard, it is helpful to note that the target leaflet may actually include two leaflets if the leaflets are calcified together. For example, with reference to FIG. 1 , if two leaflets have become calcified together along their edges or lines of coaptation, the present invention contemplates cutting a hole in a manner that traverses the leaflet edges and thereafter inserting a valve (as explained below) across both leaflet edges.
Once satisfied that the target site has been reached with the catheter delivery system 50 , the next step is to traverse the tissue of the target valve leaflet 7 . However, before the cutter die 62 is advanced through the leaflet tissue 7 , the sheath catheter 56 must be retracted until the “Insert/Cut” position has been achieved. This is accomplished by rotating the threaded sheath retraction nut 150 until the nut 150 is aligned with the “Insert/Cut” marking on the sheath retraction indicator 156 . Rotating the sheath retraction nut 150 causes the nut 150 to act against the tab 154 of the sheath hub 134 .
Referring now to FIGS. 11 a and 11 b , it can been seen that the target valve leaflet 7 has been punctured by either the guidewire 60 , in the event that a sufficiently sharp guidewire is being used, or more preferably, the needle tip 74 of the leaflet capture catheter 52 . When the needle tip 74 of the leaflet capture catheter 52 is used to puncture the leaflet, the guidewire 60 is first retracted so that it does not extend through the needle tip 74 .
In one embodiment, the needle may be configured to have a hollow sharp shaft followed by a conical shank (not shown). This will allow the needle to create an initial penetration of the tissue followed by a more traditional puncturing action from the conical shank A needle configured in this manner will also assist in positioning the delivery device over each leaflet.
The cutter die 62 is advanced through the leaflet 7 until the leaflet 7 snaps into the capture groove 72 . The conical distal end 68 , as it is being advanced through the leaflet 7 , will provide an increasing resistance that is tactily perceptible to the physician. Once the leaflet 7 encounters the flat portion 70 , the physician will detect a decreased resistance and can expect a snap when the resilient tissue snaps into the capture groove 72 . The guidewire 60 is then re-advanced into the ventricle (assuming the aortic valve is the target valve).
In this regard, it is notable that in one embodiment of the invention, the guidewire could be fabricated to include a transducer at its distal end (not shown). The guidewire could then be used to measure ventricular pressure (e.g., left ventricular pressure when treating the aortic valve) and thus provide the physician greater ability to monitor the patient during the procedure.
Once the physician is convinced that the leaflet 7 has entered the capture groove 72 , the cutting step may commence. Referring now to FIGS. 12 a and 12 b , the cutting step is demonstrated. Cutting is performed by depressing safety button 158 and squeezing the actuator 142 . After the safety button 158 and the actuator 142 are squeezed, the spring loaded safety button on 158 will travel from a first hole 160 in the actuator 142 to a second hole 162 . When the safety button 158 reaches the second hole 162 , it will snap into the second hole 162 , thereby locking the actuator 142 in place. This ensures that the cutter die is retracted into the cutter 90 , but that excess pressure is not placed on either the cutter die 62 or the cutter 90 . When the actuator 142 is squeezed, cutting is effected because the actuator 142 rotates, relative to the handle body 138 , around the pivot pin 164 . This action causes the leaflet capture catheter bracket 144 to move in a proximal direction thereby pulling the hemostatic hub 64 with it. Pulling the hub 64 causes the cannula 66 and the cutter die 62 attached thereto, to be pulled in a proximal direction relative to the delivery catheter 64 . The cutter die 62 enters the cutter 90 , thereby cutting the tissue. The clearance between the cutter die 62 and the cutter drum 96 is sufficiently minimal to prevent the occurrence of hanging “chads” in the cut. Additionally, the sharpened cutting tip 98 of the cutter 90 may be cut at an angle, or even include a point, such that the entire cut does not have to be initiated around the entire circumference of the cutter drum 96 simultaneously.
A more detailed view of the cutting action of the cutter die 62 and the cutter 90 is shown in FIGS. 13 a – 13 e . In FIG. 13 a , the needle tip 74 of the cannula 66 has just reached the leaflet 7 . The sheath 130 has been retracted to the “Insert/Cut” position as indicated by the exposed capture groove 72 of the cutter die 62 . In FIG. 13 b , the cutter die 62 is being advanced through the target leaflet 7 such that the target leaflet 7 has reached the conical distal end 68 of the cutter die 62 . In FIG. 13 c , the conical distal end 68 and the flat portion 70 of the cutter die 62 have passed completely through the target leaflet 7 , and the target leaflet 7 has snapped into the capture groove 72 . Additionally, the guidewire 60 has been re-advanced through the leaflet capture catheter 52 so that it extends beyond the needle tip 74 . The guidewire 60 will be used to retain the position of the hole cut through the leaflet 7 after the cutter die 62 is retracted. In FIG. 13 d , the physician has begun to cut by squeezing the actuator 142 ( FIG. 12 a ), as evidenced by the advancement of the cutter 90 . The cutting tip 98 of the cutter 90 has been advanced mid-way through the target leaflet 7 . This movement is relative to the position of the cutter die 62 . More accurately, the cutter die 62 is being retracted into the cutter 90 , bringing with it the tissue of the leaflet 7 . The movement of the cutter die 62 is evidenced by arrow 172 .
In FIG. 13 e , the cut is complete as the actuator 142 has been squeezed enough so that the safety button 158 has found the second hole 162 ( FIG. 12 a ), as evidenced by the position of the cutter die 62 . The cutter die 62 is retracted enough such that the capture groove 72 is completely housed within the cutter drum 96 . Notably, the cut tissue of the leaflet 7 remains trapped between the capture groove 72 and the cutter drum 96 . The trapping of this tissue prevents the tissue from traveling downstream through the blood vessel and causing damage.
Referring now to FIGS. 14 a and 14 b , once the hole in the tissue 7 is cut, the step of placing the valve implant 10 begins. First, the entire delivery system 50 is moved distally deeper into the patient such that the distal legs 42 pass through the newly formed hole in the tissue 7 . It is important that at least the distal legs 42 are located on the upstream (ventricle) side of the tissue 7 prior to deploying the valve implant 10 Once the physician is confident that the distal legs 42 extend beyond the valve leaflet tissue 7 , the sheath 130 may be retracted to release the distal legs 42 . This is accomplished by rotating the sheath retraction nut 150 until the sheath retraction nut 150 aligns with the “Distal” marking on the sheath retraction indicator 156 . Doing so causes the sheath retraction nut 150 to act against the tab 154 thereby withdrawing the sheath 130 until just the distal legs 42 are exposed. The distal legs 42 are preloaded such that they spring outwardly, as shown in FIG. 14 b , when uncovered by the catheter sheath 130 . The distal legs 42 are long enough to extend beyond the radius of the sheath 130 , such that they may act against the valve leaflet tissue 7 . Once the sheath retraction nut 150 has been rotated to the “Distal” position on the indicator 156 , the physician may pull the catheter delivery system 50 in a proximal direction until he or she feels the distal legs 42 catch or act against the valve leaflet tissue 7 . Notably, the actuator 142 remains locked in the position it was placed in during the cutting procedure. Leaving the actuator 142 in this position ensures that the valve leaflet tissue trapped between the cutter die 62 and the cutter drum 96 is not released.
The next step is illustrated in FIGS. 15 a and 15 b . The physician maintains the contact between the distal legs 42 and the valve leaflet tissue 7 . While maintaining this contact, the sheath retraction nut 150 is rotated to the “Proximal” position as indicated on the marker of the sheath retraction indicator 156 . Rotating the sheath retraction nut 150 again acts against the tab 154 causing the sheath 130 to retract further. When the proximal position has been achieved, the sheath will be retracted enough to release the proximal legs 44 . Like the distal legs 42 , the proximal legs 44 will spring outwardly when released by the sheath 130 . The proximal legs 44 act against the opposite side (aorta side) of the valve leaflet tissue 7 sandwiching the valve leaflet tissue 7 between the distal legs 42 and the proximal legs 44 . The valve implant 10 is now attached to the patient.
The next step is to inflate the balloon 108 thereby expanding the valve implant 10 . This step is best shown in FIGS. 16 a and 16 b . The physician further rotates the sheath retraction nut 150 to the “Inflate” position on the indicator 156 . The sheath retraction nut 150 again acts against the tab 154 thereby retracting the sheath 130 to a point where the valve stop 110 is at least partially exposed and the flexible sleeve 112 of the valve stop 110 is completely exposed.
Once the sheath 130 has been retracted to the “Inflate” position on the indicator 156 , the balloon 108 may be inflated. This is accomplished by injecting fluid into the balloon inflation port 118 . Fluid is injected until the sizing ring 38 has achieved its maximum diameter. The physician will feel resistance against further inflation by the sizing ring 38 . Additionally, the sizing ring 38 or other parts of the anchoring mechanism 12 may be constructed of a radiopaque material such that monitoring can be accomplished using X-ray equipment. The use of the sizing ring 38 is not required for the practice of the invention. It is, however, preferred in the preferred embodiments of the invention.
Once the inflation of the balloon 108 is complete, the next step involves deflating the balloon 108 . This is illustrated in FIGS. 17 a and 17 b . Deflating the balloon involves simply withdrawing fluid through the balloon inflation port 118 . As is shown in FIG. 17 b , when the balloon 108 is deflated, the valve implant 10 retains its inflated proportions. These inflated proportions allow easy retraction of the catheter delivery system through the valve implant 10 . As is best seen in FIG. 18 , once the delivery system 50 has been retracted, the valve implant 10 remains attached to the valve leaflet tissue 7 .
As discussed above with reference to FIGS. 19A , 19 B and 20 , one embodiment of the catheter delivery device 50 and the valve implant 10 includes the use of a tether 190 to allow the physician to retract the valve implant 10 in the event of improper deployment. With reference to FIG. 21 , the operation of the tether 190 under both proper deployment and improper deployment is disclosed.
On the left side of FIG. 21 , it is seen that the valve implant 10 has been properly deployed in the valve leaflet. As a result, the physician cuts the tether 190 and pulls the tether away from the catheter handle from the proximal legs 44 of the cuff.
On the right side of FIG. 22 , it is seen that the valve implant 10 has been improperly deployed insofar as the legs of the cuff have not adequately grasped the edge of the hole in the leaflet. As a result, the physician may retract the valve implant 10 by pulling on the tether 190 and thus removing the valve implant 10 from its improperly deployed location | A device and method for improving flow through a native blood vessel valve, such as the aortic valve, are provided. The present invention allows a miniature valve to be implanted into affected leaflets percutaneously, obviating the need for coronary bypass surgery. The method includes the cutting of small holes, on the order of 4 mm, in the leaflets of a targeted valve, thereby allowing blood to flow through the newly formed holes. The holes are used as attachment sites for the miniature valves of the present invention. | 0 |
This application is a continuation-in-part of U.S. patent application Ser. No. 08/104,122, filed Jul. 20, 1993, now U.S. Pat. No. 5,557,263, issued Sep. 17, 1996, which is a continuation-in-part of U.S. patent application Ser. No. 07/918,273, filed Jul. 22, 1992, now abandoned.
BACKGROUND OF THE INVENTION
The present invention relates to detection of electrically conductive fluids, and in particular to detecting and signaling the release of bodily fluids from human beings or animals.
For many years the objective of electrically detecting and indicating the presence of body fluids or other electrically conductive liquids has been pursued. Detecting such fluids often has involved using a pair of electrodes connected with a voltage source and a detector circuit intended to turn on an audible alarm when a gap between the electrodes is bridged by an electrically conductive fluid.
Devices for detecting body fluids are desired particularly for assisting in the prevention of diaper rash, for potty training of infants, and in curing enuretic youngsters, as well as for detecting the leakage of blood or other fluids after surgery and invasive diagnostic procedures. Such devices are also desired to monitor and record urinary incontinence and to facilitate better care for pressure sores in chronically bedridden persons.
Previously available devices for use to detect human body fluids have many disadvantages. For example, some prior art devices are too bulky and uncomfortable for use in the groin area for monitoring urinary incontinence. Some prior art devices use cumbersome and unsafe long electric wires to interconnect the necessary component parts.
Other drawbacks of previously available devices include sensors which are too large or too small, are not shaped properly, or are made of materials which are not compatible with the human body or other intended environment. In particular, prior art devices have not satisfactorily provided for early detection of small amounts of body fluids. Also, many prior art devices are too expensive to manufacture economically or are impractical to use.
What is desired, then, is a system including an improved sensor and an associated alarm system for reliably and consistently detecting and signaling the presence of electrically conductive fluids under all conditions of use, without false alarms. Such a sensor should be of small size, comfortable to use, easy to maintain, clean, and prepare for reuse, self-powered, and portable. Preferably, a system incorporating such a sensor should have the ability to provide signals to remote monitors for collection and analysis of data, and should be simple to use.
SUMMARY OF THE INVENTION
The present invention provides improved apparatus and a method for its use to overcome the aforementioned shortcomings of the prior art and, in particular, provides an improved, simple, and versatile device for signaling the presence of electrically conductive fluids, such as urine, wound exudate, feces, blood, and water, and also provides a disposable absorbent pad for use in detecting such electrically conductive fluids.
An important feature of one embodiment of the present invention is the use of comfortable, soft, nonabsorbent material to support an absorbent sensor and a housing for a signaling device including an electrical circuit which form parts of the device.
In one embodiment of the invention a fluid-absorbent sensing pad has two apart-spaced electrodes, included in the structure of the absorbent pad and available to be connected electrically to the signaling device.
One embodiment of the invention provides a sensing pad of soft, flexible, liquid-absorbent material, whose design and shape provide comfortable positioning and detection of even very small amounts of body fluids for either male or female users.
It is a feature of one embodiment of the present invention that the fluid-detecting electrode system is compatible with different signaling devices that provide vibratory, audible, visible, or wireless signals.
One embodiment of the invention provides a disposable fluid-absorbent sensor material which can be manufactured efficiently as a continuous roll that can be cut to a desired length and which is soft and flexible enough to be worn in comfort.
One embodiment of the invention includes a radio transmitter and an encoding device for sending a signal which is identifiably encoded for reception and interpretation by a remotely located receiver, which may be portable.
In one embodiment of the invention encoded information may include identification of the source of the encoded signal, while equipment associated with the receiver can record the received signal identification information as well as time of receiving a signal, and can then compute elapsed time since an earlier signal was received, and other information.
One embodiment of the invention includes the use of an FM radio transmitter which transmits on the commercial FM broadcast frequency band. Signals from such an FM transmitter can be received by conventional domestic radio receivers, enabling most users to have more than one remote receiver.
The invention also provides a method of manufacturing a disposable sensor strip by providing an elongate sheet of material including an absorbent layer and a fluid previous layer, attaching a pair of electrodes to the sheet parallel with each other and on opposite sides of a central portion, and folding the strip to bring lateral margins together and fastening them to the central portion, thereby defining a pair of parallel tubes each having an inner surface and a respective one of the electrodes attached to the inner surface.
The foregoing and other objectives, features, and advantages of the invention will be more readily understood upon consideration of the following detailed description of the invention, taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a front view of a bed-wetting detection device embodying the present invention.
FIG. 2 is a sectional view of the device shown in FIG. 1, taken along line 2--2.
FIG. 3 is a rear view of the carrier assembly portion of the bed-wetting detection device shown in FIG. 1, together with a portion of an absorbent sensor pad and a fastener for attaching the pad to the carrier assembly.
FIG. 4 is a perspective view of a housing for electronic components of a signaling device which is a part of the apparatus shown in FIG. 1.
FIG. 5 is a perspective view, taken from the opposite side, of the housing for electrical components shown in FIG. 4.
FIG. 6 is an electronic circuit diagram for an audio-output alarm which is part of a signaling device for use in the apparatus shown in FIG. 1.
FIG. 7 is a plan view of an apparatus similar to that shown in FIG. 1 and including a belt for attachment of the device to a person.
FIG. 8 is a perspective view of a device for detecting conductive fluid such as body fluids which is an alternative embodiment of the invention.
FIG. 9 is a perspective view of a roll of absorbent sensor material including absorbent layers and electrodes, according to the invention, useful as a disposable sensing pad material in detecting electrically conductive fluids in accordance with the present invention.
FIG. 10 is a sectional view, taken along line 10--10, showing the structure of the material shown in FIG. 9.
FIG. 11 is a side elevational view of the housing shown in FIG. 8, together with a disposable sensing pad.
FIG. 12 is a view similar to FIG. 11, showing the spring fingers held in a contact-releasing position by a cam.
FIG. 13 is a side elevational view of a detail of a housing similar to that shown in FIGS. 8, 11 and 12, and equipped with spring fingers which include somewhat different electrical contacts.
FIG. 14 is a view of a contact shown in FIG. 13, taken in the direction indicated by line 14--14.
FIG. 15 is a partially cut-away view of a housing for electronic circuitry for providing a quiet signal which can be felt by the wearer of a device according to the present invention, including a clip for attachment of the housing to a person's clothing.
FIG. 16 is an electronic circuit diagram illustrating a circuit for use in connection with the vibrator signaling device shown in FIG. 15.
FIG. 17 is a simplified view of a system including a radio transmitter and receiver in combination with a sensor according to the present invention for detecting the presence of electrically conductive fluids.
FIG. 18 is a view similar to FIG. 17, showing the use of a receiver in accordance with the present invention to provide a visible indication of a signal from a sensing device.
FIG. 19 is an electronic circuit diagram for a portion of a signaling device for use in accordance with the present invention, including a signal repeat timer.
FIG. 20 is a block diagram of a system according to the present invention including several body fluid detection devices each including a wireless signaling device.
FIG. 21 is a view of a system monitoring unit and several sensing devices of a system according to the present invention.
FIG. 22 is a perspective view of a roll of absorbent sensor material according to the invention, including an absorbent layer and electrodes, useful as a disposable sensing pad material for detecting electrically conductive fluids in accordance with the present invention.
FIG. 23 is a perspective view of a portion of an elongate piece of sheet material which is useful as a component of the absorbent sensor material shown in FIG. 22.
FIG. 24 is a section view of the absorbent sensor material shown in FIG. 22, at an enlarged scale, taken along line 24--24 of FIG. 22.
FIG. 25 is a section view similar to a central portion of FIG. 24, showing an alternative embodiment of the absorbent sensor material according to the invention.
FIG. 26 is a block diagram of a method for manufacturing a sensor material such as that shown in FIG. 22.
FIG. 27 is a simplified pictorial representation of the process of forming the sensor material shown in FIG. 22.
FIG. 28 is a simplified illustration of a production machinery arrangement for manufacturing a continuous strip of absorbent sensor material according to the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now to the drawings which form a part of the disclosure herein, and with particular reference to FIGS. 1-6, an apparatus for detecting the presence of electrically conductive fluids, in the form of a bed wetting detector 10, includes a sensor carrier assembly 12 having a flat, generally rectangular configuration adapted to fit, for example, against the front of a wearer's night clothes as support for the detector 10. The carrier assembly 12 includes a pair of alligator clips 14, one attached at each end, as one way to attach the carrier assembly 12 to a person's clothing, such as the elastic waistband 16 of a pair of underpants, to keep it in a desired location in which a sensor portion 18 is best positioned to receive and absorb urine when the person wearing the device first begins to urinate while sleeping.
The carrier assembly 12 is constructed of a sheet 20 of closed-cell polymeric foam material which may be 3 mm thick, for example, folded along a central slit 22 to define a horizontal bottom 24 of the carrier assembly. A recess 26 is defined on the front part of the carrier assembly 12 by a cutout in the top margin 28 of the folded sheet 20, providing a convenient location for attachment of a housing 30 containing electrical circuit components including a signaling device 32.
The sensor portion 18 of the device 10 is reusable and includes an electrode-carrying member 34 in the form of a backing layer of sheet plastic material such as polyvinylchloride 0.50 mm thick having a pair of opposite longitudinal margins, an upper portion of each of which extends laterally defining tabs 36 to which the alligator clips 14 are attached. The electrode-carrying member 34 may, for example, have a length 38, of about 23 cm overall, with about 18.7 cm depending downward below the central slit 22 in the closed-cell foam material of the sheet 20. The depending portion of the electrode-carrying member in a preferred embodiment of the invention is 7 cm wide over approximately its upper half, its lower half tapering to a width of approximately 4.5 cm at its lower end.
A rectangular piece 40 of flexible plastic material such as polyvinylchloride 0.25 mm thick extends lengthwise between the opposite halves of the folded sheet 20 of closed-cell foam material and is attached along its vertical ends to the rear side of the upper portion of the electrode-carrying member 34. The inner surfaces of the sheet 20 of closed-cell foam are attached to the flexible plastic material of the piece and of the electrode-carrying member by an adhesive, such as ADCHEM 5008B, available from Adchem Corporation of Westbury, N.Y. A space 42, open at its top and bottom is thus defined between the piece 40 of flexible plastic material and the upper portion of the electrode-carrying member 34.
Two parallel, flexible electrodes 44, 46 are attached to the electrode-carrying member 34 on its rear side, that is, the side facing toward the body of the user of the device. The electrodes 44, 46 are thus exposed, spaced apart from and parallel with each other, within the space 42 defined between the piece 40 of flexible plastic material and the electrode-carrying member 34.
The housing 30 is attached to the carrier assembly 12 by a pair of spring fingers 48 of resilient sheet metal, each of which is electrically connected appropriately to the electronic circuit components contained within the housing 30, as shown in FIG. 6, and each of which also includes a contact portion 50. The resilient spring fingers 48 attached to the housing bring each of the contact portions 50 into mechanical and electrical contact with a respective one of the electrodes 44, 46 within the space 42 defined between the flexible plastic 40 and the electrode-carrying member 34. Preferably, each of the fingers 48 has an upturned tip, to facilitate sliding the housing into position with the fingers 48 in the space 42, with each contact portion 50 contacting a respective one of the electrodes 44, 46.
Each of the electrodes 44, 46 is a strip of conductive flexible polyimide material impregnated with carbon black, such as that available from DuPont Electronics of Wilmington, Del., and known as KAPTON 400XC250, which has a suitably low resistivity of 250 ohms/sq. Each of the electrodes 44, 46 is approximately 1.3 cm wide, and a spacing 52 of approximately 1.1 cm is provided between the medial margins 54 of the two electrodes.
Preferably, an additional piece 56 of flexible plastic is attached by an adhesive to the front face of the carrier assembly to protect the closed-cell foam material of the sheet 20 from possible abrasion by the surface of the housing 30, and to facilitate removal and replacement of the housing 30 from and onto the carrier assembly 12.
An absorbent sleeve 58 fits around the electrode-carrying member 34 and the electrodes 44, 46, fitting snugly against the bottom 24 of the carrier assembly 12, adjacent the central slit 22. A flap 60 extending upward on the rear side of the sleeve 58 carries a small patch 62 of the hook-bearing material of a hook-and-loop fastener system such as that known by the trademark Velcro®, while a patch 64 of the loop-bearing material of the fastener system is attached, as by an adhesive, to the rear surface of the sheet 20 of closed-cell foam material of the carrier assembly 12, so that mating the two fastener materials 62, 64 holds the sleeve 58 appropriately in position covering the depending portions of electrode-carrying member 34 and the electrodes 44, 46.
The sleeve 58 is made of an absorbent material which is preferably washable, such as a central layer 66 of a batting of polyester fibers, covered on opposite faces by layers 68 of thin, fluid-absorbent cloth such as a cotton-polyester blend, which may be quilted, with front and rear panels of the resultant three-layer fabric being sewn together along their respective longitudinal margins and bottom margin. The entire sensor portion 18, including the sleeve 58 and the electrode-carrying member 34, is flexible but not too bulky to be worn comfortably within a user's underwear.
Referring to FIG. 6, the bed wetting detector 10 includes an audio alarm which may be contained as a signaling device 32 within the housing 30. An electronic switch 70, such as a Harris H11A10 photon-coupled current threshold switch, in which a solid-state gallium arsenide infrared-emitting diode is coupled with a silicon photo-transistor in a dual in-line package, is connected to provide power from a battery 72 to an audio transducer 74 which may, for example, be a Series AI612 electronic solid-state audio indicator unit available from Projects Unlimited, Inc. of Dayton, Ohio, capable of providing 90 dba sound pressure at a frequency of about 400 Hz.
When a circuit is completed through an electrically-conductive fluid absorbed in the sleeve 58 in a location interconnecting the electrodes 44 and 46, the current through the electrically-conductive fluid is sufficient to turn on the electronic switch 70, providing a current path from the battery 72 through the audio transducer 74, so long as the battery 72 lasts and the circuit remains intact through the sensor portion 18 of the device. Thus, when moisture, such as a sufficient quantity of urine, completes the circuit the audio transducer 74 will produce enough noise to waken the person wearing the device 10, usually a small child, to enable the child to stop urinating and to learn to awaken before wetting the bed. The noise of the transducer 74 can be stopped by simply removing the spring fingers 48 of the housing 30 from contact with the electrodes 44, 46 within the carrier assembly 12.
Once the sleeve 58 has been made wet, it can be removed, permitting the carrier assembly 12, the electrode-carrying member 34, and the electrodes 44, 46 of the sensor portion 18 of the device, and the exterior of the housing 30, to be wiped dry. Thereafter, the sleeve 58 can be replaced with a dry one and the housing 30 can be replaced on the carrier assembly 12, allowing the bed wetting detector 10 to continue to monitor the wearer.
Referring to FIG. 7, as an alternative embodiment of the apparatus shown in FIGS. 1-6, a carrier assembly 76 may include, instead of the pair of alligator clips 14 at the ends of the carrier assembly 12, a belt 78 of closed-cell foam material similar to that of the sheet 20 of the body of the carrier assembly 12. The belt 78 is equipped with mating patches 80, 82 of hook-and-loop fastener material, and excess length of the belt can be trimmed easily, so that the device can be used with people of different sizes.
Referring next to FIGS. 8-12, a body fluid detecting device 84 which is another embodiment of the invention includes a housing 86 for electronic circuitry similar to the housing 30 previously described. It includes an alligator clip 88 attached to the housing, as by a looped strip 90 of flexible plastic material engaged movably through an opening defined by a small strip 92 of plastic material fastened to the housing.
Instead of the carrier assembly 12 and the associated reusable sensor portion 18, however, the body fluid sensing device 84 shown in FIGS. 8-12 utilizes a disposable sensing pad 94 of absorbent sensor material 95 which includes a pair of electrodes 96, 98. The absorbent sensor material of the disposable sensing pad 94, as shown in FIGS. 9 and 10, has the form of an elongate strip and may be provided in the form of a roll of such material 95 which can be cut to a desired or required length. For example, for use to detect urinary incontinence, a strip of the absorbent sensor material 95 may be cut approximately the same length, in the direction indicated by the arrow 100, as the length of the electrode-carrying member 34 of the reusable sensor 18 described previously, or to a shorter or longer length, depending upon the size of the person using the device.
Two strips 102 of an adhesive material, normally covered by an easily removable protective paper tape 104, are available on one face of the disposable sensing pad 94, to be used to attach the disposable sensing pad 94 to a person's clothing. Where the device is used to detect seepage from a wound, the adhesive material may be used to attach the absorbent sensor material 95 to person's skin, instead, or to a portion of a bandage, as appropriate. An adhesive material such as that available in the form of a spirally rolled strip of adhesive and a protective paper layer from the Minnesota Mining and Manufacturing Company of Minneapolis, Minn., as its No. 924 adhesive is suitable, although an adhesive applied in fluid form and then covered with the protective paper tape 104 during the process of manufacture of the absorbent sensor material 95 would also be suitable.
The absorbent sensor material 95 of the disposable sensing pad 94 is of multi-layered construction, including a pair of inner layers 106, 108 of a continuous, absorbent soft paper or similar material having a width 110 of about 4.5 cm. The pair of flexible electrodes 96, 98 may be ribbon-like strips of polyester plastic provided with a conductive metallic coating, such as aluminum, on each face, and are attached by layers 112 of an adhesive to the sheet 108 of paper, with one metallized face of each electrode facing away from the sheet 108. The closer, or medial, longitudinal margins 114 of the electrodes are spaced apart from one another by, a distance 116 of, for example, 1.2 cm, and each electrode has a width 118 of 1.2 cm, leaving three to four tenths of a centimeter of the width 110 of the paper clear alongside the outer or lateral longitudinal margin 120 of each electrode.
The other sheet 106 of the absorbent soft paper overlies the sheet 108 to which the electrodes 96, 98 are adhesively attached, and the two sheets 106, 108 of absorbent paper are attached to each other by strips 122 of adhesive material along their longitudinal margins, and by adhesive material, preferably in the form of a continuous strip 124, located between the two electrodes 96, 98 to prevent them from being pushed into contact with each other as a result of the disposable sensing pad 94 bending to conform to a person's body or clothing during use of the device.
On each side of the disposable sensing pad 94 an outer layer 126 or 128 of flexible fluid-conducting absorbent material overlies the inner layers 106, 108. The outer layers 126, 128 are attached to each other and to the margins of the inner layer of material, as by adhesive material 130 interconnecting the longitudinally-extending lateral margins 132 of the outer layers with each other and also attaching the outer layer 128 to the inner layer 108, to which the electrodes 96, 98 are adhesively attached. Instead of the adhesive materials 112, 122, 124 and 130, ultrasonic welding may be used to bond together the inner and outer layers 106, 108, 126 and 128 if a weldable bonding agent, such as latex, is included in the materials of the inner or outer layers.
Each electrode 96, 98 is exposed within a respective tube 134 formed by the opposing surfaces of the inner layers 106, 108 of absorbent soft material. The spring fingers 136 on the outside of the housing 86, each electrically connected appropriately with the electrical components contained within the housing, fit within the tubes 134. The contacts 138 located on the spring fingers 136 thus make electrical contact with the electrodes 96, 98, while the electrodes 96, 98 are kept separate from each other by the bonded-together portions of the inner layers 106, 108.
The inner layers 106, 108 may, for example, be of a paper product available from Fort Howard Paper Company of Green Bay, Wis. as its grade 835 dry form 8-ply lightweight fabric made of bleached pulp. The outer layers 126, 128 may be of a rayon apertured fabric, print bonded with a rope pattern, and available from Fort Howard Paper Company of Green Bay, Wis., as its grade 920 Carded™ material. The material of the outer layers 126, 128 has a lower absorbent capacity but a higher wet tensile strength than the material of the inner layers 106, 108, so that the outer layers provide strength to the disposable sensing pad 94 and allow moisture to pass quickly to the inner layers 106, 108 to be absorbed and brought into contact with the electrodes 96, 98 to complete an electrical path between the electrodes.
As shown in FIGS. 8, 11 and 12, the spring fingers 136 include down-turned tips as the contacts 138, to provide electrical contact with the electrodes of the absorbent sensor material 95 of the disposable sensing pad 94. The spring fingers each include a zigzag bend, and the housing 86 includes a raised ridge 140 defining a support for a cam 142 which can be rotated toward the zigzag bend by a lever 144 to raise the contacts 138 away from the housing 86 to permit the ends of the spring fingers 136 to be inserted into the tubes 134 of the disposable sensing pad 94. When the lever 144 is returned to a position parallel with the outer surface of the housing 86 the contacts are urged against and into electrical contact with the electrodes 96, 98 by elastic spring tension in the spring fingers 136.
As shown in FIGS. 13 and 14, a spring finger 136' includes a multi-tined contact 146 in place of the down-turned contacts 138 of the spring fingers 136 just previously described. Each tine 148 has a length of, for example, about 0.06 cm, long enough to extend through the outer layer 126 and inner layer 106 of the disposable absorbent sensor material 95 to make electrical contact with the electrodes without having to be inserted within the tubes. This construction permits the absorbent sensor material of the disposable sensing pad to be used to present the adhesive 102 facing in a desired direction with respect to the housing 86, to attach the sensing pad 94 either to a patient's undergarment or to a patient's skin, depending upon the application for which the body fluid detecting device 80 is being used. Alternatively, the tines, electrically connected, could be provided on the housing 86 with the spring fingers 136 pressing the electrodes into contact with the tines.
Certain people, because of medical conditions, are unable to detect normally and reliably when uncontrollable urination is about to begin. In some of such people, however, a small amount of urine, great enough to be detected by a sensing device according to the invention, leaks from the person early enough for the person, if aware of such leakage, to proceed to a toilet to complete voiding the bladder. Such persons can utilize a body fluid sensing device 150 including a vibrator 152 as its signaling device as shown in FIGS. 15 and 16. The vibrator 152 is contained within a housing 154 similar to the housing 86, and can be felt by the wearer, allowing the person wearing the device to proceed to a restroom soon enough to avoid embarrassment by wet clothing. The device 150 itself does not cause embarrassment, however, because its signal is inaudible to nearby people. This permits the person with such a medical problem to live in a substantially normal way, without having to be catheterized or to wear diapers. A suitable vibrator circuit, shown in FIG. 16, includes a TLC 555 integrated circuit available from Tandy Corporation, of Dallas, Tex., which, when connected as shown, latches in a mode providing power to the vibrator 152 once conductivity is established, even briefly, between the spring fingers, as by urine providing a conductive path between electrodes 96, 98 of a disposable sensing pad 94 connected to the contacts 138 of the spring fingers 136 of the housing 154. A suitable vibrator 152 is a vibration pager Model 7CE-1701 WL-00, available from Namiki Precision Jewel Co., Ltd., of Rochelle Park, N.J., which includes a small coreless DC motor and an eccentrically weighted shaft.
A reusable sensor 18 or a disposable sensor 94 according to the present invention may be used in a system containing one or more of the sensing devices, each equipped with a small, low-powered radio transmitter and one or more receivers and display devices, to monitor, for example, infants, invalids, or nursing home or hospital patients suffering from, among other things, urinary incontinence, pressure sores, surgical wounds, and other problems.
For example, as shown in FIG. 17, in one basic form of such a system, a transmitter included in body fluid detecting device 160 connected with a sensing pad 94 (or with a reusable sensor 18) transmits at very low power on a frequency within the commercially used FM broadcast band. When an electrically conductive fluid completes the electrical path between electrodes of the sensing pad 94 the transmitter begins to transmit, continuing to transmit a signal until an FM receiver in the close vicinity, as within the same house, for example, alerts a person who can disconnect the device from the electrodes of the sensing pad 94, or until the battery powering the transmitter is exhausted. Preferably, the transmitting frequency is variable to avoid local commercial broadcast frequencies. A timing circuit could be connected to the transmitter (as in the circuit shown in FIG. 19) to limit battery drain.
A receiving device for use with such a transmitter for a single patient situation may simply be an ordinary household FM receiver 162, so that a caregiver could keep several receivers tuned, in different locations in the house, to receive a signal indicating that attention to the patient is required, or may carry a small portable FM receiver tuned to provide the signal no matter where the responsible person moves within the transmitting range of the device.
Another receiver device, as shown in FIG. 18, may be a special-purpose receiver 164 including an audible signaling device 166 or visible signaling device 168. A latch circuit is included to turn on the signaling device and keep it activated until turned off or reset by the responsible person.
A body fluid detecting device 170 which is another embodiment of the invention incorporates a circuit as shown in FIG. 19, and controls a transmitter 172 to provide an FM radio signal which is transmitted for only a limited time, for example one second. The transmitter 172 is reactivated periodically to send another such transmission, with a delay between transmissions which is established by the value of the resistor R T . For example, when R T is 10 megohms, the delay is two minutes, and when R T is 20 megohms the delay is four minutes. (If a first encoded signal transmission is not received by the receiver 164, the next or a subsequent transmission is received by the special purpose receiver 164 and the signaling device 166 is activated and latched "on.") The included transmitter 172 is accompanied by a digital encoding device which uniquely identifies the transmitter of the device 170. A transmitter test switch 174 and an indicator lamp 175 which are also provided.
Where there are multiple patients to be monitored, as in a hospital or nursing home, a central receiving device may be used with several sensing devices 170. Referring now to FIGS. 20 and 21, the nurses station 176 includes an internal computer 178 and an RS-232 interface 180 through which inputs and outputs to and from an external computer 183 may be directed. The station 176 includes a printer 182 on which the identity of each transmitter 172 of a sensing device 170 and the time of transmission of an incident message signal (indicating a circuit completed through sensor electrodes) or a reset message (indicating use of the transmitter test switch 174) initiates a transmission which is received by the antenna 184. The antenna 184 may be more or less efficient, depending on the needs imposed by the size of the building in which the system is used. An alarm circuit 186 responsive to signals from the computer 178 provides an audio alarm signal 188 and illuminates an indicator lamp 190 to show that a signal has been received. Control circuits 194 connected to the printer computer interface allow a programming circuit 196 to assign identification of patients to transmitters, each of which has its own unique encoded identification signal which is transmitted as a part of the transmitter protocol each time the transmitter of a body fluid sensing device such as the device 170 is activated. A visual numerical display 198 provides an identifying display of the origin of the latest received transmission.
A receiver-decoder 200 receives each transmission and passes on the significant portion of the encoded identification signal to be processed through the control circuit 194 into the internal computer 178. These elements are included in a work station receiver available from Linear Corporation of Carlsbad, Calif. as its Linear Model AC-680 receiver, which operates in conjunction with and in response to Linear Model ACT-1/318 transmitters, each enclosed in an individual housing connected to a respective sensor such as an appropriate length of the disposable absorbent sensor material 95, or an appropriately-shaped electrode-carrying member 34 provided with a pair of electrodes 44, 46 and a corresponding sleeve 58 such as those included in the bed-wetting detection device 10 described previously, or modified in size and shape to be appropriate for sensing body fluids exuded from surgical wounds and the like or body discharges from animals, where the device is used in a veterinary application.
Data accumulated in the internal computer 178 may be transmitted through the RS-232 interface 180 to the external computer 183 for assembly and calculation of statistical data, filing and retrieval, and correlation with other data concerning individual patients or groups of patients. In particular, computer-recorded photographs and medical histories of patients may be stored in a database for retrieval to evaluate patient progress and efficiency of patient care and caretaker response to body fluid loss as shown by time of receipt of incident messages and reset messages.
An alternative disposable sensing pad shown in FIGS. 22-25 may be formed as a rolled elongate strip of sensing pad material 202 which may be cut to length as desired in the same fashion as the disposable sensing pad 94 previously described. The sensing pad material 202 includes a layer 204 of an adhesive material, suitable for fastening the sensing pad material 202 to the inside of a garment, on a first face 205. A releasable cover sheet 206 protects the layer 204 of adhesive material so that the sensing pad material 202 can be stored as a roll yet unrolled easily and cut to a desired length for use in the same manner as is the sensing pad 94 in the fluid sensing device 84.
The sensing pad material 202 is preferably made from a two-ply laminate material 208, shown in FIG. 23, which includes a first layer 210 that is relatively thin and through which liquids may pass easily. The first layer 210 may be made of a paper-like material, and preferably is a non-woven carrier sheet of synthetic fibers bonded; together, for example by heat or chemical adhesives, into a thin, flexible, strong, and porous sheet, about 0.005 inch thick and with a weight of 14-20 g/m 2 , and preferably about 18 g/m 2 . A second, or inner layer 212 is relatively thick, with a thickness 213 of about 0.020-0.030 inch, for example, and preferably has a fluffy, resilient texture. The layer 212 is preferably made of a highly fluid-absorbent material which need not be particularly strong, but which may include a distributed quantity of material to help the layer 212 to be bonded thermally, as by the use of ultrasonic welding equipment. The layer 212 may thus include a quantity of a latex material intermixed with a larger quantity of cellulose wood pulp fiber material, or, preferably, the layer 212 may be an air-laid pulp layer of a mixture of cellulose fibers and thermally bondable synthetic fibers such as synthetic bicomponent fiber of polyethylene and polyester, adhering to a layer 210 of a non-woven fiber such as polyethylene, polypropylene, or a mixture of them which may be thermally bonded ultrasonically. Such a laminated material is available, for example, from Merfin International, Inc. of Delta, B.C., Canada as its product 40800N00 which has a weight of about 80 g/m 2 ,
The laminated material 208 is preferably used in manufacture of the sensing pad material 202, in the form of a long strip having parallel lateral margins 214 and 216 separated by a predetermined width 218, for example 4 5/8 inches.
As shown in greater detail in FIG. 24, the sensing pad material 202 defines a pair of separate tubes 220. Electrodes 222 and 224 are each located within a respective one of the tubes 220. The electrodes 222, 224 may each be 3/8 inch wide, for example, and each electrode 222, 224 is attached by a respective layer of adhesive material 226 to an exposed surface of the inner layer 212. Each electrode 222, 224, shown with exaggerated thickness in FIG. 24, is generally ribbon-like and is preferably of a synthetic plastic material such as a Mylar™ polyester strip 228 having layers of electrically conductive material adhered thereto, preferably on both sides as layers 230, 232, although it would be possible to omit the electrically conductive layer from one side. Preferably, the strip 228 is thin enough to be easily flexible, having a thickness 234 of, for example, 1 1/2 mils. The layers of conductive material 230, 232 may, preferably, be evaporatively deposited aluminum having a thickness in the range of about 100-200 Angstroms, for example. Preferably, the layer 226 is a thin interrupted layer of hot melt adhesive applied in a pattern using conventional equipment, and the layer 232 of conductive material is thus available for electrical contact such as by the tines 148 extending through the outer layer 210, the inner layer 212 and the layer 226 of adhesive.
The electrodes 222 and 224 extend parallel with each other separated from each other by a distance defining a central area 236 between the electrodes 222 and 224. The lateral margins 214 and 216 of the laminate material 208 are folded toward the central area 236 defined between the electrodes 222 and 224 and abut against each other, or, alternatively, may be overlapped, in the central area 236. A narrow portion of the laminate material 208 extending along each of the lateral margins 214 and 216 is fastened to the laminate material 208 within the central area 236, to form the separate tubes 220.
The electrodes 222 and 224 are thus each enclosed within a respective one of the tubes 220 separately, and the conductive material 230 on one face of each of the electrodes 222 and 224 is free from the overlying surface of the portion of the inner layer 212 adjacent the respective lateral margin 214 or 216. The tubes 220 can thus easily be expanded to receive a contact (such as the contacts 138 shown in FIG. 8) extending into an end of each tube 220 to rest upon and make electrical contact with the electrically conductive material 230 of a respective one of the electrodes 222 and 224 for use of the sensing pad material 202.
As shown in FIGS. 22 and 24, the strips of material adjacent the lateral margins 214 and 216 are attached to the central area 236 by thermal welding, as by the use of an ultrasonic welder. A strip of an adhesive material 238 could also be used, as shown in FIG. 25 to effect attachment of the narrow portions of the laminate material 208 adjacent the lateral margins 214 and 216 to the central area 236.
According to the invention, the process of manufacturing the elongate strip of sensor material 202 may be carried out as shown in FIGS. 26 and 27, using the equipment shown in FIG. 28, for example. Accordingly, as a first step 240, a roll of laminate material 208 is slit to a desired width, for example, 4 5/8 inch wide, and made ready as a supply roll 242 (FIG. 28).
Subsequently, in step 244 shown in FIG. 26, the electrodes 222, 224, which are preferably supplied from horizontally mounted reels 246, are fed beneath the nozzle 248 of a hot melt glue dispensing system 250 such as a programmable hot melt glue dispensing system available from the Nordson Corporation of Atlanta, Ga. to deposit a pattern of glue as the layer 226 on each of the electrodes 222, 224. The electrodes are then led into the appropriate positions atop the inner layer 212, as shown at 252, where a roller 254 presses the electrodes 222, 224 into contact with the inner layer 212.
A photo-optic electronic steering station 256 observes the position of the lateral margins 214, 216 and applies pressure through a servo-system as necessary to steer the strip of laminate material 208 and attached electrodes 222, 224 to direct them into a three-stage folding station 258, to perform step 260 shown in FIG. 26. In the folding station 258 the outboard portions of the strip of laminate material 208 are folded progressively upward, around and into alignment with the central area 236 between the electrodes 222 and 224, bringing the lateral margins 214 and 216 into abutment with each other above the central area 236.
The folded laminate material 208 is progressively moved further to pass through an ultrasonic stitcher 262 such as, for example, a Branson Model FS-90 ultrasonic stitcher, available from Branson Ultrasonics Corporation of Danbury, Conn., which ultrasonically welds the lateral margins 214 and 216 to the central area 236 to form the separate tubes 220, thus forming effectively useable sensing pad material 202. The sensing pad material 202 is then drawn further through an appropriate tension-regulating device 264 and into position for attachment of the layer of adhesive material 204, together with and supported by the cover sheet 206, provided from a continuous spool at 266.
The completed sensing pad material 202, with the adhesive layer 204 and cover sheet 206, is drawn continuously by a set of rubber drive rollers 268 driven by an electric motor and equipped with a measuring device such as an optical disc encoder programmable to control operation of an air-operated guillotine clipper 270 to cut the product into strips of a desired length for packaging and retail sale, either in the form of a spool from which lengths of chosen lengths may be cut by the consumer, or in the form of pre-cut ready-for-use fluid-absorbent sensor pads.
A suitable adhesive 204 and cover sheet 206, in a form allowing simultaneous application from a single spool of material, are available from 3 Sigma, a Division of Anchor Continental, of Columbia, S.C., as its No. 93004 adhesive tissue garment tack with 2-inch-wide release paper.
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. | Apparatus for detecting the presence of electrically conductive fluids, including urine and other body fluids such as exudate from wounds, includes a pair of spaced-apart electrodes covered by absorbent material, together with a housing containing a signaling device which produces a palpable vibration, a sound, a light, or a radio signal when fluid in the absorbent material provides a conductive path between the electrodes. Spring contacts on the housing provide reliable connections with the electrodes and also serve to attach the housing of the signaling device to structure supporting the absorbent material, and may also be used to attach the absorbent material to the housing in embodiments where the housing is otherwise supported. Disposable sensing pad material which is comfortably soft and flexible can be produced in indefinite lengths with moisture-previous outer layers and an inner layer of absorbent thermally-weldable material. Encoded signals from many such sensors can be identifiably related to and recorded so as to be machine-retrievable together with other patient data and analyzed statistically by a computer. | 0 |
FIELD OF THE INVENTION
The present invention relates to the field of surgical biopsy devices, and more particularly to devices intended for removal of localized breast tumors for pathological analysis.
PRIOR ART
There are many known instruments for assisting in surgical removal or sampling of tissue, for biopsy or therapy. These differ in intended situs of application, method of identifying and isolating tissue to be severed, and means for implementation. In general, tissue is sought to be cut with a sharp edge, garrotted or subjected to localized shear forces, although tearing, aspiration, electrosurgical and other methods are known.
U.S. Pat. No. 4,007,732 relates to a method for location and removal of soft tissue in human biopsy operations. A guide wire is placed radiologically for removal during a biopsy procedure. A separate knife is employed in order to sever the core biopsy sample. U.S. Pat. No. 5,375,608 relates to a core biopsy device having a cutting blade which operates transverse to the axis of insertion. U.S. Pat. No. 5,074,311 relates to a core biopsy device having severing blades which are activated by a tension on an actuator.
U.S. Pat. No. 4,971,067 relates to disposable biopsy instrument having two jaws which sever a tissue sample by a shearing action.
U.S. Pat. No. 4,774,948 relates to a device for inserting a guide wire having a distal barb.
U.S. Pat. No. 5,111,828, U.S. Pat. No. 5,197,484 and U.S. Pat. No. 5,353,804, incorporated herein by reference, relate to methods and devices for percutaneous excision breast biopsy (PEBB) of a mass localized by a guide wire. A garrotte is employed to sever the core of breast tissue.
U.S. Pat. No. 4,881,550 relates to a surgical cutting forceps or biopsy instrument having two hinged cutting blades, which are actuated by the movement of a concentric sleeve about a central body. This device is not intended for taking core biopsies.
U.S. Pat. No. 5,366,468, U.S. Pat. No. 5,112,299, U.S. Pat. No. 4,834,729, U.S. Pat. No. 4,850,354, U.S. Pat. No. 4,754,755, U.S. Pat. No. 4,368,734, U.S. Pat. No. 4,274,414, U.S. Pat. No. 4,167,943 relate to surgical instruments having an axially rotating cutting blade which cooperates with a concentric sleeve to cut using a shearing action. U.S. Pat. No. 5,312,425, U.S. Pat. No. 5,226,909, U.S. Pat. No. 5,007,917, U.S. Pat. No. 4,649,919 and U.S. Pat. No. 3,945,375 relate to surgical instruments having a helically twisted blade which rotates within a sleeve to cut tissue. U.S. Pat. No. 5,269,794 relates to a rotating blade arthroscopic surgical instrument. U.S. Pat. No. 5,224,945 and U.S. Pat. No. 4,966,604 relate to expandable arthrectomy cutters.
U.S. Pat. No. 4,210,146 relates to a surgical device which has two sharpened members which move with respect to each other for shearing. U.S. Pat. No. 5,219,354 relates to a combined dissecting and hemostapling scissors. U.S. Pat. No. 4,452,246, U.S. Pat. No. 4,726,371 relate to scissors apparatus for cutting tissue. U.S. Pat. No. 5,060,382 relates to a cutting shears.
U.S. Pat. No. 3,945,117, U.S. Pat. No. 4,185,634, U.S. Pat. No. 4,647,300, U.S. Pat. No. 4,708,138, U.S. Pat. No. 4,798,000, U.S. Pat. No. 4,922,614, U.S. Pat. No. 5,026,385, U.S. Pat. No. 5,071,427, U.S. Pat. No. 5,201,748, U.S. Pat. No. 5,217,476, U.S. Pat. No. 5,250,063, U.S. Pat. No. 5,254,128, U.S. Pat. No. 5,258,001, U.S. Pat. No. 5,292,330, U.S. Pat. No. 5,318,582, U.S. Pat. No. 5,346,503, U.S. Pat. No. 5,356,419, U.S. Pat. No. 5,370,652 relate to sharp bladed cutting instruments. U.S. Pat. No. 5,304,190 and U.S. Pat. No. 5,176,695 relate to endoscopic sharp bladed cutting instruments for severing tissue. U.S. Pat. No. 5,306,284 relates to an endoscopic cutting instrument having visualization capability. U.S. Pat. No. 4,700,702 relates to a surgical cutting device having a moving band cutting blade. U.S. Pat. No. 4,221,222 relates to a surgical tissue shaving device for obtaining planar tissue samples. U.S. Pat. No. 4,943,295 relates to a flexible bladed cutting instrument.
U.S. Pat. No. 4,832,683, U.S. Pat. No. 4,485,810, U.S. Pat. No. 4,481,057, U.S. Pat. No. 4,248,231, U.S. Pat. No. 4,232,676 relate to electrically assisted surgical cutting devices.
U.S. Pat. No. 3,990,451 relates to a biopsy device for obtaining a tissue sample core. U.S. Pat. No. 5,183,053 relates to an elliptical biopsy punch.
U.S. Pat. No. 4,989,614 relates to fine-needle aspiration cell sampling methods. The device is not intended for obtaining a core tissue sample.
BACKGROUND OF THE INVENTION
Many devices are available for the surgical removal of tissue. These devices are generally characterized as having sharp cutting blades, which sever tissue by means of a sharpened edge, having an angle of 5-30 degrees to the plane of cutting. These blades cut by applying pressure along the plane of cutting, forcing the tissue against the blade, severing connective tissue. Another system for severing tissue is a scissors, in which two edges move with respect to each other to shear the tissue. The edges generally are sharpened at an angle of 90-45 degrees from the plane of cutting. The actual cutting with a scissors occurs at the junction of the edges, which moves outward from a pivot point of the two edges as the scissor is closed. The relative motion between the two edges produces a shear force with separates the tissue. Electrosurgical methods are also known. Biopsy devices may also be implemented by blunt pressure or tension.
Another method of severing tissue is known as the garrotte method in which a thread or thin wire is formed in a loop, and the diameter of the loop is decreased, cutting through the tissue inside the loop. When used to sever a biopsy sample, a sharpened circular blade is used to place the garotte at the desired tissue depth.
It is generally desirable that biopsy devices remove the entirety of a small solid tumor in a single procedure, in order to prevent possible tumor cell seeding and to effectively remove a primary source of tumor cells. This also allows pathological examination of tumor margins. Further, it is desirable to provide a biopsy device in which tissue contact portions are disposable, in order to eliminate the possibility of cross infection of patients. However, known biopsy instruments generally are of expensive and durable construction, and may not be cost effective for single use.
It is desired that biopsy instruments be easily guided to the situs of a target area, which is generally identified radiologically, ultrasonically or in another manner. Therefore, one known technique is to insert a guide wire into a target area in a visualization procedure. Thereafter, a biopsy instrument is fed along the guide wire, and a biopsy is taken to include the tissue around the end of the guide wire. The biopsy device may also be directly guided to sample to target area using standard guiding techniques, such as ultrasonography, fluoroscopy or digital fluoroscopy.
Mechanisms are known for converting a linear movement of an actuator to a pivotal movement of a member about an axis. Known biopsy forceps include a mechanism for converting a linear trigger movement to a movement of two cups toward each other, to grasp and sever tissue. The cutting edges of traditional biopsy cup forceps are generally scissor-type cutting devices, shearing rather than cutting tissue.
A known guide wire system is the "Sadowsky Breast Marking System" (TM) (catalog # SBS-10, SBS-5) by Ranfac Corp., Avon Mass. This system facilitates insertion of a guide wire in a breast, and includes three basic elements. First, a 9 inch guide wire 0.010" diameter (spring hook wire), having a flattened spiral portion with a 3 cm pitch, an etched marking at 10 cm, and a sharp kink at one end with a 345° bend at one end with an 8 mm tail. A 23G stiffening cannula, approximately 4-6 cm long with etched markings at 1 and 2 cm from the end is provided, which has a central aperture for the guide wire. Finally, a 20G×10 cm or 20G×5 cm needle with centimeter markings is provided, through which the guide wire is inserted. In use, a lesion is located by mammography. An insertion path is selected at the discretion of the surgeon, generally minimizing the path of the guide wire through the breast tissue, though the angle should generally be parallel to the chest wall to avoid complications such as pneumothorax. The needle, without the guide wire, is then inserted to the desired depth which may be, e.g., 1 cm beyond the radiographic margin of the lesion. The guide wire is then inserted through the needle until the etched marking disappears into the needle, thus releasing and engaging the hook of the needle. The needle is then withdrawn over the guide wire, leaving the guide wire in place. Further radiographs are taken to ensure that the wire passes through the lesion, and an appropriate length stiffening cannula is placed over the guide wire, so that the tip of the stiffening cannula is at the location of the lesion. The stiffening cannula also prevents accidental bisection of the guide wire. After excision, the surgical biopsy specimen may be radiographed to ensure that the lesion is within the biopsy sample.
SUMMARY AND OBJECTS OF THE INVENTION
The present invention provides a biopsy device which provides a sharp knife-type cutting system to sever selected tissue with a circular blade which swings around a pivot.
A means for placement of a guide wire is employed, using standard techniques, to insert a guide wire in and through target tissue, which may be a tumor, suspected tumor, or other tissue of interest. The device provides means for following the guide wire placed in the tissue target, so that assurance may be had that the tissue of interest is being removed.
The device has a low cost design, and therefore is suitable for use as a disposable instrument. The cutting edge is blade sharp, and is preferably provided with integral extensions for affixing the blade to the device during assembly.
The device creates a core around and including the tissue of interest, and advantageously, the cutting edge for severing the tissue core is integral with a cutting edge for inserting the biopsy device along the guide wire to create the core, with an integral hinge portion linking the two. Therefore, a trifunctional element is preferably provided, which (a) bores deep into the tissue to the level of the biopsy location, (b) hinges the cutting edge so that it may pivot to sever the bored biopsy specimen and (c) severs the biopsy specimen from the patient. A means is also preferably provided to retain the tissue core biopsy in the body of the instrument during withdrawal from the patient. Thus, a forward cutting edge, a hinge and a lateral cutting edge are provided. Of course, the hinge need not be integral to the cutting elements, and may be provided as a separate element, such as diametrically positioned pins or rivets.
The device is constructed having a number of portions having specific functions. A handle is provided which is ergonomically designed to be held in the hand of the surgeon, with one or more fingers free for manipulation of the activation device. The handle may be any suitable material, such as a thermoformable plastic, e.g., ABS, or other plastic. The handle may also be formed of stainless steel, aluminum, or other metal. The handle is provided as an elongated member that rests in the palm of the surgeon's hand. The handle is provided to support the biopsy device, and to allow the surgeon to applying pressure axially along an elongated tubular member to bore the biopsy device to the desired location along the guide wire. The handle also has a related manual actuator, for actuating the severing device.
An actuator is provided in proximity to the handle, or may be a part of or integral to the handle. The actuator may be, for example, a trigger or depressible element which is compressed by the surgeon's fingers against the handle. It is preferred that this trigger be positioned at the front of the handle, so that pressure applied to the rear of the handle causes the device to be inserted into the patient, without accidental activation of the actuator. Other types of actuators may be used, for example, other types of mechanical actions, hydraulic, pneumatic, electrical or electronic, and other known types. The actuator may also be activated by the surgeon's free hand, as a separate element from the handle. The actuator, either directly or indirectly, when actuated, causes the cutting edge, which is semicircular, to pivot about an axis passing through the two ends of the cutting edge, which is disposed perpendicular to the axis of the elongated tubular member.
Thus, in a preferred embodiment, a member slides under compression to directly urge a portion of the cutting edge, spaced from the pivot points on the pivot axis, to apply a torque about the pivot axis, thereby swinging the cutting device through an arc to sever the tissue. In another embodiment, two cutting edges are provided which each swing through an arc to sever the tissue, meeting at a central position in front of the device.
The actuator acts through a force transmission system, such as the sliding member described above. The sliding member, or a portion thereof, may be integral to the cutting device, formed of a thin flexible steel strip. As noted above, the force transmission system may also be of other types, including other mechanical linkages, hydraulic, pneumatic, electromechanical or electronic.
Another possible linkage type includes a tension element which acts on a portion of the cutting device distal from the pivot point and opposite to the cutting edge from the pivot axis, thus applying a torque to cause outward rotation of the cutting device, cutting edge first, about the pivot axis to sever the tissue.
In a device having a compression linked strip, the strip may slide in a space within the wall of the elongated member, preventing buckling of the strip under pressure and leaving the center of the elongated member open and unobstructed to receive the tissue core. According to alternate embodiments, tension devices, hydraulic or pneumatic lines or electrical wires may also be provided in a wall of the elongated member in order to transmit the actuation signal to the biopsy device cutting system.
The elongated tubular member extends away from the handle. The elongated member is preferably a thin walled tube, of predetermined length, preferably between about 6 and 12 inches long. A variable length telescoping embodiment is also possible, with an adjustable actuator linkage system to compensate for the adjustable length between the trigger and the cutting edge. The preferred material is plastic, more preferably a rigid thermoplastic.
When a compression force transmission member is housed in the wall, the elongated member is preferably formed as an extruded dual or triple lumen tube, with a central round cross section aperture, and a thin wall with one or more eccentric rectangular cross section lumens. The elongated tubular member may also be formed of other types of plastic, metal, glass or ceramic. The round central aperture in the elongated tubular member allows the bored tissue to be trapped as a core within the elongated member, thus preserving the anatomical relation of the tissues and preventing disruption, facilitating pathological study. Further, it is believed by some that if a tumor is localized, limited manipulation during biopsy can reduce the risk of tumor seeding.
After the biopsy procedure, the instrument may be subjected to radiological inspection or by other means to ensure that the identified suspect tissue is contained within the device. Likewise, a post biopsy examination of the patient may ensure that the suspect tissue has been biopsied. Intraprocedural imaging may also be used to confirm localization prior to severing the tissue sample.
In a further embodiment, alternately or in addition to a guide wire, the area of suspect tissue may be marked to enhance its visualization by another technique, for example by injection of a radiopaque dye for radiological localization, injection of microspheres for ultrasonic localization, injection of magnetic particles for magnetic localization, and other known techniques. Therefore, a localization transducer system may be coupled to the biopsy instrument for intraprocedural localization. A sensor system may also be provided in conjunction with the device to warn the surgeon or contact or potential contact between the cutting edge and the guide wire.
In a one embodiment, the biopsy device, with the exception of the cutting edges and the force transmission system, are formed of radiotransparent materials, so that the location of the suspect tissue can be confirmed, if desired, prior to removal. Materials might also be employed which allow the entire biopsy device to be substantially radiotransparent or radiolucent, with the possible exception of a radiographic indicator, and such a device is within the intended scope of the present invention. The tissue core may then also be radiographed within the biopsy device after removal from the patient.
According to the present invention, a radiological apparatus is not necessary to conduct the biopsy, and may replaced, e.g., entirely by ultrasonic apparatus. This is desirable, for example, for outpatient or surgical office procedures. In this case, the guide wire preferably has ultrasonic markers, e.g., gas filled portions, at or near the barbed tip and at a distance away from the tip, so that the guide wire may be inserted and localized accurately under ultrasonic guidance. Ultrasonography may also be used intraprocedurally to ensure accurate placement of the biopsy instrument.
Alternate to an integral multilumen tube, the elongated tubular member may also be formed as a composite structure of cylindrical shells with spacing elements, in order to form a desired multilumen structure. Thus, outer and inner tubular shells spaced with two curved sheets forms a cylindrical member having a large central lumen and two separated lumens in the composite wall.
According to another embodiment of the present invention, a plurality of biopsy tissue samples may be obtained sequentially, and held in separate compartments within the elongated member, separated by septa. A septum may be formed by an apertured elastic membrane which selectively allows a tissue sample to pass through the aperture under pressure or vacuum, and thereafter retains it in place by the elastic force of the septum material. The design of the instrument allows a controlled unidirectional force to be applied, which moves a tissue specimen from a distal compartment to a proximal compartment. A mechanism may also be provided to selectively open and close the septa, e.g., a pursestring mechanism, thereby reducing the force necessary in order to transfer tissue samples from one compartment to the next. The force for positioning the core sample in desired chambers may be a mechanically applied force, pushing the tissue core proximally, or a pneumatic force, from a compressed gas or vacuum line, or both. A wire barb may also be used to apply traction to tissue sample. Such a multi-sample biopsy device is advantageous for, e.g., endoscopic application to avoid removal the device between samples.
The distal end of the elongated tubular member includes a boring edge, which is sharp, and cuts through tissue with slight pressure or pressure in combination with a twisting or rotating action. The preferred configuration is a curved steel sharpened blade, conforming to the shape of the elongated tubular member and extending from a distal edge thereof, having a central lobe extending further distal than the remainder, tapering proximally on both sides. The boring edge extends approximately one half of the circumference of the elongated member, and is fixed in place with respect to the elongated member. As the elongated tubular member is pressed forward, the central lobe cuts the tissue. The tapered portions are inclined to the force vector, and therefore tend to slice through the tissue. As the elongated member is rotated, e.g., ±90°, the tissue around the entire biopsy device is severed, and a core defined. Thus, the elongated member is able to advance through the tissue with a core accumulating within the central aperture of the elongated tubular member. It is noted that during insertion, both the boring edge and the cutting edge are aligned with the longitudinal axis of the elongated member, so that a sharp edge is presented around essentially the entire elongated member.
During a procedure, a guide wire is radiologically, ultrasonically or otherwise located to extend through and/or beyond a tumor or tissue to be biopsied, along an axis for providing tissue access. For example, a calcified tissue mass of about 1 cm diameter may be identified radiologically. In a preliminary procedure, a guide wire, having a distal barb, is inserted along an axis along which a later biopsy incision is to be made, so that the guide wire extends through the middle of the suspect tissue, with the barbed tip extending a short distance beyond the suspect tissue. The surgeon then makes a skin incision including the access axis, and dissects along the access axis some distance into the breast tissue, a safe distance from the suspect tissue.
The guide wire is then fed into the elongated tubular member of the device and a distal portion thereof linked to a retaining device which guides the biopsy device centered on the guide wire. The guide wire is marked in relation to the biopsy device, so that when the guide wire obtains a particular relation to the biopsy device, which is determined by markings or a positioning means, the barb is within the aperture of or in desired relation to the elongated tubular member.
After the tip of the biopsy device is located to the desires of the surgeon, the actuation device is activated, which causes the force transmission device to swing the cutting member or members about a pivot axis, to sever the tissue. The guide wire is secured by the surgeon against movement, and may be simultaneously tugged slightly, for example about 0.25 lbs. force, in order to ensure that the tip of the guide wire is safely within the swing arc of the cutting member. The cutting member swings an arc to essentially meet the boring edge, fully severing the tissue core. In another embodiment, two opposing edges pivot toward each other, and meet in a central location, severing the tissue core.
The pivot element includes a portion fixed to the elongated tubular member, and a portion which either flexes or rotates about an pivot axis, e.g., a rivet or pin. A flexion-type hinge is preferred, allowing the cutting edge and boring edge to be integral.
In a preferred embodiment, a single thin steel sheet stamping to form the cutting and boring edges is provided, having two portions, a first portion having a sharpened boring edge having a convex central lobe tapering laterally, and means proximal to the boring edge for firmly engaging to the elongated tubular member, such as a crimped edge, with is forced into a circular counterbored groove in the distal edge of the elongated tubular member. Where the tubular member is a composite structure, the inner and outer shells extend beyond the spacers to provide a gap for engaging the affixed edge of the boring member portion. The second portion is provided adjacent the first portion, having a linear sharpened cutting edge. Bridging the boring edge and the cutting edge, i.e., the first portion and the second portion, is a narrowed portion, with a "V" notch, to allow flexion in the plane of the sheet with low applied force. In the center of the side including the cutting edge, a narrow strip extends a distance away from the cutting edge, being of about equal length to that of the elongated member, or somewhat longer, and which therefore bridges the actuator with the cutting edge. The portion including the cutting edge has, opposite the "V" notch, a portion which acts as a hinge with its opposite counterpart, i.e., the lateralmost edges of the first and second portions, and is held in the counterbored groove or circular recess. The narrow strip is inserted into an aperture in the wall of the elongated member, through which it slides without buckling. The cutting edge and the boring edge are sharpened to razor sharpness using standard methods.
Instead of the flexion hinge between the first and second portions, the cutting edge and boring edge may be provided on separate members which are hinged on opposite sides of the tip of the elongated member.
According to known principles, the cutting edge or the boring edge may be electrosurgical devices. Thus, either or both of these blades may include heating elements (see U.S. Pat. No. 4,481,057, U.S. Pat. No. 4,485,810), vibrating elements (see U.S. Pat. No. 4,832,683), electrocautery elements (see U.S. Pat. No. 4,232,676, incorporated herein by reference), or electrosurgical cutting elements (see U.S. Pat. No. 4,248,231). In these cases, the blade is formed in accordance with this additional functionality as is known in the art. For example, the biopsy device may be configured with a selective electrocautery device which reduces hemorrhaging from the cut tissue edges. When employed, it is preferable that the system be arranged so that the electrocautery is applied in such manner that the biopsy sample is not adversely affected by the electrical currents, facilitating histological and pathological analysis of the tissue sample. Therefore, the electrocautery may be applied after the sample is safely inside the central aperture of the elongated member, in a secondary removal procedure. The cutting edge may therefore be provided with a leading cutting edge to sever the core biopsy sample, and a trailing electrocautery edge, to cauterize the tissue as the trailing edge passes the fresh cut tissue. Alternatively, the cutting edge may cauterize during a backswing chase from a fully extended position to a resting position. An electrocautery member near the distal edge of the boring edge or on the outer wall of the elongated member may also be activated upon device removal.
In operation, the cutting edge need not return to the open position, and may be locked in the fully extended position. The trailing edge of the cutting edge blade may include an extensible sheath, which provides a barrier to retain the tissue sample. In this event, it is preferred that the sheath be formed of an elastic silicone, latex or other rubber compound, and that the cutting edge terminate its swing arc concentrically inside the boring edge, and be retained in this position during instrument withdrawal. A spun, knit or woven cloth or coated cloth may also be employed as a sheath.
The boring and cutting edges may be recessed within the wall or in the lumen of the tubular member when not being used, and extended when boring or cutting is required. This mechanism may either retract the members having sharp edges or extend the tubular member, or portions thereof, with respect to the sharp edges. Thus, during handling prior and subsequent to the procedure, safety is enhanced. Further, after the biopsy device is inserted to an appropriate depth in the patient, the boring edge may be disengaged to prevent further insertion or adverse effects from accidental jarring.
The biopsy instrument according to the present invention may also include or be used in conjunction with optical elements, such as illumination elements, e.g., incandescent bulb, LEDs, fiber optics; laser surgical apparatus; video camera apparatus, fiber optic or standard optic endoscopic apparatus; or other known surgical optical devices. See U.S. Pat. No. 5,306,284. For example, through the elongated tubular member, a light source may be provided to enhance visualization through the central aperture during the biopsy procedure, and an endoscope provided to transmit the image from near the tip of the device to the surgeon.
The biopsy instrument according to the present invention may also include ultrasonic, radiographic, optical, magnetic, or other type of localization system, in order to assist in guiding the instrument to the site of the lesion or suspected tumor, or to allow visualization of the tissue within, surrounding or in front of the biopsy instrument. For example, an ultrasonic transponder system may be provided to determine the location of an echogenic guide wire or stiffening cannula, or to locate the suspected tumor or lesion itself.
It is therefore an object according to the present invention to provide a biopsy device for taking a core biopsy, having a sharpened leading edge for cutting the tissue to obtain the core, and a pivoted cutting edge for severing the core tissue biopsy from the body.
It is a further object according to the present invention to provide a biopsy instrument suitable for one time use having a simple construction with a sharp cutting edge.
It is a still further object according to the present invention to provide a guide wire located biopsy device having a pivoting cutting device.
The present method also provides a method for taking a tissue biopsy by inserting a guide wire, dissecting around the guide wire, placing a coring biopsy device along the guide wire beyond the suspect tissue, and severing the core tissue sample using a pivoting semicircular blade.
These and other object will become apparent through a review of the detailed description of the preferred embodiment with reference to the drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
The preferred embodiments of the invention will now be described with respect to the drawings, in which:
FIG. 1A shows a breast having a suspected tumor;
FIG. 1B shows a breast with a guide wire inserted through the suspected tumor;
FIG. 1C shows a breast with a skin incision and a guide wire inserted through a suspected tumor;
FIG. 1D shows a biopsy instrument according to the present invention inserted coaxially with a guide wire for biopsy of s suspected tumor;
FIG. 1E shows the instrument as shown in FIG. 1D inserted further coaxially over the guide wire to encircle the suspected tumor;
FIG. 1F shows the instrument as shown in FIG. 1E during an initial stage of actuation for severing the tissue core sample including the suspected tumor;
FIG. 1G shows the instrument as shown in FIG. 1F at the conclusion of the actuation, after severing the tissue core sample including the suspected tumor;
FIG. 1H shows the instrument as shown in FIG. 1G, removed from the breast with the suspected tumor in a tissue core sample contained therein, with the skin incision closed using sutures;
FIG. 2 shows a biopsy instrument according to a first embodiment of the present invention having two semicircular blades which move together to sever a tissue sample;
FIG. 3 shows a biopsy instrument according to a second embodiment of the present invention having a semicircular blade which moves toward a fixed blade to sever a tissue sample;
FIG. 4 shows a front view of an instrument according to the present invention, having a star-shaped centering device for guiding the instrument with respect to the guide wire;
FIGS. 5, 6, 7 and 8 show a multilumen component of the biopsy instrument in a perspective, side, partial cross section and end views, respectively;
FIGS. 9, 10 and 11 show a blade member according to a first embodiment of the present invention having dual lobed blades, in top, side and folded views, respectively;
FIG. 12 shows the folded blade of FIG. 11, having expanded retaining portions;
FIGS. 13, 14 and 15 show a blade member according to a second embodiment of the present invention having a lobed fixed blade, in top, side and folded views, respectively;
FIG. 16 shows the folded blade of FIG. 15, having expanded retaining portions on the lobed fixed blade;
FIG. 17 shows the folded blade of FIG. 15 juxtaposed for insertion into the tube according to FIG. 5;
FIG. 18 shows the folded blade and tube of FIG. 17 in inserted position; and
FIG. 19 shows a perspective view of a handle and actuator system of the present invention.
It should be noted that these Figures are not drawn to scale, and the relative dimensions and proportions of some parts have been greatly exaggerated or reduced for the sake of clarity and convenience in the drawing. Furthermore, some parts of the cryogenic radiation detector which it are not necessary to describe for an understanding of how to perform the present invention have not been shown in the drawings, but may be provided in known manner.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
EXAMPLE 1
A surgical biopsy device is provided for use in breast biopsy for tissue sampling of selected areas. Using state of the art mammography techniques, suspect tissue 1, e.g., tumors or other localized tissue anomalies may be detected which are smaller than 1 cm diameter. In general, tumors up to about 2 cm are suitable for biopsy with simple tools, while significantly larger tumors may require a lumpectomy or other type of procedure in order to adequately obtain the tissue sample and avoid the need for a subsequent procedure, even if the tumor is not malignant. Thus, the biopsy device includes a system for obtaining a core biopsy sample of sufficient size to encircle a suspect area. Thus, a circular cutting edge is provided at the leading edge of a tubular biopsy instrument.
Because, in the general case, the suspect tissue is identified or confirmed radiologically, its location may be verified radiologically, or by ultrasound or other method. As shown in FIGS. 1A-1H, in a fluoroscopic procedure, a standard type of specially adapted radiopaque guide wire 3 is inserted along a surgical biopsy axis, through the center of the suspect tissue 1, with a barbed retaining portion 5 extending a short marginal distance beyond the suspect tissue 1. An X-ray source 100 emits X-rays 101, which are received by an X-ray detector 102, to visualize the suspect tissue 1, in the breast 2, simultaneously with the guide wire 3, to accurately position the barb 5 beyond the suspect tissue 1 along a desired axis. Where ultrasound or other technique is employed to localize the guide wire 3, the guide wire 3 is provided with a detectable property for that localization method to allow simultaneous detection of the location of the suspect tissue 1 and the guide wire 3 for simple confirmation of placement. Of course, it is also possible to use different localization methods for the suspect tissue 1 and the guide wire 3 and employ a correlation system to correlate the respective locations.
The biopsy instrument is inserted with the guide wire 3 centrally placed along the axis of the tubular shaft 12 of the biopsy device. Centering devices 13 may be provided to self-center the guide wire 3 within the biopsy device. For example, one or more inserts 85, shown in FIG. 4, pressed against the inner wall of the tubular shaft 31, with a small central aperture 86 for the guide wire 3 may be provided. The aperture is optionally adjacent to a "V" shaped groove 133 to facilitate positioning of the guide wire 3 in the aperture 86. These may be fixed in place, or adapted to slide within the tube. The elongated tubular member 31 may also have an open end near the handle 46, so that the device may also be sight guided to the suspect tissue 1 site.
When the biopsy device is in position, the actuator 40, which is in the form of a trigger, e.g., a finger operated depressible member, is depressed, causing a force transmission element, e.g., a sliding steel member 29 in a rectangular second aperture within the wall of the tube, to slide distally. This sliding steel member 29 is fixed to a circular slide 36 by a clamp 84. The sliding steel member 29 is contained within the second lumen 80, so that it cannot buckle, exiting at aperture 82. The sliding steel member 29 is stiff enough so that it does not buckle in the region beyond the end of the tube 31, yet elastic enough that it is flexible. The sliding steel member 29 forces the steel cutting edge 51, 50 forward. The sliding steel member 29 is preferably integral with the steel cutting edge 51, 50, and linked in the central portion 55. The steel cutting edge 51, 50 is pivoted at two diametrically spaced pivot points 55, 52 about the end of the tube 31. Therefore, the pressure of the sliding steel member 29 causes the steel cutting edge 51, 50 to swing in an arc about the pivot points 55, 52. The sliding steel member 29 flexes along the arc of the steel cutting edge 51, 50.
The guide wire 3 preferably is marked or demarcated at critical lengths, so that it can be reliably verified when the apex of the arc of the cutting edge 51, 50 is beyond the end of the guide wire 3. Thus, the guide wire 3 may have a device at a fixed length from the tip, which is adapted for cooperation to the biopsy device, so that the relation may be determined by mechanical, electrical or other automated means. Otherwise, a visual indicator may be provided for visual confirmation of the relative placement of the guide wire 3 and the biopsy device. Preferably, a mechanical link of the insert 85 is provided in a portion of the elongated tubular member 31 near the handle 46. During the cutting by the cutting edge 50, a slight retraction is provided on the guide wire 3, of sufficient force to stabilize the guide wire 3 and to allow the instrument to advance, assisting the tissue core into the elongated tubular member 31, yet small of small enough magnitude not to disturb the placement of the barb 5 within the tissue. Thus, after the tissue core sample is severed, it is contained within the elongated tubular member.
After the tissue is severed, the biopsy device is removed. Standard techniques are then employed to close the wound, such as sutures 17 and provide the necessary hemostasis.
EXAMPLE 2
The biopsy device is constructed as a triple lumen elongated tubular member 31 formed of polycarbonate plastic. The tube has an ID of 2.5 cm, with a wall thickness of 2 mm. Within one portion of the wall, the second lumen is provided as a 1 mm thick, 4 mm wide rectangular opening, into which the sliding steel member 29 fits. If necessary, the sliding steel member 29 may be treated with an acceptable lubricating material, such as a PTFE film, in order to prevent binding within the sliding path of the lumen 80.
An ergonomically designed handle 46 is provided attached to the elongated tubular member 31, so that the elongated tubular member 31 is parallel to the arm of the surgeon when the handle 46 is held in the surgeon's hand. A trigger actuator 40 is attached in front of the handle 46, so that it is depressible by the surgeon's fingers. The trigger actuator 40 is attached to the sliding steel member 29 by the clamp 84 on a circular sleeve 36 which rides outside the elongated tubular member 31, so that a depression of the trigger 40 against the handle 46 causes the sliding steel member 29 to extend distally within the sliding path of the lumen 80, toward the tip of the device.
With the configuration described, the sliding steel member 29 must move approximately 1/2 πD (0.5×3.14×2.5) or 3.9 cm. Of course, this distance depends on the size and configuration of the instrument, and will vary accordingly. This movement is provided by direct action of an arm 39 linked to the trigger actuator 40 about a pivot axis 45, or a compound machine for multiplying the distance moved by the trigger, thus reducing the required trigger travel. The arm 39 slides between two guides 41, 42, and is held to the trigger actuator 40 by a pin 44 which rides in a groove 43. The arm 39 is linked by a pivot pin 38 on an extension 37 of the circular sleeve 36.
The trigger may be provided with a system to ensure that the cutting edge is not accidentally actuated, and after actuation it is reliably and full), actuated. Thus, a ratchet which does not allow the trigger to return to resting position until fully depressed, or another type mechanism may be provided. Another mechanism for assuring complete depression allows a mechanical signal to be transferred up the tube from the cutting device to indicate completion of the severing operation. This signal may be a compression-transmissive elongated member in a separate lumen of the tube wall, mechanically activated by the cutting member portion at full travel. Further, as noted above, the guide wire 3 may be provided with mild retraction, so that when the tissue is severed, it is urged into the tube. The release of the tension on the guide wire may also be used as a functional indicator of the completion of the severing operation.
At the tip of the biopsy device, a boring edge 53 is provided as the principal system for obtaining the tissue core. A central lobe 54 tapering to both sides of this sharpened steel member 71 allows a clean tissue cutting by the pressure of insertion, with a slight twisting or rotation. The lobe 54, along with the twisting, allows an inclined movement of the cutting edge with respect to the tissue to be cut, a preferred cutting method. Further, the cutting edge 50 faces forward during insertion of the device. Therefore, the sharpened cutting edge 50 may also assist in cutting the tissue core, although this is not its primary function, and it is preferred that the tissue be cylindrically cut before the cutting edge 50 reaches the tissue by a twisting of the biopsy instrument through an arc of ±90° about the long axis of the elongated tubular member 31 during insertion. In fact, an automated mechanism may also be provided to provide this twisting.
EXAMPLE 3
A multilobular boring edge may also be provided to reduce the amount of twisting necessary for this boring operation. The cutting edges 25, 26, in this case, are also provided with lobes 21, 22, and is involved in the boring operation as well. The lobes 21, 22 on the cutting edges 25, 26 may be helpful in severing the tissue core, acting in the same manner as the lobe 54 of the boring edge 53 to produce an effective inclination of the movement of the cutting edges 25, 26 with respect to the tissue to be cut. Because the cutting edges 25, 26 are involved in the boring operation, the edges 25, 26 are symmetric. Therefore, due to their symmetry, both edges 25, 26 move forward about a swing arc in the severing operation, in a jaw-like fashion to sever the tissue, reducing the cutting edge excursion approximately in half. Sliding steel members 32, 33 are provided linked to the sliding sleeve 36 by clamps 84, 87. The cutting edges 25, 26 are hinged about a flexion hinge 27, at a V-shaped notch 19, with a thin bridging portion 20. Opposite the V-shaped notch 19 is a V-shaped notch 18, which has separate edges linked to the counterbored groove 28, to form a hinge. These edges may be welded together. The trigger 40 simultaneously actuates both sliding steel members 29, 30, which may reduce trigger travel for full activation as compared to a single moving cutting member.
EXAMPLE 4
In construction, the cutting edge, boring edge, sliding member, hinge portions and means for attachment to the biopsy device of Example 1 and Example 3 are similar, shown in FIGS. 13-16 and 9-12 respectively, and formed of a single piece of stamped steel sheet. This steel sheet 70, 71 is divided into two lateral portions, the cutting side 26, 51 and the boring side 25, 53, linked by a narrow hinge section having a "V" notch 19, 57. The cutting edge 50, 24 has the steel sliding member 29 extending from a central portion thereof. The lateralmost edges of the cutting 18", 52" and boring 18', 52' portions are provided with means which cooperate to form a second hinge section, when rolled into a cylindrical form.
The side of the boring portion opposite the sharpened edge of the single-lobed embodiment of FIGS. 3, 13-16 is crimped 56 so that it can be inserted and firmly retained into a circular groove 60 in the end of the elongated tubular member 31. Thus, the sliding steel member 29 is inserted into the second aperture 80 of elongated tubular member, while boring portion 53 is mechanically attached in fixed relation to the elongated tubular member 31.
EXAMPLE 5
FIG. 2 also shows an optional electrosurgical device included with the instrument. In this case, an electrosurgical element 110, which is, for example, a heater as disclosed in U.S. Pat. No. 4,485,810 or an electrocautery system as disclosed in U.S. Pat No. 4,232,676, both of which are expressly incorporated herein by reference. The electrosurgical element is connected by wires 111, through a cable 112 from the handle 46 portion to an electrosurgical device control, not shown. A manually operated electrosurgical device control may be provided on the handle 46, or as a foot-pedal. In addition, the electrosurgical device may be automatically operated in conjunction with the trigger actuator 40.
EXAMPLE 6
Additionally, FIG. 2 shows an optical system for illuminating the area distal to the handle. For this purpose, a fiber optic member 121 is provided, having light emitting tip 120. The fiber optic member 121 is positioned inside, within the wall or outside of the elongated tubular member 31. The fiber optic member 121 is connected by fiber optic cable 122 to an external illumination source, not shown. In conjunction with an illumination system, an endoscopic viewing system and/or irrigation system may also be provided for use in conjunction with the instrument.
EXAMPLE 7
FIG. 3 shows an optional guide wire retention mechanism. The guide wire 3, with barb 5, is inserted into suspect tissue 1, within the breast 2. The biopsy instrument is then positioned coaxially around the guide wire 3, with the guide wire 3 passing through an aperture 131 in a centering device 130. The guide wire 3 is provided with a length indicator position 132 at a fixed position from the barb 5. A "V" notch 133 may be provided to facilitate positioning of the guide wire 3 in the aperture 131. When the biopsy instrument is at an appropriate depth, as determined by a relative positioning of the length indicator position 132 with the aperture 131, a lock device 134, which mays also provide some compliance and apply a slight tension, clamps the guide wire 3 in fixed relation to the aperture 131. The lock device may include a set of serrated jaws 136 which clamp, by means of a manual clamping lever 137. Alternatively, a Jacob's-type chuck (not shown in the drawings) may be used to clamp the guide wire by twisting an outer locking ring, or another type locking mechanism may be employed. As the cutting edge 50 severs the breast tissue, the biopsy core sample will be within the lumen of the elongated tubular member 31 and retained in relative position during withdrawal of the biopsy instrument. This system also ensures that the suspect tissue is within a cutting arc 135 of the cutting edge 50.
EXAMPLE 8
A biopsy instrument is provided with a central guide cannula affixed to the device, the central guide cannula having a central aperture for following the guide wire to the suspected tumor. Because of the mass of the biopsy instrument, it may be preferable to have a detachable central guide cannula with is fed over the guide wire and then attached to the biopsy device. The guide wire then extends out from the rear of the instrument. The instrument is then guided among the path of the cannula and guide wire to the suspected tumor, penetrating the breast. The end of the cannula may be echogenic, allowing ultrasonic localization.
The biopsy instrument therefore includes one or more spider-type centering devices through which the stiffening cannula passes, which orient the biopsy device. Since the end of the stiffening cannula is preferably near the end of the guide wire or hook wire, the instrument must be displaceable with respect to the stiffening cannula along its axis. The stiffening cannula may also be locked in place with respect to the instrument, by means of, e.g., a compressed rubber frictional lock or a mechanical interlock. The lock is used to prevent the instrument from accidentally pushing into the breast tissue. A shroud may also be provided around the sharpened edges of the biopsy device, which is retracted when the instrument is immediately ready for use, exposing the sharp edges. The shroud increases the safety of the surgeon, hospital staff and patient. A marker is provided on the stiffening cannula or support system to indicate that the biopsy device has reached the desired location. The cutting tip of the biopsy device moves past the tips of the guide wire and the stiffening cannula and severs the biopsy specimen. The biopsy instrument is then withdrawn with the tissue sample, guide wire, and stiffening cannula inside. The tissue sample is then removed through the front of the instrument, preferably with the shroud in place, with the guide wire and stiffening cannula disengaged from the locking mechanism.
While the present invention is described with respect to specific illustrative embodiments thereof, which are not limiting on the scope of the invention, it will be understood that it is capable of further modifications and changes may be made without departing from the spirit and scope of the present invention. Therefore, the scope of the invention is limited only by the appended claims. | A surgical core biopsy apparatus, having a hollow elongated member with an axis and a leading end, a sharpened edge at a portion of the leading end for cutting tissue along the axis, an actuator, and a cutting edge, linked to the actuator, being movable along a path including a transverse component to the axis, effective for severing tissue along an the path. The path is preferably an arcuate path, the cutting device being pivoted about an axis transverse to the axis of said hollow elongated member at said leading end. The actuator preferably acts by way of a compression force transmitted along the axis by a compression member, from a handle portion to the cutting edge. The elongated member is preferably a tube having two or more lumens, a first large centrally located lumen for accommodating a tissue core sample, and at least one other eccentrically located rectangular cross section lumen containing the compression member. The biopsy apparatus may be used, for example, to obtain a percutaneous excision breast biopsy from a tumor whose location is marked with a radiopaque guide wire. | 0 |
FIELD OF THE INVENTION
[0001] This invention relates to methods for preparing powder for injection. In particular, the present invention relates to a method for preparing tobramycin sulfate powder by spray drying.
BACKGROUND OF THE INVENTION
[0002] Tobramycin is a very hygroscopic aminoglycoside antibiotic that is extracted from the fermentation of Streptomyces tenebrarius. Two major impurities and a degradation product specified in European Pharmacopeia (EP) are kanamycin B, neamine (impurities), and nebramine (degradation product), respectively. It shows an antibacterial effect on the gram-negative bacteria when formulated as ophthalmic, inhalant, and injectable dosage forms. Generally, the injectable dosage forms of tobramycin include Tobramycin Injection and Tobramycin for Injection. The former one is a tobramycin sulfate solution with the addition of preservatives and anti-oxidants, and the latter one is tobramycin sulfate powder without any other excipients. As the Tobramycin for Injection is concerned, it is generally prepared by lyophilizing (freeze-drying) a sterile tobramycin sulfate solution. Although the lyophilization process for powder for injection is well-developed in pharmaceutical industry, it is still inefficient on drying and requires high energy consumption. Moreover, low throughput is another demerit due to the long cycle time, i.e., about 24 to 48 h. Thus, the lyophilization process is essentially time-consuming and expensive.
[0003] Spray drying is one of the conventional techniques in chemical industry since 1920s and has several advantages, compared to the lyophilization process. For example, the spray drying process can save more than 50% energy cost in comparison to the lyophilization process. Generally, the spray drying process mainly includes three stages. The first one is the atomization of the concentrated solution into numerous liquid droplets.
[0004] Second, the liquid droplets contact with the heated gas, e.g., air or N 2 , and then the liquid droplets evaporate to accompany with the nucleation of particles in a short period about a few seconds. Finally, the dried particles are collected by a cyclone system incorporated with a bag filter or wet scrubber. In view of industrial processes, the advantages of spray drying include the continuous mass production, automated controlling, higher energy efficiency, and feasible applications for both heat-resistant and heat-sensitive materials. Therefore, the application of spray dryers is widely adopted in industry. However, it is rarely in the aspect of manufacturing active pharmaceutical ingredients (APIs) so far.
[0005] In 2008, Pilcer had reported that tobramycin suspension can be spray dried to prepare tobramycin powder for inhalation in his dissertation. In the study, tobramycin suspensions were firstly prepared by using a homogenizer to disperse tobramycin powder into isopropanol solutions containing 0 to 20% (v/v) water. After the tobramycin suspension was spray dried, the prepared powders were filled with capsules as the tobramycin powder for inhalation. The same results were also disclosed in other publications.
[0006] The above prior art described the preparation of tobramycin powder for inhalation by spray drying a tobramycin suspension, in which isopropanol is used as continuous phase. However, the prepared tobramycin powder is different from tobramycin sulfate and not suitable for intravenous use in consideration of the residual isopropanol, which is toxic to health. Also the chosen isopropanol is a flammable solvent which increases the possibility of explosion during spray drying. In addition, isopropanol is not environmentally friendly. On the other hand, the solid content of prepared tobramycin suspension is merely 5% (w/v) which is much lower than the saturated solubility of tobramycin in water. Thus the production rate of spray drying tobramycin is quite low and impractical. Moreover, the injectable dosage form, i.e., powder for injection, is used more widely in comparison to the dry powder inhalation (DPI) due to its effectiveness and ready-to-use.
[0007] Accordingly, the present invention provides a method of spray drying for preparing tobramycin sulfate powder that can be formulated as Tobramycin for Injection and reconstituted for intravenous administration.
SUMMARY OF THE INVENTION
[0008] The present invention provides a method for preparing tobramycin sulfate powder. The method includes steps of: providing a sterile tobramycin sulfate solution; aseptically spray drying the tobramycin sulfate solution to obtain tobramycin sulfate powder that can be collected by a cyclone system incorporated with a wet scrubber. The prepared tobramycin sulfate powder can be formulated as Tobramycin for Injection and reconstituted for intravenous and intramuscular administration.
[0009] Preferably, the present invention further comprises steps of: dissolving the tobramycin powder in water to obtain a tobramycin solution; mixing the tobramycin solution and a sulfuric acid solution to form a tobramycin sulfate solution; and aseptically filtrating the tobramycin sulfate solution by a membrane filter.
[0010] Preferably, the tobramycin powder is made of tobramycin hydrate or tobramycin anhydrate.
[0011] Preferably, the sulfuric acid solution and the tobramycin solution are mixed with a molar ratio of sulfuric acid to tobramycin in a range between 1.10 and 2.50.
[0012] Preferably, the tobramycin sulfate solution has a concentration in a range from 4 wt % to 40 wt %.
[0013] Preferably, the tobramycin sulfate solution has a temperature in a range from 5° C. to 40° C.
[0014] Preferably, the step of aseptically spray drying the tobramycin sulfate solution is performed at an inlet temperature of drying gas in a range from 80° C. to 240° C. In various embodiments of the present application, the step of aseptically spray drying the tobramycin sulfate solution is performed with a drying gas selected from air, nitrogen, and inert gas.
[0015] Preferably, the tobramycin sulfate powder has an amorphous structure or a partially amorphous structure.
[0016] In accordance with the embodiments of the present invention, the method is constructed to manufacture tobramycin sulfate powder that can be formulated as Tobramycin for Injection and reconstituted for intravenous administration.
BRIEF DESCRIPTION OF THE DRAWINGS
[0017] FIG. 1 shows the effects of H 2 SO 4 /tobramycin molar ratios on the pH value of constituted tobramycin sulfate solution according to the present invention;
[0018] FIG. 2 shows a thermogram obtained from Differential Scanning calorimetry for spray dried tobramycin sulfate powder according to the present invention;
[0019] FIG. 3 shows a thermogravimetric analysis for spray dried tobramycin sulfate powder according to the present invention; and
[0020] FIG. 4 shows a X-ray diffraction pattern of spray dried tobramycin sulfate powder.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0021] The present invention provides a method for preparing the tobramycin sulfate powder by spray drying and such powder can be used as tobramycin for injection or reconstituted as tobramycin injection for IV administration. In the following preferred embodiments, the invention is specifically described. However it is not limited to the embodiments.
[0022] In the preferred embodiments of the invention, the tobramycin free base powder with an assay of 940 μg/mg and water content of 4.5% is supplied from a pharmaceutical company listed on the Drug Master Files (DMFs) of tobramycin API. It meets the quality specification of tobramycin in United State Pharmacopeia (USP). The sulfuric acid solution and Water for Injection are available from local suppliers.
EXAMPLE 1
[0023] In the preferred embodiments, the spray dryer, SD-06AG (from LabPlant UK Ltd.), mainly contains a peristaltic pump, a nozzle, a compressor, a blower, an electric-wire heater, a drying chamber and cyclone. In addition, a wet scrubber built by a local company is connected to the gas outlet of the spray dryer in order to recover the uncollected spray dried powder from cyclone. At the beginning of the spray drying process, the spray dryer was actuated in the preferred conditions and maintained for 30 min in order to achieve heat balance therein. In the meanwhile, the tobramycin powder was dissolved in water in a flask filled with nitrogen, and then the tobramycin solution was mixed with sulfuric acid to form a tobramycin sulfate solution. The tobramycin sulfate solution was further stirred for 15 min at a temperature ranged from 5° C. to 40° C., and then filtrated by a membrane filter with a pore size less than or equal to 0.2 μm. After that, the spray dryer was charged with the tobramycin sulfate solution. The fed tobramycin sulfate solution was atomized by a two-fluid nozzle to form numerous liquid droplets in a drying chamber, and then tobramycin sulfate powder precipitated with the evaporation of water and nucleation of tobramycin sulfate for a short period about milliseconds to a few seconds. The prepared tobramycin sulfate powder was collected by a cyclone system incorporated with a wet scrubber. Finally, The prepared tobramycin sulfate powder was maintained in a collector for 15 min for another heat balance after the tobramycin sulfate solution was drained out, and then the tobramycin sulfate powder was unload in a collector. The tobramycin sulfate powder was examined by the reported analytical HPLC method in the current USP monograph for tobramycin, and measured by Karl Fischer titrator. In addition, the absorbance is also utilized as a quantification tool for the discoloration of reconstituted solution.
EXAMPLE 2
[0024] The pH value of each constituted solution containing 40 mg tobramycin/ml was controlled by the ratio of H 2 SO 4 /tobramycin as shown in FIG. 1 . Thus the composition of tobramycin sulfate powder was modified by adjusting the molar ratio of H 2 SO 4 /tobramycin.
[0025] Due to the specified pH ranged from 6.0 to 8.0, the molar ratio of H 2 SO 4 /tobramycin was controlled in a range from about 1.10 to about 2.50.
[0026] In addition to the specified ratio of H 2 SO 4 /tobramycin, the concentration of tobramycin sulfate solution was about 4 wt % to about 40 wt %, more particularly about 6 wt % to about 30 wt %. In the process of preparing the tobramycin sulfate solution, the system was filled with nitrogen gas in order to prevent the contact of air or oxygen with the tobramycin solution, which is isothermal at 25° C.
[0027] A 30 wt % tobramycin sulfate solution with a H 2 SO 4 /tobramycin molar ratio of 2.4 was spray dried by using air as the drying gas in the form of co-current, at an inlet temperature of 200° C. for drying gas, a liquid flow rate of 192 ml/h, and a gas flow rate of 42 CMH. The spray dried tobramycin sulfate powder had the water content of 3.24% and the yield was 45%. Also the measured content of impurities remained the same as that in tobramycin API. Furthermore, the tobramycin sulfate powder was reconstituted as a solution containing 40 mg tobramycin/ml and the measured pH was 6.46 within the pH specification of tobramycin for injection in USP.
EXAMPLE 3
[0028] In another embodiment, nitrogen was used as the drying gas in the spray dryer and the other conditions remained the same as those in EXAMPLE 2. The resultant tobramycin sulfate powder had the water content of 1.86% and the yield was 59%. Moreover, the spray dried tobramycin sulfate powder was further dried by a rotary-evaporator in vacuum to obtain powder with about 0.95% water content within the specification in USP. In addition, the thermal property of tobramycin sulfate powder was analyzed by Differential Scanning calorimeter (DSC) and Thermogravimetric Analyzer (TGA). The DSC thermograph of FIG. 2 represented that the tobramycin sulfate powder had an endothermic melting point between 258° C. and 290° C. overlapping with an exothermic oxidation one at about 276° C. Furthermore, the TGA result in FIG. 3 revealed that the weight loss for oxidation of tobramycin sulfate powder had initiated at temperature higher than 200° C. In addition to the above thermal properties, the crystal structure of tobramycin sulfate powder was characterized by X-ray diffraction pattern in FIG. 4 . Apparently, the amorphous form of the spray dried tobramycin sulfate powder is attributed to the fast evaporation rate of water and rapidly primary nucleation of cluster during the short drying period. Finally, the tobramycin sulfate powder was reconstituted as a solution containing 40 mg tobramycin/ml and the pH of the solution was 6.49.
EXAMPLE 4
[0029] In another embodiment of the present application, a 6 wt % tobramycin sulfate solution and 392 ml/h liquid flow rate were used, and the other parameters remained the same as those in EXAMPLE 3. After spray drying, the tobramycin sulfate powder still had the water content of 4.38% and the yield was about 62%. Also the resultant powder was reconstituted to a tobramycin sulfate solution containing 40 mg tobramycin/ml. As to the pH and related impurities in the reconstituted solution, they were within the USP specifications.
EXAMPLE 5
[0030] In another embodiment of the present application, the inlet temperature of drying gas was controlled at 100° C. The other conditions including the drying gas, the H 2 SO 4 /tobramycin molar ratio, the liquid flow rate, and the gas flow rate were the same as those in EXAMPLE 3. The spray dried powder contained 5.58% residual water and the yield was about 47%. Furthermore, the spray dried tobramycin sulfate powder was continuously dried by a rotary-evaporator in vacuum. Thus the water content of the dried powder was decreased to about 1.34%. In addition, the bulk density and tapped density were measured to estimate the flowability of tobramycin sulfate powder according to the Carr's index. The analysis showed that the bulk density and tapped density were 0.43 g/cm 3 and 0.53 g/cm 3 , respectively. Accordingly the Carr's index of tobramycin sulfate powder was about 18.8 that represents a fair flowability. Moreover, with respect to the impurities and pH of the reconstituted tobramycin sulfate solution containing 40 mg tobramycin/ml as shown in Table 1, the spray dried tobramycin sulfate powder had an acceptable quality within the specifications provided by USP. In addition, the difference of absorbance in Table 1 was insignificant so that the discoloration of reconstituted solution was not a concern.
[0000]
TABLE 1
Tobramycin
sulfate solution
Tobramycin sulfate solution
reconstituted from
constituted from
spray dried
EXAMPLE 5
tobramycin free base
tobramycin sulfate
Nebramine
0.07%
0.06%
(HPLC, %)
pH of solution
6.22
6.56
Absorbance at 400 nm
0.027
0.038
incident light | A method for preparing tobramycin sulfate powder for injection is provided. The method includes steps of providing a sterile tobramycin sulfate solution; and aseptically spray drying the tobramycin sulfate solution to obtain the tobramycin sulfate powder. | 0 |
DESCRIPTION
The invention relates to the field of movement mechanisms for the limbs of a toy, in particular to the mechanisms for moving the legs of a doll, in order to simulate a walking motion.
A number of mechanisms for simulating the walking movements in a doll have already been designed. A common problem for these mechanisms is restricting the overall dimensions of the same so that they can be inserted in a body structure of a doll, even one small in size.
A previous patent application describes a mechanism of the above type which moves an end gear, starting from a worm screw driven by a battery-powered motor. The end gear has two off-center means, at 180° from each other, which move rigid wires placed in the legs of the doll. Difficulties have been encountered in achieving movement from a worm screw. A further disadvantage of the prior mechanism is that it can only be applied to dolls having legs integral with the body, while it cannot be usefully applied to dolls with jointed legs.
Moreover the movement mechanisms currently available on the market for the movement of jointed dolls involve a transmission with several gears, with considerable bulk, which cannot be miniaturized in order to adapt them to so-called "fashion dolls", which are normally small in size.
An object of the invention is therefore to achieve movement of the legs of a doll effectively and similarly to a walking motion, with means which are small in size.
A further object of the invention is to obtain such a system of movement which can be used for dolls with jointed or articulated legs.
These objects and others of the invention have been achieved with an assembly as mentioned in claim 1. Additional features are listed in subsequent claims.
In other words the new movement mechanism assembly comprises, starting from a driving shaft contained in a doll body structure, a gear-wheel transmission supported inside the body structure, which ends with an output wheel which holds on two opposite faces two eccentric pins, which are angularly off set by approximately 180° one in relation to the other. Each pin is rotatably engaged in a leg support-leg engaging element. Each leg support element has a U shape, with one branch of the U engaged on the eccentric pin. The leg support element is also engaged in a special opening of the body structure. The second branch of the U holds per se known means, which are suitable for engaging an end of a leg of the doll so that it can be rotated around the axis of the pin.
The new assembly can easily be manufactured in a small size and at a low cost; it allows a walking movement which is fairly similar to that of humans; it can be adapted for dolls with jointed legs.
These and other features and advantages of the invention will be made clearer hereinunder by a description thereof given only by way of a non-limiting and illustrative example, with reference to the accompanying drawings, in which:
FIG. 1 is a sectional view taken along a plane denoted schematically by 1--1 in
FIG. 2, through a body structure of a doll; the transmission mechanism is shown in side view;
FIG. 2 is a sectional view taken substantially along plane 2--2 in FIG. 1;
FIG. 3 is an enlarged sectional view of a U-shaped leg-holding element, with an upper part of the leg mounted thereon;
FIG. 4 is a side view of the leg-holding element, from the right in relation to FIG. 3;
FIG. 5 is a side view of the leg-holding element, from the left in relation to FIG. 3;
FIG. 6 shows two angularly off-set positions which the two right-hand and left-hand leg-holding elements can assume during the walking motion; the section plane of the drawing is like that of FIG. 2;
FIG. 7 shows two vertically off-set positions, which the right-hand and left-hand leg-holding elements can assume during the walking motion;
FIG. 8 shows various possible positions for the same leg-holding element during an operating cycle.
In the drawings, the assembly of the invention is referenced by 10. It comprises, in a doll's body structure as a whole referenced 12, pairs of aligned housings 14, 14' and 15, 15' vertically spaced one from the other, for holding shafts of gears or pulleys. Further housings 16, 16' and 17, 17' are made in a central body part referenced 19. A movement mechanism, referenced 20 as a whole, comprises a motor 22 whose driving shaft 24 is connected, via a belt 26 and a pulley 28, in order to rotate a shaft 30 with the ends held in the housings 14, 14'. A pinion 32 is mounted on the shaft 30 and meshes with a gear wheel 34 held by a shaft 36. The shaft 36 is rotatably housed in the housings 15, 15' of the body. The shaft 36 holds in turn a pinion 38 which meshes with a gear wheel 40 carried by a rotating hub 42 held in the housings 16, 16'. The gear wheel 40 meshes with an end gear wheel 44 carried on a hub or short shaft 46, which is rotatably held in the housings 17, 17'. Two eccentric pegs or pins, referenced 48 and 48' respectively, are integral with the cogged wheel 44, on opposite faces of the hub 46. Said pins project laterally and are peripherally spaced by 180° one from the other. Each pin 48 engages a hole 49 of a leg-holding element, or leg support element generally referenced 50. One single leg-holding element 50 is drawn; it is understood that a similar element (not shown) is engaged on the pin 48'. The leg-holding element 50 is U shaped in front view, and comprises a first branch 51 and a second branch 52. The first branch has said opening 49 and is housed in a housing 53 of the body structure of the doll formed between the central body 19 and a lateral wall 54. A lower part of the U projects through a slot 57 in the body of the doll and the branch 52 of the U is positioned partly outside the lateral wall 54 of the body structure and ends with a tapered part 55 which is housed inside the body structure through an opening 56. Either slot 57 or opening 56 has a limited extension, slightly greater than the width of the element part 50 engaged therein. The branch 52 has, on its surface which is facing outwards, a pin 58 and circumferentially spaced stop projections 59, 59. A leg G of a doll, or a substantially rigid part thereof, is mounted on toothed pin 58 by means of a bushing 60 housed in a space 62 of the leg, and a plug 64 with cavity 68. A spring 65 and washer 66 are placed between a shoulder 61 of the U-shaped element and the plug 64. The leg is restrained on the pin 58 by means of the pin teeth which engage the cavity 68 in the plug 64.
When movement is transmitted to the driving shaft 24 from the motor 22, powered for example by batteries (reference numeral 70 denotes a space for batteries in the body of the doll), each eccentric pin 48, 48' transmits to the relevant leg-holding element a reciprocating upward and downward movement and, due to the fact that the walls of opening 57 or of opening 56 act as a fulcrum, also an oscillation movement combined therewith, as can be seen in FIGS. 6, 7 and 8. This movement imitates to a considerable extent the movement of the legs of a walking person. More particularly, with reference to FIGS. 6 and 7, a right-hand leg-holding element of the doll has been denoted by 50d, and a left-hand leg-holding element by 50s. It can be seen from FIG. 6 that the two legs take up a scissors-like position when the pegs 48, 48' are arranged with their axes in a horizontal plane (FIG. 6) while they assume a vertically off-set position when the two pegs 48, 48' are aligned with their axes in a vertical plane (FIG. 7). As can be seen from FIG. 8, the leg of the doll moves in a movement which largely imitates human walking.
It can be seen how the fact of supporting the axles of the gear wheels in special housings formed in the body structure of the doll enables the mechanism to be miniaturized in order to allow its use also in small-sized dolls. | A movement assembly particularly for the legs of a doll comprises a geared transmission whereof the end wheel, supported on the body structure of the doll, has two opposite eccentric pins (48,48'), one for eah leg. On each of the pins a movable U-shoped element (50') is rotatably engaged and is mounted and restrained to the body structure of the doll in order to be driven by the respective eccentric pin in an upward and downward motion and simultaneously an oscillating movement. The U-shaped element has a pin (58) for assembly of the leg, which can be mounted thereon with the possibility of being rotated around the pin. | 0 |
CROSS-REFERENCE TO RELATED APPLICATION
This application is based upon, and claims priority from, my Provisional Application No. 61/853,269, filed Apr. 1, 2013.
FIELD OF THE INVENTION
This invention relates to ball hitch systems of the type used in trucks for pulling or towing gooseneck trailers. More particularly, this invention relates to use of a ball hitch for supporting different types of hitches or a variety of workpieces.
BACKGROUND OF THE PRIOR ART
Conventional ball hitch systems used in trucks (e.g. pickup trucks) include a ball which is secured to the frame of the truck in the bed area. A trailer can be connected to the ball for towing purposes. Normally the trailer includes a vertical stem or shank with an opening in its lower end to receive the ball. The vertical stem further includes a locking mechanism to secure the stem to the ball for towing.
Sometimes it would be of great benefit if the existing ball hitch system could be used for supporting various types of workpieces, such as a vise, or a work table, or lift bucket, for example.
U.S. Pat. No. 7,740,266 (Marcy) describes a system for attenuating intermittent forces at the interconnection between a towing vehicle and a trailer. In one embodiment the system includes an air spring or cushion which acts as a shock absorber between the trailer and the towing vehicle. The system can be connected to a ball hitch which may also include a fifth-wheel hitch for a camper trailer, for example.
There has not heretofore been provided a ball hitch conversion system having the advantages and features of the present invention.
SUMMARY OF THE INVENTION
In accordance with the present invention there is provided a system for converting a ball hitch to a support for a variety of workpieces. The workpieces may be, for example, a work table, a winch, a vise, an arm for a lift bucket (e.g. a cherry picker), a fifth-wheel hitch system, etc. In one embodiment, the support system preferably comprises:
(a) a tubular housing;
(b) attachment means for detachably securing the housing to a ball hitch in a truck bed; wherein the attachment means comprises at least one lock pin carried by the housing which is movable between retracted and extended positions; wherein when the pin is in the extended position it secures the housing to the ball hitch. A workpiece can then be secured to the tubular housing in a number of manners.
Other advantages and features of the system of this invention will be apparent from the following detailed description and accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention is described in more detail hereinafter with reference to the accompanying drawings wherein:
FIG. 1 is an elevational view (partially cut-away) of one embodiment of a ball hitch conversion system of the invention.
FIG. 2 is a side elevational view (partially cut-away) of one embodiment of ball hitch conversion system of the invention.
FIG. 3 is a side elevational view of another embodiment of ball hitch conversion system of the invention.
FIG. 4 is a top view of the ball hitch conversion embodiment of FIG. 3 .
FIG. 5 is an exploded view of one embodiment of the invention in conjunction with an air cushion.
FIGS. 6 , 7 , 8 , 9 , 10 and 11 illustrate other uses of the ball hitch conversion system of the invention.
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 shows a front elevational view, partially cut-away, of one embodiment of a ball hitch conversion system 10 of the invention. This embodiment includes housing 12 (preferably ¼ inch wall 4×4 tube) which will fit over the ball 80 of a conventional ball hitch (which is secured to a truck bed). In FIG. 1 there are shown two locking pins 13 and 14 which are adapted to move in separate guideways 13 A and 14 A between retracted and extended positions to lock the housing onto the ball. The locking pins preferably each comprise a cylinder which has internal threads in each end. A bolt 15 is threaded into each such end of each cylinder. The depth of the thread is matched to the length of the bolt so that when the bolts are tightened they do not clamp against the outside of the housing. Thus, each bolt and cylinder assembly is retained in the housing but can move freely in the guide slots 13 A and 14 A.
The means for moving the locking pins from their retracted position to their extended position may vary. FIG. 1 shows two different ways for moving the locking pins. On the left side of FIG. 1 there is shown a set screw 16 which is threadably secured in a bracket 18 welded onto the outside of the wall of the housing 12 . The leading end of this screw contacts the side of lock pin 13 and causes it to move upwardly toward the neck portion of the ball. The dotted lines show the extended position of the lock pin 13 where it makes contact with the ball. On the opposite side of the ball there is shown locking pin 14 which also moves in a guideway to contact the neck portion of the ball. This pin 14 is caused to move by means of a cam member 20 which pivots about an axle or pin 21 when associated set screw 17 is turned. Brackets 19 A and 19 B support the cam and associated set screw 17 . Bracket 19 B is welded to housing 12 and also to bracket 19 A and supports axle or pin 21 about which the cam can pivot.
Thus, FIG. 1 shows alternative means for moving the locking pins 13 and 14 from their retracted position to their extended positions in the housing to lock the housing to the ball. FIG. 1 also shows one type of centering or guide ring 22 welded within the housing to help center the ball within the housing. The guide ring should be positioned near the large diameter of the ball and can be a plate or a ring.
FIG. 2 is a side elevational view (partially cut-away) of the ball hitch conversion system of FIG. 1 . This shows locking pin 14 positioned against the neck portion of the ball 80 . It also shows the manner in which the centering ring 22 maintains the ball 80 in the center of the housing 12 .
FIG. 3 is a side elevational view of a ball hitch conversion system in which the means for moving the locking pins involves the use of two set screws 24 and 25 which contact the pins directly to cause the pins to move upwardly in the guideways on opposite sides of the ball. The set screws are threaded through brackets 26 . FIG. 4 is a top view of the ball hitch conversion of FIG. 3 .
Thus, the ball hitch conversion system comprises a housing which can be positioned over a conventional hitch ball and is centered around a vertical axis of the ball. Preferably two cylindrical wedges or locking pins are included shown which have a diameter such that they can be wedged between the inside walls of the housing and the underside of the hitch ball. The system also includes means for retaining the wedges and moving them between retracted and extended positions. When the pins or wedges are forced upwardly to their extended position, the force pushes upwardly against the ball and equally forces the housing downwardly against the base of the ball, thereby locking the housing rigidly to the ball base support. Thus, anything that is fastened to the housing is also rigidly locked to the ball and its base support.
FIG. 5 is an exploded view illustrating another embodiment of a conversion hitch system of the invention. The ball capture system 10 of the invention is secured to the lower end of an elongated shank 70 which is intended to slide into the lower end of gooseneck receiver 90 on a gooseneck trailer. Set screws 92 are tightened to hold shank 70 in place.
FIG. 5 also shows an air cushion 60 which includes a ball 62 secured on its upper side which can be captured in the system 10 in accordance with this invention. The air cushion system 60 includes an inflatable air cushion 64 held between upper and lower plates 65 and 66 . One end of plate 66 is hinged on bar 67 to enable plate 66 to move up and down to absorb shocks during towing. The underside of cushion system 60 includes a coupler 68 enabling it to fit over, and couple to, existing ball 100 on truck bed 101 . Using the system of the invention, the air cushion can be adapted to a variety of different towing connections without modifying the cushion. This avoids the need to maintain a large inventory of special cushions. Thus, the system shown in FIG. 5 enables the cushion to stay with the trailer as opposed to staying with the truck or removing it for storage elsewhere.
FIGS. 6-11 illustrate other uses of the ball hitch conversion system of the invention. In FIG. 6 there is shown a winch 110 on a shank 111 which is slidably received in and pinned to mounting post 112 . The winch includes a cable and hook 113 and electrical leads 114 . The lower end of post 112 can include the ball capture system 10 of FIG. 1 , for example, so that the post can be mounted or coupled onto a conventional ball hitch in the bed of a truck.
In FIG. 7 a work table 116 (e.g. for supporting a welding project) is pinned to the upper end of post 112 . The lower end of post 112 can include the ball capture system of the invention.
In FIG. 8 there is shown a vise 118 pinned to the upper end of post 112 . In FIG. 9 there is shown a lift bucket (e.g. a cherry picker) mounted on an arm pinned to the upper end of post 112 . A hydraulic cylinder 121 is used to raise and lower the bucket, as needed.
FIG. 10 is a front elevational view (partially cut-away) showing another use of the conversion system of the invention, i.e. to convert a conventional ball hitch 100 in a truck bed 101 to a fifth-wheel hitch system. The lower end of the tubular upright support member or post 112 is detachably secured to the ball 100 by means of lock pins 140 which are urged upwardly against the neck portion of the ball by pivoting cam members 142 . A screw 143 , threaded through bracket 144 , is adapted to pivot about point 145 on each side of the ball to urge the associated cam member against a respective locking pin into the neck portion of the ball beneath the enlarged head portion of the ball.
The upper end of support member 112 preferably includes a curved support plate 122 . Attached to the top of plate 122 is the yoke 130 of a conventional fifth-wheel hitch system. The fifth-wheel hitch system includes a receiver portion 132 for receiving and capturing a conventional king pin which is secured to the trailer to be towed. Preferably, the yoke member 130 is attached to the central portion of plate 122 by bolt 124 . Surrounding bolt 124 is spring member 123 for biasing the yoke member back to its center position. Because of the gap 126 between the outer portions of the plate 122 and the yoke, the curved plate enables the yoke member to become tilted relative to the support member 112 (for example, when the towing vehicle and the trailer are traveling over uneven ground). This feature avoids damaging twisting of the trailer relative to the towing vehicle.
FIG. 11 illustrates one type of bracing which may be used in conjunction with use of the hitch system of FIG. 10 in a truck bed 101 . In this situation, brace members 152 (located forwardly and rearwardly of the support post 112 in the truck bed) are attached at their lower ends (by means of bolts 153 ) to the legs of an elongated support base 160 lying on the floor of the truck bed 101 , as shown. Leg extension members 150 can be bolted to the base 160 with bolts 163 . The base 160 includes a centrally located opening 161 which fits around the ball 100 in the bed 101 . The bolts 153 extend through the lower end of each brace 152 and through elongated slots 162 in base member 160 . The upper ends 152 A of the braces 152 lean against opposite sides of the support post 112 beneath stop members 115 (which may be, for example, metal bars welded or otherwise secured to the support post 112 on the forward and rearward surfaces, as shown). Turnbuckles 154 are attached at opposite ends thereof to the two braces 152 . When the turnbuckles are tightened, the upper ends of braces 152 are drawn upwardly against the stop members 115 , and the lower ends of braces 152 are pulled toward the support post (sliding the bolts in the slots 162 ) to complete triangular bracing of the support post. In this manner, the support post 112 is very rigidly held in a straight upright position during use.
The use of the ball hitch conversion system in conjunction with a fifth-wheel hitch is also described in my copending application Ser. No. 13/999,677, filed of even date. Other variants are possible without departing from the scope of this invention. | A system is described for detachably securing a housing to a ball hitch (e.g. of the type used in trucks for towing). The system includes a tubular housing for fitting over the ball, and attachment means for detachably securing the housing to the ball. A workpiece can then be secured to the housing, as desired. A preferred attachment means is a pair of opposing lock pins which are movable between retracted and extended positions. When the pins are in the extended position, they secure the housing to the ball hitch. The type of workpieces may vary. For example, the workpiece may be a work table, a vise, a fifth-wheel hitch system, a winch, or an arm for a lift bucket. | 1 |
DISCUSSION OF PRIOR ART AND BACKGROUND OF THE INVENTION
The subject invention relates in general to mechanisms that are used to integrally affix to land-based motor vehicles rail wheels to enable the motor vehicle to be driven over railroad tracks, such mechanisms required to be affixed so that the railwheels do not interfere with the rubber, land-based tires or their operation.
In this regard, it is to be noted that the deployment of rail wheels on a motor vehicle requires constant attention to the rail wheel positioning and alignment on the rails. In most instances, the rail wheels have a substantial tendency to wear on the outside portion of the wheel flange, as well as on other areas. The wearing process is caused in part by the outward forces constantly imposed on the outer surfaces of the rail wheel flanges as they ride on the rails. As this wear progresses significantly, the rail wheels become weakened, and thus become structurally unsound for their intended usage. A second problem that is encountered as this wear process develops is that the rail wheels become misaligned or spread apart relative to the opposing wheel so as to eventually cause some significant difficulty in maintaining the vehicle on the track.
In the prior and existing mechanical art that is employed as a maintenance procedure to alleviate the foregoing discussed wear problem, there are limited approaches to overcome the difficulty. One of the primary methods used involved the removal of each rail wheel on the axle, as a separate operation, whenever such spacing or alignment problems evolved, and readjusting and refitting the individual wheel back on the axle to the desired and correct spacing dimension. This process of removing each wheel individually is not only cumbersome, but is expensive and a relatively difficult procedure. Other methods utilized for this problem have proven to be equally difficult and cumbersome.
In view of the relative expense and difficulty with this rail wheel adjustment process, the subject invention has been conceived as an apparatus and process as an improvement to facilitate, at minimal expense and labor, the process of adjusting the intermediate distance between such rail wheels. The following objects of the subject invention are addressed accordingly.
OBJECTS OF INVENTION
It is an object of the subject invention to provide an improved apparatus for readjusting rail wheels on a rail bound vehicle;
It is also an object of the subject invention to provide an improved undercarriage apparatus for supporting rail wheels;
It is another object of the subject invention to provide an improved support device of an adjustable nature for supporting rail wheels;
Still another object of the subject invention is to provide an improved device for minimizing the wear and maximizing the function of rail wheels on a rail bound vehicle;
Yet another object of the subject invention is to provide an improved undercarriage support structure for rail wheels deployed on a motor vehicle adapted for non-rail and rail-based usage;
It is an object of the subject invention to provide an improved undercarriage wheel support system for a vehicle;
A further object of the subject invention is to provide an improved apparatus to minimize wear on rail wheels deployed on motor vehicles used to ride on both rails and ground or highway surfaces;
Other and further objects of the subject invention will become apparent from a reading of the following description in conjunction with the claims and drawings.
DRAWINGS
In the drawings:
FIG. 1 is a side elevational view of a support collar used in the subject invention;
FIG. 2 is a top elevational view of the subject apparatus;
FIG. 3 is a perspective view of the main transverse member used in the subject apparatus;
FIG. 4 is a front elevational view of the subject apparatus showing how the subject device is affixed as an undercarriage assembly to a motor vehicle;
FIG. 5 is a side elevational view of the transverse main support member;
FIG. 6 is a front elevational view of the subject apparatus showing how the wheel base adjustment is effected;
FIG. 7 is a front elevational view of the lower support brace;
FIGS. 8, 9, and 10 are end elevational views of the lower support brace showing the internal rubber torsion system, such views showing the brace in various load positions.
DESCRIPTION OF GENERAL EMBODIMENT
The subject invention is an improved frame mechanism adapted to be deployed and otherwise integrally affixed on a land based motor vehicle that is adapted or retrofitted with rail wheels in addition to conventional land based wheels, in order to enable the motor vehicle to ride on railroad tracks, in addition to being capable of being driven on non-rail surfaces. The apparatus incorporating the features of the subject invention comprises, in general, a longitudinally extending support system adapted to hold the rail wheels therein, which support system is connected to the motor vehicle base frame in a transverse manner, said support system being constructed to be laterally shortened or elongated to move the wheel members inwardly or outwardly to correspondingly adjust the distance between the rail wheels.
DESCRIPTION OF PREFERRED EMBODIMENT
In describing the preferred embodiment of the subject invention, it is to be noted that the following description shall be of one embodiment only of several that are within the scope of the invention herein, and this description of a particular embodiment shall not be considered as limiting the scope of the invention herein. Moreover, in describing the subject invention, the following nomenclature shall be used. The word "upper" shall refer to those areas above the ground level in the motor vehicle, while the word "lower" will refer to those areas adjacent or near the ground level as appertaining to a conventionally disposed motor vehicle, as described. The words "longitudinal central axis" will refer to that axis which runs symmetrically from front to back through the front to back center line of such motor vehicle. The word "transverse" refers to direction and dispositions that are perpendicular to such longitudinal central axis.
Referring now to the drawings and particularly to FIG. 4, a conventionally disposed motor vehicle 10 is shown, in part, through a portion of its undercarriage, specifically a drive axle 20, having a differential box 25, which such drive axle having affixed rubber based wheels 30A and 30B on opposing ends of such drive axle. In the embodiment shown in FIG. 6, the drive axle is appended to the rear portion of the underside 40 of the motor vehicle. Also integrally affixed to the undersurface 40 of such motor vehicle 10 is rail support undercarriage assembly 60, which is adapted to carry and support a pair of upwardly retractable rail wheels 100A and 100B, which rail wheels are adapted to ride on the opposing rails 120A and 120B, as seen in FIG. 4. As can be seen in the drawings, the rail wheels 110A and 110B are appropriately spaced and aligned relative to one another and aligned relative to the juxtaposed rubber-based wheels 30A and 30B so that when the rail wheels 100A and 100B are retracted downwardly to fit against the rails 110A and 110B, the bottom surfaces of the adjacent rubber tires 30A and 30B ride squarely on top of the particular rails underneath the vehicle 10. It is vital to the maneuverability of the vehicle 10 on rails 110 and 110B that the rubber drive wheels 30A and 30B be squarely emplaced on such rails, since motive power during the rail drive feature is still transferred from the power train of the motor vehicle 10 directly to drive wheels 30A and 30B. Thus, any misalignment of the rubber drive wheels 30A and 30B on such rails will result not only in inefficient power transfer, but will render it difficult to keep the motor vehicle 10 properly aligned on the tracks.
Motor vehicle 10, as can be surmised, has in addition to rear drive wheels 30A and 30B, a front set of rubber-based wheels, not shown, as well as a front set of retractable rail wheels, not shown. The front set of rail wheels have a similar undercarriage support assembly 60 as that shown for the rear assembly for rear rail wheels 100A and 100B and any drawings or description of such front assembly would be redundant and thus unnecessary. Therefore, specific attention will be given to the rear support assembly 60, as more fully discussed below.
Attention is again addressed to FIGS. 4 and 6 in which a detailed view of the rail wheel undercarriage assembly 60 is shown. As seen, the undercarriage assembly 60 is basically and generally a transverse member having a retractable apparatus which raises or lowers the rail wheels between the rail driven position shown in FIG. 5 to a retracted position folded up underneath the undersurface 40 of the vehicle 10. The latter retracted position is used when the vehicle 10 is not being driven over rails, but over roads or similar non-rail surfaces. As shown in FIGS. 4 and 6, the upper portion of the undercarriage assembly 60 is comprised of a pair of vertical brace members 200A and 200B. These latter brace members 200A and 200B are adapted to be integrally affixed, in a vertically downwardly depending manner, to the frame member 40 on the undersurface of the vehicle 10, as can be seen in the drawings. Further, as can be seen from a view of FIGS. 3 and 4, each vertical brace member 200A and 200B is an L-shaped member, as viewed from an upper elevational view with the rearwardly face 210A and 210B of each brace member having a plurality of evenly-spaced openings 230A, 230B . . . 230M and 240B, 240B . . . 240M, respectively, extending in an even row in series fashion from the upper end to the lower end of each such face 210A and 210B for the opposing brace members 200A and 200B respectively. As can be seen in FIG. 3, a transverse upper brace member 250 is affixed against the respective rear faces of vertical brace members 200A and 200B, as shown. As shown in FIGS. 3 and 4, the upper transverse brace 250 is a parallelopiped member, having a rectangular cross-sectional configuration with a hollow parallelopiped shaped interior 255. Upper transverse brace member 250 is adapted to extend transversely or perpendicularly to the longitudinally extending, front to rear, central axis of the motor vehicle 10. Securing the upper transverse brace 250 against the vertical brace members 200A and 200B are a pair of C-shaped collar members such as collar member 250A shown in FIG. 1. Collar members 270A and 270B are adapted to fit securely and conformingly around the outer surface of the rectangular cross-sectional configuration of the upper transverse cross brace member 250 as shown in FIG. 3. A pair of circular openings 290A and 290B are formed into the C-shaped collar 270A to receive conforming bolt members 300A and 300B, the ends of which, in turn, are insertible into a separated pair of the various openings 230A, 230B . . . 230M in the rear face of the vertical brace members 200A. In similar fashion, C-shaped collar 270B functions to connect the opposing side of the upper cross brace 250 to the rear face of the vertical brace 200B.
As shown in FIG. 3, each collar 270A and 270B can be moved up or down along the rear faces 210A and 210B of vertical braces 200A and 200B to correspondingly move the transverse brace 250 up or down limited distances determined by the spacing and number of openings 230A . . . 240M disposed, as stated, in the rear faces of the vertical support braces 200A and 200B. This vertical adjustment of the upper transverse brace 250 is accomplished by loosening the bolt members 300A, 300B, 310A and 310B and removing such bolts from the openings and repositioning them for the desired height location, as can be readily determined from a view of FIG. 3. As can be seen in FIG. 3, and as indicated above, the C-shaped clamps are adapted to fully grasp at least three outer face portions of the upper transverse brace member 250.
Referring again to the drawings, and particularly FIGS. 4 and 6, the upper transverse brace member 250 is the upper support of member. The specific structure of the upper cross brace member 250 in the preferred embodiment of the subject invention incorporates a hollow longitudinally extending internal chamber 500, with such internal chamber generally conforming to the outer shape of the cross brace member 250.
Rotatably affixed to each end of the transverse upper brace member 250 and longitudinally extending rotatable arms 600A and 600B that are affixed on their respective upper ends to the opposing ends of each end of the upper transverse brace member 250, as shown. As shown in FIGS. 4, 5 and 6, the rotatable arms 600A and 600B are vertically depending members that are adapted to move through an arc of approximately ninety degrees from a pivotal center defined by the longitudinal central axis of the transverse brace member 250, as seen, such ninety degree arc generally extending from a horizontal plane parallel to ground to a vertically downwardly position as seen in FIG. 4. As seen in FIG. 3 the upper portions of the rotatable arms 600A and 600B are rotatable between the fixed upper horizontal position to a fixed vertically depending position through hydraulic lifting means, not shown. These respective positions are rigidly fixed with the lower position being that position with the wheels moved downwardly.
Integrally affixed to the lower or distal ends 620A and 620B of the rotatable arms 600A and 600B is the lower transverse support bar member 800, as seen in FIG. 4, which functions to support the lower portion of the rail wheel assembly, as shown. In particular, the lower transverse support member 800 is movable up and down through an arc of ninety degrees from the upper raised position to the lower position with the rails positioned on the rails, as shown. More specifically, the lower ends of the rotatable arms rotate through hydraulic means to lift the lower transverse support ball through a ninety degree arc.
Integrally affixed to the lower portion of the lower transverse support beam are separate longitudinally extending wheel support members 900A and 900B that function to indirectly support the respective rail wheel axles 950A and 950B, as shown. As shown in the drawings, these wheel support members are adjustable in a longitudinal direction along axis C--C so as to adjust the distance between the rail wheels. Specifically, in order to accomplish this aspect, the rail axle support member has adjustable collars 980A and 980B that can be loosened to slide the rail support member in or out as depicted in FIG. 6. This will permit the rail axles 1000A and 1000B to be moved in and out for adjustment purposes. | The subject invention is an improved frame mechanism adapted to be deployed and otherwise integrally affixed on a land based motor vehicle that is adapted to retrofitted with rail wheels in addition to conventional land based wheels, in order to enable the motor vehicle to ride on railroad tracks, in addition to being capable of being driven on non-rail surfaces. The apparatus incorporating the features of the subject invention comprises, in general, a longitudinally extending support system adapted to hold the rail wheels therein, which support system is connected to the motor vehicle base frame in a transverse manner, said support system being constructed to be laterally shortened or elongated to move the wheel members inwardly or outwardly to correspondingly adjust the distance between the rail wheels. | 1 |
FIELD OF THE INVENTION
[0001] This invention relates generally to the art of making and using oilfield treatment gels. More particularly it relates to gelled foam fluids made of polymer and methods of using such fluids in a well from which oil and/or gas can be produced.
BACKGROUND
[0002] The statements in this section merely provide background information related to the present disclosure and may not constitute prior art.
[0003] Water control problems are ubiquitous in oil and gas reservoirs and they have many forms. One difficult problem is that of shutting off fractures or fissures in carbonate reservoirs without impacting the hydrocarbon production. The fissure or fracture tends to dominate flow to a producing well compared to the matrix flow. Commonly, the flow of hydrocarbons may move from the matrix into the fractures and from the fractures into one or more main fractures that intersect the wellbore. Because of the huge flow potential in a sizable opening, any fluid solution must be rather large in volume and able to resist extrusion after the treatment has finished and the well is placed on production. A further complication is the reservoir may contain a range of fissures, fractures and vugs, all of which have the potential to flow. Vugs have both flow potential and large storage capacity, while the capacity of fissures and fractures depend upon the width and the cementation. Since these features cannot be easily mapped, the volumes and geometry of the features are not known, leading to difficulties in designing a plugging treatment.
[0004] A similar problem has been encountered in drilling applications where lost circulation zones exist. These features tend to capture the expensive drilling fluid and must be plugged prior to continuing the drilling process. Cementing pipe in hole is subject to these features as well, and poor cementing can result because the cement is diluted by underground rivers or the fluid loss is so high that the cement cannot be propagated throughout the area requiring cement.
[0005] Various solutions exist for combating these problems and they generally are referred to as lost circulation material (LCM), lost circulation pills, plugs, gels, cement plugs, formation damage plugs, solids laden plugs, bentonite plugs, fiber plugs, etc. Some solutions include pumping water reactive materials in a non-aqueous fluid (clays and especially bentonite, organic polymers, cement) that tend to set when water is encountered; aqueous fluids that set into stiff gels (crosslinked-water soluble organic polymers, inorganic monomers that gel such as silicates and aluminum compounds, organic monomers that polymerize in situ); non-aqueous fluids such as resins; slurries of solids in aqueous or non-aqueous carrier fluids that plug indiscriminately such as walnut shells, diatomaceous earth or silica flour; and non-compatible waters which precipitate upon meeting in the reservoir.
[0006] Polymer gels have been widely used for conformance control of naturally fissured/fractured reservoirs. For an overview of existing polymer compositions, reference is made to the U.S. Pat. Nos. 5,486,312 and 5,203,834 which also list a number of patents and other sources related to gel-forming polymers.
[0007] Some of these solutions have been foamed with gas to plug a larger volume with the same amount of chemicals. Foams are often stabilized with polymers which restrict the drainage of the foam boundaries or plateau borders. Foamable gel compositions are described for example in the U.S. Pat. Nos. 5,105,884, 5,203,834, and 5,513,705, wherein the polymer content is reduced at constant volume of the composition.
[0008] The typical components of a foamable gel composition are (a) a solvent, (b) a crosslinkable polymer, (c) a crosslinking agent capable of crosslinking the polymer, (d) a surfactant to reduce the surface tension between the solvent and the gas, and (e) the foaming gas, itself.
[0009] A new gelled foam having enhanced properties of foam stability is proposed herewith.
SUMMARY
[0010] In a first aspect, a composition is disclosed. The composition is for use in a wellbore and consists essentially of a solvent, a surfactant, a foaming gas and a foam enhancer, wherein the foam enhancer by its own increases the viscosity of the composition and the stability of the foam. Also, the composition can be a gel composition for use in a wellbore comprising a solvent, a surfactant, a foaming gas, a foam enhancer, a crosslinkable polymer, and a crosslinking agent capable of crosslinking the polymer, wherein the foam enhancer increases the foam half-life of the gel composition compared to the gel composition without the foam enhancer.
[0011] In a second aspect, a method is disclosed. The method comprises injecting into a wellbore, a composition consisting essentially of a solvent, a surfactant, a foaming gas and a foam enhancer; and allowing viscosity of the composition to increase.
[0012] In a third aspect, the method comprises injecting into a wellbore, a composition comprising a solvent, a surfactant, a foaming gas, a foam enhancer, a crosslinkable polymer, and a crosslinking agent capable of crosslinking the polymer, wherein the foam enhancer increases the foam half-life of the gel composition compared to the gel composition without the foam enhancer; and allowing viscosity of the composition to increase and form a gel.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] FIG. 1 is a graph showing rheology of foam composition according to the invention versus time.
DETAILED DESCRIPTION
[0014] At the outset, it should be noted that in the development of any actual embodiments, numerous implementation-specific decisions must be made to achieve the developer's specific goals, such as compliance with system and business related constraints, which can vary from one implementation to another. Moreover, it will be appreciated that such a development effort might be complex and time consuming but would nevertheless be a routine undertaking for those of ordinary skill in the art having the benefit of this disclosure.
[0015] The description and examples are presented solely for the purpose of illustrating embodiments of the invention and should not be construed as a limitation to the scope and applicability of the invention. In the summary of the invention and this detailed description, each numerical value should be read once as modified by the term “about” (unless already expressly so modified), and then read again as not so modified unless otherwise indicated in context. Also, in the summary of the invention and this detailed description, it should be understood that a concentration range listed or described as being useful, suitable, or the like, is intended that any and every concentration within the range, including the end points, is to be considered as having been stated. For example, “a range of from 1 to 10” is to be read as indicating each and every possible number along the continuum between about 1 and about 10. Thus, even if specific data points within the range, or even no data points within the range, are explicitly identified or refer to only a few specific, it is to be understood that inventors appreciate and understand that any and all data points within the range are to be considered to have been specified, and that inventors possession of the entire range and all points within the range disclosed and enabled the entire range and all points within the range.
[0016] As used herewith the term “gel” means a substance selected from the group consisting of (a) colloids in which the dispersed phase has combined with the continuous phase to produce a viscous, jelly-like product, (b) crosslinked polymers, and (c) mixtures thereof.
[0017] According to a first embodiment, the gel composition is a composition made from: a solvent, a surfactant also called a foaming agent, a foaming gas and a foam enhancer.
[0018] The solvent may be any liquid in which the crosslinkable polymer and crosslinking agent can be dissolved, mixed, suspended or otherwise dispersed to facilitate gel formation. The solvent may be an aqueous liquid such as fresh water or a brine.
[0019] Surfactant is used to reduce the surface tension between the solvent and the foaming gas. The surfactants may be water-soluble and have sufficient foaming ability to enable the composition, when traversed by a gas, to foam and, upon curing, form a foamed gel. Typically, the surfactant is used in a concentration of up to about 10, about 0.01 to about 5, about 0.05 to about 3, or about 0.1 to about 2 weight percent.
[0020] The surfactant may be substantially any conventional anionic, cationic or nonionic surfactant. Anionic, cationic and nonionic surfactants are well known in general and are commercially available. Preferred foaming agents include those that have good foam formation and stability as measured by half-life. An additional feature is to continue to foam in the presence of hydrocarbons, which are known defoamers. Betaines, mixture of ammonium C6-C10 alcohoUethoxysulfate 2-Butoxyethanol (EGMBE)/Ethanol and amphoterics such as amphoteric alkyl amine surfactant are good foamers.
[0021] Exemplary surfactants include, but are not limited to, alkyl polyethylene oxide sulfates, alkyl alkylolamine sulfates, modified ether alcohol sulfate sodium salt, sodium lauryl sulfate, perfluoroalkanoic acids and salts having about 3 to about 24 carbon atoms per molecule (e.g., perfluorooctanoic acid, perfluoropropanoic acid, and perfluorononanoic acid), modified fatty alkylolamides, polyoxyethylene alkyl aryl ethers, octylphenoxyethanol, ethanolated alkyl guanidine-amine complexes, condensation of hydrogenated tallow amide and ethylene oxide, ethylene cyclomido 1-lauryl, 2-hydroxy, ethylene sodium alcoholate, methylene sodium carboxylate, alkyl arylsulfonates, sodium alkyl naphthalene sulfonate, sodium hydrocarbon sulfonates, petroleum sulfonates, sodium linear alkyl aryl sulfonates, alpha olefin sulfonates, condensation product of propylene oxide with ethylene oxide, sodium salt of sulfated fatty alcohols, octylphenoxy polyethoxy ethanol, sorbitan monolaurate, sorbitan monopalmitate, sorbitan trioleate, polyoxyethylene sorbitan tristearate, polyoxyethylene sorbitan tristearate, polyoxyethylene sorbitan monooleate, dioctyl sodium sulfosuccinate, modified phthalic glycerol alkyl resin, octylphenoxy polyethoxy ethanol, acetylphenoxy polyethoxy ethanol, dimethyl didodecenyl ammonium chloride, methyl trioctenyl ammonium iodide, trimethyl decenyl ammonium chloride, and dibutyl dihexadecenyl ammonium chloride.
[0022] In one embodiment the gel composition comprises a surfactant made of alcohol ether sulfates (AES). Alcohol ether sulfates provide a good foaming performance in acid brines with a broad range of ionic strength and hardness. They allow the liquid phase of the foam to form a strong and robust gel under acid conditions.
[0023] The foaming gas is usually a noncondensable gas. Exemplary noncondensable gases include air, oxygen, hydrogen, noble gases (helium, neon, argon, krypton, xenon, and radon), natural gas, hydrocarbon gases (e.g., methane, ethane), nitrogen, and carbon dioxide. Nitrogen and carbon dioxide are typically readily available in the oil field. Steam could be used for treating high temperature wells; however, the steam may condense and collapse the foam.
[0024] The amount of gas injected (when measured at the temperature and pressure conditions in the subterranean formation being treated) is generally about 1 to about 99 volume percent based upon the total volume of treatment fluids injected into the subterranean formation (i.e., the sum of the volume of injected gas plus the volume of injected foamable, gel-forming composition). According to one embodiment, the amount of gas injected is about 20 to about 98, and more preferably about 40 to about 95, volume percent based upon the total volume of injected treatment fluids. Foam enhancers are generally formed from water soluble polymers but can also be other organic extenders. Polymers have been used as they increase viscosity in the liquid borders and minimize drainage of the films which lead to bubble collapse. Especially good foam extenders include polymers which have a yield stress behavior at low shear rate such as xanthan and diutan. Other polymers include guar and guar derivatives, welan gum, locust bean gum, polyacrylamides and copolymers containing monomers of acrylamide, acrylic acid, sodium AMPS and vinyl pyrrolidone. Examples include polysaccharides such as substituted galactomannans, such as guar gums, high-molecular weight polysaccharides composed of mannose and galactose sugars, or guar derivatives such as hydroxypropyl guar (HPG), carboxymethylhydroxypropyl guar (CMHPG) and carboxymethyl guar (CMG), hydrophobically modified guars, guar-containing compounds, and synthetic polymers. Cellulose derivatives are also used in an embodiment, such as hydroxyethylcellulose (HEC) or hydroxypropylcellulose (HPC), carboxymethylhydroxyethylcellulose (CMHEC) and carboxymethycellulose (CMC). Xanthan, diutan, and scleroglucan, three biopolymers, have been shown to have excellent foaming enhancement properties.
[0025] According to a second embodiment, the gel composition further comprises a crosslinkable polymer, and a crosslinking agent capable of crosslinking the polymer. The result is a permanent gelation of the foam structure. According a third embodiment, the gel composition further comprises a delay agent to allow delayed crosslinking.
[0026] A crosslinked polymer is generally formed by reacting or contacting proper proportions of the crosslinkable polymer with the crosslinking agent. However, the gel-forming composition need only contain either the crosslinkable polymer or the crosslinking agent. When the crosslinkable polymer or crosslinking agent is omitted from the composition, the omitted material is usually introduced into the subterranean formation as a separate slug, either before, after, or simultaneously with the introduction of the gel-forming composition. The composition may comprise at least the crosslinkable polymer or monomers capable of polymerizing to form a crosslinkable polymer (e.g. acrylamide, vinyl acetate, acrylic acid, vinyl alcohol, methacrylamide, sodium AMPS, ethylene oxide, propylene oxide, and vinyl pyrrolidone). In another embodiment, the composition comprises both (a) the crosslinking agent and (b) either (i) the crosslinkable polymer or (ii) the polymerizable monomers capable of forming a crosslinkable polymer.
[0027] Typically, the crosslinkable polymer is water soluble. Common classes of water soluble crosslinkable polymers include polyvinyl polymers, polymethacrylamides, cellulose ethers, polysaccharides, lignosulfonates, ammonium salts thereof, alkali metal salts thereof, as well as alkaline earth salts of lignosulfonates. Specific examples of typical water soluble polymers are acrylic acid-acrylamide copolymers, acrylic acid-methacrylamide copolymers, polyacrylamides, partially hydrolyzed polyacrylamides, partially hydrolyzed polymethacrylamides, polyvinyl alcohol, polyvinyl pyrrolidone, polyalkyleneoxides, carboxycelluloses, carboxyalkylhydroxyethyl celluloses, hydroxyethylcellulose, galactomannans (e.g., guar gum), substituted galactomannans (e.g., hydroxypropyl guar), heteropolysaccharides obtained by the fermentation of starch-derived sugar (e.g., xanthan gum), and ammonium and alkali metal salts thereof. Other water soluble crosslinkable polymers include hydroxypropyl guar, partially hydrolyzed polyacrylamides, xanthan gum, polyvinyl alcohol, and the ammonium and alkali metal salts thereof.
[0028] The crosslinkable polymers are typically synthetic polymers for long term stability but could include biological polymers as well with a biocide.
[0029] The crosslinkable polymer is available in several forms such as a water solution or broth, a gel log solution, a dried powder, and a hydrocarbon emulsion or dispersion. As is well known to those skilled in the art, different types of equipment are employed to handle these different forms of crosslinkable polymers.
[0030] With respect to the crosslinking agents, these agents are organic and inorganic compounds well known to those skilled in the art. Exemplary organic crosslinking agents include, but are not limited to, aldehydes, dialdehydes, phenols, substituted phenols, and ethers. Phenol, phenyl acetate, resorcinol, glutaraldehyde, catechol, hydroquinone, gallic acid, pyrogallol, phloroglucinol, formaldehyde, and divinylether are some of the more typical organic crosslinking agents. The organic crosslinker can also take the form of a polymer such as polyalkyleneimines such as polyethyleneimine or polyalkylenepolyamines such as polyethylenepolyamines and polypropylenepolyamines as disclosed in patents numbers U.S. Pat. Nos. 4,773,481 and 6,192,986 incorporated by reference herewith. Typical inorganic crosslinking agents are polyvalent metals, chelated polyvalent metals, and compounds capable of yielding polyvalent metals. Some of the more common inorganic crosslinking agents include chromium salts, aluminates, gallates, dichromates, titanium chelates, aluminum citrate, chromium citrate, chromium acetate, and chromium propionate.
[0031] Suitable delay agents vary with the type of polymer and crosslinker employed. Some examples include organic complexing agents such as lactic acid, malonic acid and maleic acids for the metals, ammonium and carbonates salts for the amines, precursors that generate active crosslinkers such as trioxane, hexamethylenetetramine, acetic acid trimer, dioxane, etc.
[0032] According to a fourth embodiment, the gel composition further comprises a gelling accelerator or activator.
[0033] In some cases the temperature of application is lower than desired to promote crosslinking of the polymer. For example, below about 93° C., hexamethylenetetramine does not thermally degrade into the active crosslinking species quickly enough. In such cases, application of acid to the mixture can force the decomposition of the hexamethylenetetramine and begin the crosslinking reaction and subsequent gelation. However, in some application, as for example in carbonate rocks, some or all of the acid can be lost in reactions with the rock.
[0034] The gelling accelerator can be an encapsulated acid to prevent reaction with the rock until the fluid has been placed. The capsule then releases the acid, so most of the acid will be available for interaction with the delayed crosslinker rather than being spent on the rock during flow through the fracture, fissure or fault. Suitable acids include encapsulated acids or acidic salts that reduce pH upon dissolution. Some examples include acetic acid, acetic anhydride, formic acid, hydrochloric acid, fumaric acid, ammonium bisulfite, sodium bisulfate, potassium bisulfate, ammonium sulfate, etc. The chemicals can be encapsulated by various means including sprayed on coatings, fluidized bed coating, pan coating, coating formed by interfacial polymerization, organic coatings used for drug and vitamin delivery such as lipids, etc.
[0035] The gelling accelerator can be embodied in or as part of the foaming gas. The gas can be a binary foam defined as a mixture of nitrogen and carbon dioxide. Since carbon dioxide is an acidic gas that interacts with the aqueous medium, the acid functionality can be used to alter the gelation time of the organic crosslinked gel. The crosslinker precursor, hexamethylenetetramine, breaks down into the active crosslinker at a rate that is dependent upon temperature and/or pH. At lower temperatures below about 93° C., the breakdown can be accelerated by applying an acid. Increasing acidic strength speeds up the breakdown and thus, the gelation of the system by crosslinking of the gel. By adjustment of the carbon dioxide content in the gas phase, the gelation time of the foamed gel mixture can be controlled. Since the amount of carbon dioxide available for pH adjustment depends upon the equilibrium conditions of the application (temperature, pressure and partial pressure of carbon dioxide), the design will involve equations of state for prediction of the pH and the subsequent gelation time.
[0036] For higher temperature applications, the use of both temperature and pH can accelerate gelation. One example is adding polylactic acid (PLA) solids to the composition. This chemical is largely inert until a certain temperature is reached, at which time the PLA decomposes to provide lactic acid that accelerates the gelation. A similar effect could be achieved by using encapsulated acid or acidic salts that have a capsule wall that does not release until a higher temperature is achieved.
[0037] In a fifth embodiment, the gel composition further comprises a gelling enhancer.
[0038] The gelling enhancer can be a colloidal solid. Examples include fly ash, silica, fumed silica, titanium dioxide, natural solids such as clays, synthetic clays, talc, calcium carbonate, latexes, nanocarbons, and minerals such as boehmite (Böhmite), carbon black, graphite, etc. Other gelling enhancers for fracture plugging can include solids as fine silica flour, ground nut shells, diatomaceous earth, ground seashells, calcium carbonate, fibers and other minerals. Fibers can be used as synthetic fibers e.g. Kevlar fibers or metal fibers e.g. cast iron fibers.
[0039] In a sixth embodiment, the gel composition further comprises a swellable polymer to trap oil and/or water.
[0040] If used for removing water, swellable polymers include super absorber polymers based on crosslinked polyacrylates.
[0041] If used for trapping oil, swellable polymers include EPDM, EPM, SBR, butyl rubber, neoprene rubber, silicone rubber, and ethylene vinyl acrylate.
[0042] Optionally, the liquid components are mixed at the surface and foaming gas is added on the fly just before the combined streams enter the wellbore. Other potential options are to apply some of the gas and liquid phases in separate streams which meet partway or near the bottom of the well. Foam generators are an option for delivering optimal foam properties. The composition gels are compatible with other fluids or material as for example hydrocarbons such as mineral oil, proppants or additives normally found in well stimulation. Current embodiments can be used in various applications including temporary plugs of a formation, kill plugs, or multiple fracturing steps for treating subterranean formations having a plurality of zones of differing permeabilities. However, the primary target is plugging of fractures, fissures and faults within subterranean reservoirs accessed via a wellbore.
[0043] To facilitate a better understanding of some embodiments, the following examples of embodiments are given. In no way should the following examples be read to limit, or define, the scope of the embodiments described herewith.
Examples
[0044] Series of experiments were conducted to demonstrate properties of compositions and methods as disclosed above.
[0045] In the following tests, various compositions were examined for the ability to foam, the foam volume, foam stability as measured by half-life and foam quality. The half-life is the time for 50 mL to separate and drain from the foam using a loaded volume of 100 mL of liquid. Foam volume is the volume of foam immediately after foaming energy is stopped. The time for the half-life is started at this time as well. Foam quality is the gaseous content of the foam. As can be seen in Table 1, the addition of the foam enhancer vastly improved the foam half-life, but decreased the foam volume and quality. Use of higher molecular weight substituted polyacrylamide polymer (3 million Daltons) lowered the foam volume versus acrylamide sodium acrylate copolymer (0.5 million Daltons). As the gel time might be 2-4 hours, an extender is needed to maintain the foam after pumping is stopped and before the gelation begins.
[0046] The polymers were fully hydrated in water prior to adding the other components. Next, 100 mL of the solution was added to a graduated beaker and foamed by operating a Silverson mixer at 4000 rpm for three minutes. A separate study of mixing speed confirmed that 4000 rpm provides the most foam volume and does not shear degrade the polymer viscosity. The foam volume was recorded and the stop watch started after the beaker was removed from the mixer. The acrylamide sodium acrylate copolymer solutions also included 0.21 wt % of hexamethylenetetramine and 0.21 vol % of acetic acid. The substituted polyacrylamide solution also contained 0.2 wt % hexamethylenetetramine, 0.18 vol % phenyl acetate and 0.3 vol % acetic acid. A separate sample of the formulations was heated in capped bottles to 100° C. and good gels were formed, showing none of the components were incompatible. The samples with acrylamide sodium acrylate copolymer and substituted polyacrylamide with guar were stiff and did not move when the bottle was inverted. However, the sample with substituted polyacrylamide alone formed a tonguing gel that extended several inches from the bottle top upon inversion. It was found that cocamidopropyl Betaine/isopropanol/2-Butoxyethanol (EGMBE) mixture was insensitive to oil contamination whereas foams prepared with the other foamers would collapse with oil contamination.
[0000]
TABLE 1
Fluid
Foam
Foam Half-life,
composition
Polymer
Foaming agent
Foam enhancer
Volume, mL
minutes
Foam Quality, %
A
3.1%
0.5 vol % ammonium
650
15
84.6
acrylamide
C6-C10 alcohol
sodium
ethoxysulfate/ethanol/2-
acrylate
Butoxyethanol (EGMBE)
copolymer
mixture
B
3.1%
1 vol % ammonium C6-C10
1000
17
90
acrylamide
alcohol
sodium
ethoxysulfate/ethanol/2-
acrylate
Butoxyethanol (EGMBE)
copolymer
mixture
C
3.1%
2 vol % ammonium C6-C10
1220
16.1
91.8
acrylamide
alcohol
sodium
ethoxysulfate/ethanol/2-
acrylate
Butoxyethanol (EGMBE)
copolymer
mixture
D
3.1%
0.5 vol % ammonium
0.24% guar
375
82.5
73.3
acrylamide
C6-C10 alcohol
sodium
ethoxysulfate/ethanol/2-
acrylate
Butoxyethanol (EGMBE)
copolymer
mixture
E
3.1%
2 vol % dicoco dimethyl
0.24% guar
200
55
50.0
acrylamide
ammonium
sodium
chloride/ethanol mixture
acrylate
copolymer
F
3.1%
5 vol % dicoco dimethyl
0.24% guar
300
171
66.6
acrylamide
ammonium
sodium
chloride/ethanol mixture
acrylate
copolymer
G
3.1%
10 vol % dicoco dimethyl
0.24% guar
300
125
66.6
acrylamide
ammonium
sodium
chloride/ethanol mixture
acrylate
copolymer
H
3.1%
10 vol % dicoco dimethyl
0.24% guar
350
85
71.4
acrylamide
ammonium
sodium
chloride/ethanol mixture +
acrylate
1 vol % 2-
copolymer
butoxyethanol (EGMBE)
I
1% substituted
0.5 vol % ammonium
720
36.7
86
polyacrylamide
C6-C10 alcohol
ethoxysulfate/ethanol/2-
Butoxyethanol (EGMBE)
mixture
J
1% substituted
0.5 vol % ammonium C6-C10
0.24% guar
475
100
78.9
polyacrylamide
alcohol
ethoxysulfate/ethanol/2-
Butoxyethanol (EGMBE)
mixture
K
3.1%
1.0 vol %
0.7 wt %
—
>5
74.0
acrylamide
cocamidopropyl
diutan
hours
sodium
Betaine/isopropanol/2-
acrylate
Butoxyethanol (EGMBE)
copolymer
mixture
[0047] The fluid composition K in the above table was evaluated further in a circulating foam loop at 100° C. using nitrogen. The hexamethylenetetramine was not included to prevent gelation during the test. The foam was formulated at a quality of 72%. A constant shear rate of 100 s −1 was maintained throughout the test except for three shear ramps where the shear rate was reduced to 75, 50 25 and then increased to 50, 75 and 100 s −1 . Table 2 shows the calculated power law parameters, for the foam versus elapsed time, and includes the R 2 or goodness of fit parameter. Clearly the foam maintains its viscosity and its shear thinning properties with only minor changes over the test time of 3.5 hours. The rheology trace is included in FIG. 1 . Pictures of the foam segregated in a view cell (data not shown) show that some coarsening of the foam is evident, but the foam has no drainage over the 3.5 hour test time.
[0000]
TABLE 2
Elapsed Time,
Temperature,
hr:min:sec
° C.
n′
K′, lbf-s n′ /ft 2
R 2
1:14:32
100.3
0.435
0.0120
0.977
2:28:36
101.2
0.449
0.0974
0.987
3:25:40
101.3
0.456
0.0888
0.992
[0048] The fluid composition K was further augmented with 5 vol % of silicate solution (colloidal silica solution). This formulation showed nearly identical properties to the fluid composition K except the gel was visibly stronger and the foamed volume was enhanced. Picture of the formulation (data not shown) shows a stronger gel when put upside down.
[0049] The particular embodiments disclosed above are illustrative only, as the invention may be modified and practiced in different but equivalent manners apparent to those skilled in the art having the benefit of the teachings herein. Furthermore, no limitations are intended to the details herein shown, other than as described in the claims below. It is therefore evident that the particular embodiments disclosed above may be altered or modified and all such variations are considered within the scope of the embodiments described herewith. Accordingly, the protection sought herein is as set forth in the claims below. | The invention provides a method made of steps of injecting into a wellbore, a composition comprising a solvent, a surfactant, a foaming gas, a foam enhancer, a crosslinkable polymer, and a crosslinking agent capable of crosslinking the polymer, wherein the foam enhancer increases the foam half-life of the gel composition compared to the gel composition without the foam enhancer; and allowing viscosity of the composition to increase and form a gel. | 2 |
TECHNICAL FIELD
This invention relates to the field of environmental protection, and particularly to apparatus for supplying air of acceptable purity to an enclosed space from an ambient atmosphere which may become polluted with noxious gaseous, biological, or particulate contaminants.
BACKGROUND OF THE INVENTION
There are occasions where an isolated enclosed space must be used even though the atmosphere ambient to the space becomes polluted with contaminants noxious to personnel or damaging to equipment in the space. It is known in such situations to maintain the atmosphere in the space at a pressure higher than ambient, and to supply air to the space through filtering equipment designed to remove the contaminant. It often happens that for long intervals the ambient air is free from contaminants, yet the possibility is present that contaminants may appear on very short notice, and for the sake of security all air admitted to the space is continuously purified. For completeness the purifier must include an adsorptive filter such as one using activated charcoal, and it is well known that for numerous gaseous pollutants the efficacy of activated charcoal is lessened and eventually destroyed by the action of water vapor, present in all ambient atmospheres. Thus even though no specific demand for adsorptive filtering has arisen, filters must nevertheless be periodically discarded and replaced simply as a precautionary measure.
A partial solution lies in retaining the adsorptive filters in the hermetic wrappings in which they are supplied by the manufacturers, but this involves the need to locate the filter, unwrap it, and rapidly install it properly under the stress of emergency conditions, and is not practically acceptable.
BRIEF SUMMARY OF THE INVENTION
The present invention comprises an air purifier having installed therein a canister containing the filter hermetically sealed, and further having means for rupturing the hermetic seal and establishing flow of air through the filter by a simple, rapid operation. By this means the filter remains in ready condition for days, months, even years, and yet is rendered operative almost instantly when the need arises. A feature of the invention is that means are also provided to enable use of the apparatus for ventilating the space by bypassing the filter, when the ambient air is of acceptable purity for that purpose.
Various advantages and features of novelty which characterize the invention are pointed out with particularity in the claims annexed hereto and forming a part hereof. However, for a better understanding of the invention, its advantages, and objects attained by its use, reference should be had to the drawing which forms a further part hereof, and to the accompanying descriptive matter, in which there are illustrated and described certain preferred embodiments of the invention.
BRIEF DESCRIPTION OF THE DRAWING
In the drawing, in which like reference numerals indicate corresponding parts throughout the several views,
FIG. 1 is a perspective view of an air purifier according to the invention;
FIG. 2 is an exploded perspective view of the air purifier, portions thereof being broken away;
FIG. 3 is an enlarged sectional view taken along line 3--3 of FIG. 1;
FIG. 4 is a further enlarged fragmentary view of one of the activators shown in FIG. 3;
FIG. 5 is a fragmentary view, portions broken away, showing the activator gears;
FIG. 6 is a top plan view of a closure member;
FIG. 7 is an enlarged fragmentary sectional view taken along line 7--7 of FIG. 6;
FIG. 8 is a sectional view similar to FIG. 3 showing an alternate embodiment of the invention; and
FIG. 9 is a view like FIG. 8, showing an alternate portion of the activators.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
An air purifier 19 according to the invention is shown in FIG. 1 to comprise a support 20 arranged for receiving a filter canister 21 and having an inlet plenum 22 and an outlet plenum 23. An auxiliary air mover or coaxial fan 24 is mounted on support 20 and supplies air to inlet plenum 22 through a conduit 25. Air from the purifier is supplied through outlet plenum 23 to conduits 26 and 27.
Referring now to FIG. 2, the support 20 conveniently comprises a casting 30 having a generally flat circular end 31 and a curved wall 32 extending therefrom. The circular end 31 is ribbed for strength and includes a plurality of tapped holes 33 to receive fasteners for mounting the support on a bracket 34, which may be positioned in any orientation. The casting 30 includes a large axial opening 35 and a similar paraxial opening 36 spaced radially therefrom. These openings 35, 36 are surrounded by flat pads 37, 40 respectively for mounting plenum 22. The wall 32 is generally semi-circular. Its ends 41 are arranged to accept fasteners 42 for a band clamp 43 by which the canister 21 is secured in the support 20.
The inlet plenum 22 is generally in the form of a box having a first flat surface 44 with openings 45 and 46, as can be seen in FIG. 3, sized and positioned to accord with openings 35, 36 in support 20, and surrounded by gasket rings 47, 50 respectively for sealing against the pads 37, 40. See FIG. 4. An inlet opening 51 is provided at one end of plenum 22, and a partition or barrier 52 divides the plenum into an inlet chamber 53 and an outlet chamber 54. The outlet chamber 54 has a lateral outlet opening 55 communicating with the outlet plenum 23.
Referring again to FIG. 2, a pair of further openings 56, 57 is provided in the face 60 of the inlet plenum 22. The plenum face 60 is opposite the first surface 44. As can be seen in FIG. 3, the openings 56, 57 are located on opposite sides of the partition 52, and are surrounded by gasket rings 61, 62 respectively for sealing engagement with a bypass member 63 which is secured against the inlet plenum 22 by clamp screws 64 and 65. The bypass member 63 comprises a relatively shallow closed box having opposite surfaces 66, 67 either of which may be positioned against the face 60 of the inlet plenum 22. The upper surface 66 is imperforate, while the lower surface 67 has a pair of openings 70, 71, sized and positioned to mate with openings 56, 57 in the plenum 22. The ends 68, 69 of the bypass member 63 are each configured to accept a screw 64, 65 respectively. A pair of shafts 72, 73, as shown in FIG. 3, extend transversely across the chambers 53, 54 for a purpose presently to be described.
Referring now to FIGS. 2 and 3, the canister 21 comprises a housing 74 having an axis 75 and including a container 76 and an end cap 77. The container 76 has a bottom 78, and a top wall member 79. The top wall member 79 has an axial aperture 80 and a paraxial aperture 81 sized and positioned in accordance with the openings 35, 36 in the casting 30. A first mounting bracket 82 is secured to the inner surface of the container top wall member 79. The bracket extends downwardly and is designed to receive a stud 83 which is attached to the inwardly dished inner surface 84 of the end cap 77, to draw the container 76 and the end cap 77 together. A baffle 85 has a radially inward portion 86, sealed to the inside of the top wall member 79 to surround the axial opening 80, and a radially outward portion 87. The outward portion 87 is spaced from the top wall member 79 by a plurality of arcuate bracketes 89 secured to the top wall member 79 and designed to contact the baffle 85 at its periphery. The brackets are spaced apart peripherally to provide radial air passages 90 therebetween.
The canister 21 includes a pair of hollow cylindrical filters 91, 94 positioned coaxial about the axis 75 for traversal radially outwardly by the air which is to be treated. The inner filter 91 is to remove particulate matter, and is of pleated paper: it is sealed against the baffle 85 and the end cap 77 by a pair of gaskets 92, 93 respectively. The outer filter 94 is an adsorptive filter of material such as activated charcoal, for removal from the air of noxious gaseous impurities: it is sealed against the baffle 85 and the end plate 77 by a pair of gaskets 95, 96 respectively.
To assemble the canister, the filters 91, 94 are placed in the container 76 with the gaskets 92, 95 bearing against the baffle 85, the gaskets 93, 96 are properly placed, and the end cap 77 is positioned so that the stud 83 passes through the bracket 82. A nut 97 is then tightened by a tool passed through the axial opening 80. The end cap 77 is then soldered to the container 76 around its entire periphery. This assembly then provides only one path for air flowing in at the axial opening 80, and that is radially outward through the filters 91, 94 into the space between the outer filter 94 and the housing 74, then axially upward, and finally through the spaces 90 between the brackets 89 to the paraxial opening 81.
At this point the canister is now hermetically enclosed except for the canister openings 80, 81. These openings are next sealed by closures 100, 101, like the familiar pop-top closures used, for example, in marketing items such as snack foods. Examples of the state of the art for such closures are illustrated in the following patents: U.S. Pat. No. 4,044,915, issued Aug. 30, 1977 to La Croce et al.; U.S. Pat. No. 3,670,919, issued June 20, 1972 to Prayer et al.; and U.S. Pat. No. 3,643,833, issued Feb. 22, 1972 to Fraze et al. In the preferred embodiment of the invention, as shown in FIGS. 6 and 7, the easy-open closures 100, 101 are soldered around their peripheries into the openings 80, 81 respectively, with respective pull tabs or gripping rings 102, 103 extending toward one another along a radius from axis 75, as can be seen in FIG. 3. A peripheral score line 98 defines a central portion 99 which is removed when sufficient force is exerted upon the pull tab to rupture the seal existing between the openings 80, 81 and their respective score lines. However, prior to destroying the hermetic seal, the canister 21 can be stored indefinitely without deterioration.
It is preferable that a usable filter canister 21 be in the support 20 at all times, ready for immediate use if the atmosphere ambient to the inlet 51 becomes noxious. To accomplish this a canister is inserted into the support with the closures 100, 101 aligned with the inlet plenum openings 80, 81. Suitable optical indications or mechanical interlocks are provided to ensure this orientation. A plurality of latches 104, 105 (see FIGS. 1 and 3), are spaced around the periphery of the support 20 and include hooks 106 for engaging the out-turned rim 107 of the end cap 77: the hooks 106 slide on threaded shafts 110 having stop collars 111 against which compression springs 112 bear at first ends. The opposite ends of the springs 112 bear against the hooks 106. When the nuts 113 are tightened on the shafts 110, the canister 21 is drawn into tight sealing contact with the support 20. The band clamp 43 may then be secured by fasteners 42 to hold the canister 21 even more securely in the support 20. The shafts 110 may be connected to the support 20 either rigidly, as shown at 108 in FIG. 3, or pivotally, as shown at 109 in FIGS. 1 and 2.
It will be clear that even though the canister 21 is hermetically sealed, a first bypass path for airflow around the partition 52 nevertheless extends from the inlet 51 through the chamber 53, into the bypass member 63, to the chamber 54 and then to the outlet opening 55. If desired the fan 24 may be used for vantilation purposes independently of the filters.
The arrangement by which the canister 21 is quickly made operable will now be explained. Refer now to FIGS. 3 and 5. The shafts 72 and 73 are interconnected outward of the plenum 22 by a pair of meshing pinions 114, 115. The shaft 73 carries an actuating arm 116 to which is connected an actuating pull cord (not shown). The arm 116 is retained in either of two positions by a pair of spring detents 120 and 121 (see FIG. 2) secured to the access cover 122 placed over an opening 123 in the plenum 22. A solid stop member 124 is also provided. Inside the plenum 22 the shafts 72, 73 carry respective actuators 125, 126 for rupturing the closures 100, 101 and giving access to the filters 91, 94 in the canister 21.
From FIG. 4 the construction of the actuators can be understood. Only one actuator 125 is shown, and comprises, as does the other actuator, a substantially rigid arm 127 secured to the shaft 72 and carrying at its end a hook 130, with a distal curved end 131 and a retainer 132 adjacent the curved end 131. When the arm 116 is in a first position shown in FIGS. 1 and 2, the actuators 125, 126 are as shown in FIG. 3. With the actuators in this position, the mounting of canister 21 in the storage and use position of FIG. 3 causes the hook 130 to engage the top of the closure 100 so that the curved end 131 of the hook slides into and through the loop 134 of the pull tab 102, with the retainer 132 passing over the loop to enable this movement. Alternatively, with the canister 21 locked in place, the arm 127 can be rotated to cause the curved end 131 of the hook 130 to pass through the loop 134, engage the surface of the closure 100, and slide under the pull tab 102, while the retainer slips over the pull tab as shown. Reverse operation of the arm 116 then causes the hook 130 to lift the pull tab 102, first breaking the seal and then tearing the closure along its score line 98 which is a weakened perimeter. At the same time the actuator 126 similarly opens the closure 101 so that access if free to the inner and outer surfaces of the filters 91, 94. As illustrated by broken lines in FIG. 3, the central portion 99 of the closure is removed and remains suspended on the hook 130 by its pull tab, being held there by the retainer 132. It will be appreciated by those familiar with the poptop closure art that upon removal the central portion 99 may curve or flex in upon itself. For purposes of illustration only, the removed central portion 99 is shown in FIG. 9 as remaining substantially flat and rigid after its removal. Also, screws 64, 65 are loosened and the bypass member 63 is inverted. The upper bypass openings 56, 57 are thus occluded. The only path for airflow from the inlet opening 51 to the outlet opening 55 is through the filters 91, 94, an alternate bypass around the partition 52.
The embodiment of the invention above described requires two distinct operations for transformation from a "ready" state to an "operating" state: not only must the arm 116 be moved to cause the actuators 125, 126 to engage and open the closures 100, 101, but the bypass member 63 must also be inverted. Neither of these operations is sufficient by itself to convert the air purifier to an "operating state". A second embodiment of the invention modifies the inlet plenum so that only operation of the arm 116 is required, all portions of the apparatus other than the inlet plenum being as previously described.
In FIGS. 8 and 9, a modified inlet plenum 140 has generally the form of a box having a first flat surface 141 with openings 142, 143, sized and positioned to accord with the openings 35, 36 in the support 20, and each being surrounded by gasket rings 144, 145 respectively for sealing against the pads 37, 40. An inlet opening 146 is provided at one end of the plenum 140, and a partition or barrier 147 divides the plenum into an inlet chamber 150 and an outlet chamber 151, the latter having a lateral outlet opening 152 communicating with the outlet plenum 23.
A pair of shafts 153 and 154 extend transversely across respective chambers 150, 151 and also included are meshing pinions 114, 115 and an actuating arm 116 as shown in FIG. 5 to enable the operation of the actuators 155, 156 to remove the closures 100, 101 as described above.
The partition or barrier 147 has a large central opening 157, connected by a bleed hole 160 with the exterior of plenum 140. The actuators 155, 156 differ from the actuators 125, 126 previously described in that they carry valving discs 161, 162 each having sealing rings 163, 164, respectively. In a first position of the shafts 153, 154, the barrier opening 157 is not occluded, and air may flow freely from the inlet opening 146 through the barrier opening 157 to the outlet opening 152. In a second position of the shafts 153, 154, the discs 161, 162 occlude the barrier opening 157 on both sides of the partition or barrier 147, with any slight leakage past the rings 163, 164 being vented to ambience through the bleed hole 160.
The actuators 155, 156 are provided with hooks and retainers as described above, and function similarly to remove the closures 100, 101 of the canister 21. Thus, when the opening 157 of the partition 147 has been sealed by the valving discs 161, 162, as shown in FIG. 9, incoming air must flow through axial opening 80, into the canister 21, axially outward through the filters 91, 94, into the space between the outer filter 94 and the housing 74, axially upward and then through the spaces 90 between the brackets 89, and on to paraxial opening 81. The filtered air then exits the outlet chamber 151 through the opening 152 and is carried by the conduits 26, 27 to a location where the air may be safely inhaled.
From the foregoing it can be appreciated that the present invention provides an air purifier which is hermetically sealed until filtration of the air is necessary. The present invention also prevents degradation of the filter when filtration is not required. Furthermore, either ventilation of the ambient air or of filtered air may be provided as the situation warrants. The filters are disposable and thus minimize any potential decontamination problems.
The foregoing disclosure is illustrative only, and changes may be made in detail, especially in matters of shape, size, and arrangement of parts, within the principle of the invention, to the full extent indicated by the broad general meaning of the terms in which the appended claims are expressed. | The invention is an air purifying apparatus having an air inlet plenum (22, 140) mounted to a filter canister (21) and containing a bypass (63, 157). A barrier (52, 147) divides the inlet plenum (22, 140) into an inlet chamber (53, 150) and an outlet chamber (54, 151). In one embodiment the bypass is formed as a box (63) attached to the plenum (22) and containing openings (70, 71) which communicate respectively with the inlet chamber (53) and the outlet chamber (54) to define a bypass flow path from the inlet chamber (53), through the box (63) and into the outlet chamber (54). In another embodiment the bypass is formed as an opening (157) in the barrier (147) to allow direct communication between the inlet (150) and outlet (151) chambers. The filter canister (21) containing filters (91, 94) is normally hermetically sealed and is mounted to the plenum (22, 140) to allow air flow from the inlet chamber (53, 150), through the filters (91, 94) and into the outlet chamber (54, 151) when the hermetic seal is destroyed and the bypass flow path is occluded. Actuators (125, 126 or 155, 156) in the plenum (22, 140) are operably connected to closures (100, 101) on the filter canister (21). In a first position, the actuators (125, 126 or 155, 156) maintain the hermetically sealed condition of the filter canister (21). In a second position the actuators (125, 126 or 155, 156) destroy the hermetic seal by removing the closures (100, 101) and create an alternate air flow path through the filters (91, 94). The bypass flow path is occluded upon activation of the actuators either by inversion of the box (63) to close its openings (70, 71) or by valves (161, 162) which are carried on the actuators (155, 156) and which close the bypass opening (157) upon removal of the closures (100, 101). | 1 |
FIELD OF THE INVENTION
The present invention relates generally to the support of a child upon birth, and more particularly, to a birthing gown that is worn around a birthing assistant's neck and can be used to form a birthing cradle for support and transfer of a child upon birth.
BACKGROUND OF THE INVENTION
It is commonly known that during childbirth a newborn child can be easily dropped. Childbirth is a process in which a child is expelled from the uterus of a woman through a birth canal. During childbirth, the woman is subjected to contractions of the uterus commonly referred to as labor. As labor progresses the contractions increase in frequency and severity. While giving birth a woman is typically assisted by at least one person who directs the child through the last section of the birth canal and is available for supporting the child upon delivery. As the woman is subjected to disabling contractions throughout the duration of labor, she is typically incapable of providing assistance in support of the child. Further, in many cases the woman prefers anesthesia to alleviate the pain which has a side effect of lessening the woman's alertness.
The problem in delivery is that the birthing assistant must not only attend to the comfort of the woman but must further assist in safely directing the child into the world. However, the child is born with a fluid secreted from the woman's mucous membranes that moistens and protects the skin of the newborn child. Mucous is a thick slimy secretion which makes the child extremely slippery and difficult to hold. Should the birth assistant utilize latex gloves or the like material, the fluid operates with the gloves resulting in an extreme condition. Thousands of babies are dropped by birthing assistants including highly trained medical personnel, all to the detriment of the newborn. The cause may be a combination of slippery surfaces or inattention while trying to assist during delivery. In other instances, the child is grasped so firmly to prevent dropping that the child can be easily bruised. In any event, the fall of a child can result in a severe injury, physically to the child and mentally to the birthing parent.
For these reasons various attempts have been made to correct the problem including the use of hospitals requiring at least two birthing assistants during delivery. Support drapes such as that disclosed in U.S. Pat. No. 5,027,832 set forth a version of a commonly used drape capable of retaining fluid as well as preventing the fall of a child during birth.
U.S. Pat. No. 5,287,860 discloses a birthing drape used primarily for catching body fluids expelled during child birth by use of a catch basin that is placed below the body of the birthing mother and hooked over each of the woman's extended legs.
U.S. Pat. No. 4,823,418 discloses a birth safety net directed to preventing the dropping of a newborn child by use of a five cornered net which is coupled to a portion of the birthing chair or birthing bed. The problem with this disclosure is that the device must be attached to a special table and is used only as a safety net. Thus, the birthing assistant must still pick up the child leaving no "safety net" during the movement of the child. Finally, the use of birthing chairs and beds is archaic and seldom practiced.
Thus, what is needed in the art is a device that can be used during childbirth so as to provide a safety net to prevent a newborn child from falling and can be used in transferring of the child from one position to another.
SUMMARY OF THE INVENTION
The instant invention is a birthing gown that can be worn by the birthing assistants. The gown is positioned over the front of the person and is secured to the person's neck in such a manner that it cannot become dislodged. During childbirth the gown may operate to prevent fluids from spoiling the garments of the assisting personnel but more importantly, used to correctly position the assisting personnel during delivery. In operation the gown is secured to the neck of a birthing assistant and a free end of the birthing gown is placed beneath the birthing mother or hooked to attachment fasteners on the birthing table. During delivery the birthing assistants are free to use their arms to assist during birth and may rely upon the gown to provide emergency support for the child. Upon delivery, the child is placed onto the gown which then operates as a birthing cradle. Arm attachment holders are provided to turn the gown into a cradle with the free end now available as thumb loops allowing the person to have free hands yet fully support the child for transfer.
An alternative embodiment of the instant invention allows the assisting personnel to place their arms through the birthing gown which provides a lower cost of manufacture but maintains the ability to have free hands for directing the child into the formed birthing cradle. Attachments to the neck, biceps and forearms forms the support for the birth cradle as well as eliminates the possibility of delivery personnel squeezing when trying to prevent the child from slipping and allows those having inadequate hand strength to assist in holding of a child.
Thus, an objective of the instant invention is to provide a birthing gown that operates as a safety net during delivery, forms into a birthing cradle, and allows for the safe transportation of a newborn child.
Another objective of the instant invention is to provide a birthing gown that allows the delivery personnel to assist in childbirth by the use of free hand movement.
Still another objective of the instant invention is to provide a means for transferring a newborn child's weight to the shoulders and arms of a birthing assistant to accommodate a person having inadequate hand strength.
Yet still another objective of the instant invention is to provide a drape so as to aid in directing body fluids from the woman into the birthing cradle.
Another objective of the instant invention is to provide a birthing gown that can be worn by all of the delivery personnel so as to prevent the spoiling of clothing yet provide each person with the ability to act as a transferring person and force the proper positioning of at least one person during delivery.
Other objectives and advantages of this invention will become apparent from the following detailed description taken in conjunction with the accompanying drawings wherein are set forth, by way of illustration and example, certain embodiments of this invention. The drawings constitute a part of this specification and include exemplary embodiments of the present invention and illustrate various objectives and features thereof.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a top plane view of the preferred embodiment of the instant invention;
FIG. 2 is a perspective view of the instant invention in use as a birthing cradle;
FIG. 3 is a top plane view of an alternative embodiment to the instant invention; and
FIG. 4 is a top plane view of an alternative embodiment.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Although the invention is described in terms of a specific embodiment, it will be readily apparent to those skilled in this art that various modifications, rearrangements and substitutions can be made without departing from the spirit of the invention. The scope of the invention is defined by the claims appended hereto.
Now referring to FIG. 1 shown is a top plane view of the birthing gown 10 of the instant invention. The gown 10 consists of a substantially rectangular shaped base section 12 constructed from cotton, nylon, lycra, plastic or the like flexible material. The base support section 12 is defined by a first end, a second end and two spaced apart side edges disposed therebetween with two side surfaces all of which forms into a birthing cradle.
The first end leads to a neck hoop insertion 14 section which can be integrated into the support section 12 or consist of a neck hoop attachment 14 that is placed over a person's head for positioning around their neck. The neck hoop insertion 14 is preferably a circular device that will not loosen or become dislodged from the neck providing a means for securing around the neck of a birthing assistant. Alternatively, the neck portion may be a component tied or fastened around the neck with a primary objection of being able to transfer the weight of a child to the shoulders of the person yet maintain sufficient securement so as to prevent premature release.
Along each side edge of the birthing cradle is a means for coupling the base 12 to the arms of the birthing assistant. Left 16 and right 18 bicep connectors allow insertion of the upper arms of the person forcing the gown to be positioned parallel to the chest by directing the gown from the neck portion downward to the natural positioning of the biceps. The bicep connectors may use elasticity so as to accommodate various sized upper arms but need only provide sufficient room for insertion of the arms. Forearm attachment is provided by left sleeve 20 and right sleeve 22 which allow outward extension of the forearm, positioning the basis for the birthing cradle along a horizontal plane.
The biceps and forearm sleeves may be of a single piece with an articulation point therebetween allowing the birthing cradle to conform to the shape of the particular person's arms. Separate arm connectors allow the use of the gown for various size personnel wherein the elbows can be positioned between the biceps and forearm coupling sections.
Along each corner of the free end of the birthing cradle 12 is located attachment hoops 24 and 26 for coupling to a birthing bed or for attachment to the wearer's thumbs. When the gown is used to catch fluid or as a safety net, the attachment points 24 and 26 can be coupled to the birthing table allowing complete mobility of birthing assistant's arms by means of a direct connection to the birthing table. Before delivery the birthing assistant may place their arms in position so as to provide support for the child wherein the hands remain free to help place the child into position. The hooks may then be placed over the birthing assistant's thumbs to prevent the cradle from sliding up the arm. When the birthing gown is not in use, straps 28 and 30 may be used to secure the gown behind the wearer's back to operate as a protective gown for clothing.
Now referring to FIG. 2 depicted is a person 100 having the instant invention 10 placed around their neck and coupled to their arms with bicep connectors 16 and 18 and forearm connectors 20 and 22. In this embodiment the birthing cradle 12 is formed by use of the biceps to form a back to the cradle and the forearms providing a support for the base. Attachment hooks 24 and 26 are placed over the wearer's thumbs 104 and 106 to prevent the cradle from sliding up the arms. Child 200 is positioned between the arms and allowed to rest comfortably within the birthing cradle. The person's hands are shown in a free position extending beyond the cradle length so as to operate as bumpers should the person inattentively walk into an object thus protecting the child's body. Further the design prevents the operator from grasping the baby with excessive force to overcome the skin surface immediately after child birth. Once the child has been cleaned of the mucous fluid, the operator can lightly grasp the child without fear of sudden movement which would otherwise cause the infant to drop. Proper positioning of the birthing cradle operates to position a majority of the weight about the shoulder of the birthing assistant which is imperative in clinics where a birthing assistant may be exhausted from multiple births.
FIG. 3 is an alternative embodiment of the instant invention having a simplified construction consisting of a single sheet of material such as nylon, cotton, lycra, plastic, spandex, or silk 50 which has a reinforced perimeter edge 52 leading to a neck hole 54. Through holes 56 and 58 are provided for the biceps as are through holes 60 and 62 for the forearms. Through holes 64 and 66 provide thumb loop attachments which can further be used to attach to the birthing table. This embodiment provides a low cost alternative to the birthing gown as the bicep and forearm sleeves are replaced with reinforced through holes eliminating a major cost of sleeve construction during manufacture. The intent of the invention is not altered as both embodiments provide a means for preventing a newborn child from dropping, as well as providing a means for transferring the child without human hand contact.
If an expectant mother is a known carrier of aids, the birthing gown may be made of plastic so as to prevent contact with fluids. An open net design provides the birthing personnel with the ability to see through the gown during the delivery process. A cotton birthing gown will allow the operating personnel to reuse the gown upon cleaning and sterilization.
Now referring to FIG. 4 is an embodiment of the instant invention having a body portion 70 consisting of a single sheet of material with through holes 72 provided for insertion of a carrier's arm as well as adjoining arm holes 74 allowing the operator to weave their upper and lower arm into position as previously described for connection to thumb fastener loops 76 and 78. In this embodiment a flexible band strap 80 sets forth a pouch 82 which operates to catch fluids. This embodiment sets forth a separating line 84 which distinguishes the position for a child between an upper vertical surface 86 and a lower horizontal surface 88. In operation, a child placed on the lower surface 88 would be held at a substantially horizontal plane wherein excess fluid would flow into the formed pouch 82 with expansion flex band 80 preventing accidental droppage of the child should the operator's arms become so weak as not be able to maintain the surface 88 horizontally. The weight of the child will depress the horizontal surface 88 while the expansion flex band maintains sufficient resiliency so as to form the pouch.
Height adjustment collars provide the device with the ability to be used with personnel of various heights. The user simply chooses which height adjustment collar is suitable for their use and places their neck through opening 92, 94, or 96. The solid adjustment collar is deemed necessary in most instances in light of the fragile cargo to be carried. As provided by this embodiment should the operator's arms become too weak to carry the child, the adjustment collar must be able to support the child entirely if the child falls into the pouch 82 when the operator's arms are placed at their side.
It is to be understood that while I have illustrated and described certain forms of my invention, it is not to be limited to the specific forms or arrangement of parts herein described and shown. It will be apparent to those skilled in the art that various changes may be made without departing from the scope of the invention and the invention is not to be considered limited to what is shown in the drawings and described in the specification. | A birthing gown that is placed around the neck of a birthing assistant having sleeves or through holes available for placement of the birthing assistant's biceps and forearms so as to allow the birthing gown to be simply worn as a garment protector or transformed into a birthing cradle. Attachments are provided for insertion of the birthing assistant's thumb so as to prevent slippage of the birthing cradle as well as provide the ability to move a newborn child without grasping of the child with a human hand until mucous fluid of the newborn child has been removed. | 0 |
BACKGROUND
[0001] 1. Field of the Invention
[0002] The present invention relates to methods and formulations for treating liver damage, and particularly to treating liver damage and preventing CCL4 (carbon tetracloride) induced liver damage comprising the prophylactic administration of extracts of Morinda citrifolia.
[0003] 2. Background of the Invention
[0004] Liver damage from hepatitis C, alcohol, or carbon tetracloride is well documented. However, many of the treatments result in undesirable side effects.
[0005] Carbon tetrachloride (CC14) is a common environmental pollutant and liver carcinogen. CC14 is leached into the soil through agricultural run-off, spills, landfill contamination, and dumping illegal. Surface waters become contaminated due to industrial and agricultural activities, wastewater release, particularly from iron and steel manufacturing, as well as other major industries.
[0006] CC14 is used in alkalies, chlorine, industrial inorganic chemicals and in petroleum refining, agricultural chemicals, refrigerants, solvent for oils, fats, lacquers, varnishes, rubber waxes, rubber cement, resins, starting material in the manufacture of organic compounds cleaning agents for machinery, electrical equipment, and pharmaceuticals. In the past, it was used as a dry cleaning agent, a fire extinguisher, a grain fumigant, a pesticide, as well as a component of aerosol can propellants. CC14 gets in the air by industrial emission and evaporation from both soil and surface waters. The amount of CC14 has been increasing in the atmosphere in recent years because it is so stable in the troposphere. It has a residence time of 30 to 100 years. The most at-risk exposure groups are workers involved in the manufacture and use of CC14.
[0007] Over the last 50 years, carbon tetrachloride (CC 14) is the classic model compound used in the induction of liver injury and tumor. As a potent hepatotoxin, CC14 produces centrolobular necrosis, which causes liver damage. It has been widely accepted that the liver injury induced by CC14 depends upon its metabolism by cytochrome 2E 1 into the highly reactive form of the trichloromethyl (CC13) radicals that initiate lipid peroxidation of cell membrane. Others have suggested that active oxygen molecules, such as superoxide anion radicals (SAR), may plan an important role in the inflammation process after intoxication by CC14.
[0008] In order to protect the liver from environmental toxicants such as CC14, thousands of plants have been screened. Morinda citrifolia is an herb that has a wide range of medical properties, such as anti-cancer, anti-inflammatory, and detoxification. The major component in the Morinda citrifolia is proxeronine, named by Dr. Ralph Heinicki, which is a protein initiator and regulator. More than 100 other chemicals in different parts of the Morinda citrifolia tree have been identified. All of these compounds are beneficial to the human body. Data indicates that Morinda citrifolia is able to prevent cancer at the initiation stage of carcinogenesis by blocking carcinogen (DMBA)-induced DNA adduct formation, scavenging free radicals, quenching lipid hydroproxides, and selectively inhibiting COX-2.
[0009] The liver is an extremely vital organ that serves to metabolize carbohydrates and store them as glycogen, metabolize lipids (including cholesterol and certain vitamins), and proteins, manufacture bile, filter impurities and toxic material from the blood, produce blood-clotting factors, and destroy old, worn-out red blood cells. Certain reticuloendothelial cells (the Kupffer cells) play a role in immunity. These are able to regenerate themselves after being injured or diseased. If a disease progresses beyond the tissue's capacity to regenerate new cells, the body's entire metabolism is severely disturbed. Any number of disorders can affect the liver and interfere with the blood supply, the hepatic and Kupffer cells, and the bile ducts. The incredible complexity of liver chemistry and its fundamental role in human physiology is so daunting to researchers that the thought of simple plant remedies might have something to offer is both laughable and even insulting! This highlights again the limiting trap of the current research paradigm. Morinda citrifolia , a powerful antioxidant, anti-inflammatory nutritional supplement may possess a liver protection property.
SUMMARY AND OBJECTS OF THE INVENTION
[0010] The present invention provides a prophylactic regimen to prevent damage to the liver when that damage results from disease or the side-effects of other treatments. The present invention features a method for preventing carbon tetracloride induced liver damage in mammals, inhibiting further liver damage in mammals, and preventing cancerous growth, in the liver of mammals, at the initiation stages of carcinogenesis by blockage of carcinogen-DNA adduct formation.
[0011] [0011] Morinda citrifolia is believed to have broad therapeutic effects including anticancer and anti-inflammatory activity. Experiments conducted by the inventors indicates that Morinda citrifolia possesses a cancer preventive effect at the initiation stage of carcinogenesis. In these studies, the protective effect of Morinda citrifolia on carbon tetrachloride (CC 14)-induced liver injury in female SD rats was examined. Twelve female SD rats were divided into two groups: placebo and Morinda citrifolia. Animals were supplied with 20% placebo or 20% Morinda citrifolia for 12 days, respectively. On the last day, three animals from each group were fed 0.25 ml/kg CC14. Another three animals were maintained as controls. All animals were sacrificed at 6 hours after CC14 treatment. Livers were removed for light microscopic (LM) and electron microscopic (EM) examination; superoxide anion radical (SAR) assay and lipid hydroperoxide (LPO) determination. Liver sections in placebo and Morinda citrifolia control groups demonstrated normal lobular architecture at the LM level and normal ultrastructure. Liver sections in the placebo+CC14 group showed acute liver damage at the LM: focal vacuolated, lipid-containing or necrotic hepatocytes surrounding central veins and focal inflammatory cells scattered throughout the lobule. There was a significant decrease in the number of swollen, lipid containing, and apoptotic hepatocytes in the Morinda citrifolia +CC14 group, compared to the placebo+CC14. At the EM level, glycogen depletion and lipid droplets in the cell plasma were observed in both CC14 treated groups. Swollen mitochondria, disorganization of RER with loss of ribosomes, and abundant focal areas of SER were scattered throughout the cytoplasm. Interestingly, Golgi complexes in placebo+CC14 group contain small low-density vesicles. Golgi complexes in the Morinda citrifolia +CC14 contain large vesicles with increased electron density, Golgi cisternal stacks were well developed, while those in the placebo+CC14 group were often swollen and diminished. Liver SAR and LPO levels in Morinda citrifolia +CC14 group were decreased to 50% and 20% of that in the placebo+CC14 group, respectively. In conclusion, Morinda citrifolia may protect liver from CC14 exposure by scavenging free radicals and blocking the lipid peroxidation.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0012] It will be readily understood that the components of the present invention, as generally described and illustrated in the figures herein, could be arranged and designed in a wide variety of different configurations. Thus, the following more detailed description of the embodiments of the system and method of the present invention, and represented in FIGS. 1 through *, is not intended to limit the scope of the invention, as claimed, but is merely representative of the presently preferred embodiments of the invention.
[0013] It will be readily understood that the components of the present invention, as generally described herein, could be arranged and designed in a wide variety of different methods, configurations or formulations. Thus, the following more detailed description of the embodiments of the methods of the present invention, is not intended to limit the scope of the invention, as claimed, but is merely representative of the presently preferred embodiments of the invention.
[0014] The Indian Mulberry plant, known scientifically as Morinda citrifolia L., is a shrub, or small or medium sized tree 3 to 10 meters high. It grows in tropical coastal regions around the world. The plant grows in the wild, and it has been cultivated in plantations and small individual growing plots. The Indian mulberry plant has somewhat rounded branches and evergreen, opposite (or spuriously alternate), dark, glossy, wavy, prominently-veined leaves. The leaves are broadly elliptic to oblong, pointed at both ends, 10-30 cm in length and 5-15 cm wide.
[0015] The Indian mulberry flowers are small, white, 3 to 5 lobed, tubular, fragrant, and about 1.25 cm long. The flowers develop into compound fruits composed of many small drupes fused into an ovoid, ellipsoid or roundish, lumpy body, 5-10 cm long, 5-7 cm thick, with waxy, white or greenish-white or yellowish, semi-translucent skin. The fruit contains “eyes” on its surface, similar to a potato. The fruit is juicy, bitter, dull-yellow or yellowish-white, and contains numerous red-brown, hard, oblong-triangular, winged, 2-celled stones, each containing about 4 seeds.
[0016] When fully ripe, the fruit has a pronounced odor like rancid cheese. Although the fruit has been eaten by several nationalities as food, the most common use of the Indian mulberry plant was as a red and yellow dye source. Recently, there has been an interest in the nutritional and health benefits of the Indian mulberry plant.
[0017] Because the Morinda citrifolia fruit is for all practical purposes inedible, the fruit must be processed in order to make it palatable for human consumption and included in food products used to treat various ailments and diseases. Processed Morinda citrifolia juice can be prepared by separating seeds and peels from the juice and pulp of a ripened Morinda citrifolia fruit; filtering the pulp from the juice; and packaging the juice. Alternatively, rather than packaging the juice, the juice can be immediately included as an ingredient in another food product, frozen or pasteurized. In some embodiments, the juice and pulp can be pureed into a homogenous blend to be mixed with other ingredients. Other processes include freeze drying the fruit and juice. The fruit and juice can be reconstituted during production of the final juice product. Still other processes include air drying the fruit and juices, prior to being masticated.
[0018] In a currently preferred process of producing Morinda citrifolia juice, the fruit is either hand picked or picked by mechanical equipment. The fruit can be harvested when it is at least one inch (2-3 cm) and up to 12 inches (24-36 cm) in diameter. The fruit preferably has a color ranging from a dark green through a yellow-green up to a white color, and gradations of color in between. The fruit is thoroughly cleaned after harvesting and before any processing occurs.
[0019] The fruit is allowed to ripen or age from 0 to 14 days, with most fruit being held from 2 to 3 days. The fruit is ripened or aged by being placed on equipment so it does not contact the ground. It is preferably covered with a cloth or netting material during aging, but can be aged without being covered. When ready for further processing the fruit is light in color, from a light green, light yellow, white or translucent color. The fruit is inspected for spoilage or for excessively green color and firmness. Spoiled and hard green fruit is separated from the acceptable fruit.
[0020] The ripened and aged fruit is preferably placed in plastic lined containers for further processing and transport. The containers of aged fruit can be held from 0 to 30 days. Most fruit containers are held for 7 to 14 days before processing. The containers can optionally be stored under refrigerated conditions prior to further processing. The fruit is unpacked from the storage containers and is processed through a manual or mechanical separator. The seeds and peel are separated from the juice and pulp. The juice can be filtered from the pulp.
[0021] The juice can be packaged into containers for storage and transport. Alternatively, the juice can be immediately processed into finished juice product. The containers can be stored in refrigerated, frozen, or room temperature conditions. The pulp can be blended in with the juice to make a puree. The Morinda citrifolia juice and puree can then be blended in a homogenous blend and mixed with other ingredients. The other ingredients consist of, but are not limited to water, fruit juice concentrates, flavorings, sweeteners, nutritional ingredients, botanicals, and colorings. The finished juice product is preferably heated and pasteurized at a minimum temperature of 181° F. (83° C.) or higher up to 212° F. (100° C.).
[0022] The product is filled and sealed into a final container of plastic, glass, or another suitable material that can withstand the processing temperatures. The containers are maintained at the filling temperature or may be cooled rapidly and then placed in a shipping container. The shipping containers are preferably wrapped with a material and in a manner to maintain or control the temperature of the product in the final containers.
[0023] Pure juice can be processed by separating the pulp from the juice through filtering equipment. The filtering equipment preferably consists of, but is not limited to, a centrifuge decanter, a screen filter with a size from 1 micron up to 2000 microns, more preferably less than 500 microns, a filter press, reverse osmosis filtration, or any other standard commercial filtration devices. The operating filter pressure preferably ranges from 0.1 psig up to about 1000 psig. The flow rate preferably ranges from 0.1 gpm up to 1000 gpm, and more preferably between 5 and 50 gpm.
[0024] In addition to the processing methods described above, other methods of processing fruit into oil product, fiber product, and juice product are contemplated and may be employed. Several embodiments of formulations of processed juice, oil, and fiber can be used.
[0025] It is believed that the many health benefits of Morinda citrifolia is found in its ability to isolate and produce Xeronine, which is a relatively small alkaloid physiologically active within the body. Xeronine occurs in practically all healthy cells of plants, animals and microorganisms. Even though Morinda citrifolia has a negligible amount of free xeronine, it contains appreciable amounts of the precursor of xeronine, called Proxeronine. Further, Morinda citrifolia contains the inactive form of the enzyme Proxeronase which releases Xeronine from proxeronine. A paper entitled, “The Pharmacologically Active Ingredient of Morinda citrifolia ” by R. M. Heinicke of the University of Hawaii, indicates that Morinda citrifolia is “the best raw material to use for the isolation of xeronine,” because of the building blocks of proxeronine and proxeronase. These building blocks aid in the isolation and production of Xeronine within the body. The function of the essential nutrient Xeronine is fourfold.
[0026] First, Xeronine serves to activate dormant enzymes found in the small intestines. These enzymes are critical to efficient digestion, calm nerves, and overall physical and emotional energy.
[0027] Second, Xeronine protects and keeps the shape and suppleness of protein molecules so that they may be able to pass through the cell walls and be used to form healthy tissue. Without these nutrients going into the cell, the cell can not perform its job efficiently. Without pro-xeronine to produce xeronine our cells, and subsequently the body, suffer.
[0028] Third, Xeronine assists in enlarging the membrane pores of the cells. This enlargement allows for larger chains of peptides (amino acids or proteins) to be admitted into the cell. If these chains are not used they become waste.
[0029] Fourth, Xeronine, which is made from pro-xeronine, assists in enlarging the pores to allow better absorption of nutrients.
[0030] Each tissue has cells which contain proteins which have receptor sites for the absorption of xeronine. Certain of these proteins are the inert forms of enzymes which require absorbed Xeronine to become active. Thus Xeronine, by converting the body's procollagenase system into a specific protease, quickly and safely removes the dead tissue from skin. Other proteins become potential receptor sites for hormones after they react with Xeronine. Thus the action of Morinda citrifolia in making a person feel well is probably caused by Xeronine converting certain brain receptor proteins into active sites for the absorption of the endorphin, the well being hormones. Other proteins form pores through membranes in the intestines, the blood vessels and other body organs. Absorbing Xeronine on these proteins changes the shape of the pores and thus affects the passage of molecules through the membranes.
[0031] Because of its many benefits, Morinda citrifolia has been known to provide a number of anecdotal effects in individuals having cancer, arthritis, headaches, indigestion, malignancies, broken bones, high blood pressure, diabetes, pain, infection, asthma, toothache, blemishes, immune system failure, and others.
[0032] In one example, which is not meant to be limiting in any way, the beneficial Morinda citrifolia is processed into Tahitian Morinda citrifolia ® juice manufactured by Morinda, Incorporated of Orem, Utah.
[0033] To practice the invention, Morinda citrifolia is administered to the patient exhibiting one or more of the signs of liver damage sufficient to eliminate or at least alleviate one or more of the signs or symptoms.
[0034] The preferred dosage is at least two ounces of Morinda citrifolia liquid administered twice daily. Greater doses do not create side effects and have been found beneficial. For example, in one embodiment, up to one liter was administered daily with a significant prophylactic effect and no side effects. Some anecdotal evidence also seems to indicate that remedial benefits may also be experienced.
[0035] Through several clinical experiments, it has been found that Morinda citrifolia is capable of treating liver damage, inhibiting the proliferation of further cell deterioration within the liver, and even preventing cancer at the initiation stages of carcinogenesis by blockage of carcinogen-DNA adduct formation. The following examples illustrate the results obtained from these experiments and are for illustrative purposes only. These are not meant to be limiting in any way as one ordinarily skilled in the art will recognize the various parameters and control groups that may be used to carry out the intended function of the present invention as intended herein.
EXAMPLE ONE
[0036] [0036] Morinda citrifolia possesses a cancer preventive effect at the initiation sage of carcinogenesis by preventing carcinogen-DNA adduct formation, scavenging oxygen free radicals, quenching lipid peroxides, selectively inhibiting COX II and anti-inflammatory activity. Consuming 10% Morinda citrifolia in drinking water for seven days was able to reduce DMBA-induced DNA adducts by 70% in the liver of male C57 BL/6 mice. Our recent studies indicated that Morinda citrifolia is the strongest antioxidant among the four tested well-known antioxidants including Vitamin C, pycnogenol, and grape seed powder. The antioxidant activity of TNJ shows a dose-dependent effect against superodixe anion radicals (SAR) and lipid hydroperoxides (LPO) in vitro. These results indicate that Morinda citrifolia is a strong antioxidant. The latest data shows that Morinda citrifolia is a selective inhibitor of COX II in vitro. We already have reported positive data demonstrating liver protection using Morinda citrifolia from our preliminary study. Pre-consuming 10% and 20% TNJ in drinking water for 12 days was able to protect liver from CC14 exposure in female SD rats.
[0037] We hypothesize that Morinda citrifolia may possess a liver protective effect in a liver injury model induced by CC14 in vivo.
[0038] The aim of one experiment was to determine the preventive effect of TNJ on the acute liver injury induced by CC 14 in female SD rats and to examine the therapeutic effect of Morinda citrifolia on the damaged liver induced by CC14 in female SD rats.
[0039] The experiment was designed to determine the preventive effect of Morinda citrifolia against CC 14 induced hepatotoxicity and the therapeutic effect of Morinda citrifolia on the damaged liver induced by CC14 in female SD rats. Five-week old, 80-100 g virgin female SD rats were purchased from Harlan Sprague Dawley, Inc. (Indianapolis, Ind.), and housed in the animal facility.
[0040] Dose-dependent liver damage-induced by CC14: Animals were exposed to CC14 at 0.25, 0.5, and 1.0 ml/kg. The degree of liver damage caused by different doses of CC14 were examined by light and electron microscopy. Time-dependent liver injury induced by CC14: Animals were sacrificed at 0, 1, 3, 6, 9, 12, 16, and 24 hours after 0.5 mg/kg CC14 administration. The time dependent CC14-induced liver injury was examined by light microscopy.
[0041] Preventive effect of TNJ on the liver injury induced by CC14 and Prevention or delay of the onset of CC 14-induced liver injury: Preventive effect of TNJ on liver injury induced by CC14 was examined at different time points after 0.5 mg/kg CC14 administration by pretreating animals with 10% Morinda citrifolia compared with that of 10% placebo. Forty-eight female SD rats were divided into two groups: Placebo and Morinda citrifolia group. Animals in these two groups received 10% placebo, or 10% Morinda citrifolia , respectively. After 12 days, 24 rats from each group intragastrically received CC14 0.25 ml/kg. Three rats were sacrificed from each group at 0, 1, 3, 6, 9, 12, 16, and 24 hours after CC14 administration. The liver was removed for the examination by LM, EM, and for other biomarkers.
[0042] Dose-dependent protection of Morinda citrifolia : Twenty-seven rats were divided into seven groups, three animals of each group received water, 5%, 10%, 20%, 50% Morinda citrifolia or placebo for 12 days, respectively. After 12 days, all the animals received CC15 0.25 ml/kg for 6 hours. Then all the animals were sacrificed and the liver was removed for examination of LM, EM, and other biomarkers.
[0043] Based upon the results of different doses of CC14 treatment and different length of CC14 exposure times, we were able to choose an optimum exposure time as our positive liver damaged model, such as six or nine hours time points after CC14 administration. We treated those sick animals with damaged livers by using different doses of Morinda citrifolia , such as 5%, 10%, 20%, and 50% in drinking water to observe the healing processing of CC14 at different time points. The same doses of placebo were supplied to the sick animals as positive controls. The healing process was monitored by LM and EM examination. Liver functions were monitored before TNJ treatment and at the end of experiment. The results were compared with the placebo-treated animals.
[0044] Biomarkers Selected in this Project:
[0045] 1. Superoxide anion radical (SAR) level in target organ-liver will be tested by TNB asay.
[0046] 2. Lipid hydroperoxide (LPQ) level in target organ-liver will be tested by LMB assay.
[0047] 3. CC14-induced liver damage and the protection by Morinda citrifolia will be observed by light microscopic observation on the cellular and tissue levels.
[0048] 4. Electron microscopic observation of CC14-induced liver damage and the protection of TNJ a the ultrastructure level.
[0049] 5. Immunochemistray staining for expression of signal transduction signals, such as COX II, COX I, and other markers.
[0050] All examined parameters were compared between the different groups. The preventive effect of Morinda citrifolia and the therapeutic effect on the CC14-induced liver injury model will be evaluated based upon the changes of the examined biomarkers between Morinda citrifolia and placebo groups. The correlation between LPO and SAR levels in liver were evaluated. It was found that the levels were higher in the CC 14 group than in the control placebo group. Accordingly, other biomarkers were compared. The histological examination showed that a protective effect of Morinda citrifolia on the centrollubelous necrosis induced by CC14. The antioxidant effect and liver protective effects were evaluated carefully. A comparison was made between Morinda citrifolia and placebo groups. The student T test was selected to estimate the significance between the different groups of this experiment.
[0051] In this experiment, findings indicated that juice made from Morinda citrifolia fruits might prevent cancer at the initiation stage of carcinogenesis by blockage of carcinogen-DNA adduct formation, a strong antioxidant activity, and selective COX-2 inhibition. Consumption of 10% Morinda citrifolia juice for 7 days was able to prevent 70% of DMBA-DNA adducts in the liver of mice. In this study, the protective effect of Morinda citrifolia juice on the liver injury induced by carbon tetrachloride (CC14) in female SD rats was examined by light and electron microscopy. Animals were supplied with 10% placebo or 10% Morinda citrifolia juice for 12 days, respectively. On the last day, each animal was fed 0.5 ml/kg of CC14. Animals were sacrificed at 0, 1, 3, 6, 9, 12, 16, and 24 hours after CC14 administration. Another three animals were supplied with water as normal controls. Livers were removed for light and electron microscopic (LM and EM) examinations. Liver sections in placebo, water, and Morinda citrifolia juice control groups demonstrated normal lobular architecture at the LM level and normal ultrastructure. Liver sections in the placebo+CC14 group showed acute liver damage at the LM level in a time-dependent manner. Changes included a gradual increase of focal cellular vacuolization, lipid-containing or necrotic hepatocytes surrounding central veins, and focal inflammatory cells that were scattered throughout the lobules at 24 hours. Acute liver damage in the Morinda citrifolia juice+CC14 group was significantly delayed and there was a decrease in the number of swollen, lipid containing, and apoptotic hepatocytes compared to that of the placebo+CC14 group at different time points. At the EM level, glycogen depletion and lipid droplets in the cell plasma were observed in both CC14 treated groups. Swollen mitochondria, disorganization of RER with loss of ribosomes, and abundant focal areas of SER scattered throughout the cytoplasm were demonstrated in the placebo+CC14 group. Interestingly, golgi complexes in the Morinda citrifolia juice+CC14 group contained large electron dense vesicles with well-developed cistemal stacks, while golgi in the placebo+CC14 group contained small low-density vesicles and the cistemal stacks were often swollen and diminished. These observations coincided with the decrease of liver superoxide anion radicals and lipid hydroperoxide levels in the Morinda citrifolia +CC14 group when compared to the placebo+CC14 group (decreased 50% and 80%, respectively).
EXAMPLE TWO
[0052] In an additional experiment, a high dose of Morinda citrifolia juice (20%) showed significant decrease in liver injury when induced by a lower dose of CC 14 (0.25 ml/kg). In conclusion, this is the first finding of hepatic protection by Morinda citrifolia juice on acute liver injury induced by CC 14, indicating that Morinda citrifolia may protect the liver from carcinogen exposure. Therefore, it may prevent cancer at the initiation stage of hepatic carcinogenesis.
[0053] The present invention may be embodied in other specific forms without departing from its spirit of essential characteristics. The described embodiments are to be considered in all respects only al 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 | There is disclosed a method for preventing CCL4 (carbon tetracloride) induced liver damage comprising the prophylactic administration of extracts of Morinda citrifolia . The Morinda citrifolia may be administered in solid or liquid forms. Several regimens are disclosed including the administration of 2 ounces twice daily in a liquid form such as that sold by Morinda, Inc. | 0 |
FIELD OF THE INVENTION
[0001] The invention is directed to ocular solutions containing antioxidant compositions which have been stabilized to retard their deterioration.
BACKGROUND
[0002] The eye is naturally bathed internally and externally by ocular fluids. The external portion of the eye is lubricated by lacrimal fluids (tears). The internal portion of the eye has two fluid-containing chambers: the anterior chamber contains the aqueous humor or aqueous, and the posterior chamber contain the vitreous humor or vitreous.
[0003] Various conditions require the need to introduce fluids into or on the surface of the eye to replace or replenish naturally occurring fluids. The loss of naturally occurring ocular fluids may be due to normal aging, pathological conditions, surgical intervention, etc. For example, during ocular surgery, the vitreous is frequently removed and must thereafter be replaced. Commercially available irrigating solutions are often used to replace some or all of the vitreous, such as irrigating solutions infused to replace vitreous removed during vitrectomy and thereby to maintain the shape of the globe. The composition and other properties of these solutions may affect the surgical outcome for the patient, for example, a solution that affects the clarity of the cornea and lens may result in decreased visual acuity. Additionally, swelling of the cornea during vitrectomy may be influenced by components of the irrigating solution. Other conditions such as dry eye disease result in decreased external lubrication, and topical solutions such as eye drops are often used to provide relief. Eye wash solutions are used to remove foreign material from the eye.
[0004] Ocular solutions, for either topical application or introduction into the eye, should be physiologically compatible and should maintain the physiologic integrity of the eye. They should be easy to prepare and should be stable in composition. The invention describes such compositions and method of using the compositions.
SUMMARY OF THE INVENTION
[0005] Ocular solutions containing an antioxidant provide beneficial properties, for example, the antioxidant scavenges free radicals in the solution which may cause the solution to deteriorate. However, antioxidants are themselves extremely susceptible to oxidation. A stabilizing agent for the antioxidant retards or prevents the antioxidant from undesirable reactions and thus enhances its ability to stabilize the ocular solution. This in turn enhances the physiological properties of the ocular solution, which may be a topical solution such as eye drops, or a surgical ocular irrigation or volume replacement solution.
[0006] One embodiment of the invention is a composition comprising an ocular solution containing Vitamin C or Vitamin E and at least one stabilizing agent in an amount effective to stabilize the solution against oxidation. The stabilizing agent may be cysteine, L-cystine, glutathione, L-methionine, and/or N-acetyl-L-cysteine. Vitamin C or Vitamin E may be in a concentration in the range of about 1 μg/ml to about 10 mg/ml.
[0007] The stabilizing agent may be a solution of up to about 12% water and at least one water miscible organic solvent such as N-propanol, isopropanol, methanol, propylene glycol, butylene glycol, hexylene glycol, glycerine, sorbitol (polyol), di-propylene glycol, polypropylene glycol, a mixture of propylene glycol and butylene glycol with propylene glycol at about 25% by weight to about 80% by weight and butylene glycol at about 5% by weight to about 30% by weight. The stabilizing agent may be magnesium ions in at least 14 parts by weight to 100 parts by weight of a vitamin antioxidant. The stabilizing agent may be at least one phosphonic acid derivative and at least one metabisulfite. The stabilizing agent may be acrylic and methacrylic polymers, or xanthans. The stabilizing agent may be an extract of the fruit of the Emblica officinalis plant.
[0008] The ocular solution may be formulated as a true solution, or may be a suspension, a cream, a gel, an emulsion, or an ointment; the term solution is intended to encompass the different formulations and physical states.
[0009] In one embodiment, Vitamin C or Vitamin E is in a nonaqueous or substantially anhydrous silicone vehicle that is at least 50% by weight of the composition.
[0010] Various concentrations of Vitamin C or Vitamin E are possible. For example, Vitamin C or Vitamin E may range from about 0.025 mg/ml to about 1.2 mg/ml; from about 0.1 mg/ml to about 0.3 mg/ml; up to about 10% of the ocular solution; in the range of about 10% of the ocular solution to about 15% of the ocular solution within the limits of solubility.
[0011] Where the stabilizing agent is free cysteine, it may be present at a concentration by weight of the antioxidant in the range of about 0.4%, about 0.5%, about 0.6%, about 0.7%, about 0.8%, about 0.9%, about 1%, about 2.5%, or about 5%.
[0012] In various embodiments, free cysteine may be present at a concentration, relative to Vitamin C and/or Vitamin E, from about 0.2% to about 2.3%, or from about 0.2% to about 1.25%, or from about 0.3% to about 0.9%.
[0013] A composition may contain Vitamin C and/or Vitamin E in the range between about 1% by weight to about 25% by weight, glutathione in the range between about 0.01% by weight to about 10% by weight, a source of selenium at a concentration in the range from about 0.001% by weight to about 2.0% by weight, and a sulfur-containing amino acid at a concentration in the range of about 0.001% by weight to about 2.0% by weight.
[0014] In another embodiment, a composition comprising a physiologically acceptable formulation of Vitamin C and at least one stabilizing agent capable of retarding Vitamin C deterioration for use in a physiologically acceptable ocular solution is disclosed. Vitamin C, also called ascorbic acid, may be present in the form of derivatives or salts, such as sodium ascorbate, potassium ascorbate, calcium ascorbate, magnesium ascorbate, ascorbyl palmitate ester, ascorbyl laureate ester, ascorbyl myristate ester, ascorbyl stearate ester, magnesium ascorbyl phosphate, ascorbyl-phosphoryl-cholesterol, dipalmitate ascorbate, and ascorbate anhydrides.
[0015] Vitamin C may be at a concentration in the range of about 1 μg/ml of the ocular solution to about 10 mg/ml of the ocular solution, or in the range of about 0.025 mg/ml of the ocular solution to about 1.2 mg/ml of the ocular solution, or in the range of about 0.1 mg/ml of the ocular solution to about 0.3 mg/ml of the ocular solution, or at a concentration up to about 10% of the ocular solution, or in the range of about 10% of the ocular solution to about 15% of the ocular solution within the limits of solubility, or at a concentration in the range of about 0.025 mg/ml of the ocular solution to about 1.2 mg/ml of the ocular solution. Free cysteine as the stabilizing agent may be present at a concentration by weight, relative to Vitamin C, ranging from about 0.2% to about 2.3%, or ranging from about 0.2% to about 1.25%, or ranging from about 0.3% to about 0.9%.
[0016] In one embodiment, the composition is Vitamin C in the range between about 1% by weight to about 25% by weight, glutathione in the range between about 0.01% by weight to about 10% by weight, a source of selenium at a concentration in the range from about 0.001% by weight to about 2.0% by weight, and a sulfur-containing amino acid at a concentration in the range of about 0.001% by weight to about 2.0% by weight.
[0017] A method for stabilizing an ocular solution is also disclosed where a stabilizing agent is provided to an ocular solution containing Vitamin C, with the amount of the stabilizing agent sufficient to retard oxidation of Vitamin C and thus stabilize the ocular solution. The ocular solution may be for external use, such as a topical lubricant, contact lens solution, or eye wash solution. The ocular solution may be for internal use, such as an irrigating solution or a volume replacement solution.
[0018] A method for stabilizing an ocular solution is also disclosed by providing a stabilizing agent to an ocular solution containing an antioxidant. The stabilizing agent may be cysteine, magnesium ions, magnesium sulfate heptahydrate, L-methionine, N-acetyl-L-cysteine, glutathione, a mixture of propylene glycol and butylene glycol, at least one phosphonic acid derivative and at least one metabisufite, a combination of polysilicone-11, dimethicone, and cyclomethicone; xanthan polymers; acrylic and methacrylic polymers; or an extract of the fruit of the Emblica officinalis plant. The amount of stabilizing agent added is effective to retard oxidation of the antioxidant.
[0019] These and other advantages will be apparent in light of the following figures and detailed description.
DETAILED DESCRIPTION
[0020] An ocular solution containing an antioxidant that has been stabilized to retard deterioration of the antioxidant is disclosed. The ocular solution containing a stabilized antioxidant is able to participate in reactions that scavenge free radicals and thus preserve the physiological benefits of the antioxidant. In contrast, because antioxidants are inherently unstable and readily participate in free radical reactions during which they are auto-oxidized, an ocular solution containing an antioxidant that has not been stabilized is extremely susceptible to oxidation. This renders the antioxidant less active, and decreases, retards, or prevents the antioxidant from providing its beneficial properties to the ocular solution.
[0021] The ocular solution to which the stabilized antioxidant is added may be any physiologically compatible ocular solution for use in any manner, either topically or invasively. It will be appreciated that the ocular solution containing the stabilized antioxidant need not be in the physical form of a true solution, but instead may be a suspension, a cream, an ointment, an emulsion, a gel, etc. Thus, the term solution is used for convenience but encompasses other physical states in which the stabilized form of the antioxidant and the other components are present. It will also be appreciated that the stabilized antioxidant may be included in the formulation for preparing an ocular solution, or may be added in dry form or in the form of a concentrated solution to an already prepared ocular solution.
[0022] The ocular solution may be one that is used as an ocular irrigating solution or as a volume replacement during ocular surgery. It may also be one that is used topically, and thus encompasses eye drops, eye wash solutions, and contact lens solutions. It may be used in over the counter (OTC) ocular solutions for topical application, for example, in ocular solutions such as artificial tears or lubricants. One commercially available ophthalmic lubricant (Viva-Drops®, available from Vision Pharmaceuticals, Inc. (Mitchell S.D.)) is reported to contain polysorbate 80 as an antioxidant active ingredient, and sodium citrate, citric acid, EDTA, retinyl palmitate, and sodium pyruvate as inactive ingredients and antioxidants. It may also be used in prescription (Rx) ocular solutions for topical application. Examples of prescription ophthalmic compositions include, but are not limited to, the following: loteprednol etabonate ophthalmic suspension 0.5% (Lotemax™) as an ophthalmic topical antiinflammatory corticosterioid; loteprednol etabonate ophthalmic suspension 0.2% (Alrex™) as an ophthalmic topical anti-inflammatory cortocosteroid; metipranolol ophthalmic solution 0.3% (OptiPranolol™) as a non-selective beta-adrenergic receptor blocking agent; sodium chloride 2% or 5% solution or ointment (Muro 128R) as a treatment for corneal edema by drawing water out of the cornea of the eye, all available from Bausch and Lomb Pharmaceuticals (Tampa Fla.); and trifluridine ophthalmic solution 1% (ViropticR) available from Monarch Pharmaceuticals, Inc. (Bristol Tenn.).
[0023] The inventive composition may be used in physiologic ophthalmic irrigating solutions. One example is Balanced Salt Solution (BSS®, Alcon Laboratories (Randburg, South Africa), containing per ml 0.64% sodium chloride, 0.075% potassium chloride, 0.048% calcium chloride, 0.03% magnesium chloride, 0.39% sodium acetate, and 0.17% sodium citrate dihydrate, as well as sodium hydroxide and/or hydrochloric acid to adjust pH, and water for injection. Another example is Ocular Irrigation Solution® (Allergan, Irvine Calif.). Another example is lactated Ringer's solution. Another example is a normal saline solution. Another example is normal saline adjusted to pH 7.4 with sodium bicarbonate. The inventive composition may be used in ophthalmic volume replacement solutions for introduction into the posterior chamber of the eye to replace the vitreous that is removed during vitrectomy. As another example, it may be used as an ocular wash solution.
[0024] Any antioxidant in a physiological formulation for ocular administration may be used. One antioxidant is Vitamin C, which is also known as ascorbic acid or L-ascorbic acid. Vitamin C is unstable in the presence of oxygen and decomposes to form L-ascorbic acid 2-hydrogen sulfate, and then dehydroascorbic acid. Providing a stabilizing agent with Vitamin C reduces or eliminates its tendency to be oxidized in solution, and hence the stabilizing agent guards against Vitamin C deterioration. Another example of an antioxidant is Vitamin E (α-tocopherol). Vitamin E may be in the form of tocopherol or its esters, for example, tocopheryl acetate. Another example of an antioxidant is Vitamin A, which may be in the form of retinol or its ester or acids, for example, retinyl palmitate or retinoic acid. Thus, it will be appreciated that derivatives of Vitamins C, E, and A are also included within the scope antioxidants. A stabilized form of any of these antioxidants may be used separately or in combination in the ocular solution.
[0025] An antioxidant and a stabilizing agent for the antioxidant is included with ocular solutions for any use. The antioxidant and stabilizing agent may be added together or separately as individual components in the preparation of an ocular solution. Alternatively, a solution of the antioxidant and stabilizing agent may be prepared and then added to the ocular solution. It will be appreciated that, if the ocular solution to which the antioxidant is to be added itself contains a stabilizing agent, then the separate addition of a stabilizing agent may be optional and the antioxidant may be added directly to the solution to result in a stabilized antioxidant. For example, some commercially available ocular solutions contain glutathione, which is an antioxidant stabilizing agent. The solutions may be commercial irrigating solutions that contain other known components, such as various anions and cations, buffers to regulate pH, adenosine, calcium, glucose, bicarbonate, dextrose, dextran 40 (a low molecular weight colloidal osmotic agent), gentamicin, dexamethasone, selenium, zinc, and gluconide. The antioxidant and stabilizing agent may be added to commercial ocular lubricating solutions, such as artificial tears. The antioxidant and stabilizing agent may be added to commercial ocular wash solutions. Any solution for ocular administration, either administration to the exterior surface of the eye or to one of the interior chambers of the eye, may contain the antioxidant and stabilizer.
[0026] In one embodiment, a sterile solution of the antioxidant such as Vitamin C is prepared. A stabilized form of Vitamin C is prepared by including in the Vitamin C solution one or more components which inhibit, minimize, prevent, or decrease the extent of oxidation. One example of such a stabilizing component is cysteine. Another example of such a component is L-cystine. Another example is a solution of water up to about 12% water and at least one organic solvent miscible with water, namely, ethanol, N-propanol, isopropanol, methanol, propylene glycol, butylene glycol, hexylene glycol, glycerine, sorbitol (polyol), di-propylene glycol, polypropylene glycol (claim 1 of '382 patent), or a mixture of propylene glycol and butylene glycol with propylene glycol at about 25% by weight to about 80% by weight and butylene glycol at about 5% by weight to about 30% by weight and optionally including other glycols. Another example is glutathione, such as reduced glutathione with selenium as a cofactor. Another example is N-acetyl-L-cysteine. Another example is L-methionine. Another example is magnesium ions in at least 14 parts by weight to 100 parts by weight Vitamin C. Another example is a combination of at least one phosphonic acid derivative and at least one metabisulfite. Another example is an antioxidant in a nonaqueous or substantially anhydrous silicone vehicle where the silicone vehicle comprises at least 50% by weight of the composition. Another example is acrylic and methacrylic polymers, or xanthans. Another example is an extract of the fruit of the Emblica officinalis plant, which contains, by weight, gallic/ellagic acid derivatives of 2-keto-glucono-δ-lactone at about 35% to about 55%; Punigluconin (2,3-di-O-galloyl 4,6-(S)-hexahydroxy-diphenoylgluconic acid at about 4% to about 15%; Pedunculagin (2,3,4,6-bis-(S)-hexahydroxydiphenoyl-D-glucose at about 10% to about 20%; Rutin (flavanol-3)glycoside at about 5% to about 15%; low to medium molecular weight gallo-ellagi tannoids at about 10% to about 30%, gallic acid from 0% to about 5%, and ellagic acid from 0% to about 5%, available as CAPROS from Natreon Inc. (New Brunswick N.J.).
[0027] The antioxidant Vitamins C, A, and E are available commercially from a number of sources (e.g., Sigma-Aldrich Fine Chemicals, St. Louis Mo.). A solution of Vitamin C is prepared in a desired concentration. In one embodiment, the solvent is water. In another embodiment, the solvent is water and at least one organic liquid miscible with water. Vitamin C derivatives may also be used, example of which include alkali salts such as sodium ascorbate and potassium ascorbate, alkaline earth salts such as calcium ascorbate and magnesium ascorbate, esters such as ascorbyl palmitate, ascorbyl laureate, ascorbyl myristate, ascorbyl stearate, other salts such as magnesium ascorbyl phosphate, ascorbyl-phosphoryl-cholesterol, dipalmitate ascorbate, and ascorbate anhydrides.
[0028] The stabilizing agents are available commercially from a number of sources (e.g., Sigma-Aldrich). Cysteine and methionine are available as a hydrochloride salt or another physiologically acceptable salt, and may be added to the solution in amounts to yield an appropriate amount of the free base.
[0029] Embodiments of the invention include various concentrations of the antioxidants and stabilizer sufficient to stabilize the antioxidants against oxidation. Concentrations of the antioxidant and stabilizer(s) may depend upon the use for the composition, as is known to one skilled in the art. Thus, the invention is not limited to a specific concentration of either Vitamin C or the stabilizing agent. In general, the antioxidant is present in the ocular solution at concentrations ranging from about 1 μg/ml to about 10 mg/ml. In embodiments, Vitamin C, Vitamin A, or Vitamin E at concentrations in the range of about 0.025 mg/ml to about 1.2 mg/ml may be used, or concentrations in the range of about 0.1 mg/ml to 0.3 mg/ml may be used, or a concentration up to about 10% of the final solution may be used, or a concentration in the range of about 10% of the final solution to about 15% of the final solution within the limits of solubility may be used. Free cysteine is included at concentrations by weight of the vitamin of about 0.4%, about 0.5%, about 0.6%, about 0.7%, about 0.8%, about 0.9%, about 1%, about 2.5%, or about 5% may be used, or within the range of about 0.2% of the vitamin to about 2.3% of the vitamin, or within the range of about 0.2% of the vitamin to about 1.25% of the vitamin, or within the range of about 0.3% of the vitamin to about 0.9% of the vitamin. In one embodiment, an ocular solution contains Vitamin C, Vitamin A, or Vitamin E at a concentration in the range between about 1% by weight to about 25% by weight, glutathione in the range between about 0.01% by weight to about 10% by weight, a source of selenium as a cofactor for glutathione at a concentration in the range from about 0.001% by weight to about 2.0% by weight, and a sulfur-containing amino acid at a concentration in the range of about 0.001% by weight to about 2.0% by weight.
[0030] In various embodiments, other precautions may also be taken to minimize or reduce oxidization and thus further enhance the stability of the ocular solution. For example, the ocular solution containing antioxidant may contain a chelating agent such as ethylenediamine tetraacedic acid (EDTA), it may be packaged under nitrogen, its exposure to light may be minimized, etc.
[0031] The ocular solution may be an ocular wash solution, an ocular lubricating solution, an ocular irrigating solution, an ocular therapeutic solution, etc. The following references disclose methods which may be used in embodiments of the invention and are expressly incorporated by reference herein in their entirety: U.S. Pat. Nos. 3,958,017; 4,983,382; 5,281,196; 5,516,793; 5,703,122; 5,906,811; 6,804,110; 6,087,393; 6,103,267; 6,110,476; 6,146,664; 6,183,729; 6,211,231; 6,235,721; 6,299,889; 6,361,783. The following examples are illustrative only, and do not limit the scope of the invention.
EXAMPLE 1
[0032] An aqueous solution of up to about 10% Vitamin C, containing in the range of about 1% cysteine to about 5% cysteine is prepared. The stabilized Vitamin C solution is prepared with or is incorporated into an ocular solution to achieve a final Vitamin C concentration of about 0.1% by weight to about 5% by weight.
EXAMPLE 2
[0033] An aqueous solution containing in the range of about 0.025 mg/ml Vitamin C to about 1.2 mg/ml Vitamin C, and in the range of about 1% cysteine to about 5% cysteine, is prepared. The stabilized Vitamin C solution is prepared with or is incorporated into an ocular solution to achieve a final Vitamin C concentration of about 0.1% by weight to about 5% by weight.
EXAMPLE 3
[0034] An aqueous solution containing about 0.228 mg/ml Vitamin C and in the range of about 1% cysteine to about 5% cysteine is prepared. The stabilized Vitamin C solution is prepared with or is incorporated into an ocular solution to achieve a final Vitamin C concentration of about 0.1% by weight to about 5% by weight.
EXAMPLE 4
[0035] An aqueous solution containing about 0.1 mg/ml Vitamin C to about 0.3 mg/ml Vitamin C and in the range of about 1% cysteine to about 5% cysteine is prepared. The stabilized Vitamin C solution is prepared with or is incorporated into an ocular solution to achieve a final Vitamin C concentration of about 0.1% by weight to about 5.0% by weight.
EXAMPLE 5
[0036] Vitamin C at about 0.78 mg/ml (23.04 mg/ounce) and free cysteine in the range of about 0.0097 mg/ml (about 0.288 mg/1 ounce) to about 0.019 mg/ml (about 0.576 mg/1 ounce) is prepared with or is incorporated into an ocular solution to achieve a final Vitamin C concentration of about 0.1% by weight to about 5% by weight.
EXAMPLE 6
[0037] Vitamin C in the range between about 0.29 mg/ml to about 0.39 mg/ml, and cysteine hydrochloride anhydrous at a concentration of about 0.002 mg/ml as free cysteine, or in the range between about 0.505% to about 0.685% free cysteine by weight Vitamin C, is prepared with or is added to an ocular solution.
EXAMPLE 7
[0038] An ocular solution that may be a contact lens solution, a eye wash solution, an irrigating solution, a volume replacement solution, a therapeutic solution available either by prescription or over the counter, or a lubricant solution contains about 0.0340% by weight Vitamin C and 0.0002% cysteine.
EXAMPLE 8
[0039] An ocular solution containing up to about 10% Vitamin C and cysteine at a concentration in the range of about 0.2% by weight of Vitamin C to about 2.3% by weight of the Vitamin C is prepared.
EXAMPLE 9
[0040] An ocular solution containing up to about 10% Vitamin C and cysteine at a concentration of about 0.588% by weight Vitamin C is prepared.
EXAMPLE 10
[0041] An ocular solution containing in the range of about 0.0025% Vitamin C to about 0.12% Vitamin C, and cysteine at a concentration of about 0.588% by weight Vitamin C, is prepared.
EXAMPLE 11
[0042] An ocular solution containing in the range of about 30 mg Vitamin C to about 2000 mg Vitamin C, and magnesium ions at least at 14 parts by weight in 100 parts of Vitamin C, is blended at concentrations in the range of about 1.5 mEq/liter to about 35 mEq/liter.
EXAMPLE 12
[0043] In 50 mM phosphate buffer (pH 6), magnesium sulfate heptahydrate is dissolved at 2.054 g/liter, and Vitamin C at 0.2 g/liter. The solution is transferred into polyethylene bags, replaced with nitrogen, and sterilized under nitrogen pressure for 15 min at 115° C. It is added to or formulated with an ocular solution to achieve a final Vitamin C concentration in the range between about 0.1% by weight to about 5% by weight.
EXAMPLE 13
[0044] To an ocular solution, the following components are added: 334 mg/liter Vitamin C, 4 g/liter L-methionine, 1.1 g/liter N-acetyl-L-cysteine, and 2.054 g/liter magnesium sulfate heptahydrate.
EXAMPLE 14
[0045] To an ocular solution, at least 5% Vitamin C and a mixture of propylene glycol and butylene glycol, with propylene glycol at about 25% by weight to about 80% by weight and butylene glycol at about 5% by weight to about 30% by weight, and optionally including other glycols, is added
EXAMPLE 15
[0046] To an ocular solution, at least 5% Vitamin C and a mixture of propylene glycol and butylene glycol, with propylene glycol at about 25% by weight to about 80% by weight and butylene glycol at about 5% by weight to about 30% by weight, and optionally including other glycols, is added
EXAMPLE 16
[0047] Vitamin C is added to an ocular solution in an oil phase dispersion of particles. Vitamin C, water, and a water soluble or water dispersible polymer(s) is prepared. The polymers may be natural or synthetic polymers, including but not limited to methacrylates, cellulosic polymers, polyethylene glycols and copolymers, natural or modified natural resins, polyvinyl resins, water-solubilized or water-dispersible polyurethanes, water-solubilized or water-dispersible ethers, etc. A solution of Vitamin C (in various embodiments, by weight of the dispersion/suspension, at least 5%, at least 5.5%, at least 6%, at least 7%, at least 8.5%, at least 10%, and up to 40%, 50%, 60%, 75%), water, and a water-soluble polymer is prepared and mixed with a solution of oil and water in a surface active agent having an hydrophilic-lipophilic balance of less than 12. The solutions are dispersed to form a mixture, which is cooled to solidify the Vitamin C containing solution to form particles dispersed in oil. Emulsifying is performed at a temperature greater than 40° C.
EXAMPLE 17
[0048] An ocular solution is prepared with Vitamin C at a concentration in the range of about 0.01% to about 20%, at least one phosphonic acid derivative at a concentration between about 0.005% to about 5%, and at least one metabisulfite in a concentration between about 0.005% to about 5%. The phosphonic acid derivative may be ethylenediaminetetra(methylenephosphonic acid), hexamethylenediaminetetra(methylenephosphonic acid), diethylenetriaminepenta(methylenephosphonic acid), and their salts. The metabisulfite may be an alkali-metal, alkaline-earth, metal, or ammonium salt of anhydrosulfonic acid. The weight ratio between metabisulfite and phonphonic acid derivative ranges from 1 to 1000. In one embodiment, the weight ratio ranges from 1 to 5.
EXAMPLE 18
[0049] Vitamin C in a nonaqueous or substantially anhydrous silicone vehicle is prepared. In various embodiments, Vitamin C is at a concentration (all percentages are by weight) of at least 0.1%, at least 1%, from about 2% to about 30%, from about 5% to about 20%, from about 8% to about 12%, or about 40% of undissolved ascorbic acid. The carrier is an anydrous silicone carrier in an amount of about 50% by weight to about 80% by weight. The silicone vehicle may be a oil, gel, or solid. Silicone includes organosiloxanes and polyorganosiloxanes. Other antioxidants may be included.
[0050] Polysilicone-11 (from about 0.1% to about 68%), dimethicone (from about 0.1% to about 36%), and cyclomethicone (from about 0.1% to about 56%) are combined and the optional vitamins, if used, are added. Solid Vitamin C (10%) is dispersed with agitation and is ground using a three-roll mill until the particle size is less than 20 μm and the mixture is uniform. In one embodiment, the particle size is less than 12.5 μm.
EXAMPLE 19
[0051] In various embodiments, Vitamin C is at a concentration ranging from about 5% to about 70%, from about 10% to about 60%, or from about 20% to about 60%. Xanthan or acrylic and methacrylic polymers are added to a concentration ranging from about 0.1% to about 5%. The composition is prepared with or is incorporated in an ocular solution at a Vitamin C concentration in the range between about 0.1% to about 5%. Linoleic acid or an ester of linoleic acid may also be included.
EXAMPLE 20
[0052] In various embodiments, Vitamin C or derivatives of Vitamin C and an extract of the fruit of the Emblica officinalis plant are combined in a weight ratio of about 1:10 or about 10:1. The use of the fruit extract of Emblica officinalis as a stabilizer for Vitamin C is described in U.S. Pat. No. 6,235,721 which is expressly incorporated by reference herein in its entirety. The extract contains, by weight, (1) and (2) about 35-55% of the gallic/ellagic acid derivatives of 2-keto-glucono-δ-lactone; (3) about 4-15% of 2,3-di-O-galloyl 4,6-(S)-hexahydroxydiphenoyl-gluconic acid; (4) about 10-20% of 2,3,4,6-bis-(S)-hexahydroxydiphenoyl-D-glucose; (5) about 5-15% of 3′,4′,5,7-tetrahydroxyflavone-3-O-rhamnoglucoside; and (6) about 10-30% of tannoids of gallic/ellagic acid, gallic acid (0-5%); ellagic acid (0-5%) at a concentration ranging from about 5% to about 70%, from about 10% to about 60%, or from about 20% to about 60%. Xanthan or acrylic and methacrylic polymers are added at a concentration ranging from about 0.1% to about 5%. The composition is incorporated in an ocular solution at a Vitamin C concentration in the range between about 0.1% to about 5%.
[0053] Other variations or embodiments of the invention will also be apparent to one of ordinary skill in the art from the above figures and descriptions. Thus, the forgoing embodiments are not to be construed as limiting the scope of this invention. | Ocular solutions containing an antioxidant provide beneficial properties, for example, the antioxidant scavenges free radicals in the solution which may cause the solution to deteriorate. However, antioxidants are themselves extremely susceptible to oxidation. A stabilizing agent for the antioxidant retards or prevents the antioxidant from undesirable reactions and thus enhances its ability to stabilize the ocular solution. This in turn enhances the physiological properties of the ocular solution, which may be a topical solution such as eye drops, or a surgical ocular irrigation or volume replacement solution. | 0 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates generally to birdhouses and similarly configured feeders, and more specifically, to the convenient repeated depth adjustment capability of a false floor by means permanently containable within such structures to allow variation in depth settings for feeding, encouraging and protecting nestings of desirable birds, and discouraging nestings of undesirable birds.
2. Description of Prior Art
Various beneficial and desirable native birds, such as bluebirds and chickadees benefit from artificial nesting and feeding structures (bird houses and similarly constructed feeders; a bird house may also be considered a bird feeder if bird feed is placed inside an unoccupied nesting box and may be referred to as a birdhouse, birdbox, nesting box, feeding box, nesting/feeding box, or box. These structures are most beneficial with human management such as removal of old nests, undesirable birds' nests, parasites, etc. These structures are often, though not necessarily, built with four side wall panels, preferably with one side wall panel hinged or removable to permit access for human management. These structures are traditionally built with the floor at a permanently fixed depth below the bird entry hole. This fixed depth does not suit the varying biological conditions and purposes of these nesting/feeding boxes.
Predators such as raccoons and cats insert paws and forelegs through the bird entry holes of birdhouses, reaching down to seize nests, eggs, nestlings or incubating adults. Birdhouses built with greater fixed depth from bird entry hole to fixed floor may afford greater protection from this sort of predation, however some desirable birds demonstrate an aversion to nest in these deeper boxes. Those birds which do accept deeper boxes often negate the protective intent of the deeper box by filling the extra depth with additional nesting material, thus raising the egg cup at the top of the nest to a level dangerously close to the bird entry hole after all.
These deeper, built up nests are also unhealthy for desirable birds, as once dampened by driven rain, the nest will remain damp and cold longer, and harbor more blood sucking avian parasite blowfly larvae than will shallow nests. Some desirable birds such as bluebirds will cease nest building once the first egg is laid, and will then tolerate the lowering of the nest to a safer level. Wildlife managers sometimes lower the nest cup by inserting the fingers between the upper nest cup and the excess material of the lower portion of the nest, and removing the latter. This undermining may, however, disrupt the interwoven structure of the upper nest cup, and spillage of any removed material may attract predators by scent. This method is inconvenient, unsanitary, and exposes the hands to various pests which may inhabit the nest, such as mice, fleas, and ticks. For these reasons this method of lowering a nest is inferior to that permitted by the present invention.
Desirable native birds compete with undesirable destructive alien birds, such as English sparrows, for use of nesting boxes. English sparrows destroy nests, eggs, nestlings and incubating adults of native species while usurping nesting boxes intended for the latter. Ongoing field research suggests that while some desirable native birds such as bluebirds may prefer shallow nesting boxes, the undesirable English sparrow may have an aversion to shallow boxes.
A prior art device to vary the depth of bluebird houses to discourage nesting by English sparrows has been described in Sialia, the quarterly journal of the North American Bluebird Society in Volume 6, Number 1, pages 5-7, (Winter 1984). The device simply consists of one or more wood blocks placed or stacked on the fixed floor inside a birdhouse, prior to nest building, creating a shallow box less attractive to English sparrows but acceptable to bluebirds. The blocks may also be removed later to protectively lower the nest of desirable birds that build a shallow nest atop the blocks.
Just as some desirable birds are reluctant to enter a deep box to nest, some are reluctant to enter a deep box to feed, or are initially unable to discover feed placed low on the fixed floor of a deep box, away from the illumination of the bird entry hole.
A prior art device to lessen the depth of a bluebird nesting box, thereby adapting the box for use as a feeder, has been described in Bluebird News, a monthly wildlife management newsletter, on page 5 of the August 1989 issue. A small container, or wood blocks, are placed on the fixed floor inside a birdhouse. A feed tray is placed atop the container or blocks to hold bird feed closer to the bird entry hole, where it is more likely to be discovered by desirable birds. The description mentions that it may be necessary to lower the feed tray thereafter, if undesirable birds or animals too large to enter the feeding box attempt to reach the feed within.
These prior art depth adjustment devices, whether they be a container, other object, or one or more wood blocks simply placed on, or removed from, the fixed floor inside a nesting/feeding box, are inconvenient to use. These objects must be carried to or from the nesting/feeding box to effect a box depth adjustment, and must be handled and stored elsewhere when not in use in the box. This is especially inconvenient and unsanitary for those wildlife managers who maintain several, even hundreds, of boxes, often far afield. Also; removal of depth adjusting objects from a box may result in spillage of fine debris, creating a scent trail for predators leading back to the box. For these reasons prior art depth adjustment devices are inferior to the present invention.
As mentioned above, bird nests may become damp and often harbor the blood sucking parasitic larvae of the blowfly. Either condition is unhealthy for nestlings and may cause death.
A prior art device, described in Sialia, Volume 6, Number 2, page 70 (Spring, 1984), has been found to control both problems to some extent. This device is formed from a rectangle of hardware cloth (wire mesh) by making two right angle bends parallel to the two opposite short sides. This formed channel is inverted and stood on its legs which rest on the fixed floor of a birdhouse. (This elevated wire platform may be considered to be a form of false floor, though not intended for box depth adjustment. Some wildlife managers place a square of cardboard on this wire platform, hiding the unnatural looking wire until the nest building is complete.) The nest is built or retroactively placed on the wire platform. Rainwater which penetrates the nestbox will drain through the wire platform to the fixed floor, and out of the bottom of the box through drain holes drilled in or cut from the corners of the fixed floor. The airspace below the wire platform isolates the bottom of the nest from the damp fixed floor, and ventilates the underside of the nest and fixed floor, by permitting flow of air through the drainage holes. The drier nest is warmer for young nestlings and less hospitable to parasitic blowfly larvae. Also, larvae which fall through this wire mesh trap have some difficulty climbing back up to the nest. However, the legs of the wire platform may serve as a ladder, enabling some parasites to climb back up to the nest. The legs interfere somewhat with the free flow of water and air through drain holes cut from the corners of the fixed floor, limiting the beneficial drainage and ventilation effect. The legs also interfere with efforts to clean the surface below to remove trapped parasites and debris, unless the wire platform and nest are lifted. This prior art wire platform, dependent on legs bearing on the fixed floor for support, is inferior to the wire mesh or perforated platform support configuration permitted by the present invention.
SUMMARY OF THE INVENTION
It is, in general, an object of the present invention to provide a conveniently repeatable false floor depth adjustment capability and an improved means of support for a wire mesh or perforated drainage/ventilation/parasite trap, well integrated into bird nesting/feeding box design and permitting improved management practice, as specified in further objects stated below.
It is a further object of the present invention to provide repeatable false floor depth adjustment capability by means permanently containable within a nesting/feeding box through all biologically desirable depth settings, thereby eliminating the unsanitary and inconvenient handling, storage and carrying of depth adjusting objects to and from the box.
It is a further object of the present invention, by virtue of the permanent containability within a nesting/feeding box of these depth adjusting means, to minimize or eliminate spillage outside the box of scented debris, removed nest material, or feed, all of which could attract predators.
It is a further object of the present invention to provide false floor depth adjustment which is quickly and conveniently set by hand, requiring only minimal fingertip contact with the adjusting mechanism and unsanitary nest material.
It is a further object of the present invention to provide an improved means of support for the drainage/ventilation/parasite trap wire mesh or perforated platform, which improved support means will not interfere with drainage and ventilation through fixed floor corner drain holes, and will not assist the escape of trapped parasites nor interfere with cleaning of the surface below the wire mesh or perforated platform.
It is a further object of the present invention to permit more effective, convenient, and full integration of the potential functions of the (prior art) loose, thin, solid panel (the cardboard square sometimes placed on the wire mesh platform to temporarily hide the unnatural wire mesh until nestbuilding is complete). Thus it is an object to fully utilize a more durable version of this solid hiding panel for also holding feed, and catching falling parasites and debris below the elevated nest to permit a more convenient, thorough cleaning method.
It is a further object of the present invention to provide false floor depth adjusting means which are economical to manufacture and affordable to use in bird nesting/feeding boxes, traditionally inexpensive items often required in large numbers by wildlife managers. Therefore it is a further object to provide various embodiments of the present invention which vary in regard to cost of manufacture, convenience of use, or suitability for various applications such as inclusion in new box construction versus retrofitting of old boxes.
The present invention fulfills the foregoing objects in specific ways to be described after this brief description of the general form and function common to the various embodiments: all embodiments rely on at least one of the box vertical side walls for support of the adjustable depth horizontal false floor. The horizontal false floor may be grasped with the thumb and fingers and moved up or down within the box and re-set at a different desired depth. The minimal thickness of the false floor permits use of very nearly the full potential fixed box depth when adjusted all the way down. The minimal thickness of the false floor permits a beneficial space below the nest to be maintained when adjusted to be slightly above the fixed floor, while still affording just slightly less than full box depth. This beneficial space is clear of obstruction.
The present invention eliminates the need for unsanitary and inconvenient handling, storage, and carrying of depth adjusting objects to and from the box. As the minimal thickness of the false floor of the present invention permits use of very nearly the full potential fixed box depth when adjusted down, it is not necessary to remove the present invention when protectively lowering a nest or feed tray. As the false floor may be permanently contained within the box, it is not necessary to store or carry false floor depth adjusting objects back to the box when desirable to raise a false floor for the next nesting or feeding cycle.
The present invention, by virtue of this permanent containability of the depth adjusting means within a nesting/feeding box, minimizes the chance of spillage outside the box of scented debris, removed nest material, or feed, all of which could attract predators.
The present invention, by virtue of simply engaging and disengaging adjustment means, permits quick and convenient depth adjustment by hand, with only minimal thumb and fingertip contact with the adjusting means and unsanitary nest material.
The present invention, by virtue of side wall support of a false floor of minimal thickness, permits unobstructed space below the nest when so adjusted. When the present invention false floor is of wire mesh or perforated construction, rainwater which inadvertently enters the box and drains through to the surface below will then more freely drain out drain holes cut from the corners of the fixed floor without the obstruction (dam effect) caused by debris collecting around the prior art wire mesh platform support legs. Ventilation of the underside of the nest through corner drain holes is similarly enhanced. Elimination of support legs also eliminates a means of escape for fallen trapped parasites attempting to climb back up to the nest. Elimination of support legs permits convenient cleaning of the fixed floor when the false floor is, or has been, in a position spaced above the fixed floor. A broad, thin, horizontally hand-held tool can be inserted in the unobstructed space to quickly scrape fallen parasites and debris from the fixed floor into a hand-held small plastic bag for removal from the site. No third hand is needed to lift the obstructing support legs as is needed when cleaning under the prior art wire mesh platform.
The present invention, by virtue of side wall support of a false floor of minimal thickness, permits more effective, convenient, and full potential use of the simple prior art device (cardboard square) sometimes used to hide the unnatural-looking wire mesh until nest building is complete. A thin panel, sized slightly smaller than the fixed floor (preferably of a material more durable than cardboard), may be placed loosely atop a wire mesh or perforated version of the false floor of the present invention to more effectively hold feed or to hide the wire/perforated false floor until nesting is complete. This thin panel may then be easily slid out from under the nest and placed below the wire/perforated false floor on the fixed floor to catch fallen parasites and debris. It may thereafter be slid out and tipped into a hand-held plastic bag and then returned atop the fixed floor, thereby very conveniently cleaning the birdhouse floor. This multi-use thin panel may also be re-inserted between the wire/perforated false floor if ventilation of the underside of the nest is not desirable due to a return of unseasonably cold weather. Thus the present invention permits and suggests this fuller, more convenient, and beneficial use of this simple prior art device.
The present invention is provided in various embodiments which vary in cost of manufacture, convenience of use, or suitability for new construction versus retrofitting of old nesting/feeding boxes.
While adjustable support of a false bottom of minimal thickness by at least one interior side wall is of fundamental importance in fulfilling the objects of the present invention, this adjustable side wall support may be embodied in many forms which exemplify the principles of the invention. Some of the possible embodiments will be described briefly here and more thoroughly in the Detailed Description to follow later.
In one embodiment, a vertically slotted vertical adjusting extension is connected at a right angle to the horizontal false floor. This slotted vertical adjusting extension is frictionally but movably held against at least one side wall by at least one fastener passing through the vertical slot. A washer or friction plate beneath the head of the fastener may be incorporated to provide smooth movement. The slot and fasteners allow vertical movement when fingertip pressure is applied, but pre-set friction, applied by the adjustment of the fasteners (typically screws) bearing on the slotted vertical adjusting extension holding it frictionally against the inside side wall surface, will retain the relatively lightweight false floor assembly with nest and contents at a desired adjusted depth.
In a similar embodiment, a plain vertical adjusting extension is connected at a right angle to the horizontal false floor. This plain vertical extension is held against at least one inside wall surface by a friction/guide clip attached to the wall. The friction/guide clip allows vertical movement of the false floor when fingertip pressure is applied, but pre-set friction of the friction/guide clip, bearing on the plain vertical extension of the false floor assembly will retain the false floor assembly at a desired adjusted depth.
In another embodiment, a similar vertical extension is again connected at a right angle to the horizontal false floor. This vertical extension, however, is formed at regularly spaced intervals to engage corresponding regularly spaced mating formations on at least one of the inside walls. These corresponding regularly spaced mating formations extend up and down to permit fingertip controlled engagement and disengagement at varying depths.
In another embodiment, a horizontal extension is connected to or supportive of the horizontal false floor. The male horizontal support extension is formed to matingly engage female formations spaced up and down at least one wall to permit fingertip controlled withdrawal and reinsertion to adjust depth. This embodiment would be well suited for economical manufacture in new boxes as the female formations could take the form of drilled holes or deep horizontal saw kerfs machined in the inner wall surface of the (typically wooden) nesting/feeding box.
In another embodiment, the horizontal false floor is supported by wedge, compression, or spring pressure, or some combination of these forces, exerted by a mechanism built into the false floor, and bearing on opposing wall surfaces. As bird nests and contents are very light in weight, a minimum of easily exertable and releasable pressure on the side walls would support the false floor and yet permit quick and convenient depth adjustment by hand. This embodiment would be well suited to retrofitting standard sized old boxes in the field.
Each of the foregoing embodiments briefly described above fulfills the objects of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a bird nesting/feeding box with one side wall removed showing a naturally occurring bird nest built up dangerously close to the bird entry hole.
FIG. 2 is a perspective view of a bird box with one side wall removed showing a shallow nest built on prior art depth adjusting removable wooden blocks.
FIG. 3 is a perspective view of box (one side wall removed) showing prior art depth adjusting wooden blocks removed and nest lowered to safer level.
FIG. 4 is a perspective view of box (one side wall removed) showing a prior art container supporting a feed tray relatively closer to the bird entry hole.
FIG. 5 is an enlarged perspective view of the prior art wire mesh drainage/ventilation/parasite trap platform.
FIG. 6 is a perspective view of box (one side wall removed and upper portion cut away) showing prior art wire mesh in place on fixed floor of box.
FIG. 7 is a perspective view of nesting/feeding box interior with two side walls and roof removed to show slotted false floor assembly at a greater depth position.
FIG. 8 is a perspective view of box interior with two side walls and roof removed to show slotted false floor assembly being manually adjusted to an intermediate depth position.
FIG. 9 is a perspective view of box interior with two side walls and roof removed to show slotted false floor assembly at a lesser depth position.
FIG. 10 is an enlarged detail perspective view of the retaining/aligning fasteners, friction plate and portion of slotted vertical adjusting extension.
FIG. 11 is a perspective view of box interior with two side walls and roof removed to show flat false floor assembly set in one of the horizontal adjusting grooves at a lesser depth position.
FIG. 12 is a perspective view of box interior with two side walls and roof removed to show flat false floor assembly being inserted at an intermediate depth position.
FIG. 13 is a an enlarged detail side elevation view of a portion of a side wall with horizontal adjusting grooves and flat false floor assembly.
FIG. 14 is a perspective detail view of a portion of a side wall with spaced adjusting holes and adjusting pin false floor support variation.
FIG. 15 is a perspective view of box interior with two side walls and roof removed to show plain false floor assembly set at an intermediate depth position.
FIG. 16 is an enlarged detail perspective view of portion of side wall and plain vertical adjusting extension retained by friction guide clip and fasteners.
FIG. 17 is a perspective view of box interior with two side walls and roof removed to show notched false floor assembly with solid false floor variation set at an intermediate depth position.
FIG. 18 is an enlarged detail perspective view of portion of side wall and notched vertical adjusting extension barely disengaged from engaging formations.
FIG. 19 is a view of a box interior with one side wall and roof removed to show wedge/compression false floor assembly set at an intermediate depth position. Double arrow shows direction of wedge/compression force on opposing walls.
FIG. 20 is an elevation view of wedge/compression false floor assembly.
FIG. 21 is a plan view of wedge/compression false floor assembly with wedge in released position. Arrow shows direction of wedge movement to compress assembly against opposing sidewalls.
DESCRIPTION OF THE PREFERRED EMBODIMENT
A brief explanation of the prior art in reference to the drawings will provide an understanding of the objects of the invention and the limitations of the prior art (FIG. 1 to FIG. 6).
Referring to the drawings, FIG. 1 shows typical nesting/feeding box 1 with one side wall removed to expose the interior, as might occur in opening such a box. In addition to the removed side wall, remaining side walls 2, roof 12, and fixed floor 3 typically form such a box. Corner drain holes 4 have been cut from the corners of fixed floor 3. Fixed floor 3 is at a permanently fixed depth below bird entry hole 5. Built up bird nest 6 is dangerously close to bird entry hole 5.
FIG. 2 shows shallow bird nest 7 dangerously close to bird entry hole 5, having been built on depth adjusting wood blocks 8, previously placed on fixed floor 3.
FIG. 3 shows depth adjusting wood blocks 8 removed from fixed floor 3 of nesting/feeding box 1, and shallow bird nest 7 lowered to a safer level on fixed floor 3.
FIG. 4 shows container 9 resting on fixed floor 3 to support feed tray 10 in a position closer to bird entry hole 5.
FIG. 5 shows wire mesh platform (with legs) 11.
FIG. 6 shows wire mesh platform (with legs) 11 installed on fixed floor 3 of nesting/feeding box 1 (shown with top cut away) as it would be under a bird nest.
While the invention may be embodied in many different forms, a preferred embodiment is illustrated and will be described in specific form with the understanding that the disclosure is to be considered as an exemplification of the principles of the invention and is not intended to limit the invention to the specific embodiment illustrated and described.
Referring to the drawings again, FIG. 7 shows slotted false floor assembly 20 attached to one of side walls 2. It is set at a depth position whereby perforated false floor 21 is spaced at a great distance from bird entry hole 5 and yet spaced at a slight distance from fixed floor 3. A shallow nest built at a lesser depth position (as shown in FIG. 9) would be protected when lowered to the position shown in FIG. 7. The space between perforated false floor 21 and fixed floor 3 is clear of obstruction, and therefore beneficial as described previously.
As shown in FIG. 7, slotted false floor assembly 20 is formed from horizontal perforated false floor 21, which is slightly smaller than fixed floor 3 and of a shape corresponding to the shape of fixed floor 3 (often square), and slotted vertical adjusting extension 22 which is connected at a right angle to perforated false floor 21. Adjusting slot 23 is formed in slotted vertical adjusting extension 22 along a line perpendicular to the line which defines the intersection of the plane of horizontal perforated false floor 21 and the plane of slotted vertical adjusting extension 22. When slotted false floor assembly 20 is positioned and attached to one of the side walls 2, by retaining/aligning fasteners 24 aligned vertically on side wall 2 and passing through adjusting slot 23, adjusting slot 23 is held in a parallel alignment with the planes and corners of the side walls 2 and slotted vertical adjusting extension 22 is held against one of the side walls 2, while perforated false floor 21 is held in a horizontal plane parallel to fixed floor 3.
Adjustment of retaining/aligning fasteners 24 (which may simply be round headed screws) may pre-set a greater or lesser pressure of the retaining/aligning fastener 24 bearing on the slotted vertical adjusting extension 22 which in turn bears on side wall 2. This pre-set pressure may allow vertical movement of slotted false floor assembly 20 up and down within a nesting/feeding structure by hand but with sufficient but slight friction to hold a relatively lightweight bird nest and contents at a desired depth setting.
FIG. 8 shows slotted false floor assembly 20 being manually adjusted through an intermediate depth position to a lesser depth position as shown in FIG. 9. This lesser depth position, whereby the perforated false floor 21 is closer to bird entry hole 5, would be appropriate for inducing certain desirable birds to begin to nest or feed. Through the range of possible depth positions, perforated false floor 21 is maintained parallel to fixed floor 3.
FIG. 10 shows a detail of the adjustable friction attachment of sliding slotted vertical adjusting extension 22 to side wall 2 by vertically aligned and spaced retaining/aligning fasteners 24 passing through adjusting slot 23. Optional friction plate 25 (or ordinary washer) may be incorporated as shown in FIG. 10 to permit smooth sliding movement.
A valuable alternative embodiment shown in FIG. 11, FIG. 12, and FIG. 13 fulfills the objects of the invention by a different means.
In FIG. 11, one of the side walls 2 is preferably of greater thickness to accommodate horizontal adjusting grooves 31 spaced regularly between the bird entry hole 5 and fixed floor 3. These horizontal adjusting grooves 31 may be deeply cut saw kerfs economically machined at time of manufacture. If formed on the same side wall 2 in which the bird entry hole 5 is located, these horizontal adjusting grooves 31 can serve a beneficial dual purpose also as a toe hold ladder for birds climbing from low in a nesting/feeding box up to exit through the bird entry hole 5. (Some birds are fatally trapped in smooth walled structures, and better prior art boxes have knife cuts or very shallow single purpose saw kerfs to aid birds in climbing to the entry/exit hole.)
FIG. 13 shows a side elevation detail of a thicker side wall 2 with spaced horizontal adjusting grooves 31. Flat false floor assembly 30 is shown to correspond in thickness approximately to the width of horizontal adjusting grooves 31, to permit easy insertion of the horizontal adjusting extension 32 into any of horizontal adjusting grooves 31. Perforated false floor 21, in this embodiment, may be formed economically in one piece with horizontal adjusting extension 32 to create flat false floor assembly 30 from a stiff durable material such as sheet metal or plastic.
FIG. 11 shows flat false floor assembly 30 inserted into one of horizontal adjusting grooves 31, with horizontal adjusting extension 32 hidden from view in horizontal adjusting groove 31. Perforated false floor 21 is thus supported at a lesser depth setting parallel to the plane of fixed floor 3.
FIG. 12 shows manual insertion of flat false floor assembly 30 into another of the horizontal adjusting grooves 31 for an intermediate depth setting.
FIG. 14 shows in a detail perspective view how spaced adjusting holes 41 formed in one of the side walls are capable of accepting adjusting pin 42, which pin may be an extension of or supportive of a false floor not shown.
FIG. 15 shows another alternative embodiment similar to the preferred embodiment of FIG. 7 through FIG. 10 in that it has a frictionally held, vertically adjustable, sliding mechanism to set depth of a false floor. Plain false floor assembly 50 is formed of horizontal support 55 supporting flat wire mesh false floor variation 51 (which may be welded together) and plain vertical adjusting extension 52.
FIG. 16 shows how friction guide clip 53 is attached by fasteners 54 to side wall 2 to hold plain vertical adjusting extension 52 against side wall 2 thereby permitting smooth guided vertical movement.
FIG. 17 shows another embodiment wherein notched false floor assembly 60 is vertically adjustable in a nesting/feeding box. Solid false floor variation 61 is connected at a right angle to notched vertical adjusting extension 62. Adjusting notches 63 regularly formed along one vertical edge of notched vertical adjusting extension 62 correspond with engaging formations 64 spaced vertically on one of the side walls 2.
FIG. 18, a perspective detail view, shows the upwardly angled notches barely disengaged from engaging/retaining formations as is done when shifting from one depth setting to another.
FIG. 19 shows how a different alternative embodiment might be used to vary the depth of a box. As mentioned previously, releasable wedge, compression, or spring pressure exerted by a false floor assembly against opposite inner side walls to hold a false floor at a desired depth could be considered to be a means of fulfilling the objects of the invention. As an exemplification, wedge/compression false floor assembly 70 bears on two of the opposing side walls 2 to hold the relatively light weight of a bird nest and contents. Tapered false floor panel 71 is held by pressure of compressed compression strip 73 (rubber or similar material) and wedge 72 against opposing side walls 2. The double arrow shows the direction of the holding force.
FIG. 20 shows an elevation view of wedge/compression false floor assembly 70 comprised of tapered false floor panel 71, wedge 72, and compression strip 73.
FIG. 21 is a plan view of wedge/compression false floor assembly 70 with wedge 72 released to adjust depth. The arrow shows the direction of movement for the groove guided wedge 72 to tighten the wedge/compression false floor assembly 70 against opposing walls when so set in a box. | A false floor for a bird nesting/feeding box, bearing on at least one of the inner side walls for support, conveniently adjustable to various depths by hand, and, being of minimal thickness, capable of remaining permanently within the bird box even when desirable to lower the bird nest protectively to distance it from the bird entry hole through which predators insert body parts to seize nest contents. The invention permits improved drainage, ventilation, parasite control, and more convenient and thorough cleaning. The invention permits more convenient adapting of a nesting box to a feeding box. | 0 |
INTRODUCTION
This invention relates to safety device to prevent accidental unloading of pipe from a delivery vehicle.
Hundreds of times each day throughout this country pipe, most often concrete pipe, is loaded onto large trucks with long, flat cargo beds for delivery to construction sites. These trucks are often equipped with hydraulically operated lifts or elevators attached to the rear of the cargo bed. These lifts usually include two sturdy steel fingers which protrude upward from the rear of the cargo bed a sufficient length to prevent the pipe from rolling off of the rear of the truck. Pipe may be unloaded by rolling a piece of pipe against the fingers and hydraulically lowering the fingers and the pipe to ground level. The fingers are attached to a mount at the rear of the cargo bed so that they pivot at a point below the cargo bed and, thus, move from a vertical or nearly vertical position to a horizontal or nearly horizontal position. During unloading pieces of pipe ride on the fingers and move in an are from the level of the cargo bed to the level of the ground or other work surface. Pipe is ordinarily loaded onto these trucks by either a forklift or a crane.
Typically such pieces of pipe are very heavy weighing much more than a person can lift and are often loaded onto trucks more than one level high. Due to the pieces of pipe on the higher levels and, often, the angle of the cargo bed, pieces of pipe on such trucks have a tendency to roll off of the cargo bed. This tendency is extremely dangerous as rolling, moving, or falling pipe may strike workers resulting in injury or death. As a consequence various materials, usually wooden blocks, are placed against the bottom of the rearwardmost piece of pipe to prevent rolling. During unloading one piece of pipe is unloaded while the rest of the pipe is blocked to prevent movement.
Accidents occur during pipe unloading. At least one person is known to have died as a result of such an accident. For various reasons the blocking described above is inadequate to prevent pipe unloading accidents. On some occasions the blocking material has slipped or otherwise failed and pipe has rolled causing injuries. On other occasions workers have forgotten to place the blocks during unloading.
The instant invention promotes worker safety and prevents pipe unloading accidents by providing a blocking mechanism which automatically rises into place above the rear of the cargo bed when the fingers of the pipe lift are lowered to unload a piece of pipe.
BRIEF SUMMARY OF THE INVENTION
The instant invention includes a vertical tube which is welded to the side of the lift mount at the rear of a pipe truck cargo bed. The top of this tube is flush with the top of the lift mount and the top surface of the cargo bed. A bar slides vertically up and down within the tube. One end of a cable is attached to the bottom of the bar. The cable passes through a pulley which is affixed to the tube. The other end of the cable is attached to the lift fingers at a point below the level of the pulley.
When the lift fingers are in the vertical or storage position the top of the bar is slightly below the level of the top of the tube. During unloading the movement of the lift fingers pulls the attached end of the cable down and away .from the tube. Because of the pulley, this movement causes the bar to rise and slide upward through the tube. Thus, as one piece of pipe rides downward on the fingers and is unloaded, the bar automatically slides upward and blocks the remaining pieces of pipe to prevent them from rolling off the rear of the cargo bed.
A stop is also attached to the lift mount below the bar at a level such that the bar is allowed sufficient movement to perform its blocking function, but such that the bar may not slide downward completely out of the tube.
In the preferred embodiment safety blocks are used in pairs with one affixed to either side of the lift mount.
One objective of the present invention is to prevent injuries and promote worker safety by preventing pipe from accidentally rolling off of a pipe truck cargo bed during the unloading process; another objective of the present invention is to make the operation of the invention automatic and, thus, greatly reduce the likelihood of accidents caused by worker error; another objective of the present invention is to provide a stop such that no element of the present invention may drop from the pipe truck and become a hazard. These and other objects of the invention will be apparent to those skilled in this art from the following derailed description of a preferred embodiment of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention is further described in connection with the accompanying drawings, in which:
FIG. 1 is an orthographic view of a safety block constructed in accordance with the teachings of the present invention;
FIG. 2 is an orthographic view of the safety block shown in FIG. 1 shown in operation in the storage position; and
FIG. 3 is an orthographic view of the safety block shown in FIG. 1 shown in operation in the unloading position.
DETAILED DESCRIPTION OF INVENTION
The safety block is an apparatus which prevents accidents and promotes worker safety by preventing pipe from accidentally rolling off of the end of a pipe truck cargo bed during the unloading process. While one piece of pipe is being unloaded the safety block automatically causes a bar to rise above the rear end of the cargo bed and form a barrier which prevents other pieces of pipe from accidentally rolling off the rear end of the cargo bed. With reference to the drawings the preferred embodiment of the safety block is described in detail below.
The general configuration of the preferred embodiment of the safety block is shown in FIG. 1. The safety block includes a slide tube 1 which is oriented vertically. In the preferred embodiment the slide tube 1 is a rectangular steel tube 8 inches long with cross-sectional outside measurements of 2.5 inches by 1.5 inches and 3/16 inch thick walls, but other materials such as iron and tubes with other shapes and dimensions could be used. The slide tube 1 has a forward face and a rearward face which have the width of the narrower of the two cross-sectional dimensions. A bar 2 slides vertically up and down within the slide tube 1. In the preferred embodiment the bar is rectangular and made of iron and is 24 inches long with cross-sectional measurements of 2 inches by 1 inch, but other materials such as steel could be used. A bar 2 with other shapes and dimensions could also be used provided the shape of the bar 2 is the same as the shape of the slide tube 1, the cross-sectional dimensions of the bar are slightly less than the inside cross-sectional dimensions of the slide tube 1, and the bar 2 slides freely, but smoothly within the slide tube 1. The bar 2 has a forward face and a rearward face which have the width of the narrower of the two cross-sectional dimensions. A pulley 3 is affixed to the slide tube 1 near the bottom of the rearward face of the slide tube 1. In the preferred embodiment a conventional 2 inch pulley is used and the pulley 3 is welded to the slide tube 1, but other sizes or types of pulley could be used and other methods of attachment could be used. In the preferred embodiment the center of the pulley 3 is 1/4 inch above the bottom of the slide tube 1. A pin 4 is also provided. In the preferred embodiment the pin used is a 3/4 inch stub bolt, but other types of bolts or pins could be used. Two wire clamps 5 are also provided. Each wire clamp 5 includes two nuts 6, an anchor 7, and a "U" bolt 8. There is a groove 9 cut into the bottom of the bar 2. The groove 9 runs from a point slightly above the bottom of the rearward face of the bar 2 to a point on the bottom of the bar 2 slightly rearward of the bottom of the forward face of the bar 2. A stop nut 10 is attached to the bottom of the bar 2 at a point slightly rearward of the bottom of the forward face of the bar 2. In the preferred embodiment the stop nut 10 is a conventional 1/2 inch nut welded to the bar 2 with the hole through the nut running parallel with the longer of the two cross-sectional dimensions of the bar 2. A cable 11 is provided. The forward end of the cable 11 passed through the stop nut 10 and one of the cable clamps 5 is affixed to the forward end of the cable 11 and prevents the end of the cable 11 from pulling through the stop nut 10. The cable 11 passes through the pulley 3 and the rearward end of the cable 11 is wound around the pin 4 and attached to the pin 4 by the second cable clamp 5. The cable 11 fits within the groove 9. A stop 12 is also provided. In the preferred embodiment the stop is made from a piece of angle iron 6 inches long with 1 inch legs, but other materials in other sizes and shapes could be used.
Referring now to the orthographic view in FIG. 2 which shows the safety block in operation in the storage position, the rearward end of the cargo bed of a conventional pipe truck is shown. The figure shows a conventional pipe lift attached to the rearward end of a pipe truck. The lift mount 13 is attached to the rearward end of the cargo bed 14 such that the top of the lift mount 13 is flush with the top of the cargo bed 14. The lift fingers 15 are attached to the lift mount 13 and pivot around pivot pins located near the bottom of the rearward end of the lift mount 13. In storage position as shown in this figure the lift fingers 15 are vertical and extend above the top of the cargo bed 14. The lift fingers 15 each have an outside face and an inside face. In operation a pipe 16 is rolled rearward until it rests against the lift fingers. Said slide tube 1 is welded to the lift mount 13 such that the top of said slide tube 1 is flush with the top of the lift mount 13. In the preferred embodiment the forward face of said slide tube 1 is 2 inches from the forward face of the lift mount 13. Said pin 4 is welded to the outside face of the lift fingers 15 such that the longitudinal axis of said pin 4 is perpendicular to the outside face of the lift fingers 15. In the preferred embodiment the center of said pin is located 13 inches above the bottom of the lift fingers 15 and 1 inch rearward of the rearward face of the lift mount 13. Said stop 12 is welded to the lift mount 13. Said stop 12 is positioned with the legs upward and with the tops of the legs level. Said stop 12 is further centered on the lift mount 13 and the top of the welded leg is 2.5 inches above the bottom of the mount 13. In the storage position the top of said bar 2 is no less than 3.75 inches above the bottom of said slide tube 1.
Referring now to the orthographic view in FIG. 3 which shows the safety block in operation in the unloading position, the rearward end of the cargo bed of a conventional pipe truck is shown. In this figure a piece of pipe has been unloaded from the truck and said lift fingers 15 remain in the unloading or down position. As said lift fingers 15 pivot downward and move in an are from the storage position shown in FIG. 2 to the unloading position shown in this figure said cable 11 is pulled downward and away from said slide tube 1. Because of said pulley 3, said cable 11 lifts said bar 2 automatically as the lift fingers 15 move downward. Said bar 2 slides upward through said slide tube 1 and forms a barrier which prevents other pieces of pipe 17 from rolling off the rearward end of said cargo bed 14 during the unloading process. Said stop 12 is positioned such that said bar 2 can not slide downward out of said slide tube 1 and drop from the truck. In the preferred embodiment safety blocks are employed in pairs with one safety block attached to each side of said lift mount 13.
The dimensions given above for placement of elements including said slide tube 1, said bar 2, said pin 4, and said stop 12, and the length of said cable 11 are set out for the preferred embodiment of the safety block. In the preferred embodiment said bar is 24 inches long. Each of these dimensions and positions are coordinated to provide the appropriate movement of said bar 2. Such dimensions and positions may be varied provided that they are coordinated to provide such appropriate movement of said bar 2.
In the preferred embodiment said cable 11 is attached to the bottom of said bar 2 by said stop nut 12 and said cable clamp 5 and said cable 11 is placed inside said groove 9, but other means of attaching said cable 11 to said bar 2 may be used provided such means of attachment is sufficiently strong and provided said bar 2 slides freely within said slide tube 1. In the preferred embodiment said cable 11 is attached to said lift finger 15 by said pin 4 and said cable clamp 5, but other means of attaching said cable 11 to said lift finger 15 may be used provided such means of attachment is sufficiently strong, provided said bar 2 slides freely within said slide tube 1, and provided said cable 11 does not interfere with the operation of said lift fingers 15 and said cable 11 does not rub against said lift fingers 15. In the preferred embodiment the cable 11 is made from 1/8 inch woven steel aircraft cable 40 inches long, but other types of cable could be used provided they are sufficiently strong, sufficiently supple, and wear sufficiently well for proper operation of the safety block.
While the preferred embodiment of the invention has been shown and described, it will be apparent to those skilled in this art that various modification may be made in this embodiment without departing from the spirit of the present invention. For that reason, the scope of the invention is set forth in the following claims: | A safety block is disclosed which may be attached to the rearward end of the cargo bed of a pipe truck which has a powered pipe lift. The safety block includes a bar which automatically raises when pipe is being unloaded using the powered pipe lift and forms a barrier which prevents injuries and promotes worker safety by creating a barrier to prevent other pieces of pipe from rolling off of the rear of the cargo platform. | 1 |
BACKGROUND OF THE INVENTION
The present invention is directed to a weight compensation device or counterbalance device for a height-adjustable apparatus or device that is connected to a flexible supply line conducted to the mounted device from above. The compensation or counterbalancing device comprises a cable drum that accepts a first carrying cable loaded with the height-adjustable device and that is loaded by a force directed opposite to the weight of the height-adjustable mounted device.
Weight compensation devices or counterbalance devices are utilized in many height-adjustable devices or apparatuses so that the height-adjustable device can be effortlessly and exactly positioned in height without exerting increased force to overcome the force of gravity and will remain in this position that has been set. A typical area of employment for such weight compensation devices occurs in the field of medical-technical devices, such as x-radiators, etc., which are often secured in the x-ray room via a ceiling mount and that must be freely positionable in all three spatial directions with the assistance of the ceiling mount and must additionally be pivotable around a vertical and/or horizontal swiveling axis.
U.S. Pat. No. 6,065,705, whose disclosure is incorporated herein by reference thereto and which claims priority from German 197 47 393, shows an example of such an x-radiator suspended in a ceiling mount. The ceiling mount is composed of what is referred to as a telescope carriage that is displaceable along a bridge mounted underneath the ceiling of the x-ray room. In order to achieve the two-dimensional adjustment, the bridge is seated at corresponding suspensions in the room movable transversely to the motion direction of the telescope carriage. At its underside, the telescope carriage comprises a telescoping column at whose lower end the x-radiator is, in turn, suspended. Pivotable around the telescoping column, the x-radiator is secured to the telescoping column by means of a support mount. The telescope carriage includes a weight compensation device, wherein the cable drum is situated inside the telescope carriage and a carrying cable proceeds downward through the telescoping column proceeding from the cable drum. The cable drum is loaded by a coil spring arranged inside the cable drum that will exert a force on the cable drum that opposes the weight of the x-radiator device and mount.
The x-radiator is also connected via various lines in a standard way to other devices belonging to the x-ray apparatus. For example, an x-ray generator supplies the x-radiator with a high voltage via a high-voltage line. Over and above this, the x-radiator is connected, for example, to control signal or data lines by which data and control signals can be exchanged between other components of the x-ray apparatus and the x-radiator. These various lines are combined inside a hose, for example a ribbed or corrugated hose, that is conducted upward from the terminal location of the x-radiator to the telescoping carriage and proceeds from the latter via the bridge to a terminal location in the room or, respectively, to the other devices. Such lines shall be referred to as supply lines hereinafter, regardless of whether they are a matter of a hose with a plurality of separate lines located therein, of electrical lines or, for example, of compressed air, gas, water and/or hydraulic lines, and regardless of the exact function of these lines.
One problem with such a height-adjustable device with supply lines brought in from above is that the supply lines must be dimensioned with respect to their length so that the maximum lowering in a vertical direction is not negatively affected. This, in turn, has the disadvantage that the supply lines are too long in and of themselves when the device is in the upper position and hang into the working area and, thus, limit the user-friendliness of the device, especially given a very high working position of the device, for example, given only a very slight extension of the telescoping column of the ceiling mount. In the extreme case, swiveling around the vertical axis can even be greatly impeded by the dangling supply line. This problem is necessarily all the more pronounced the greater the height adjustment range of the device.
SUMMARY OF THE INVENTION
It is, therefore, an object of the present invention to create a weight compensation device with the improvement of being user-friendly. This object is achieved by a weight compensation device for a height-adjustable apparatus that is connected to a flexible supply line conducted to the apparatus from above. The compensation device comprises a cable drum that accepts a first carrying cable loaded with the height-adjustable apparatus and that is loaded by a force directed opposite to the weight of the apparatus. The improvements are a second carrying cable accepted by the cable drum that is secured to the supply line so that, given an upward adjustment of the apparatus, the fastening location of the supply line is automatically pulled upward as well as the second carrying cable.
Inventively, the weight compensation device comprises a second carrying cable accepted by the cable drum that is secured to the supply line in a region at a distance from the terminal location of the supply line at the height-adjustable apparatus. Thus, given an upward adjustment of the apparatus, the supply line is automatically pulled upward as well by the second carrying cable in the region around the fastening location of the second carrying cable. By employing the additional cable, which has one end accepted on the cable drum that is already present for the first carrying cable, the supply lines can be automatically pulled upward out of the work area matched to the respective height adjustment of the apparatus, as a result whereof the accessibility to the field of operation of the apparatus is improved and, thus, the operation thereof is simplified and more pleasant. In particular, an unimpeded pivotability of the apparatus around the vertical axis, for example around the telescoping column, is assured, even in an extremely high position for the height-adjusted apparatus.
The invention is therefore especially suited for devices with ceiling mounts, as initially set forth. Over and above this, the invention can also be employed in all other height-adjustable apparatuses wherein corresponding supply lines are conducted up and that comprise a suitable weight compensation or counterbalancing device.
Steel cables are preferably employed as the carrying cable. Alternatively, however, arbitrary other cables or even chains, belts or the like having adequate carrying power and resistance to tearing or breaking can be employed as the first and/or second carrying cable. Below, the term “carrying cable”, therefore, also explicitly covers chains, belts and the like.
In order to generate an adequate force on the cable drum that counters the weight of the apparatus, for example a spring integrated in the cable drum, particularly a coil spring or motive spring, as shown in the above-mentioned U.S. Pat. No. 6,065,705, has been proposed. A structure composed of a plurality of individual springs like these can be employed. Alternatively, other methods can also be employed for the weight compensation, for example a coupling of the cable drum to corresponding counterweights. The employment of coiled springs or motive springs, however, has the advantage that these designs are extremely compact and, thus, space-saving.
In a first version, the weight compensation device is built so that the second carrying cable is taken up or, respectively, unwound by the same length when the first carrying cable is taken up or unwound from the cable drum by a certain length. For example, the vertical path of the second carrying cable to which the supply line is secured exactly corresponds to the vertical path of the first carrying cable to which the adjustably mounted apparatus is secured. Thus, the distance between the region of the supply line to which the second carrying cable is secured and the apparatus itself will always remain constant, even given a height adjustment.
This can be realized in a very simple way in that the first and second carrying cables proceed in a common channel in the cable drum or in two parallel channels that proceed on the same diameter.
Alternatively, the cable drum can also be composed of a plurality of separate, discrete rollers for the carrying cables that are coupled to one another via a suitable gearing having a 1:1 transmission.
In a second version, the weight compensation device is designed so that the second carrying cable is unwound or, respectively, taken up by a longer or shorter length when the first carrying cable is unwound from or taken up onto the cable drum by a certain length. For example, the path of the second carrying cable is lengthened or, respectively, shortened with respect to the first carrying cable holding the device itself.
This, for example, can likewise be achieved by separate rollers in the cable drum that are coupled via corresponding gearing with the suitable transmission ratio.
In an especially preferred exemplary embodiment, a different path length of the carrying cable is realized, however, in that the first and second carrying cables are accepted in separate channels that proceed on different diameters in the cable drum. This realization is especially simple and cost-beneficial, since corresponding channels merely have to be introduced into a single cable drum.
A design is thereby especially preferred wherein the second carrying cable transverses a shorter path than the first carrying cable, and this is capable of being realized in that the channel for the acceptance of the second carrying cable proceeds on a smaller diameter in the cable drum than the channel for the acceptance of the first carrying cable. In such a version, the second carrying cable can preferably be attached in a region of the supply line that comprises a relatively great distance from the terminal location of the operating lines on the height-adjustable apparatus, so that the supply line is just still suspended by the second carrying cable so that unimpeded operation is possible in the highest possible position. As a result of the different path lengths of the first and second carrying cables, the distance of the suspension point of the supply line at the second carrying cable displaces farther and farther upward away from the apparatus when the apparatus is lowered, as a result whereof more and more space is made available to the operator.
In an especially preferred exemplary embodiment, the weight compensation device comprises an arrester cable additionally guided on the cable drum that secures the apparatus given a breaking of the first carrying cable. For example, this arrester cable extends parallel to the first carrying cable and is dimensioned in terms of its lengths so that it is only loaded if the first carrying cable breaks. An arbitrary cable, a chain, a belt or the like with adequate carrying power and resistance to breaking or tearing can likewise be employed as the arrester cable.
If there is a great range of height adjustment with particularly long supply hoses, it is desirable that the weight compensation device includes a plurality of second carrying cables, for example two separate carrying cables, that are secured to the supply line in different locations in order to, thus, pull the supply line up at a plurality of locations in common with the apparatus. The second carrying cables can thereby be respectively mounted in the cable drum so that they traverse a precisely defined, suitable path length, so that the supply hose is optimally held in every height position. In addition, it is also possible that a carrying cable is secured to a supply line at a plurality of locations.
The employment of a plurality of second carrying cables is also handy when various separate supply lines proceed to the apparatus that, for example, cannot be guided in common within a single hose. These second carrying cables can then be respectively secured to the various supply lines and correspondingly pull these up out of the work area when the device is adjusted upward. However, it is also possible that a single second carrying cable is simultaneously secured to a plurality of separate supply lines and pulls these supply lines up in common.
Other advantages and features of the invention will be readily apparent from the following description, the claims and drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of an x-radiator secured to a ceiling mount in a retracted position with a weight compensation device according to the prior art;
FIG. 2 is a front view of the device of FIG. 1 in an extended condition but with the inventive weight compensation device having a second carrying cable for the supply line;
FIG. 3 is a perspective view of the device according to FIG. 2 ;
FIG. 4 is a perspective view of the device according to FIGS. 2 and 3 in a retracted condition, as seen from the front, right side;
FIG. 5 is a perspective view of the device according to FIG. 4 in the same adjusted condition but from the left, front side;
FIG. 6 is a schematic cross-sectional view of a cable drum of the inventive weight compensation device in a first exemplary embodiment; and
FIG. 7 is a schematic cross-sectional view of a cable drum of the inventive weight compensation device in a second exemplary embodiment
DESCRIPTION OF THE PREFERRED EMBODIMENTS
An x-radiator 1 , which is secured to a ceiling mount which has a telescoping column 7 in a standard way is illustrated in FIG. 1 . For weight compensation, the device is equipped with a traditional weight compensation device 8 known from the prior art. This is composed of a cable drum seated in a cable drum housing 9 , which cable drum accepts a carrying cable 10 that is conducted downward through the tubular telescopic or telescoping column 7 from the cable drum and has its end connected to the x-radiator 1 or, respectively, a bracket or carriage 3 for the x-radiator 1 and, thus, the cable 10 supports the load of the x-radiator and the bracket.
The x-radiator 1 is supplied with the necessary high voltage and required data signals or, respectively, control signals, which may be sent back and forth between the x-radiator 1 and additional components of the x-ray device through a supply line 4 , which may be a ribbed or corrugated hose. As illustrated, the supply line 4 extends to a junction 20 , which is held by a bracket 21 above the carriage 3 . A second supply line 6 extends from the junction 20 to the actual x-ray control panel 2 of the x-radiator 1 . The supply line 4 is dimensioned with such a length that the device 1 can be moved into the lowest position, wherein the telescoping column 7 is entirely extended.
As illustrated in FIG. 1 , the problem occurs when the x-radiator 1 is pushed up into its highest position. The supply line 4 , which is too long for this position, rests on the x-radiator 1 or, respectively, the bracket 3 and thereby impedes the operation of the device. In particular, the x-radiator 1 can no longer be pivoted unimpeded around the longitudinal axis of the telescoping column 7 . In the extreme case, the supply line 4 can also cover the control panel 2 of the x-radiator 1 .
In order to largely avoid such limitations of the user-friendliness in an upper position of the x-radiator 1 , a second carrying cable 11 (see FIGS. 2-5 ) is inventively employed and is accepted by the cable drum of the weight compensation device 8 . It has an end that is secured to a fastening location 5 on the supply line 4 that is located a certain distance above the connection of the supply line 6 to the x-radiator 1 . This second carrying cable sees to it that the supply line 4 is located above the x-radiator 1 in every position of the x-radiator 1 .
A comparison of FIGS. 4 and 5 to FIG. 1 particularly shows how the supply line 4 is held above the x-radiator 1 with the second carrying cable 11 when the x-radiator is in the upper position, i.e., when the telescoping column 7 is retracted, so that the x-radiator 1 is freely pivotable and the control panel of the x-radiator 1 is freely accessible. The second carrying cable 11 can thereby be conducted out from the cable drum housing 9 at an arbitrary location and can be guided as wanted via deflection rollers 12 , so that the carrying cable can pull the fastening location 5 and the supply line 4 up unimpeded.
FIGS. 6 and 7 show two different versions for fashioning the cable drum 14 and 14 ′ of the weight compensation device. Both cable drums 14 and 14 ′ are a respective matter of conically tapering cable drums in which various channels, such as 16 , 17 , 18 and 19 are introduced for carrying cables and arrester cables 10 , 11 and 13 .
In detail, three cables 10 , 11 and 13 run in both cable drums 14 and 14 ′, whereby one cable 10 is the first carrying cable and a cable 13 running parallel is the arrester cable that holds the x-radiator 1 when the carrying cable 10 breaks and prevents an uncontrolled pancaking of the x-radiator 1 . The inventive second carrying cable 11 is guided in either the channel 18 , as illustrated in FIG. 6 , or the channel 19 , as illustrated in FIG. 7 .
In both exemplary embodiments, the cable drums 14 and 14 ′ are rotatably mounted on a shaft 15 via two bearings 21 . The shaft 15 is torsionally held in bearings 20 within the cable drum housing 9 at its respective ends. The force opposing the weight of the x-radiator 1 and the bracket 3 is exerted via coil springs 22 and 23 that have a radially inward end secured to the torsional shaft 15 and their other end, which is a radially outwardly disposed end secured to the cable drum 14 . These springs provide a force which counterbalances and oppose the weight of the x-radiator 1 and the associated carriage 3 . The force via the springs 22 and 23 is set so that the x-radiator 1 can be effortlessly moved into any arbitrary height position nearly without exertion of force and remains at that position. The user of two parallel coils springs 22 and 23 has the advantage that, if one spring here breaks, the device is at least still held by a second spring, although it is with half the force.
In the first exemplary embodiment of FIG. 6 , the channel 18 for the second carrying cable 11 proceeds exactly parallel to the channels 16 and 17 for the first carrying cable 10 and the arrester cable 13 , so that the peripheral length of the paths on the cable drum are the same. The second carrying cable 11 for the supply line, therefore, always traverses exactly the same distance as the carrying cable 10 and the parallel arrester cable 13 . Regardless of the height setting, the distance between a fastening point 5 of the supply line 4 to which the second carrying cable 11 is secured and the x-radiator 1 itself will remain the same. This is shown in FIGS. 2-5 .
In the second exemplary embodiment according to FIG. 7 , the second carrying cable 11 for the supply line 4 lies in a channel 19 that is arranged close to the end of the conical cable drum 14 ′ and has a smaller circumference, so that the peripheral path of the channel 19 is less than the paths for the channels 16 and 17 . For example, this channel 19 proceeds on a smaller circumference than the channels 16 and 17 for the first carrying cable 10 and the arrester cable 13 , which proceed parallel in the exemplary embodiment according to FIG. 6 . As a result thereof, the second carrying cable 11 for the supply line 4 will traverse only a shorter distance given an adjustment of the x-radiator 1 by a certain path length.
In the second exemplary embodiment, the length of the second carrying cable 11 for the supply line 4 is selected so that the same relationships as shown for the first exemplary embodiment in FIGS. 4 and 5 are present in the retracted position, i.e., in its highest position of the x-radiator 1 . The supply hose is therefore located above the x-radiator 1 just barely sufficing for an unimpeded operation of the x-radiator 1 . When, however, the x-radiator 1 is pulled farther down into its second version and the telescoping column 7 is extended, then the region of the supply line 4 to which the end of the second carrying cable 11 is secured traverses less of a distance than the x-radiator 1 itself. As a result thereof, the distance between the x-radiator 1 and the fastening location 5 of the second carrying cable increases, so that the operator's freedom of movement becomes greater and greater. This results therein that the operator is usually provided with more space, except in the highest position for the x-radiator 1 , than in the arrangement of FIG. 6 with the second carrying cable 11 and the first carrying cable 10 extending on parallel paths on the drum 14 .
The Figures show how, given an upward adjustment of the x-radiator 1 , the supply line 4 is also pulled up away from the work area and, thus, the user-friendliness is considerably improved. Such an inventive device is therefore particularly advantageous when it is operated in a room having a relatively low ceiling height, so that, for example, a ceiling mount is very frequently operated in a retracted condition or position. Since the path of the second carrying cable 11 needed for moving the supply line 4 is realized via the spring traction that is already present and, moreover, needed for the compensation of the weight of the x-radiator 1 , a very cost-beneficial application of the invention is also possible.
Although various minor modifications may be suggested by those versed in the art, it should be understood that we wish to embody within the scope of the patent granted hereon all such modifications as reasonably and properly come within the scope of our contribution to the art. | A height-adjustably mounted apparatus has a flexible supply line that is conducted to the apparatus from above and is provided with a weight compensation device so that the apparatus can be easily adjusted to different vertical positions. The weight compensation device includes a cable drum that accepts a first carrying cable which is loaded with the height-adjustably mounted apparatus and is subjected to a force directed opposite to the weight of the device and the weight compensation device includes a second carrying cable that is accepted on the cable drum and has an end secured to a supply line at a fastening location, so that the fastening location is lifted by the second carrying cable during vertical adjustment of the apparatus. | 1 |
BACKGROUND OF THE INVENTION
[0001] This invention relates to water-soluble polymers. Water-soluble polymers are used in many applications ranging from improved oil recovery, metal working fluid lubrication, and gellants in the food industry. It is known that the production of large amounts of water from oil and gas wells constitutes one of the major expenses in the overall recovery of hydrocarbons from a subterranean reservoir and that some water-soluble polymers reduce such water production. See, for example, Treybig et al. U.S. Pat. No. 6,569,983 and Ahmed et al. U.S. Pat. No. 6,051,670.
[0002] It is also well known that polymers and gelled or crosslinked water-soluble polymers have been used to alter the permeability of subterranean formations in order to enhance the effectiveness of water flooding operations. Generally, the polymers are injected into the formation and permeate into the regions having the highest water permeability. It is theorized that the polymer blocks the water permeable zones in the formation, thus reducing the amount of water produced with the oil. Existing polymers, such as polyacrylamides, do reduce water production but they also reduce oil production.
[0003] It would be desirable to provide water-soluble polymers that reduce water production but does not affect oil production.
SUMMARY OF THE INVENTION
[0004] In a first aspect, the present invention is a water-soluble polymer comprising a copolyhydroxyaminoether having side-chains of polyalkylene oxides.
[0005] In a second aspect, the present invention is a composition comprising an aqueous fluid and the water-soluble polymer of the first aspect.
[0006] In a third aspect, the present invention is a process for preparing the water soluble polymer of the first aspect which comprises reacting (1) a primary amine, a bis(secondary) diamine, or a mono-amine-functionalized poly(alkylene oxide) or mixtures thereof with (2) a diglycidyl ether, a diepoxy-functionalized poly(alkylene oxides) or mixtures thereof under conditions sufficient to cause the amine moieties to react with the epoxy moieties to form a polymer backbone having amine linkages, ether linkages and pendant hydroxyl moieties.
[0007] In a fourth aspect, the present invention is a process for preparing the water soluble polymer of the first aspect which comprises reacting an equivalent or excess of a difunctional amine or mixtures thereof with an excess or equivalent amount of a diglycidyl ether of a bisphenol or mixtures thereof, optionally in the presence of a monofunctional nucleophile which functions as a terminating agent and, optionally, in the presence of a catalyst and/or a solvent.
[0008] In a fifth aspect, the present invention is a process for preparing the water soluble polymer of the first aspect which comprises dissolving in an organic or non-organic solvent an amine selected from the group consisting of primary amine, a bis(secondary) diamine, or a mono-amine-functionalized poly(alkylene oxide) or mixtures thereof, adding to the amine solution an epoxide selected from the group consisting of a diglycidyl ether, a diepoxy-functionalized poly(alkylene oxides) or mixtures thereof in an amine hydrogen equivalent to epoxide equivalent ratio of from 1.01:1 to 1.1:1 under conditions sufficient to cause the amine moieties to react with the epoxy moieties to form a polymer backbone having amine linkages, ether linkages and pendant hydroxyl moieties.
[0009] Other aspects of the present invention will become apparent from the following detailed description and claims.
DETAILED DESCRIPTION OF THE INVENTION
[0010] Preferably, the copolyhydroxyaminoether is represented by the formula:
wherein R is hydrogen or alkyl; R 1 is an aromatic or substituted aromatic moiety; Y is an organic moiety that does not contain an epoxy group and Z is an organic moiety, optionally containing an epoxy group; x is 0-0.99; and n is 5-400; each A is individually an amino group represented by one of the formulas:
wherein R 2 is hydrocarbyl or substituted hydrocarbyl; R 3 is C 2 -C 10 hydrocarbylene or substituted hydrocarbylene; R 4 is C 2 -C 20 hydrocarbylene or substituted hydrocarbylene, wherein the substituent(s) is hydroxyl, cyano, halo, arlyloxy, alkylamido, arylamido, alkylcarbonyl, or arylcarbonyl; and each B is represented by the formula:
wherein R 5 is hydrocarbyl; R 6 is hydrogen, methyl, ethyl, hydrocarbyl, or mixtures thereof; and x is 0-0.99 when q is greater than 40; but less than 0.2 or greater than 0.8 when q is less than 40.
[0014] For purposes of this invention, the term “hydrocarbyl” means a monovalent hydrocarbon such as alkyl, cycloalkyl, aralkyl, or aryl and the term “hydrocarbylene” means a divalent hydrocarbon such as alkylene, cycloalkylene, aralkylene or arylene.
[0015] In the more preferred embodiment of this invention, R is hydrogen; R 1 is isopropylidenediphenylene, 1,4-phenylene, 1,3-phenylene, methylenediphenylene, thidodiphenylene, carbonyldiphenylene, or combinations thereof; R 2 is methyl, ethyl, phenyl, benzyl, 2-hydroxyethyl, 3-hydroxypropyl, 2-hydroxypropyl, 2,3-dihydroxypropyl, 2-(acetamido)ethyl, or combinations thereof; R 3 and R 4 are independently ethylene, 1,2-propylene, 1,2-butylene, or combinations thereof; and R 5 is C 1 -C 20 alkyl.
[0016] In the most preferred embodiment of this invention, R 1 is isopropylidenediphenylene, R 2 is 2-hydroxyethyl; R 5 is hydrogen, methyl, ethyl, propyl, butyl, benzyl or combinations thereof; R 6 is a mixture of hydrogen and methyl; Y and Z are N-(2-hydroxyethyl)piperazinyl or bis(2-hydroxyethyl)amino, q is 20-50, and n is 10-25.
[0017] The water-soluble polymer can be recovered from the reaction mixture by conventional methods. For example, the reaction mixture containing the polymer and optional solvent can be diluted with a suitable solvent such as dimethylformamide, cooled to room temperature, and the polymer isolated by precipitation into a non-solvent. The precipitated polymer can then be purified by washing or multiple washings by the non-solvent. The polymer is collected by filtration, washed with a suitable non-solvent and then dried. The water-soluble polymer can also be recovered from solution by volatilization of the solvent by combination of temperature and vacuum.
[0018] The difunctional amines which can be employed in the practice of the present invention include the bis-secondary amines and primary amines.
[0019] The primary amines which can be employed in the practice of the present invention to prepare the polymers include aniline and substituted anilines, e.g., 4-(methylamido)aniline, 4-methylaniline, 4-methoxy-aniline, 4-tert-butylaniline, 3,4-dimethoxyaniline, 3,4-dimethylaniline; alkylamines, and substituted alkyl amines, e.g., butylamine and benzylamine; and alkanol amines; e.g., 2-aminoethanol and 1-aminopropan-2-ol. Preferred primary amines are aniline, 4-methoxyaniline, 4-tert-butylaniline, butylamine, and 2-aminoethanol. The most preferred primary amine is 2-aminoethanol.
[0020] The bis-secondary amines which can be employed in the practice of the present invention to prepare the polymers include piperazine and substituted piperazines, e.g., dimethylpiperazine and 2-methylamidopiperazine; bis(N-methylamino)benzene, 1,2-bis(N-methylamino)ethane, and N,N′-bis(2-hydroxyethyl)ethylenediamine. Preferred bis-secondary amines are piperazine, dimethylpiperazine, and 1,2-bis(N-methylamino)ethane. The most preferred bis-secondary amine is piperazine.
[0021] The amine-functionalized poly(alkylene oxides) which can be employed in the practice of the present invention to prepare the polymers include those materials represented by the general formula:
wherein R 6 is hydrogen, methyl, ethyl, hydrocarbyl or mixtures thereof; R 5 is hydrocarbyl and q is from about 1 to about 1000. Typical of amines of this class are the “M” series Jeffamine™ products manufactured by Huntsman. They are typically prepared by polymerizing ethylene oxide, propylene oxide, butylene oxide, and the like or mixtures thereof with aliphatic alcohol initiators and then subsequently converting the resulting terminal hydroxyl group to an amine moiety.
[0023] Epoxy-functionalized poly(alkylene oxides) can be employed also in the practice of the present invention to prepare the polymers, and they can be mixed with diglycidyl ethers of bisphenols. Suitable epoxy-functionalized poly(alkylene oxides) are those represented by the general formula:
wherein R 1 is hydrogen, methyl, or mixtures thereof; and y is from about 1 to about 40. Typical of epoxides of this class are the “700” series D.E.R.™ epoxy resins manufactured by The Dow Chemical Company. They are synthesized by polymerizing ethylene oxide, propylene oxide, or mixtures thereof with hydroxide initiators and then reacting the resulting poly(alkylene oxide) diol with epichlorohydrin.
[0025] The diglycidyl ethers which can be employed in the practice of the present invention for preparing the polymers include 9,9-bis(4-hydroxyphenyl)fluorene, 4,4′-methylene bisphenol (bisphenol F), hydroquinone, resorcinol, 4,4′-sulfonyldiphenol, 4,4′-thiodiphenol, 4,4′-oxydiphenol, 4,4′-dihydroxybenzophenone, tetrabromoisopropylidenebisphenol, dihydroxy dinitrofluorenylidenediphenylene, 4,4′-biphenol, 4,4′-dihydroxybiphenylene oxide, bis(4-hydroxyphenyl)methane, .alpha.,.alpha.-bis(4-hydroxyphenyl)ethylbenzene, 2,6-dihydroxynaphthalene and 4,4′-isopropylidene bisphenol (bisphenol A) and the diglycidyl ethers of the amide-containing bisphenols such as N,N′-bis(hydroxyphenyl)alkylenedicarboxamides, N,N′-bis(hydroxyphenyl)arylenedicarboxamides, bis(hydroxybenzamido)alkanes or bis(hydroxybenzamido)arenes, N-(hydroxyphenyl)hydroxybenzamides, 2,2-bis(hydroxyphenyl)acetamides, N,N′-bis(3-hydroxyphenyl)glutaramide, N,N′-bis(3-hydroxyphenyl) adipamide, 1,2-bis(4-hydroxybenzamido)ethane, 1,3-bis(4-hydroxybenzamide)benzene, N-(4-hydroxyphenyl)-4-hydroxybenzamide, and 2,2-bis(4-hydroxyphenyl)-acetamide. The more preferred diglycidyl ethers are the diglycidyl ethers of 9,9-bis(4-hydroxyphenyl)fluorene, hydroquinone, resorcinol, 4,4′-sulfonyldiphenol, 4,4′-thiodiphenol, 4,4′-oxydiphenol, 4,4′-dihydroxybenzophenone, bisphenol F, tetrabromoisopropylidenebisphenol, dihydroxy dinitrofluorenylidenediphenylene, 4,4′-biphenol, 4,4′-dihydroxybiphenylene oxide, bis(4-hydroxyphenyl)methane, .alpha.,.alpha.-bis(4-hydroxyphenyl)ethyl-benzene, 2,6-dihydroxynaphthalene and 4,4′-isopropylidene bisphenol (bisphenol A). The most preferred diglycidyl ethers are the diglycidyl ethers of 4,4′-isopropylidene bisphenol (bisphenol A), 4,4′-sulfonyldiphenol, 4,4′-oxydiphenol, 4,4′-dihydroxybenzophenone, 9,9-bis(4-hydroxy-phenyl)fluorene and bisphenol F.
[0026] The monofunctional nucleophiles which function as terminating agents which can be employed in the practice of the present invention include secondary amines, hydrogen sulfide, ammonia, ammonium hydroxide, a hydroxyarene, an aryloxide salt, a carboxylic acid, a carboxylic acid salt, a mercaptan or a thiolate salt. Preferably, the hydroxyarene is phenol, cresol, methoxyphenol, or 4-tert-butylphenol; the aryloxide salt is sodium or potassium phenate; the carboxylic acid is acetic acid or benzoic acid; the carboxylic acid salt is sodium acetate, sodium benzoate, sodium ethylhexanoate, potassium acetate, potassium benzoate, potassium ethylhexanoate, or calcium ethylhexanoate; the mercaptan is 3-mercapto-1,2-propanediol or benzenethiol; and the thiolate salt is sodium or potassium benzenethiolate.
[0027] Preferred catalysts include metal hydroxides, quaternary ammonium salts or quaternary phosphonium salts. Especially preferred catalysts include sodium hydroxide, potassium hydroxide, ammonium hydroxide, ethyltriphenylphosphonium acetate, tetrabutylammonium bromide and bis(triphenylphosphoranylidene)ammonium chloride.
[0028] The conditions at which the reaction is most advantageously conducted are dependent on a variety of factors, including the specific reactants, solvent, and catalyst employed but, in general, the reaction is conducted under a non-oxidizing atmosphere such as a blanket of nitrogen, preferably at a temperature from about 40° C. to about 190° C., more preferably at a temperature from about 50° C. to about 150° C. The reaction can be conducted neat (without solvent or other diluents). However in some cases, in order to ensure homogeneous reaction mixtures at such temperatures, it can be desirable to use inert organic solvents or water as solvent for the reactants. Examples of suitable solvents include dipropylene glycol methyl ether, available commercially as Dowanol™ DPM, a product of The Dow Chemical Company, and the ethers or hydroxy ethers such as diglyme, triglyme, diethylene glycol ethyl ether, diethylene glycol methyl ether, dipropylene glycol methyl ether, propylene glycol phenyl ether, propylene glycol methyl ether and tripropylene glycol methyl ether as well as aprotic amide solvents like 1-methyl-2-pyrrolidinone, N,N-dimethylacetamide, and mixtures thereof.
[0029] It is most preferred that the polyalkylene oxide chain be rich in ethylene oxide relative to propylene oxide. The length of the polyalkylene side-chain can be from 1 alkylene oxide units to 1000 alkylene oxide units, preferably from 2 alkylene oxide units to 500 alkylene oxide units, more preferably from 5 alkylene oxide units to 250 alkylene oxide units and, most preferably, from 10 alkylene oxide units to 100 alkylene oxide units.
[0030] Preferably, the copolyhydroxyaminoether has a molecular weight of from about 1000 to about 500,000, more preferably from about 2000 to about 250,000 and, most preferably, from about 5000 to about 100,000. The copolymer molecular weight can be controlled by either off-stoichiometry of the N—H to epoxy ratio or by introduction of monofunctional terminating agents, described previously, at the start of the polymerization process or added during or at the end of the polymerization process.
[0031] Advantageously, the polyalkylene oxide containing polymer repeat units is used in an amount of from about 1 to about 99 mole %, more preferably, in an amount of from about 1 to about 25 mole %.
[0032] Preferably, the copolyhydroxyaminoethers have glass transition temperatures of from about (−)60° C. to about 150° C.
[0033] Aqueous solutions of copolyhydroxyaminoethers can exhibit a cloud point or lower critical solution temperature (LCST), such that an aqueous solution of copolyhydroxyaminoethers flow at some temperature below the boiling point of water, preferably room temperature, and becomes more viscous and/or gels with the possible optical transition from clear-to-hazy/opaque/turbid at more elevated temperatures. The term cloud point is a term that can be used to describe the optical transition. As used herein, the term “LCST” describes the temperature at which the polymer solution experiences a phase transition going from one phase (homogeneous solution) to at least a two-phase system (a polymer rich phase and a more solvent rich phase) as the solution temperature increases. The cloud point or LCST can be changed by the addition of salts, acids, or bases to the aqueous solutions of polyhydroxyaminoethers. The cloud point or LCST can also be changed as a function of concentration of polyhydroxyaminoether in aqueous solutions as well as the molecular weight of the polyhydroxyaminoether.
[0034] The following working examples are given to illustrate the invention and should not be construed as limiting its scope. Unless otherwise indicated, all parts and percentages are by weight.
[0035] The following materials are used in the Examples:
D.E.R.™ 332 A high purity bisphenol A diglycidyl ether manufactured by THE DOW CHEMICAL COMPANY. JEFFAMINE™ XTJ506 A polyoxyalkylenemonoamine with a propylene oxide/ethylene oxide ratio of ˜3/19 and a molecular weight of ˜1000 manufactured by Huntsman. JEFFAMINE™ M2070 A polyoxyalkylenemonoamine with a propylene oxide/ethylene oxide ratio of ˜10/32 and a molecular weight of 2000 and manufactured by Huntsman.
EXAMPLE 1
Solution, D.E.R. 332/MEA/JEFFAMINE XTJ506, 100/80/20 (m/m/m), DP˜15, hydroxyethylpiperazine)
[0039] Into a 1 L resin kettle is loaded D.E.R. 332 (180.00 grams, EEW 171), JEFFAMINE XTJ 506 (101.75 grams, Mn ˜1030), ethanolamine (24.10 grams), 1-(2-hydroxethyl)piperazine (8.60 grams), and N,N-dimethylacetamide, anhydrous (250 mL). Stirred reaction mixture under positive nitrogen is initially warmed to ˜45° C. When initial exotherm subsides, reaction setpoint is raised to 75° C. and after temperature rise stabilizes, setpoint is raised to 140° C. and held at that temperature for ˜1 hour. Reaction mixture is cooled with N,N-dimethylacetamide subsequently removed under vacuum at ˜95° C. Product has an inherent viscosity of 0.18 dL/g (N,N-dimethylformamide, 30.0° C., 0.5 g/dL). Half-height glass transition by DSC at 10° C./min heating rate is 6° C. A 20 wt % solution of the product in water is prepared that is of low viscosity and essentially clear at room temperature; at ˜50° C. the solution becomes translucent/opaque white and a soft-gel of high viscosity; when solution is cooled to room temperature it once again becomes of low viscosity and essentially clear.
EXAMPLE 2
Solution, D.E.R. 332/MEA/JEFFAMINE XTJ506, 100/85/15 (m/m/m), DP-25, hydroxyethylpiperazine
[0040] Into a 1 L resin kettle is loaded D.E.R. 332 (76.00 grams, EEW 171), JEFFAMINE XTJ 506 (35.59 grams, Mn ˜1031), ethanolamine (10.93 grams), 1-(2-hydroxethyl)piperazine (2.28 grams), and N,N-dimethylacetamide, anhydrous (150 mL). Stirred reaction mixture under positive nitrogen is initially warmed to ˜45° C. When initial exotherm subsides, reaction setpoint is raised to 75° C. and after temperature rise stabilizes, setpoint is raised to 100° C. for less than ½ hour, setpoint raised to 140° C. and held at that temperature for ˜1.25 hour. Reaction mixture is cooled with N,N-dimethylacetamide subsequently removed under vacuum at ˜95° C. Product has an inherent viscosity of 0.23 dL/g (N,N-dimethylformamide, 30.0° C., 0.5 g/dL). Half-height glass transition by DSC at 10° C./min heating rate is 13° C. A 15 wt % solution of the product in water is prepared at room temperature that at ˜50° C. becomes a translucent, white gel.
EXAMPLE 3
Solution, D.E.R. 332/MEA/JEFFAMINE XTJ506, 100/85/15 (m/m/m)
[0041] Into a 100 mL resin kettle is loaded D.E.R. 332 (12.000 grams, EEW 171), Jeffamine XTJ 506 (5.426 grams, Mn ˜1031), ethanolamine (1.822 grams), and N,N-dimethylacetamide, anhydrous (25 mL). Stirred reaction mixture under positive nitrogen is initially warmed to ˜45° C. When initial exotherm subsides, reaction setpoint is raised to 75° C. and after temperature rise stabilizes, setpoint is raised to 100° C. for less than ¾ hour, setpoint raised to 140° C. and held at that temperature for ˜3.25 hour. Reaction mixture is held at 100° C. overnight. Ethanolamine (0.026 g) in N,N-dimethylacetamide (2 mL) is added to kettle and after 30 minutes at 100° C., temperature is raised to 140° C. for ˜2 hours with subsequent cooling. N,N-dimethylacetamide is subsequently removed under vacuum at ˜95° C. Product has an inherent viscosity of 0.33 dL/g (N,N-dimethylformamide, 30.0° C., 0.5 g/dL). Half-height glass transition by DSC at 10° C./min heating rate is 16° C. No terminator is used in the reaction. A 20 wt % solution of the product in water is prepared.
EXAMPLE 4
Solution, D.E.R. 332/MEA/JEFFAMINE XTJ506, 100/88.75/11.25 (m/m/m)
[0042] Into a 100 mL resin kettle is loaded D.E.R. 332 (13.000 grams, EEW 171), Jeffamine XTJ 506 (4.409 grams, Mn ˜1031), ethanolamine (2.061 grams), and N,N-dimethylacetamide, anhydrous (25 mL). Stirred reaction mixture under positive nitrogen is initially warmed to ˜45° C. When initial exotherm subsides, reaction setpoint is raised to 75° C. and after temperature rise stabilizes, setpoint is raised to 100° C. for less than ˜½ hour, setpoint raised to 140° C. and held at that temperature for ˜3 hour. Reaction mixture is held at 100° C. overnight. Ethanolamine (0.022 g) in N,N-dimethylacetamide (2 mL) is added to kettle and temperature is raised to 140° C. for ˜1.5 hours. Product is precipitated in ice-water, water washed, and dried at ˜55° C. in a vacuum oven. Product has an inherent viscosity of 0.34 dL/g (N,N-dimethylformamide, 30.0° C., 0.5 g/dL). Half-height glass transition by DSC at 10° C./min heating rate is 31° C. No terminator is used in the reaction. The polymer produced is not water soluble.
EXAMPLE 5
Solution, D.E.R. 332/MEA/Jeffamine XTJ506, 100/92.5/7.5 (m/m/m))
[0043] Into a 100 mL resin kettle is loaded D.E.R. 332 (14.000 grams, EEW 171), Jeffamine XTJ 506 (3.165 grams, Mn ˜1031), ethanolamine (2.313 grams), and N,N-dimethylacetamide, anhydrous (25 mL). Stirred reaction mixture under positive nitrogen is initially warmed to ˜45° C. When initial exotherm subsides, reaction setpoint is raised to 75° C. and after temperature rise stabilizes, setpoint is raised to 100° C. for ˜1 hour, setpoint raised to 140° C. and held at that temperature for ˜3.25 hour. Reaction mixture is held at 100° C. overnight. Ethanolamine (0.022 g) in N,N-dimethylacetamide (2 mL) is added to kettle and temperature is raised to 140° C. for ˜1 hours with subsequent addition of N,N-dimethylacetamide (10 mL) and cooling. Product is precipitated in ice water, water washed, and dried under vacuum at ˜55° C. Product has an inherent viscosity of 0.46 dL/g (N,N-dimethylformamide, 30.0° C., 0.5 g/dL). Half-height glass transition by DSC at 10° C./min heating rate is 46° C. No terminator is used in the reaction. The polymer produced is not water soluble.
EXAMPLE 6
MELT, D.E.R. 332/MEA/Jeffamine XTJ506 100/80/20 (m/m/m) DP ˜15, hydroxyethylpiperazine
[0044] Into a 1L resin kettle is loaded D.E.R. 332 (345.15 g, EEW 172.7), Jeffamine XTJ 506 (189.24 g, Mn ˜1010), ethanolamine (45.78 g), and 1-(2-hydroxyethyl)piperazine (16.27 g). Initial setpoint for the stirred reaction is 45° C. under positive N 2 . Reaction mixture starts self-heating with cooling applied with temperature kept below ˜140-150° C. After temperature rise subsides, reaction is kept at 140° C. for 30 minutes with product then cooled to room temperature. Product has an inherent viscosity of 0.19 dL/g (N,N-dimethylformamide, 30.0° C., 0.5 g/dL) . Half-height glass transition by DSC at 10° C./min heating rate is 6° C. An aqueous solution of product is prepared by adding 312.5 grams in portions to a stirred 2 L resin kettle containing water (1193.1 g) and acetic acid (1.37 g) at ˜40° C. Aqueous sodium hydroxide (45.5 mL, 0.50 N) is subsequently added to the solution with a 10 mL water rinse.
EXAMPLE 7
MELT, D.E.R. 332/MEA/JEFFAMINE M2070 100/87.5/12.5 (m/m/m) DP ˜13.7, diethanolamine
[0045] Into a 1L resin kettle is loaded D.E.R. 332 (317.97 g, EEW 172.7), JEFFAMINE M2070 (223.39 g, Mn ˜2083), ethanolamine (45.86 g), and diethanolamine (13.15 g). Initial setpoint for the stirred reaction is 45° C. under positive N 2 . Reaction mixture starts self-heating with cooling applied with temperature kept below ˜140-150° C. After temperature rise subsides, reaction is kept at 140° C. for 30 minutes with product then cooled to room temperature. Product has an inherent viscosity of 0.17 dL/g (N,N-dimethylformamide, 30.0° C., 0.5 g/dL). Half-height glass transition by DSC at 10° C./min heating rate is 2° C. An aqueous solution of product is prepared by adding 312.5 grams in portions to a stirred 2 L resin kettle containing water (1193.1 g) and acetic acid (1.37 g) at ˜40° C. Aqueous sodium hydroxide (45.5 mL, 0.50 N) is subsequently added to the solution with a 10 mL water rinse.
EXAMPLE 8
Solution, D.E.R. 332/MEA/JEFFAMINE M2070, 100/85/15 (M/M/M)
[0046] Into a 100 mL resin kettle is loaded D.E.R. 332 (10.000 grams, EEW 171), JEFFAMINE M2070 (8.932 grams, Mn ˜2083), ethanolamine (1.484 grams), and N-methylpyrrolidinone, anhydrous (20 mL). Stirred reaction mixture under positive nitrogen is initially warmed to ˜45° C. When initial exotherm subsides, reaction setpoint is raised to 75° C. and after temperature rise stabilizes, setpoint is raised to 100° C. for ˜2 hours, setpoint raised to 140° C. and held at that temperature for ˜3.25 hour. Reaction mixture is held at 100° C. overnight. Ethanolamine (0.026 g) in N,N-dimethylacetamide (2 mL) is added to kettle and after 30 minutes at 100° C., temperature is raised to 140° C. for ˜3.75 hours with subsequent cooling to 100° C. overnight. Ethanolamine (0.017 g) in 2 mL N-methylpyrrolidinone is added to kettle with temperature raised to 140° C. for ˜4.25 hours and cooled. Product does not precipitate in water. Product precipitate in cold isopropanol and is washed with cold and ambient isopropanol with product dried at ˜110° C. under vacuum. Product has an inherent viscosity of 0.75 dL/g (N,N-dimethylformamide, 30.0° C., 0.5 g/dL). Half-height glass transition by DSC at 10° C./min heating rate is ˜15° C. No terminator is used in the reaction.
EXAMPLE 9
Water Polymerization, D.E.R. 332/MEA/JEFFAMINE M-2070 and DEA
[0047] Into a 30 gal stainless steel reactor is loaded 8137.5 g water and mixing started at 100 RPM's. JEFFAMINE M-2070 (6437.1 g, Mn ˜1040), ethanolamine (1321.5 g) and diethanolamine (378.9 g) are added then heated to 54-63° C. temperature. Pressure was 19.1-21.7 PSIA and mixing increased to 200 RPM's. D.E.R. 332 (9084 g, EEW 172.7) was added over a time period of 1 hour and 48 minutes via a 2 gal stainless steel (SS 316) charge pot. The reaction mixture was digested for 34 minutes and then water (133.8 lbs) was added over a 31 minute time. The resulting solution was mixed for 1 hr and 39 minutes then cooled to 25° C. and filtered via a 25 micro Nomex bag filter system into polyethylene containers.
EXAMPLE 10
Dowanol PM Polymerization, D.E.R. 332/MEA/JEFFAMINE M-2070 and DEA
[0048] Into a 30 gal stainless steel (SS 316) reactor is loaded 8137.5 g of Dowanol PM and mixing started at 100 RPM's. JEFFAMINE M-2070 (6437.1 g, Mn ˜1040), ethanolamine (1321.5 g) and diethanolamine (378.9 g) are added then heated to 87-91.6° C. temperature. Pressure was 19.1-21.7 PSIA and mixing increased to 200 RPM's. D.E.R 332 (9082 g, EEW 172.7) was added over a time period of 1 hour and 34 minutes via a 2 gal stainless steel charge pot. The reaction mixture was digested for 2 hr and 43 minutes at a temperature of 89-101° C. and then water (133.7 lbs) was added over a 36 minute time. The resulting solution was mixed for 1 hr at 67.1-89° C. and 150 RPM's then cooled to 26° C. and filtered via a 25 micro Nomex bag filter system into polyethylene containers. | A water soluble polymer comprising a copolyhydroxyaminoether having side-chains of polyalkylene oxides, an aqueous solution of said polymer and process for preparing the copolyhydroxyaminoether. | 2 |
This application is a continuation of prior application Ser. No. 11/025,185, filed Dec. 29, 2004, (now U.S. Pat. No. 8,444,698 issued May 21, 2013), the entire contents of which are herein incorporated by reference.
BACKGROUND OF THE INVENTION
The present invention relates to joint prosthesis, and particularly to prosthesis having an articulating head component. More specifically, the invention relates to a system for achieving infinitely variable positions for the head component relative to a bone engaging portion of the prosthesis.
Repair and replacement of human joints, such as the knee, shoulder, elbow and hip, has become a more and more frequent medical treatment. Longer life spans mean that the joints endure more wear and tear. More sports activities mean greater likelihood of serious joint injuries. Treatment of injuries, wear and disease in human joints has progressed from the use of orthotics to mask the problem, to fusion of the joint, to the use of prostheses to replace the damaged joint component(s).
As the success rate for total or partial joint replacements has increased, so too has the need for modularity and universality in the joint prosthesis. Patient variety means that no single size or configuration of joint prosthesis will suffice. The physical dimensions of a patient's joint components vary, as well as the bio-mechanic relationship between these components. For instance, in a shoulder prosthesis, the relationship between the articulating humeral and glenoid components can be significantly different between patients. These relationships are especially important where only one component of the joint is being replaced and must integrate with the existing natural opposing joint component.
In joint replacement procedures, the proximal end of a bone, such as the humerus, is resected to form a stable platform to receive a joint implant. In some cases, it is discovered after the implant has been fixed within the bone that the resection was inappropriate for the patient's joint. Correction of this problem requires, at a minimum, removal of the implant and implantation of a new implant to fit the resected surface. The availability of a differently sized or configured implant component is very beneficial, and even more important where further resection of the bone is necessary.
For instance, in many shoulder surgeries, only the humeral component is replaced, leaving the glenoid component intact. In this case, it is imperative that the articulating surface of the humeral component match the articulating surface of the glenoid component as perfectly as possible, both statically and dynamically. With a typical humeral prosthesis, version and inclination are adjusted by the geometry of the head of the prosthesis. In other words, certain pre-determined head geometries are available that can be selected for a mating glenoid component. Absent an infinite variety of pre-determined head geometries, the resulting humeral prosthesis can often only achieve a best-fit relationship to the glenoid component of the shoulder joint.
In a typical surgical procedure, a trial component will be used to determine the optimum final component to be fixed to the bone. In most cases, the surgeon is able to make a good selection that fits the joint very well. However, in some cases, the accuracy of the fit cannot be determined until the surgery is completed and the patient has had an opportunity to exercise the repaired joint. Where significantly problems arise, a revision surgery may be necessary to replace an improperly sized or configured joint component. One typical revision surgery requires removal of the entire prosthesis from the bone and replacement with a different prosthesis.
There is a significant need for a joint prosthesis that is both modular and universal. Such a prosthesis would be easily manipulated during the surgery and capable of achieving nearly infinite version and inclination angles. Moreover, an optimum prosthesis would be readily available for modification in a revision surgery without having to remove the entire prosthesis.
SUMMARY OF THE INVENTION
These and other needs of the prior art are met by the present invention in which a joint prosthesis includes a removable component to which the articulating component of the prosthesis is connected. The removable component permits adjustment of the angular orientation of the articulating component so that the joint prosthesis is truly universal.
In one aspect of the invention, the joint prosthesis includes a bone engaging portion having a first recess portion, and an internal wall defining a second recess portion, an articulating component, an insert component having (i) a first insert portion configured to snugly fit within said second recess portion in contact with the internal wall, and (ii) a projecting portion that fixedly projects from said first insert portion and is configured to snugly fit with the first recess portion so as to rotationally fix the first insert portion within the second recess portion, said insert component also having a first coupling portion, and a mating component configured to mate with said articulating component and having a second coupling portion configured to mate with the first coupling portion to form a fixed male/female couple at variable version and inclination angular orientations with respect to the insert component.
In a specific embodiment of the invention, a joint prosthesis includes a bone engaging portion configured for engagement within a bone of a patient, said bone engaging portion having a substantially cylindrical cavity and a platform surface defining a platform plane, an articulating component configured for articulating engagement with an opposing aspect of a joint, an insert component having a cylindrical portion configured to mate with said cavity by insertion of the cylindrical portion into the cavity through the platform plane, wherein said insert component is configured to mate with said bone engaging portion in a rotationally keyed configuration which rotationally fixes the insert component in the cavity at a predetermined rotational angle, and a mating component configured to mate with said articulating component and having a spherical portion configured to mate in a press-fit engagement with a tapered bore of said insert component.
In accordance with a method of the present invention, a joint prosthesis is constructed by placing an insert component into a complementary configured cavity defined in the proximal portion of a bone engaging implant, such as a stem. A fixation element, such as a screw, is used to fix the insert within the stem. A mating component is engaged with the insert component, such as by a press-fit engagement between a tapered bore in the insert and a compressible ball portion on the mating component. An articulating component, such as a femoral head, is then mated with the mating component, such as through a press-fit engagement.
In a further feature of the present invention, a revision procedure includes the step of accessing the fixation element through openings defined in at least the mating component. The fixation element is released from engagement with the stem so that the insert component is no longer fastened thereto. The insert component is then removed, preferably with the mating component and head components fastened undisturbed.
In yet another aspect, the removed insert component with the undisturbed mating component and head component can be transported to a replication instrument. The angular position of at least the mating component may be ascertained relative to a fixed datum using the instrument. That angular position can be conveyed to a new insert and mating component using the instrument. Once the three-dimensional angles have been properly replicated in the new prosthesis components, the mating component can be fixed within the insert component, preferably by impaction. The head component may also be engaged to the mating component, also preferably by impaction. The completed assembly is then conveyed to the stem that has not been removed from the patient's bone. The insert component is placed within the insert cavity in the stem and the fixation element is used to rigidly connect the insert component to the stem with the mating component and head component in their proper anatomic relation to the patient's bone. These steps can be implemented in a true revision surgery to replace an existing prosthesis, or can be carried out during an original joint replacement procedure.
It is one object of the invention to provide a joint prosthesis that is both modular and universal. This object is achieved by features that permit infinitely variable positioning of a mating joint component relative to a bone engaging portion of the prosthesis.
Another object is to provide a prosthesis that is readily available for modification, whether during initial implantation or during a subsequent revision procedure. One benefit of the invention is that this modification can occur without removing or disturbing the bone engaging component, or stem, of the implant.
These and other objects and benefits of the invention will be appreciated upon consideration of the following written description together with the accompanying figures.
DESCRIPTION OF THE FIGURES
FIG. 1 is a side view of a prior art humeral prosthesis.
FIG. 2 is an enlarged cross-sectional view of a portion of a joint prosthesis with a mounting element configured for articulating engagement with the stem of the prosthesis to permit angular positioning of a head component in multiple degrees of freedom.
FIG. 3 is a side exploded view of a modular prosthesis in accordance with one embodiment of the present invention that is adapted to facilitate modification or revision of the implant.
FIG. 4 is a front cross-section view of the modular prosthesis shown in FIG. 3 in an assembled configuration.
FIG. 5 is a front perspective of a stem component of the modular prosthesis shown in FIGS. 3-4 .
FIG. 6 is an enlarged cross-section view of a portion of the stem depicted in FIG. 5 .
FIG. 7 is a top perspective view of an insert component of the modular prosthesis illustrated in FIGS. 3-4 .
FIG. 8 is a side cross-section view of the insert component shown in FIG. 7 .
FIG. 9 is a side cross-section view of a mating component of the modular prosthesis shown in FIGS. 3-4 .
FIG. 10 is a side view of a fixation component of the modular prosthesis shown in FIGS. 3-4 .
FIG. 11 is a side view of a replication instrument for use in replicating the orientation of the mating component of the prosthesis shown in FIGS. 3-4 .
FIG. 12 is a perspective view of a dummy stem for use in the replication instrument shown in FIG. 11 .
DESCRIPTION OF THE PREFERRED EMBODIMENTS
For the purposes of promoting an understanding of the principles of the invention, reference will now be made to the embodiments illustrated in the drawings and described in the following written specification. It is understood that no limitation to the scope of the invention is thereby intended. It is further understood that the present invention includes any alterations and modifications to the illustrated embodiments and includes further applications of the principles of the invention as would normally occur to one skilled in the art to which this invention pertains.
The present invention contemplates a joint prosthesis with an articulating component that must be positioned at a particular angular orientation to replicate and accommodate anatomic features of the patient's joint. In the following description, the prosthesis is identified as a humeral prosthesis for a shoulder implant. It is understood, however, that the principles of this invention can be applied to other prosthesis that include an adjustable component. The present invention is particularly suited for prostheses that are amenable to replacement or adjustment in a revision surgery.
By way of background, a typical joint prosthesis of the prior art is illustrated in FIG. 1 . The prosthesis 10 is the humeral component of a shoulder prosthesis that can be implanted in the humerus bone for articulating engagement with the natural glenoid or with a glenoid prosthesis. The prosthesis 10 includes a stem 12 configured to be implanted within the humerus bone in a conventional manner. The stem 12 forms a platform surface 15 that faces the glenoid component of the joint when the prosthesis is in its operative position. The platform surface 15 defines a tapered bore for use in mounting the articulating head component 14 . The head component includes a tapered post 18 that can be press-fit or friction-fit within the tapered bore 16 to firmly mount the head component to the stem 12 .
The prosthesis 10 can be a modular prosthesis, meaning that a number of stem and head geometries can be provided from which a selection can be made that most closely approximates the natural joint components of the patient. Thus, the angle of the platform surface 15 can be different among stems 12 . While all head components 14 will include a generally spherical bearing surface 19 , the orientation of this surface relative to the platform surface 15 can be changed. Specifically, the location of the post 18 relative to the bearing surface 19 can be offset from the center of the surface (i.e., an eccentric head). In some cases, the angle of the post can be different between head components 14 .
An improved modular prosthesis introduces an articulating mounting element 30 between the stem 12 and a head component 20 , as shown in FIG. 2 . This mounting element 30 is shown and described in co-pending application Ser. No. 10/748,448 (the '448 application), entitled JOINT PROSTHESIS WITH INFINITELY POSITIONABLE HEAD, filed on Dec. 30, 2003, and owned by the assignee of the present invention. While the '448 application provides a more detailed disclosure of the mounting element, which disclosure is incorporated herein by reference, following is a general description to facilitate an understanding of the present invention.
This mounting element 30 of the '448 application includes a proximal portion 33 that mates with the head component 20 . In a specific embodiment, the proximal portion 33 defines a tapered surface that is press-fit or friction-fit within a complementary bore 21 defined in the head component.
The mounting element 30 further includes an articulating portion 34 that is preferably in the form of a spherical ball joint. The articulating portion is sized to achieve a press-fit engagement within a tapered bore 16 of the stem 12 when the portion 34 is pushed sufficiently far into the bore. The spherical shape of the articulating portion 34 allows the mounting element 30 to rotate about three dimensional axes x, y, z. Thus, the mounting element can rotate about its own axis (the x axis), pivot about a version axis (they axis) or pivot about an inclination axis (the z axis).
In addition to the press-fit engagement, a second fixation capability is disclosed in the '448 application that augments the engagement between the articulating portion 34 and the tapered bore 16 . In particular, a machine screw 40 may be provided that includes a threaded portion 46 configured to mate with a threaded bore 18 in the stem 12 . The bore 18 is concentrically disposed at the base of the tapered bore 16 . The screw 40 is introduced into the threaded bore 18 through the articulating mounting element 30 .
As shown in FIG. 2 , the mounting element 30 defines a central passageway 36 that extends through the length of element and that is open at its proximal and distal ends. The passageway defines an internal bearing surface 38 at the distal end of the element, or more specifically at the base of the articulating portion 34 . The screw includes a head 42 that includes an underside surface 44 that is complementary with the internal bearing surface. These two surfaces form a spherical bearing interface that allows the mounting element 30 to experience its full range of angular motion without interference from the screw 40 , even when the screw is loosely threaded into the threaded bore 18 . The articulating portion 34 defines a relief 39 at the distal end of the passageway 36 to facilitate this full range of movement of the mounting element.
The passageway 36 in the mounting element allows introduction of the screw 40 through the mounting element and into the threaded bore 18 . The screw can be loosely threaded into the bore to permit movement of the mounting element. Once the proper position for the mounting element 30 has been achieved, the screw can be tightened using a tool engaged within the tool recess 43 on the head 42 of the screw. As the screw is tightened, it drives the articulating portion 34 deeper into the angled bore 16 , thereby fixing the mounting element against further articulation. The screw thus combines with the friction or press-fit feature to lock the construct.
The mounting element 30 disclosed in the '448 application represents a significant improvement over the prior art prosthesis 10 in that it greatly simplifies the process of aligning the mounting element, and ultimately the humeral head, at the proper anatomic angle for the patient's shoulder joint. Moreover, the mounting element 30 allows infinite positioning of the humeral head, in lieu of the limited selection of pre-defined angles available with the prosthesis of the prior art.
Even though the mounting element 30 presents a significant advance over the prior prostheses, problems still arise when a revision surgery is indicated. During some primary implant procedures, the surgeon may discover that a different humeral head is needed after the final implant stem has been fixed within the humerus. In some cases, the accuracy of the fit of the prosthetic components cannot be determined until the surgery is completed and the patient has had an opportunity to exercise the repaired joint. Where significant problems arise, a revision surgery may be necessary long after the primary surgery to replace an improperly sized or configured joint component. In most cases, the modular components of the prosthesis cannot be removed without also removing the component, or stem, fixed within the bone. Removal and replacement of an implanted stem is often problematic and runs the risk of creating a revision construct of poor integrity.
The present invention addresses the problem of revision surgeries on prosthetic implants by providing an insert component that allows the bone implanted component to remain within the bone. In accordance with one embodiment of the invention, a prosthesis 50 is provided as illustrated in FIGS. 3-4 that includes a stem 52 , an insert component 54 , a fixation element 56 and a mating component 58 . The stem 52 is configured to be implanted within a bone of a patient and may be identical in most respects to prior stems used for similar joint replacement procedures. More particularly, the portion of the stem 52 that is implanted within the prepared intramedullary canal of the humerus may be identical to the prior art stem 12 shown in FIG. 1 . As with the prior art stems, the stem 52 includes a platform surface 60 that is aligned toward the mating aspect of the joint, or the glenoid aspect in the case of a shoulder prosthesis.
However, the platform surface 60 of the stem 50 in the present invention takes on different characteristics from the prior art. In particular, the platform surface is configured to receive an insert component 54 and a fixation element 56 operable to rigidly fix the insert component to the stem. The insert component 54 is adapted for engagement with the mating component 58 under conditions that allow adjustment of the angular orientation of that component. The mating component 58 is configured to receive an articulating component, such as the humeral head 20 shown in FIG. 2 .
Referring to FIGS. 5-6 , details of the platform surface 60 of the stem 50 are illustrated. The platform surface defines an insert cavity 62 with a base recess 64 embedded within the stem and a plate recess 66 opening into the platform surface. As shown in FIG. 5 , the base recess 64 is preferably cylindrical, for ease of manufacturing and to facilitate placement of the insert component 54 within the insert cavity 62 . However, other cross-sectional configurations for the base recess may be acceptable.
The plate recess 66 is generally rectangular with an edge 67 that opens at the superior end 61 of the platform surface 60 . The plate recess preferably includes a rounded inboard end to facilitate manufacture of the recess 66 . For instance, the base recess 64 can be formed by drilling to a certain depth into the platform surface 60 of the stem 52 . The plate recess 66 can be initially formed by drilling concentrically with the base recess, but at a larger diameter and to a shallower depth. The platform surface can then be milled to carve out the open edge 67 of the plate recess.
The insert component 54 is configured to fit snugly within the insert cavity 62 , as can be seen from FIGS. 7-8 . In particular, the insert component includes a base portion 70 that is configured to be snugly received within the base recess 64 . Thus, the cross section of the base portion preferably emulates the cross section of the base recess—i.e., the base portion 70 is cylindrical in the illustrated embodiment. The insert component further includes a plate portion 72 that is also configured to be snugly received within the plate recess 66 . As with the base portion, the plate portion 72 follows the configuration of the plate recess 66 so that the base portion is generally rectangular with a rounded inner edge. In the preferred embodiment, the plate portion 54 includes a tab 80 that extends from the cylindrical base portion 70 so that the free end 81 of the tab is accessible at the open edge 67 of the plate recess. Preferably, the free end 81 is substantially coincident with the open edge.
The plate portion 72 defines a lower surface 78 that rests within the plate recess 66 . The insert component is preferably sized so that the base portion 70 is slightly offset from the bottom wall 77 of the base recess 64 when the lower surface 78 of the plate portion 72 is situated within the plate recess. The free end 81 of the plate portion 72 includes a lower rounded edge 79 to provide a small access for a removal tool between the insert component and the insert cavity, as discussed in more detail herein.
In one feature of the invention, the insert component 54 defines a tapered bore 74 . The tapered bore mates in press-fit engagement with engagement surface 85 of a ball portion 84 of the mating component 58 ( FIG. 9 ). This press-fit engagement accomplishes final fixation of the mating component 58 with the stem 52 . This interface may be similar to the press-fit engagement described in the '448 application incorporated by reference. The mating component preferably includes a tapered cylinder 82 that is configured for press-fit engagement within the complementary bore 21 of the humeral head 20 ( FIG. 2 ). The mating component includes a central bore 87 that may be configured for a press-fit engagement with a male feature on the humeral head, in lieu of or in addition to the press-fit against the outer surface of the tapered cylinder 82 .
In order to secure the mating component to the stem 52 , a fixation element 56 is provided that fixes the insert component 54 to the stem. In the preferred embodiment, the insert cavity 62 of the stem defines a threaded bore 68 in the base recess 64 . The fixation element 56 constitutes a screw, as shown in FIG. 10 , with a threaded stem 92 adapted to engage the threaded bore 68 . The head 94 of the screw preferably includes a hex recess 96 for receiving a hex driving tool of known design. The insert component 54 includes a fastener bore 76 through the bottom wall 77 of the component to receive the fastener therethrough. Thus, the insert component is fixed to the stem 52 using the fixation element or screw 56 , as shown in FIG. 4 . The ball portion 84 of the mating component 58 preferably defines a flared opening 89 to prevent contact between the mating component and the head of the screw when the mating component 58 is impacted within the tapered bore 74 .
The fixation element 56 represents one beneficial feature of the prosthesis 50 of the present invention. Specifically, the fixation element allows removal of the insert component 54 from the prosthesis stem 52 at any time, including when the mating component 56 is in solid engagement with the insert component. This feature facilitates revision of the articulating component, or humeral head, at any time by simply unscrewing the fixation element 56 from the threaded bore 68 in the stem. When the fixation element 56 is removed, the insert component 54 can be readily extracted from the insert cavity 62 in the stem. Preferably, a tool can be pressed between the rounded edge 79 of the tab portion 80 of the insert component and the platform surface 60 of the stem to help dislodge the insert without contacting the mating component 58 . Once removed, the insert component and mating component can serve as a trial component that is replicated in a final prosthesis.
Whether as a final implant or a trial implant, when the mating portion 58 is installed in the tapered bore 74 , the ball portion 84 may be initially loosely situated within the bore 74 so that the angular orientation of the mating component 58 can be adjusted. This adjustment may occur with the articulating head component 20 mounted on the mating component. Once the proper angles have been determined, the mating component can be fixed within the tapered bore by impaction in a known manner, and the humeral head can be added in a similar fashion. It can be appreciated that since the mating component is engaging a removable insert component 54 the impaction steps may occur apart from the implant stem 52 . Thus, the impaction of the mating component into the insert component, and the impaction of the articulating head onto the mating component can occur on a fixture. Rigid fixation of the final implant may be accomplished through means other than impaction, but this fixation may still occur apart from the stem implanted within the patient's bone.
Preferably, the adjustment of the angular position of the mating component for use in a final prosthesis can occur using a replication instrument, such as the instrument disclosed in co-pending application Ser. No. 10/879,261 (the '261 application), entitled INSTRUMENTATION FOR RECORDING AND REPLICATING ORTHOPAEDIC IMPLANT ORIENTATION, owned by the assignee of the present invention, the disclosure of which is incorporated herein by reference.
While details of the instrument are found in the '261 application, following is a general description of the instrument 100 as depicted in FIG. 11 . In particular, the instrument includes a base assembly 102 that carries a stationary clamp element 104 and a movable clamp element 106 . An adjustment mechanism 108 may be manually operated to move the movable clamp element toward the stationary element 104 . The neck of the prosthesis stem 52 is provided with positioning grooves 53 a and 53 b . The superior groove 53 a accepts the fixed clamp element 104 , while a pair of inferior grooves 53 b are configured to mate with the movable clamp element 106 . When the neck of the stem is engaged by the clamp elements 104 , 106 , a fixed datum D is established that is perpendicular to the platform surface 60 . The spatial angular orientation of the mating component 58 is gauged relative to this datum. The base assembly 102 thus establishes a fixed spatial position for this datum that can be used to replicate the angles of the mating component.
To achieve this replication, the instrument 100 further includes a replication fixture 110 that is mounted on the base assembly 102 . The fixture includes a platform 112 with legs 114 that are supported on the base assembly. The platform 110 includes an annular dome 116 which supports a spherical washer 118 on one surface and a cannulated guide member 120 on the opposite surface. The guide member includes a hollow stem portion 121 that passes through the dome 116 and washer 118 . The stem portion 121 is threaded to receive a locking nut 122 to fix the angular orientation of the guide member 120 relative to the datum D.
As explained in more detail in the '261 application, the guide member 120 cannula allows passage of an alignment tool 125 , and more particularly the guide shaft 127 of the tool. The distal end of the guide shaft is sized to fit snugly within the bore 87 of the tapered cylinder 58 . When the guide shaft 127 is situated within the cylinder of the mating component used as part of the trial assembly, the guide member 120 and spherical washer 118 assume a corresponding spatial angle relative to the dome 116 . At this point in the method, the locking nut is tightened, thereby fixing the three-dimensional angular position of the guide member 120 . The replication fixture 110 is then removed and stem 52 is released from the base assembly. A final humeral prosthesis configured as the prosthesis 50 shown in FIGS. 3-4 may then clamped within the base assembly with a final mating element 58 loosely engaged within the tapered bore 74 of a final insert component 54 . The alignment tool is reinserted into the guide member and the guide shaft is engaged with the mating component to replicate the angular orientation of the trial component. The alignment tool 125 is configured with an impaction end 129 that can be struck with a mallet to impact the mating element into the insert component to form the replicated final construct. Once the humeral head is impacted onto the mating component, the insert component can be positioned within the insert cavity 62 of a stem 52 implanted within the prepared intramedullary canal of the patient's bone. The insert component is then fixed in place using the fixation element 56 .
As shown in FIG. 11 , the replication instrument 100 engages a prosthesis 50 that can be configured as a final or a trial prosthesis. However, for the purposes of providing a baseline for replicating the angular orientation of the articulating components of the joint, an entire bone implant is not necessary. Thus, in an alternative method for replicating the necessary angles, a dummy prosthesis 150 is provided as shown in FIG. 12 . The dummy prosthesis 150 meticulously emulates the proximal portion of the trial or final prosthesis 50 to provide the proper alignment of the datum line D ( FIG. 11 ). Thus, the dummy prosthesis includes a truncated stem 152 that includes positioning grooves 153 a , 153 b that are identical to the grooves 53 a , 53 b described above. These dummy grooves are engaged by the clamp elements 104 , 106 , in the manner described above. The proximal end of the dummy prosthesis 150 defines an insert cavity 162 with a base recess 164 and plate recess 166 , all configured to receive the insert component 54 .
The dummy prosthesis 150 functions the same as a final or trial prosthesis when mounted within the replication instrument 100 . However, the dummy stem 152 does not require the features found on an implantable stem, since the dummy prosthesis 150 is not configured for implantation within the patient's bone. Preferably, the stem 152 is about ⅓ the length of the final prosthesis stem so that the dummy prosthesis is easy to manipulate and fix within the replication instrument.
As explained above, the illustrated embodiment provides a prosthesis for the humeral aspect of the shoulder joint. Thus, the prosthesis 50 and its components are appropriately dimensioned for implantation within the humerus bone of the patient. In a specific embodiment, the base portion 70 of the insert component 54 has a diameter of 0.5 inches and a height of 0.183 inches to fit within a comparably dimensioned base recess 64 . The plate portion 72 has a width of 0.525 inches, a thickness of 0.1 inches, and an overall length of 0.752 inches to fit within a plate recess 66 of the same dimensions. The threaded stem 92 of the fixation screw 56 has a length of 0.197 inches to pass through the bottom wall 77 of the insert portion and into a bore 76 threaded to a depth of 0.175 inches. Preferably, the plate portion 72 of the insert is sized to sit substantially flush with the platform surface 60 of the prosthesis 50
Furthermore, the components of the prosthesis are formed of acceptable medical grade materials appropriate for the particular function being served by the components. For instance, the stem is formed of a material appropriate for implantation within a prepared intramedullary canal. The insert component and mating component are formed of a biocompatible material appropriate for the mating engagement between these components.
While the invention has been illustrated and described in detail in the drawings and foregoing description, the same should be considered as illustrative and not restrictive in character. It is understood that only the preferred embodiments have been presented and that all changes, modifications and further applications that come within the spirit of the invention are desired to be protected.
For instance, the mating interface between the insert component and the mating component can be reversed. Specifically, the tapered bore may be incorporated into the mating component, while the ball portion projects from the insert component. The same modification can be made to the mating interface between the humeral head and the mating portion.
In the preferred embodiment, the fixation element is a machine screw; however, other forms of fixation or fastening are contemplated. For instance, rather than a screw that requires multiple turns for complete fixation, the element can incorporate a rotating locking cam or bayonet mount arrangement. As a further alternative, the fixation element can incorporate a press-in feature in which the element is pressed into the bore and locks in place, such as a spring clip construction. The fixation element must be capable of achieving a rigid attachment of the insert component to the stem. Moreover, it is preferred that the fixation element be capable of removal without disturbing or damaging the implanted stem.
In accordance with the preferred embodiment of the invention, the insert component is removable to facilitate revision or replacement of the angularly adjustable components. In one specific application, the insert component is implemented solely as a trial implant wherein the insert component is removably fixed to the stem to permit positioning of the mating component and femoral head in a proper anatomic orientation. With the mating component locked in its acceptable position, the insert component can be removed and placed within a replication instrument. The orientation of the mating component may then be replicated in a final prosthesis that does not include the insert component.
The present invention provides advantages even if the insert component is permanently fixed to the stem. Where the final implant includes the insert component, the insert component may be permanently fixed to the implanted stem with an appropriate fixation element. This variation still takes advantage of the ability to establish a final angular orientation of the mating component outside the surgical site. | A joint prosthesis includes a bone engaging portion having a first recess portion, and an internal wall defining a second recess portion, an articulating component, an insert component having (i) a first insert portion configured to snugly fit within said second recess portion in contact with the internal wall, and (ii) a projecting portion that fixedly projects from said first insert portion and is configured to snugly fit with the first recess portion so as to rotationally fix the first insert portion within the second recess portion, said insert component also having a first coupling portion, and a mating component configured to mate with said articulating component and having a second coupling portion configured to mate with the first coupling portion to form a fixed male/female couple at variable version and inclination angular orientations with respect to the insert component. | 0 |
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application is a Division of prior copending U.S. application Ser. No. 12/857,709 which was filed on Aug. 17, 2010, the contents of which are incorporated herein by reference thereto.
FIELD OF THE INVENTION
[0002] The invention relates to a system for reducing CO concentration in an ethylene rich stream.
DESCRIPTION OF RELATED ART
[0003] Industrial processes for producing ethylene include catalytic and thermal cracking of hydrocarbon feedstocks. In at least some cases, the cracking process effluent contains carbon monoxide. For example, certain product separation and recovery systems produce a vapor stream rich in ethylene and containing hydrogen, methane, acetylene, ethane and other contaminants such as CO, CO 2 , and H 2 S that must be removed in order to produce a high purity ethylene product. Acetylene in polymer grade ethylene is typically limited to a maximum of 5 vol ppm. A typical polymer grade ethylene specification is shown in Table 1.
[0000]
TABLE 1
Typical Polymer Grade Ethylene Specifications
Ethylene
99.90
vol % min
Methane plus ethane
1000
vol ppm max
Ethane
500
vol ppm max
Acetylene
5
vol ppm max
C3 and heavier
10
vol ppm max
CO
2
vol ppm max
CO 2
5
vol ppm max
Sulfur
2
wt ppm max
[0004] Acetylene removal is typically effected by acetylene conversion to ethylene via selective hydrogenation. Carbon monoxide (CO) attenuates the activity of the commonly used acetylene selective hydrogenation catalysts and thus excessive CO concentration can be problematic.
[0005] Hence it would be beneficial to be able to control the amount of CO that enters the acetylene conversion unit.
SUMMARY OF THE INVENTION
[0006] The present invention relates to controlling CO concentration in a stream prior to subjecting the stream to an acetylene selective hydrogen catalyst.
[0007] One embodiment of the invention is directed to a system for acetylene selective hydrogenation of an ethylene rich gas stream comprising: (a) an ethylene rich gas supply comprising at least H 2 S, CO 2 , CO, and acetylene; (b) a first treatment unit for removing H 2 S and, optionally, CO 2 from the gas stream; (c) a CO oxidation reactor to convert CO to CO 2 and forming a CO-depleted gas stream; (d) a second treatment unit for removing the CO 2 from the CO-depleted gas stream; and (e) an acetylene selective hydrogenation downstream of the CO oxidation reactor.
[0008] Another embodiment of the invention is directed to a process for acetylene selective hydrogenation of an ethylene rich gas stream comprising: (a) supplying an ethylene rich gas comprising at least H 2 S, CO 2 , CO, and acetylene to a first treatment unit and removing H 2 S and, optionally, CO 2 from the gas stream; (b) supplying the H 2 S and CO 2 free gas stream to an CO oxidation reactor and converting CO to CO 2 to form a CO-depleted gas stream; (c) supplying the CO-depleted gas stream to a second treatment unit to remove the CO 2 from the CO-depleted gas stream; and (d) treating the CO-depleted or CO-depleted gas stream to an acetylene selective hydrogenation unit to convert the acetylene to ethylene.
[0009] These and other embodiments relating to the present invention are apparent from the following Detailed Description.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] FIG. 1 is a schematic of part of a PetroFCC™ product treating and recovery system.
[0011] FIG. 2 is a schematic of an ethylene rich lean gas preferential CO oxidation reactor system in accordance with one embodiment of the invention.
[0012] FIG. 3 is a schematic of ethylene rich lean gas preferential CO oxidation reactor system in accordance with another embodiment of the invention.
[0013] The same reference numbers are used to illustrate the same or similar features throughout the drawings. The drawings are to be understood to present an illustration of the invention and/or principles involved.
DETAILED DESCRIPTION
[0014] FIG. 1 is a schematic of a separation scheme for recovering ethylene and propylene. A vapor stream ( 2 ) comprised of ethylene and propylene is compressed ( 4 ) to produce a propylene rich liquid stream ( 6 ) and an ethylene rich vapor stream ( 7 ). The ethylene vapor stream ( 7 ) is treated and concentrated in a primary absorber ( 8 ) and a sponge absorber ( 10 ) to form an ethylene rich lean sponge gas ( 12 ). The lean sponge gas ( 12 ) includes other light hydrocarbons, primarily hydrogen, methane, acetylene, ethane and other contaminants such as CO, CO 2 , and H 2 S that must be removed in order to produce a high purity ethylene product.
[0015] The ethylene and propylene stream may be obtained from any industrial process for producing ethylene including catalytic and thermal cracking of hydrocarbon feedstock product streams. For example, US20080078692 discloses a hydrocarbon cracking process and subsequent treatment of the effluent streams. US 20080078692 discusses various conventional terms and process steps used in processes for recovering ethylene and propylene after a hydrocarbon cracking process, see especially paragraphs 0012-0018, 0034-0041, 0045-0055, and is hereby incorporated by reference in its entirety,
[0016] The ethylene purification scheme shown in FIG. 1 includes an amine treatment unit ( 14 ) to remove H 2 S and CO 2 from the ethylene rich lean sponge gas ( 12 ) forming stream ( 22 ). Treatment in the amine treatment unit reduces the H 2 S to less than about 0.1 ppm and CO 2 to less than about 50 ppm. The stream ( 22 ) is then fed to an acetylene selective hydrogenation unit ( 16 ) to hydrogenate the acetylene into ethylene.
[0017] In the scheme shown in FIG. 1 , acetylene is hydrogenated upstream of the demethanizer ( 18 ) and ethane-ethylene splitter fractionators ( 20 ). For this example, stream ( 22 ) includes sufficient hydrogen for hydrogenating the acetylene in the gas to ethylene. Hence, no additional hydrogen is required to be added to the feed stream into the acetylene selective hydrogenation unit ( 16 ). Additionally, the acetylene selective hydrogenation unit ( 16 ) normally operates above ambient temperature while the demethanizer ( 18 ) and ethane-ethylene splitter ( 20 ) typically operate sub-ambient. Positioning the CO oxidation reactor and acetylene conversion reactor upstream of the demethanizer lessens feed heating and effluent cooling duty compared to an arrangement that includes CO oxidation and acetylene conversion in the sub-ambient section of the process.
[0018] The concentration of CO in stream ( 22 ) is variable, generally in a range of 0 to 6 vol %. It is desirable to maintain the CO concentration of the stream ( 22 ) (the acetylene selective hydrogenation reactor feed stream) within a certain operating range, typically about 1 to 0.2 vol %. In general, as the CO concentration of the acetylene selective hydrogenation reactor feed stream increases, the operating window of the acetylene selective hydrogenation reactor system and the time between catalyst regenerations decreases.
[0019] The operating window is the set of operating conditions that enables selective and stable performance. Specifically, allowing complete hydrogenation of acetylene while minimizing hydrogenation of ethylene to ethane. The operating window is affected by process conditions including reactor inlet temperature, feed acetylene, hydrogen, and CO concentrations, space velocity, and catalyst type.
[0020] Thus, as discussed above, the feed stream ( 22 ) entering the acetylene selective hydrogenation unit ( 16 ) often contains unacceptably high carbon monoxide (CO) concentrations. The present invention is directed to a process of controlling or reducing the amount of CO in feed stream ( 22 ) entering an acetylene selective hydrogenation unit ( 16 ).
[0021] The feed stream ( 12 ) from the sponge absorber contains unacceptably high levels of CO. An oxidation reactor will oxidize CO in the feed stream using elemental oxygen as an oxidant: “CO+0.5 O 2 →CO 2 ”. The CO to CO 2 conversion selectivity depends on the catalyst choice and composition of the feed stream. However, the feed stream ( 12 ) from the sponge absorber contains H 2 S which is a catalyst poison for oxidation and must be removed from the feed stream prior to entering the oxidation reactor.
[0022] It was discovered that placing a CO oxidation reactor downstream of the amine treatment unit ( 14 ) enables control of the CO concentration in the feed to the acetylene selective hydrogenation unit ( 16 ). As shown in FIG. 2 , the ethylene rich stream ( 12 ) from the sponge absorber (not shown) flows to a first amine treatment unit ( 14 ). For this illustration, it is assumed that the first amine treatment unit ( 14 ) removes both H 2 S and CO 2 even though CO 2 removal upstream of the oxidation reactor is not required. Thus, the process does not require CO 2 removal at this stage.
[0023] The ethylene rich stream from the amine treatment unit ( 14 ), essentially H 2 S and CO 2 free, is combined with a stream ( 32 ) that provides a source of elemental oxygen, for example, air or oxygen enriched air. The combined gases A (H 2 S and CO 2 -depleted stream) flow to the CO oxidation reactor ( 30 ). After CO conversion to CO 2 , the effluent stream B (CO-depleted stream) continues to a second amine treatment unit ( 34 ) downstream of CO oxidation reactor ( 30 ). This second amine treatment unit ( 34 ) removes CO 2 from effluent stream B. The CO 2 -depleted effluent then continues to the acetylene selective hydrogenation unit ( 16 ).
[0024] As also shown in FIG. 2 , the amine treating arrangement uses a common amine regenerator ( 36 ) to regenerate rich amine from both the first and second amine treatment units ( 14 ) and ( 34 ). In doing so, amine treating equipment is minimized. The combination of the preferential CO oxidation reactor ( 30 ) and amine treatment unit ( 14 ) to remove H 2 S enables control of the CO concentration within a suitable range for subsequent acetylene conversion via conventional selective hydrogenation technology.
[0025] A sensor ( 38 ) may be placed in the effluent B stream after the CO oxidation reactor ( 30 ) to detect the amount of CO in the stream. The sensor may be placed at any position subsequent to the CO oxidation reactor where CO is present in detectable levels. The sensor may signal whether the amount of oxygen or air supplied by line ( 32 ) should be modified. The effluent stream B ideally comprises less than about 50 ppm-vol CO.
[0026] The oxidation temperature in the CO oxidation reactor ( 30 ) is typically between about 70° C. and about 160° C.
[0027] Suitable catalysts for selectively oxidizing CO using air or oxygen enriched air include, but are not limited to ruthenium metal disposed on an alumina carrier, such as those described in U.S. Pat. No. 6,299,995, hereby incorporated by reference in its entirety. The ruthenium metal comprises well dispersed ruthenium crystals having an average crystal size less than or equal to about 40 angstroms. Other suitable catalysts utilize platinum and copper.
[0028] Other treatments may be used instead of amine treatment units. Alternative treatment units include absorbers with amine or solvent flow arranged in a cascading relationship. As shown in FIG. 3 , an ethylene rich feed gas ( 12 ) flows into a first absorber ( 40 ) wherein H 2 S and CO 2 are removed by absorption. The ethylene rich stream from the first absorber ( 40 ), essentially H 2 S and CO 2 free, is combined with a stream ( 47 ) that provides a source of elemental oxygen. The combined gases A (H 2 S and CO 2 -depleted stream) flow to the CO oxidation reactor ( 42 ). After CO conversion to CO 2 , the effluent stream B (CO-depleted stream) continues to a second absorber ( 44 ) downstream of CO oxidation reactor ( 42 ). This second absorber ( 44 ) removes CO 2 from effluent stream B. The CO 2 -depleted effluent then continues to an acetylene selective hydrogenation unit (not shown). The CO 2 rich amine from the second absorber ( 44 ) flows to first absorber ( 40 ). The CO 2 and H 2 S rich amine from the first absorber ( 40 ) flows to an amine regenerator ( 46 ). The lean amine from the amine regenerator ( 46 ) then flows into the second absorber ( 44 ). A CO sensor (not shown) may be placed downstream of CO oxidation reactor ( 42 ) similar to the system shown in FIG. 2 in order to control the amount of air or oxygen added to combined gases A.
[0029] In the amine treatment unit ( 14 ) shown in FIGS. 1 , ( 14 ) and ( 34 ) shown in FIGS. 2 , ( 40 ) and ( 44 ) shown in FIG. 3 selective removal of H 2 S and CO 2 can be achieved using amine-containing chemical solvents. For example, UOP AMINE GUARD™ FS may be used to remove the H 2 S and CO 2 . Such solvents provide selective removal of H 2 S via amine selection. Other treatment units may use other chemical solvents. Chemical solvents are used to remove the acid gases by a reversible chemical reaction of the acid gases with an aqueous solution of various alkanolamines or alkaline salts in water.
[0030] Other treatment units may utilize physical solvents. With a physical solvent, the acid gas loading in the solvent is proportional to the acid gas partial pressure. For example, the UOP SELEXOL™ process may be used which uses a physical solvent made of dimethyl ether of polyethylene glycol. Chemical solvents are generally more suitable than physical or hybrid solvents for applications at lower operating pressures.
[0031] As discussed above, in accordance with the present invention, a CO oxidation reactor is placed upstream of the acetylene selective hydrogenation unit to enable control of the CO concentration within a suitable range for the acetylene selective hydrogenation reaction occurring in the acetylene selective hydrogenation unit. Further aspects of the invention are therefore directed to a method for controlling the CO concentration in an acetylene selective hydrogenation unit feed stream by preferential CO combustion (i.e. oxidation) with air or oxygen enriched air providing the oxygen.
EXAMPLES
[0032] The following examples and tables summarize the expected performance of the preferential CO oxidation reactor processing a typical ethylene-rich lean gas as shown in FIG. 2 . Stream “A” is oxidation reactor feed and “B” is oxidation reactor effluent. The examples assume selectivity based on a ruthenium on alumina catalyst.
Example 1
[0033] The lean gas (i.e. H 2 S and CO 2 removed) from the amine treatment unit is mixed with air. The oxygen available for oxidizing CO is controlled to limit the CO conversion to ˜50%. As shown in Table 2, the CO concentration is reduced from ˜2600 ppm to ˜1300 ppm.
[0034] Specifically, stream A is introduced into a CO oxidation reactor and stream B exits the reactor under the following conditions:
[0000]
Inlet
Outlet
Reactor Temperature (° F.)
194
221
Reactor Pressure (psia)
246.7
Air to Reactor (lbmol/hr)
66
[0000]
TABLE 2
Stream “A”
Stream “B”
Mole
Mole
Fraction
Mole %
Fraction
Mole %
H 2 O
0.003869
0.387
H2O
0.005189
0.519
Oxygen
0.001314
0.131
Oxygen
0.000000
0.000
Nitrogen
0.068311
6.831
Nitrogen
0.068401
6.840
Hydrogen
0.106621
10.662
Hydrogen
0.105446
10.545
CO
0.002615
0.262
CO
0.001303
0.130
CO 2
0.000005
0.001
CO 2
0.001321
0.132
Methane
0.248449
24.845
Methane
0.248775
24.878
Acetylene
0.000503
0.050
Acetylene
0.000504
0.050
Ethylene
0.485833
48.583
Ethylene
0.486472
48.647
Ethane
0.076446
7.645
Ethane
0.076546
7.655
Propylene
0.006035
0.604
Propylene
0.006043
0.604
Example 2
[0035] The lean gas (i.e. H 2 S and CO 2 removed) from the amine treatment unit is mixed with air. The oxygen available for oxidizing CO is controlled to limit the CO conversion to ˜75%. The CO concentration is reduced from ˜2600 ppm to ˜600 ppm, see Table 3. Undesirable side reactions include “H 2 +0.5 O 2 →H 2 O”, as well potential oxidation of light hydrocarbons including olefin products. Assuming sufficient reactant, the CO oxidation reactor essentially completely removes CO.
[0036] Stream A is introduced into a CO oxidation reactor and stream B exits the reactor under the following conditions:
[0000]
Inlet
Outlet
Reactor Temperature (° F.)
194
234
Reactor Pressure (psia)
246.7
Air to PreFOX Reactor (lbmol/hr)
99
[0000]
TABLE 3
Stream “A”
Stream “B”
Mole
Mole
Fraction
Mole %
Fraction
Mole %
H 2 O
0.003857
0.386
H 2 O
0.005833
0.583
Oxygen
0.001965
0.196
Oxygen
0.000000
0.000
Nitrogen
0.070561
7.056
Nitrogen
0.070700
7.070
Hydrogen
0.106289
10.629
Hydrogen
0.104530
10.453
CO
0.002607
0.261
CO
0.000644
0.064
CO 2
0.000005
0.001
CO 2
0.001973
0.197
Methane
0.247674
24.767
Methane
0.248161
24.816
Acetylene
0.000501
0.050
Acetylene
0.000502
0.050
Ethylene
0.484318
48.432
Ethylene
0.485271
48.527
Ethane
0.076207
7.621
Ethane
0.076357
7.636
Propylene
0.006016
0.602
Propylene
0.006028
0.603
[0037] In view of the present disclosure, it will be appreciated that other advantageous results may be obtained. Those having skill in the art, with the knowledge gained from the present disclosure, will recognize that various changes can be made in the above apparatuses and methods without departing from the scope of the present disclosure. Mechanisms used to explain theoretical or observed phenomena or results, shall be interpreted as illustrative only and not limiting in any way the scope of the appended claims. | A system and process for acetylene selective hydrogenation of an ethylene rich gas stream. An ethylene rich gas supply comprising at least H 2 S, CO 2 , CO, and acetylene is directed to a first treatment unit for removing H 2 S and optionally CO 2 from the gas stream. A CO oxidation reactor is used to convert CO to CO 2 and form a CO-depleted gas stream. A second treatment unit removes the CO 2 from the CO-depleted gas stream and an acetylene selective hydrogenation treats the CO-depleted gas stream. | 2 |
[0001] The present invention is a continuation of U.S. patent application Ser. No. 10/614,646, which is a continuation-in-part of U.S. patent application Ser. No. 09/911,638 filed Jul. 23, 2001, which is a continuation-in-part of U.S. patent application Ser. No. 09/412,174 filed Oct. 4, 1999, the entirety of the disclosures of which are expressly incorporated herein by reference.
FIELD OF THE INVENTION
[0002] The present invention relates generally to medical compositions and methods, and more particularly to certain disinfectant/antimicrobial preparations and methods for using such preparations i) to disinfect or preserve articles or surfaces, ii) as a topical antiseptic for application to body parts, iii) to prevent or deter scar formation; iv) to treat dermatological disorders such as wounds, burns, ulcers, psoriasis, acne and other scar forming lesions; and v) to treat ophthalmic disorders such as infections, inflamation, dry eye, wound healing, and allergic conjunctivities.
BACKGROUND OF THE INVENTION
A. Antimicrobial and Disinfectant/Antiseptic Agents Used for Disinfection/Antisepsis and Topical Treatment of Wounds, Burns, Abrasions and Infections
[0003] The prior art has included numerous antimicrobial agents which have purportedly been useable for disinfection of various articles and/or for topical application to a living being for antisepsis and/or treatment of dermal disorders (e.g., wounds, burns, abrasions, infections) wherein it is desirable to prevent or deter microbial growth to aid in healing. Such topical antimicrobial agents have contained a variety of active microbicidal ingredients such as iodine, mercurochrome, hydrogen peroxide, and chlorine dioxide.
[0004] i. Prior Chlorine Dioxide Preparations
[0005] Chlorite, a precursor of chlorine dioxide, is known to be useable as a disinfectant for drinking water and as a preservative for contact lens care solutions. However, chlorite exhibits only weak microbicidal activity within a concentration range that is acceptable and safe for topical application to the skin (e.g., 50-1000 parts per million). Thus, chlorite has not been routinely used as an active microbicidal ingredient in preparations for topical application to the skin.
[0006] In view of the limited usefulness of chlorite as an antiseptic or topical microbicide, various compositions and methods have been proposed for activation or enhancement of the microbicidal activity of chlorite. Examples of such compositions and methods for activation or enhancement of the microbicidal activity of chlorite are described in U.S. Pat. Nos. 4,997,616 (describing general activation); 5,279,673 (describing acid activation) and 5,246,662 (describing transitional metal activation).
[0007] Chlorine dioxide (ClO 2 ) and “stabilized chlorine dioxide” are known to be useable as antiseptics. Chemically, chlorine dioxide is an oxidizing agent which has strong microbicidal activity. Chlorine dioxide is generally regarded as superior even to gaseous chlorine in certain water treatment applications where it is used as to eliminate algae and other organic material and/or to remove odors or tastes. Chlorine dioxide is also effective as a microbicide, for elimination of bacteria, viruses, and microbial spores.
[0008] In addition to its use as a microbicide, chlorine dioxide is a highly reactive, unstable radical which is useable as an oxidizing agent in a number of other chemical and biochemical applications. For example, as described in U.S. Pat. No. 4,855,135, chlorine dioxide can be used for (a) oxidation of double bonds between two carbon atoms; (b) oxidation of unsaturated fatty acids (lipids) via double bonds between two carbon atoms; (c) acceleration of hydrolysis of carboxylic anhydrides; (d) oxidation of aldehydes to the corresponding carboxylic acids; (e) oxidation of alcohols; (f) oxidation of amines; (g) oxidation of phenols, phenolic derivatives and thiophenolic compounds; (h) moderate oxidation of hydroquinones; (i) oxidation of amino acids, proteins and polyamides; j) oxidation of nitrates and sulfides; and (k) alteration of the CHO and CH 2 OH radicals of carbohydrates to produce carboxylic functionality.
[0009] Concentrated chlorine dioxide in its liquid or gaseous state is highly explosive and poisonous. As a result, concentrated chlorine dioxide must be handled and transported with great caution. For this reason, it is generally not feasible to dispense pure chlorine dioxide for use as a topical antimicrobial agent or disinfectant. Instead, some antimicrobial or disinfectant preparations have been formulated to provide for “acid generation” of chlorine dioxide. Such acid generation solutions contain a metal chlorite (i.e., a precursor of chlorine dioxide available in powdered or liquid form) in combination with an acid which will react with the chlorite to liberate or release chlorine dioxide. Generally, any acid may be used for acid generation of chlorine dioxide, including strong acids such as hydrochloric acid and sulfuric acid and relatively weak acids such as citric and tartaric acid. Drawbacks or problems associated with these prior chlorine dioxide generating systems include a) the inconvenience of handing two separate containers or chemical components, b) the difficulty of delivering such two-component systems to the intended site of application, and c) the fact that these prior systems are of acid, rather than neutral, pH. Moreover, the prior chlorine dioxide generating systems which utilize acid-induced generation of chlorine dioxide can, if uncontrolled, cause the generation of chlorine dioxide to occur quite rapidly and, as a result, the disinfectant or antimicrobial potency of the solution may be short lived. Increasing the concentration of chlorite and acid within the solution may prolong its disinfectant or antimicrobial shelf life, but such increased concentrations of these chemicals can result in toxicities or (in topical applications) skin irritation. Such increased concentrations may also result in the generation of more chlorine dioxide than is required.
[0010] Various methods have been described to limit or control the rate at which chlorine dioxide is produced in “acid generation” solutions. For instance, U.S. Pat. No. Re. 31,779 (Alliger) describes a germicidal composition which comprises a water soluble chlorite, such as sodium chlorite, in combination with lactic acid. The particular composition possesses improved disinfectant properties, properties not attained by using the same composition but replacing the lactic acid with other acids such as phosphoric acid, acetic acid, sorbic acid, fumaric acid, sulfamic acid, succinic acid, boric acid, tannic acid, and citric acid. The germ killing composition is produced by contacting an acid material containing at least 15% by weight of lactic acid with sodium chlorite in aqueous media. The methods disclosed of disinfecting and sanitizing a germ-carrying substrate, such as skin, include either application of the germ-killing composition, or application of the reactants to provide in situ production thereof. Also, U.S. Pat. No. 5,384,134 (Kross) describes acid induced generation of chlorine dioxide from a metal chlorite wherein the chlorite concentration is limited by the amount of available chlorous acid. In particular, the Kross patent describes a method for treating dermal disorders wherein a first gel, which comprises a metal chlorite, is mixed with a second gel, which comprises a protic acid. The chlorite ions present in such solution as chlorous acid purportedly comprise no more than about 15% by weight of the total chlorite ion concentration in the composition, and the mixture of the two gels purportedly generates chlorine dioxide over an extended time of up to 24 hours.
[0011] Other prior patents have purported to describe the use of “stabilized” chlorine dioxide as a means of chlorine dioxide generation. The term stabilized chlorine dioxide refers to various compositions in which the chlorine dioxide is believed to be held in solution in the form of a labile complex. The stabilization of chlorine dioxide by the use of perborates was disclosed in U.S. Pat. No. 2,701,781 (de Guevara). According to the de Guevara patent, an antiseptic solution of stabilized chlorine dioxide can be formed from an aqueous solution of chlorine dioxide and an inorganic boron compound with the boron compound and the chlorine dioxide being present in the solution as a labile complex. The chlorine dioxide, fixed in this stable condition, is an essential ingredient of the antiseptic solution. The de Guevara patent discloses that the chlorine dioxide may be introduced into the compositions either by in situ generation or it may be generated externally and introduced into the solution, as by bubbling the chlorine dioxide gas into the aqueous solution. Various methods may be employed for the external production of the chlorine dioxide, such as reaction of sulfuric acid with potassium chlorate or the reaction of the chlorate with moist oxalic acid. Alternatively, chlorine dioxide can be generated in situ by reaction of potassium chlorate and sulfuric acid. Note that whether the chlorine dioxide is produced in situ or externally, it is essentially an acid-induced liberation of the chlorine dioxide from potassium chlorate.
[0012] U.S. Pat. No. 4,317,814 (Laso) describes stabilized chlorine dioxide preparations for treatment of burns in humans. Aqueous mixtures of perborate stabilized solutions of chlorine oxides, such as chlorine dioxide, in combination with glycerin are described for topical application to burned areas and may also be administered by oral application for treatment of burns. The aqueous solutions of perborate stabilized chlorine oxides are disclosed as being prepared by mixing with water the following: sodium chlorite, sodium hypochlorite, hydrochloric acid, sulfuric acid, an inorganic perborate, and a peroxy compound, such as sodium perborate. Thus, the solutions prepared in accordance with the Laso patent contain chlorine dioxide, hypochlorite and peroxy compounds as strong oxidizing agents and appear to utilize acid activation of the chlorine dioxide. The Laso patent states that the methods disclosed therein resulted in an immediate subsidence of burn related pain in many cases, that healing was rapid and characterized by an absence of infection or contraction, and that the burn scars were smooth and resembled normal tissue, thus eliminating the need for plastic surgery in certain cases. However, long term storage and stability are issues with the aqueous solutions described in the above-identified Laso patent, because such mixtures tend to generate chlorine dioxide very quickly, thus diminishing the long term stability of such mixtures.
[0013] U.S. Pat. No. 3,271,242 (McNicholas et al.,) describes stabilized chlorine dioxide solutions which are formed by combining chlorine dioxide gas with an aqueous solution containing a peroxy compound, and subsequently heating the solution to a temperature which is high enough to drive off all free peroxide, but low enough not to destroy the chlorine dioxide. McNicholas et al., states that temperatures “much below” 70 degrees C. are ineffective to drive off the free peroxide in the solution and that temperatures should not exceed 92 degrees C. because at higher temperatures the chlorine dioxide will be driven off. McNicholas further states that, although not “entirely understood,” it was believed that heating of the solution to drive off free peroxide was necessary because any free hydrogen peroxide allowed to remain in the solution would act as a leaching agent to release the chlorine dioxide from the solution.
[0014] ii. Antibiotic Preparations
[0015] Antibiotic compounds have also been commonly used for the therapeutic treatment of burns, wounds, and skin and eye infections. While antibiotics may provide an effective form of treatment, several dangers are often associated with the use of antibiotics in the clinical environment. These dangers may include but are not limited to: (1) changes in the normal flora of the body, with resulting “superinfection” due to overgrowth of antibiotic resistant organisms; (2) direct antibiotic toxicity, particularly with prolonged use which can result in damage to kidneys, liver and neural tissue depending upon the type of antibiotic; (3) development of antibiotic resistant microbial populations which defy further treatment by antibiotics.
B. Difficult-To-Treat Dermal Disorders Other Than Wounds, Burns, Abrasions and Infections
[0016] While even minor wounds and abscesses can be difficult to treat in certain patients and/or under certain conditions, there are well known dermal disorders such as psoriasis and dermal ulcerations, which present particular challenges for successful treatment.
[0017] i. Psoriasis
[0018] Psoriasis is a noncontagious skin disorder that most commonly appears as inflamed swollen skin lesions covered with silvery white scale. This most common type of psoriasis is called “plaque psoriasis”. Psoriasis comes in many different variations and degrees of severity. Different types of psoriasis display characteristics such as pus-like blisters (pustular psoriasis), severe sloughing of the skin (erythrodermic psoriasis), drop-like dots (guttate psoriasis) and smooth inflamed lesions (inverse psoriasis).
[0019] The cause of psoriasis is not presently known, though it is generally accepted that it has a genetic component, and it has recently been established that it is an autoimmune skin disorder. Approximately one in three people report a family history of psoriasis, but there is no pattern of inheritance. There are many cases in which children with no apparent family history of the disease will develop psoriasis.
[0020] The occurrence of psoriasis in any individual may depend on some precipitating event or “trigger factor”. Examples of “trigger factors” believed to affect the occurrence of psoriasis include systemic infections such as strep throat, injury to the skin (the Koebner phenomenon), vaccinations, certain medications, and intramuscular injections or oral steroid medications. Once something triggers a person's genetic tendency to develop psoriasis, it is thought that in turn, the immune system triggers the excessive skin cell reproduction.
[0021] Skin cells are programmed to follow two possible programs: normal growth or wound healing. In a normal growth pattern, skin cells are created in the basal cell layer, and then move up through the epidermis to the stratum corneum, the outermost layer of the skin. Dead cells are shed from the skin at about the same rate as new cells are produced, maintaining a balance. This normal process takes about 28 days from cell birth to death. When skin is wounded, a wound healing program is triggered, also known as regenerative maturation. Cells are produced at a much faster rate, theoretically to replace and repair the wound. There is also an increased blood supply and localized inflammation. In many ways, psoriatic skin is similar to skin healing from a wound or reacting to a stimulus such as infection.
[0022] Lesional psoriasis is characterized by cell growth in the alternate growth program. Although there is no wound at a psoriatic lesion, skin cells (called “keratinocytes”) behave as if there is. These keratinocytes switch from the normal growth program to regenerative maturation. Cells are created and pushed to the surface in as little as 2-4 days, and the skin cannot shed the cells fast enough. The excessive skin cells build up and form elevated, scaly lesions. The white scale (called “plaque”) that usually covers the lesion is composed of dead skin cells, and the redness of the lesion is caused by increased blood supply to the area of rapidly dividing skin cells.
[0023] Although there is no known cure for psoriasis, various treatments have been demonstrated to provide temporary relief in some patients. However, the effectiveness of the currently accepted treatments for psoriasis is subject to considerable individual variation. As a result, patients and their physicians may have to experiment and/or combine therapies in order to discover the regimen that is most effective. The currently available treatments for psoriasis are often administered in step-wise fashion. Step 1 treatments include a) topical medications (e.g., topical steroids, topical retinoids), b) systemic steroids, c) coal tar, d) anthralin, e) vitamin D3, and sunshine. Step 2 treatments include a) phototherapy (e.g, ultraviolet radiation), b) photochemotherapy (e.g., a combination of a topically applied radiation-activated agent followed by radiation to activate the agent) and c) combination therapy. Step 3 treatments include a) systemic drug therapies such as methotrexate, oral retinoids and cyclosporin and b) rotational therapy.
[0024] ii. Dermal Ulcerations
[0025] Dermal ulcerations are known to occur as a result of pressure, wear, or primary/secondary vascular disorders. Dermal ulcerations are generally classified according to their etiology, as follows:
[0026] a. Decubitus/Pressure Ulcers—A decubitus ulcer or pressure sore is a lesion caused by unrelieved pressure resulting in damage of the underlying tissue. Decubitus ulcers usually develop over a bony prominence such as the elbow or hip. The unrelieved pressure, along with numerous contributing factors, leads to the skin breakdown and persistent ulcerations.
[0027] b. Venous Ulcers—Venous ulcers may result from trauma or develop after chronic venous insufficiency (CVI). In CVI, venous valves do not close completely, allowing blood to flow back from the deep venous system through the perforator veins into the superficial venous system. Over time, the weight of this column of blood causes fluid and protein to exude into surrounding tissues, resulting in swollen, hyperpigmented ankles, tissue breakdown, and ulceration. Venous ulcers may be shallow or extend deep into muscle.
[0028] c. Arterial Ulcers—Leg ulcers also can develop in patients with arterial insufficiency caused by arterial vessel compression or obstruction, vessel wall changes, or chronic vasoconstriction. Smokers face an especially high risk of arterial disease because nicotine constricts arteries, encourages deposits of atherosclerotic plaque, and exacerbates inflammatory arterial disease (Buerger's disease) and vasoconstrictive disease (Raynaud's disease or phenomenon). Arterial ulcers, caused by trauma to an ischemic limb, can be very painful.
[0029] d. Diabetic Ulcers—Arterial insufficiency can be the cause of a nonhealing ulcer in a patient with diabetes. However, most diabetic ulcers result from diabetic neuropathy—because the patient cannot feel pain in his foot, he is unaware of injuries, pressure from too-tight shoes, or repetitive stress that can lead to skin breakdown.
[0030] There remains a need in the art for the formulation and development of new disinfectants and topically applicable preparations for the treatment of dermal disorders, such as wounds, burns, abrasions, infections, ulcerations, psoriasis and acne.
C. Contact Lens Soaking and Disinfection
[0031] Whenever a contact lens is removed from an eye, it should be placed in a soaking and disinfecting solution until it is worn again. Soaking and disinfecting solutions have the following functions:
[0032] 1. Assist in cleaning the lens of ocular secretions after the lens is removed form the eye;
[0033] 2. To prevent eye infections by a bacterial contaminated lens; and
[0034] 3. To maintain the state of hydrated equilibrium, which the lens achieves while it is being worn.
D. Contact Lens Cleaning
[0035] During lens wear mucus material, lipids and proteins accumulate on contact lenses, making lens wear uncomfortable due to irritation, burning sensation, and redness. Accordingly, vision becomes blurry. To alleviate the discomforting problem, the soft or rigid contact lenses should be taken out of the eye, to be cleaned and disinfected regularly, using an enzymatic cleaner and a disinfecting solution. One of the serious complications associated with soft lenses can be a Giant Papillary Conjunctivitis (GPC). It is believed to be that the occurrence of the giant papillary conjunctivitis is mostly due to an inflammatory reaction associated with soft contact lens complication. This is almost always caused by protein deposits on contact lenses. GPC produces symptoms ranging from asymptomatic to itching, upper eye-lid edema, red eye, mucoid discharge, progressive contact lens intolerance. The in-the-eye cleaner of the present invention effectively cleans the protein deposits and maintains corneal epithelial cells healthy by keeping the corneal surface from microbial infection as well as by supplying molecular oxygen. Thereby, it provides convenience and benefits to both soft and rigid contact lens wearers.
E. Treatment of Ophthalmic Disorders
[0036] i. Dry Eye
[0037] Dry eye is a syndrome in which tear production is inadequate or tear composition is inappropriate to properly wet the cornea and conjunctiva. A variety of disorders of the ocular tears causes sensations of dryness of the eyes, discomfort of presence of a foreign object to occur in the eye. In most instances, the tear film loses its normal continuity and breaks up rapidly so that it cannot maintain its structure during the interval between spontaneous blinks. All of those tear abnormalities may have multiple causes. Perhaps the most common form of dry eye is due to a decreased aqueous component in the tears. Untreated dry eye can be further deteriorated to produce more severe epithelial erosion, strands of epithelial cells, and local dry spots on the cornea, which can be further complicated by microbial infection. In its mild form, however, a feeling of dryness and irritation of the eye can be solved with artificial tears. Thus, artificial tear solution which has a broad spectrum antimicrobial activity with corneal lubricating property, can provide not only comfort but also beneficial effects on recovery of damaged corneal surface.
[0038] ii. Allergic Conjunctivitis
[0039] Airborne or hand borne allergens usually produce allergic conjunctivitis due to IgE-mediated hypersensitivity reaction. It presents itching, tearing, dry and sticky eyes, including lid-swelling, conjunctival hyperemia, papillary reaction, chemosin, and ropy mucoid discharge. The presence of hyaluronic acid in the tear, which is included in the formulation of artificial tear, would protect corneal surface from contacting the allergens. The broad spectrum antimicrobial agent of the present invention keeps the corneal surface from bacterial infection and also maintains the corneal epithelial cells healthy by supplying molecular oxygen. Thus, it provides beneficial effects on the eyes sensitive to allergens.
[0040] iii. Bacterial Invasion
[0041] Bacterial keratitis is one of the leading causes of blindness in the world. In the United States, an estimated 30,000 cases occur annually, with the popularity of contact lens wear having contributed to a rising incidence in the developed world. Statistical investigation indicates that about 30 of every 100,000 contact lens wearers develop ulcerative keratitis annually in the United States, thus making the disease a significant public health issue in view of potential blindness that can occur. While eyelids, blinking of the eyelids, and corneal and conjunctival epithelial cells provide barriers to microbial invasion, one or more of these defense mechanisms can become compromised. Such compromises can include lid abnormalities, exposure of the corneal surface, poor tear production, epithelial problems, medication toxicity, trauma, and incisional surgery. Ocular manifestations of bacterial keratitis are found in staphylococcus and streptococcus infections that tend to cause severe infiltration and necrosis which over time can lead to perforation. Pseudomonal keratitis tends to progress rapidly. This organism produces destructive enzymes, such as protease, lipase, and elastase, and exotoxins, which result in necrotic ulceration and perforation. Serratia keratitis starts as a superficial para-central ulcer, with the secretion of exotoxins and protease which can produce aggressive ulceration and perforation. In order for the bacterial keratitis to become established, microbial adhesions must bind to host cell receptors. Once this attachment has occurred, the destructive process of inflamation, necrosis, and angiogenesis can ensue.
[0042] Present treatment for bacterial keratitis relies primarily upon the use of broad spectrum antibiotic therapy. Such antibiotics include sulfonamides, trimethaprin, and quinolones. Also included are beta-lactams, penicillins, cephalasporins, aminoglycosides, tetracyclines, chloramphenicol, and erythromycin. While such antibiotics are in wide spread use, they can also become misused where antibiotic resistant pathogens emerge. Additionally, antibiotics only halt the proliferation of bacteria, but do not inhibit the activity of protease enzymes, endotoxins, or exotoxins. As is therefore apparent, a significant need is present for a bactericidal agent that addresses the proliferation of not only bacteria, but also protease enzymes, endotoxins and exotoxins.
SUMMARY OF THE INVENTION
[0043] The present invention provides antimicrobial preparations (e.g., solutions, gels, ointments, creams, etc.) for disinfection of articles or surfaces (e.g., contact lenses, counter tops, etc.), antisepsis of skin or other body parts, prevention or minimization of scarring, and/or treatment or prophylaxis of dermal (i.e., skin or mucous membrane) disorders (e.g., wounds, burns, infections, cold sores, ulcerations, psoriasis, scar forming lesions, acne) , and the treatment of ophthalmic disorders (e.g., infection, inflamation, dry eye, allergic conjunctivitis, and wound healing). The antimicrobial preparations of this invention generally comprise from about 0.001% to about 0.20% by weight of a metal chlorite in combination with from 0.001% to 0.05% of a peroxy compound such as hydrogen peroxide. Additionally, the chlorite/peroxide preparations of the present invention may contain additional components such as polymeric lubricants and surfactants, and/or may be formulated in a polymeric drug delivery system or liposomal preparation. The chlorite/peroxide preparations of the present invention have broad antimicrobial activity, including for example activity against gram negative and gram positive bacteria, yeasts and fungi. Moreover, when applied or administered to treat dermal disorders (e.g., wounds, burns, infections, ulcerations, acne and psoriasis) , the chlorite/peroxide preparations of the present invention will not only prevent or lessen microbial infection, but will additionally provide oxygen to the affected tissue, assist in healing and deter scar formation.
[0044] Further, in accordance with the invention, there are provided methods for disinfection of items (e.g., contact lenses) and methods for treatment of dermal disorders (e.g., wounds, burns, infections, ulcerations and psoriasis) by application or administration of a chlorite/peroxide preparation of the present invention. With respect to contact lens disinfecting solution, as well as product formulations that will clean contact lenses in the eye without removing the lenses from the eye for cleaning, the concentration of the metal chlorite is between about 0.002% to about 0.20%. With respect to in-eye application, the present bactericidal product is a sterile, isotonic, buffered, clear, colorless solution that additionally contains polymeric lubricant and surfactant. The product has a two-year shelf life when stored in a container (e.g., a white opaque plastic bottle) at room temperature as a stabilized peroxy chloral complex of chlorite and peroxide.
[0045] In addition, the invention includes product formulations shown to have efficacy in the treatment of dry eye, wound healing, and allergic conjunctivitis.
[0046] Further in accordance with the invention, there are provided methods for deterring scar formation by application or administration of a chlorite/peroxide preparation of the present invention.
[0047] Further, in accordance with the invention, there are provided product formulations shown to have supra-additive efficacy in broad spectrum antimicrobial activity.
[0048] Furthermore, in accordance with the invention, there are provided methods for deterring eye infections, eye perforations and inflamation by application or administration of a chlorite/peroxide preparation of the present invention.
[0049] Further aspects and objects of the present invention will become apparent to those of skill in the art upon reading and understanding of the following detailed description and the examples set forth therein.
BRIEF DESCRIPTION OF THE DRAWINGS
[0050] FIGS. 1-6 are graphs demonstrating the non-production of chlorine dioxide at room temperature in the chlorite/peroxide preparation of the present invention at pH levels of 7.3, 8.0, 8.8, 7.0, 6.44 and 6.0, respectively; and
[0051] FIG. 7 is a graph demonstrating the production of chlorine dioxide at room temperature in the chlorite/peroxide preparation of the present invention at a pH level of 1.5.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0052] The following detailed description and examples are provided for the purpose of describing certain exemplary embodiments of the invention only, and are not intended to limit the scope of the invention in any way.
[0053] The present invention provides preparations which contain chlorite (e.g., a metal chlorite such as sodium chlorite) in combination with a small amount of hydrogen peroxide in neutral aqueous (pH 6.0-8.8, preferably pH 7.0-7.8, and more preferably pH 7.0-7.4) solution. These preparations exhibit synergistic antimicrobial activity without generating chlorine dioxide during storage at room temperature, thereby rendering the stability of these solutions acceptable for pharmaceutical use. For example, an aqueous solution containing 400 ppm chlorite plus 100 ppm hydrogen peroxide remains stable beyond 18 months at room temperature, and is effective to reduce candida albicans activity by 1.0 log within six hours of challenge, even though the individual components of such solution are ineffective when applied separately at the same concentrations to reduce candida albicans activity. Additionally, the hydrogen peroxide present within the chlorite/peroxide solutions of the present invention readily decomposes into molecular oxygen and water, upon contact with the peroxidase and catalase enzymes present in tissue and/or some body fluids. Such in situ generation of molecular oxygen contributes to cell vitality and enhances wound healing.
[0054] The chlorite/H 2 O 2 solutions of the present invention are sufficiently stable to be formulated in combination with polymeric lubricants (non-ionic and/or anionic; e.g., HPMC, Methocel, CMC, hyaluronic acid, etc.,) and/or in combination with block polymer based surfactants (e.g., pluronics). For example, an aqueous chlorite/hydrogen peroxide system can be formulated together with methocel or hyaluronic acid as a lubricant and pluronics as a surfactant for contact lens disinfectant solution (viscosity up to 50 cps at 25 degrees C.) in an ophthalmically acceptable tonicity (e.g., osmolality of at least about 200 mOsmol/kg) and a buffer to maintain the pH of the formulation within an acceptable physiological range. The formulation of the contact lens disinfection solution, artificial tear solution, and in-eye cleaner solution, contains chlorite preferably from about 0.005 to about 0.06 weight/volume percent and hydrogen peroxide preferably from about 0.0002 to about 0.05 weight/volume percent. Again, the presence of hydrogen peroxide provides the beneficial oxygen molecule to the cornea upon contact with catalase in the tear.
A. Formulations
[0055] The chlorite/peroxide preparations of the present invention may be formulated in various ways, including liquid solutions, gels, ointments, creams, sprays, etc. Set forth herebelow are a few examples of the types of specific formulations which may be prepared in accordance with this invention.
[0056] i. Stable Chlorite/Peroxide Liquid Solutions
[0057] The following Formula 1 is a first preferred formulation of a liquid chlorite/peroxide solution of the present invention:
FORMULA 1 Sodium Chlorite 0.005%-0.10% Hydrogen Peroxide 0.005%-0.05% Methocel A 0.05%-0.2% Boric Acid 0.15% Sodium Chloride 0.75% Pluronic F-68/F-127 0.1% HCl or NaOH Adjust pH 7.4 Purified water Q.S. to volume
[0058] The following Formula 2 is a second preferred formulation of a liquid chlorite/peroxide solution of the present invention:
FORMULA 2 Sodium Chlorite 0.05% Hydrogen Peroxide 0.02% Carboxymethyl Cellulose 0.01% Boric Acid 0.15% Sodium Chloride 0.75% Pluronic F-68/F-127 0.1% HCl or NaOH Adjust pH 7.3 Purified water Q.S. to volume
[0059] The chlorite/peroxide solutions of the present invention, such as the solution of the above-shown preferred formulation, may be used for a variety of medical and non-medical applications including but not necessarily limited to a) disinfection of articles and surfaces such as contact lenses, medical/dental instruments, counter tops, treatment tables, combs and brushes, etc.; antisepsis of skin or body parts (e.g., a disinfectant hand wash, antiseptic facial scrub, etc.,) and b) treatment or prophylaxis of dermal (i.e., skin or mucous membrane) disorders such as wounds, burns, infections, ulcerations, cold sores, psoriasis, acne, and c) deterrence or prevention of scar formation, and d) treatment of ophthalmic disorders (e.g., infections or inflammations caused by bacterial keratitis).
[0060] As pointed out earlier, the chlorite/hydrogen peroxide system of the present invention is sufficiently stable to be formulated in a polymeric gel form or in a paste form. Furthermore, such polymeric gel or paste formulation can contain polymers which delay or control the release of the chlorite/hydrogen peroxide (e.g., a sustained release delivery system). Such sustained release formulations provide outstanding benefits of increasing therapeutic index by maintaining the effective concentration of chlorite/H 2 O 2 for a prolonged time on the injured sites, by preventing the injured sites from external microbial contamination by forming a seal over the injured sites, and by providing oxygen molecule to the injured tissues. Unlike the conventional ointment, the polymeric gel provides a dry, clean, and comfortable coating on the injured sites upon application. Such gel formulations may contain polymeric drug delivery vehicles like hydroxypropyl methylcellulose (HPMC), methylcellulase (Methocel), hydroxyethylcellulose (HEC), hyaluronic acid, and carboxymethylcellulose (CMC), etc.
[0061] ii. A Stable Chlorite/Peroxide Gel
[0062] The following Formula 2 is a presently preferred formulation of a chlorite/peroxide gel of the present invention:
FORMULA 3 Sodium Chlorite 0.02%-0.10% Hydrogen Peroxide 0.005%-0.05% Methocel A 2.0% Boric Acid 0.15% Sodium Chloride 0.75% Pluronic F-68/F-127 0.1% HCl or NaOH Adjust pH 7.4 Purified water Q.S. to volume
[0063] Any of the preparations of the present invention may be formulated for sustained release of the active components by forming liposomes of the preparing in accordance with well known liposomal forming techniques and/or by adding to the formulation a pharmaceutically acceptable and effective amount (e.g., typically 1-20 percent by weight) of a sustained release component such as a polymer matrix or one or more of the following:
[0064] a cellulose ester;
[0065] hydroxymethylpropyl cellulose;
[0066] methylhydroxyethyl cellulose;
[0067] hydroxypropyl cellulose;
[0068] hydroxyethyl cellulose;
[0069] carboxymethyl cellulose;
[0070] a salt of a cellulose ester;
[0071] cellulose acetate;
[0072] hydroxypropylmethyl cellulose phthalte;
[0073] methacrylic acid-methyl methacrylate copolymer;
[0074] methacrylic acid-ethyl acetate copolymer;
[0075] polyvinylpyrolidone;
[0076] polyvinyl alcohol;
[0077] hyaluronic acid;
[0078] a phospholipid;
[0079] cholesterol;
[0080] a phospholipid having a neutral charge;
[0081] a phospholipid having a negative charge;
[0082] dipalmytoyl phoshatidyl choline;
[0083] dipalmytoyl phoshatidyl serine; and,
[0084] sodium salts thereof.
[0085] iii. A Stable Chlorite/Peroxide Ophthalmic Solution
[0086] The following Formula 3 is a presently preferred formulation of a chlorite/peroxide contact lens disinfecting solution for use in cleaning contact lenses residing in or out of the eye. The formulation additionally functions as a tear product for lubrication in dry-eye subjects.
FORMULA 4 Sodium Chlorite 0.002%-0.20% Hydrogen Peroxide 0.005%-0.05% Hyaluronic Acid 0.001%-0.50% Boric Acid 0.15% Sodium Chloride 0.75% Pluronic 127 0.05%-2.0% HCl or NaOH Adjust pH to 7.4 Purified Water Q.S. to Volume
[0087] As indicated earlier, the chlorite/peroxide preparation of the present invention, whether it be in the form of liquid solution, gel, ointment, cream, spray, etc., is specifically composed to maintain chlorite such as sodium chlorite and hydrogen peroxide as active ingredients at a pH range of 6.0-8.8 without generating chlorine dioxide during storage at room temperature. By way of illustration, multiple experiments were conducted on the liquid sodium chlorite/hydrogen peroxide solution in accordance with Formula 2 at different levels of pH within the specified range. However, it should be expressly stated herein that such experimentations should in no way be limited to liquid solution forms only, but are performed to illustrate the non-production of chlorine dioxide in the various forms of the present chlorite/peroxide preparation at different pH levels.
[0088] The following experimentations were designed to demonstrate the stability of chlorite such as sodium chlorite and hydrogen peroxide antibacterial formulation at neutral, basic and acidic levels of pH. More specifically, the quantitative levels of sodium chlorite and the generation of chlorine dioxide were determined at the pH levels of 7.3, 8.0, 8.8, 7.0, 6.44 and 6.0. 0.1 Normal hydrochloric acid solution and 0.1 Normal sodium hydroxide solution were applied to adjust the pH levels in the experimentations. Sterile 0.9% sodium chloride sterile solution was also applied. A placebo solution with the following formulation was further applied in a spectrophotometer (e.g., Lambda 20 Model UV-Vis. spectrophotometer) to find and measure the levels of sodium chlorite and the generation of chlorine dioxide at varying pH levels:
Placebo Solution Hydrogen Peroxide 0.02% Carboxymethyl Cellulose 0.01% Boric Acid 0.15% Sodium Chloride 0.75% Pluronic F-68/F-127 0.1% HCl or NaOH Adjust pH 7.3 Purified water Q.S. to volume
[0089] Experiment 1: pH Level of 7.3
[0090] Experiment: Fill the first cuvette with the placebo solution, wipe it clean, and place the cuvette in the standard beam path of the spectrophotometer. Fill the second cuvette with the liquid sodium chlorite/hydrogen peroxide solution, wipe it clean and place the cuvette in the sample beam path of the spectrophotometer. Scan the solutions from 200 nm to 400 nm and record the results. Plot and printout the results, as illustrated in the graph shown in FIG. 1 .
[0091] Result: The liquid solution contained sodium chlorite and hydrogen peroxide as active ingredients, as well as buffering and tonicity agents at the pH level of 7.3. The placebo solution contained hydrogen peroxide as active ingredient, as well as buffering and tonicity agents at the pH level of 7.3.
[0092] Hydrogen peroxide does not absorb in the 200 nm to 400 nm range. Therefore, as seen in FIG. 1 , absorption peaks for hydrogen peroxide were not detected.
[0093] Sodium chlorite has an absorption maximum at 260 nm, while chlorine dioxide which is a degradation product of sodium chlorite has an absorption maximum at 355 nm-358 nm.
[0094] Scanning the solutions that have a pH of 7.3 between the 200 nm and 400 nm will give a quantitative value for sodium chlorite as well as chlorine dioxide in the same scan.
[0095] Interpretation: The liquid sodium chlorite/hydrogen peroxide solution does show sodium chlorite peak at 260 nm, but does not show any chlorine dioxide peak at 355 nm-358 nm.
[0096] This clearly indicates that at pH level of 7.3, the liquid sodium chlorite/hydrogen peroxide solution has only sodium chlorite, and does not contain any quantities of chlorine dioxide. This is a clear indication that sodium chlorite is stable at pH level of 7.3, and the sodium chlorite is not breaking up and forming the chlorine dioxide.
[0097] Experiment 2: pH Level of 8.0
[0098] Experiment: Dispense 25 mL. of the placebo solution and 25 mL. of the liquid sodium chlorite/hydrogen peroxide solution into 2 clean containers. Add 0.1 Normal sodium hydroxide solution to each container so as to adjust the pH of both the placebo solution as well as the liquid solution to a pH level of 8.0.
[0099] Fill one of the cuvette with the placebo solution, wipe it clean, and place the cuvette in the standard beam path of the spectrophotometer. Fill the second cuvette with the liquid sodium chlorite/hydrogen peroxide solution, wipe it clean and place the cuvette in the sample beam path of the spectrophotometer. Scan the solutions from 200 nm to 400 nm and record the results. Plot and printout the results, as illustrated in the graph shown in FIG. 2 .
[0100] Result: The liquid sodium chlorite/hydrogen peroxide solution contained sodium chlorite and hydrogen peroxide as active ingredients, as well as buffering and tonicity agents at the pH level of 8.0. The placebo solution contained hydrogen peroxide as active ingredient, as well as buffering and tonicity agents at the pH level of 8.0.
[0101] As mentioned shortly above, hydrogen peroxide does not absorb in the 200 nm to 400 nm range. Therefore, as seen in FIG. 2 , absorption peaks for hydrogen peroxide were not detected. As also mentioned above, sodium chlorite has an absorption maximum at 260 nm, while chlorine dioxide which is a degradation product of sodium chlorite has an absorption maximum at 355 nm-358 nm.
[0102] Scanning the solutions that have a pH level of 8.0 between the 200 nm and 400 nm will give a quantitative value for sodium chlorite as well as chlorine dioxide in the same scan.
[0103] Interpretation: The liquid sodium chlorite/hydrogen peroxide solution does show sodium chlorite peak at 260 nm, but does not show any chlorine dioxide peak at 355 nm-358 nm. This clearly indicates that at the pH level of 8.0, the liquid sodium chlorite/hydrogen peroxide solution has only sodium chlorite, and does not contain any quantities of chlorine dioxide. This is a clear indication that sodium chlorite is stable at the pH level of 8.0, and the chlorite is not breaking up and forming chlorine dioxide.
[0104] Experiment 3: pH Level of 8.8
[0105] Dispense 25 mL. of the placebo solution and 25 mL. of the liquid sodium chlorite/hydrogen peroxide solution into 2 clean containers. Add 0.1 Normal sodium hydroxide solution to each container so as to adjust the pH of both the placebo solution as well as the liquid solution to a pH level of 8.8.
[0106] Fill one of the cuvette with the placebo solution, wipe it clean, and place the cuvette in the standard beam path of the spectrophotometer. Fill the second cuvette with the liquid sodium chlorite/hydrogen peroxide solution, wipe it clean and place the cuvette in the sample beam path of the spectrophotometer. Scan the solutions from 200 nm to 400 nm and record the results. Plot and printout the results, as illustrated in the graph shown in FIG. 3 .
[0107] Result: The liquid sodium chlorite/hydrogen peroxide solution contained sodium chlorite and hydrogen peroxide as active ingredients, as well as buffering and tonicity agents at the pH level of 8.8. The placebo solution contained hydrogen peroxide as active ingredient, as well as buffering and tonicity agents at the pH level of 8.8.
[0108] As already discussed, hydrogen peroxide does not absorb in the 200 nm to 400 nm range. Therefore, as seen in FIG. 3 , absorption peaks for hydrogen peroxide were not detected. As also discussed, sodium chlorite has an absorption maximum at 260 nm, while chlorine Dioxide which is a degradation product of sodium chlorite has an absorption maximum at 355 nm-358 nm.
[0109] Scanning the solutions that have a pH level of 8.8 between the 200 nm and 400 nm will give a quantitative value for sodium chlorite as well as chlorine dioxide in the same scan.
[0110] Interpretation: The liquid sodium chlorite/hydrogen peroxide solution does show sodium chlorite peak at 260 nm, but does not show any chlorine dioxide peak at 355 nm-358 nm. This clearly indicates that at the pH level of 8.8, the liquid sodium chlorite/hydrogen peroxide solution has only sodium cholorite, and does not contain any quantities of chlorine dioxide. This is a clear indication that sodium chlorite is stable at the pH level of 8.8, and the chlorite is not breaking up and forming chlorine dioxide.
[0111] Experiment 4: pH Level of 7.0
[0112] Experiment: Dispense 25 mL. of the placebo solution and 25 mL. of the liquid sodium chlorite/hydrogen peroxide solution into 2 clean containers. Add 0.1 Normal hydrochloric acid solution to each container so as to adjust the pH of both the placebo solution as well as the liquid solution to a pH level of 7.0.
[0113] Fill one of the cuvette with the placebo solution, wipe it clean, and place the cuvette in the standard beam path of the spectrophotometer. Fill the second cuvette with the liquid sodium chlorite/hydrogen peroxide solution, wipe it clean and place the cuvette in the sample beam path of the spectrophotometer. Scan the solutions from 200 nm to 400 nm and record the results. Plot and printout the results, as illustrated in the graph shown in FIG. 4 .
[0114] Result: The liquid sodium chlorite/hydrogen peroxide solution contained sodium chlorite and hydrogen peroxide as active ingredients, as well as buffering and tonicity agents at the pH level of 7.0. The placebo solution contained hydrogen peroxide as active ingredient, as well as buffering and tonicity agents at the pH level of 7.0. Hydrogen peroxide does not absorb in the 200 nm to 400 nm range. Therefore, as seen in FIG. 4 , absorption peaks for hydrogen peroxide were not detected.
[0115] Sodium chlorite has an absorption maximum at 260 nm, while chlorine dioxide which is a degradation product of sodium chlorite has an absorption maximum at 355 nm-358 nm. Scanning the solutions that have a pH of 7.0 between the 200 nm and 400 nm will give a quantitative value for sodium chlorite as well as chlorine dioxide in the same scan.
[0116] Interpretation: The sodium chlorite/hydrogen peroxide solution does show sodium chlorite peak at 260 nm, but does not show any chlorine dioxide peak at 355 nm-358 nm. This clearly indicates that at the pH level of 7.0, the liquid solution has only sodium cholorite, and does not contain any quantities of chlorine dioxide. This is a clear indication that sodium chlorite is stable at pH of 7.0, and the chlorite is not breaking up and forming chlorine dioxide.
[0117] Experiment 5: pH Level of 6.44
[0118] Experiment: Dispense 25 mL. of the placebo solution and 25 mL. of the liquid sodium chlorite/hydrogen peroxide solution into 2 clean containers. Add 0.1 Normal hydrochloric acid solution to each container so as to adjust the pH of both the placebo solution as well as the liquid solution to a pH level of 6.44.
[0119] Fill one of the cuvette with the placebo solution, wipe it clean, and place the cuvette in the standard beam path of the spectrophotometer. Fill the second cuvette with the liquid solution, wipe it clean and place the cuvette in the sample beam path of the spectrophotometer. Scan the solutions from 200 nm to 400 nm and record the results. Plot and printout the results, as illustrated in the graph shown in FIG. 5 .
[0120] Result: The liquid sodium chlorite/hydrogen peroxide solution contained sodium chlorite and hydrogen peroxide as active ingredients, as well as buffering and tonicity agents at the pH level of 6.44.
[0121] The placebo solution contained hydrogen peroxide as active ingredient, as well as buffering and tonicity agents at pH=6.44. Hydrogen peroxide does not absorb in the 200 nm to 400 nm range, and thus no absorption peaks for hydrogen peroxide were detected. Sodium chlorite has an absorption maximum at 260 nm, while chlorine dioxide which is a degradation product of sodium chlorite has an absorption maximum at 355 nm-358 nm.
[0122] Scanning the solutions that have a pH of 6.44 between the 200 nm and 400 nm will give a quantitative value for sodium chlorite as well as chlorine dioxide in the same scan.
[0123] Interpretation: The liquid sodium chlorite/hydrogen peroxide solution does show sodium chlorite peak at 260 nm, but does not show any chlorine dioxide peak at 355 nm-358 nm. This clearly indicates that at pH of 6.44, the liquid solution has only sodium cholorite, and does not contain any quantities of chlorine dioxide. This is a clear indication that sodium chlorite is stable at pH of 6.44, and the chlorite is not breaking up and forming chlorine dioxide.
[0124] Experiment 6: pH Level of 6.0
[0125] Experiment: Dispense 25 mL. of the placebo solution and 25 mL. of the liquid sodium chlorite/hydrogen peroxide solution into 2 clean containers. Add 0.1 Normal hydrochloric acid solution to each container so as to adjust the pH of both the placebo solution as well as the liquid solution to a pH level of 6.0.
[0126] Fill one of the cuvette with the placebo solution, wipe it clean, and place the cuvette in the standard beam path of the spectrophotometer. Fill the second cuvette with the liquid sodium chlorite/hydrogen peroxide solution, wipe it clean and place the cuvette in the sample beam path of the spectrophotometer. Scan the solutions from 200 nm to 400 nm and record the results. Plot and printout the results, as illustrated in the graph shown in FIG. 6 .
[0127] Result: The liquid sodium chlorite/hydrogen peroxide solution contained sodium chlorite and hydrogen peroxide as active ingredients, as well as buffering and tonicity agents at the pH level of 6.0. The placebo solution contained hydrogen peroxide as active ingredient, as well as buffering and tonicity agents at the pH level of 6.0. Hydrogen peroxide does not absorb in the 200 nm to 400 nm range. Therefore, as seen in FIG. 6 , absorption peaks for hydrogen peroxide were not detected.
[0128] Sodium chlorite has an absorption maximum at 260 nm, while chlorine dioxide which is a degradation product of sodium chlorite has an absorption maximum at 355 nm-358 nm. Scanning the solutions that have a pH of 6.0 between the 200 nm and 400 nm will give a quantitative value for sodium chlorite as well as chlorine dioxide in the same scan.
[0129] Interpretation: The sodium chlorite/hydrogen peroxide solution does show sodium chlorite peak at 260 nm, but does not show any chlorine dioxide peak at 355 nm-358 nm. This clearly indicates that at pH level of 6.0, the liquid solution has only sodium cholorite, and does not contain any quantities of chlorine dioxide. This is a clear indication that sodium chlorite is stable at pH of 6.0, and the chlorite is not breaking up and forming chlorine dioxide.
[0130] Experiment 7: pH Level of 1.5
[0131] Experiment: Dispense 25 mL. of the placebo solution and 25 mL. of the liquid sodium chlorite/hydrogen peroxide solution into 2 clean containers. Add 0.1 Normal hydrochloric acid solution to each container so as to adjust the pH of both the placebo solution as well as the bactericidal solution to a pH of 1.5.
[0132] Fill one of the cuvette with the placebo solution, wipe it clean, and place the cuvette in the standard beam path of the spectrophotometer. Fill the second cuvette with the liquid solution, wipe it clean and place the cuvette in the sample beam path of the spectrophotometer. Scan the solutions from 200 nm to 400 nm and record the results. Plot and printout the results, as illustrated in the graph shown in FIG. 7 .
[0133] Result: The liquid sodium chlorite/hydrogen peroxide solution contained sodium chlorite and hydrogen peroxide as active ingredients, as well as buffering and tonicity agents at pH of 1.5. The placebo solution contained hydrogen peroxide as active ingredient, as well as buffering and tonicity agents at pH of 1.5. As explained earlier, hydrogen peroxide does not absorb in the 200 nm to 400 nm range, and as such, no absorption peaks for hydrogen peroxide were detected.
[0134] Also explained earlier, sodium chlorite has an absorption maximum at 260 nm, while chlorine dioxide which is a degradation product of sodium chlorite has an absorption maximum at 355 nm-358 nm. Scanning the solutions that have a pH of 1.5 between the 200 nm and 400 nm will give a quantitative value for sodium chlorite as well as chlorine dioxide in the same scan.
[0135] Interpretation: The liquid sodium chlorite/hydrogen peroxide solution does not show sodium chlorite peak at 260 nm, but does show a large chlorine dioxide peak at 355 nm-358 nm. This clearly indicates that at the pH level of 1.5, the liquid sodium chlorite/hydrogen peroxide solution does not have any sodium chlorite. Rather, it clearly shows that the sodium chlorite has been degraded and converted to chlorine dioxide. This is a clear indication that at pH of 1.5, sodium chlorite is very unstable, and all chlorite that is present in the liquid solution is converted to chlorine dioxide.
[0136] Results for Experiments 1-7
[0137] The liquid sodium chlorite/hydrogen peroxide solution contained sodium chlorite and hydrogen peroxide as active ingredients, as well as buffering and tonicity agents at the pH levels of 1.5, 6.0, 6.44, 7.0, 7.3, 8.0 and 8.8.
[0138] The placebo solution contained hydrogen peroxide as active ingredient, as well as buffering and tonicity agents at the pH levels of 1.5, 6.0, 6.44, 7.0, 7.3, 8.0 and 8.8.
[0139] Hydrogen peroxide does not absorb in the 200 nm to 400 nm range.
[0140] Sodium chloride has an absorption maximum at 260 nm, while chlorine dioxide has an absorption maximum at 355 nm-358 nm.
[0141] Scanning the solutions between the 200 nm and 400 nm gave a quantitative value for sodium chlorite as well as chlorine dioxide in the same scan.
[0142] Interpretation of Results for Experiments 1-7
[0143] The liquid sodium chlorite/hydrogen peroxide solutions at the pH levels of 6.0, 6.44, 7.0, 7.3, 8.0 and 8.8 does show the presence of sodium chlorite peak at 260 nm, but does not show the presence of chlorine dioxide peak at 355 nm-358 nm.
[0144] In contrast, the liquid sodium chlorite/hydrogen peroxide solution at pH of 1.5 does not show the presence of sodium chlorite peak at 260 nm, but does show the presence of chlorine dioxide peak at 355 nm-358 nm.
[0145] Conclusion of Results for Experiments 1-7
[0146] The results clearly show that one can quantitatively determine the level of sodium chlorite as well as chlorine dioxide which is present in the liquid sodium chlorite/hydrogen peroxide solution at the pH levels of 1.5, 6.0, 6.44, 7.0, 7.3, 8.0 and 8.8.
[0147] The results also show that the storage of the liquid sodium chlorite/hydrogen peroxide solution at about room temperature (e.g., in a white opaque bottle exposed to air at room temperature) does not produce any chlorine dioxide as determined by the absence of any absorbance at 355 nm-358 nm.
[0148] In conclusion, the liquid sodium chlorite/hydrogen peroxide solution contains only sodium chlorite. It does not contain chlorine dioxide when it is manufactured, nor does the solution degrade to generate chlorine dioxide after storage at about room temperature at the pH levels of 6.0, 6.44, 7.0, 7.3, 8.0 and 8.8. The liquid solution, however, degrades and generates chlorine dioxide upon the acidification of the solution to pH of 1.5.
[0149] This is clear evidence that the liquid sodium chlorite/hydrogen peroxide solution of the present invention has its bactericidal properties because of the sodium chlorite and hydrogen peroxide. This is very much unlike other prior art inventions that have as starting material as sodium chlorite, but the active bactericide is the chlorine dioxide, which is generated by the acidification of the sodium chlorite.
B. Examples of Therapeutic Applications
[0150] The following are specific examples of therapeutic applications of the chlorite/peroxide preparations of the present invention.
[0151] i. Example 1: Treatment of Psoriasis—No Crossover
[0152] A human patient having psoriasis plaques present on both arms is treated as follows:
[0153] Twice daily application to plaques on the left arm only, of a chlorite/peroxide solution having the following formulation:
Sodium Chlorite 0.06% Hydrogen Peroxide 0.01% HPMC 2.0% Boric Acid 0.15% HCl or NaOH to adjust pH 7.4 Purified water Q.S. to volume
Twice daily application to plaques on the right arm only of a commercially available 0.1% triamcinolone acetonide cream.
[0155] The chlorite/peroxide treated psoriatic plaques on the right arm began to become less severe within 24 hours of beginning treatment and had substantially disappeared within three days of beginning treatment. However, the triamcinolone acetonide treated psoriatic plaques present on the left arm remained unchanged and inflamed during the two week treatment period.
[0156] ii. Example 2: Treatment of Psoriasis-Crossover
[0157] A human patient having psoriasis plaques present on both arms is treated for two weeks, as follows:
[0158] Twice daily application to plaques on the left arm only, of a chlorite/peroxide solution having the following formulation:
Sodium Chlorite 0.06% Hydrogen Peroxide 0.01% HPMC 2.0% Boric Acid 0.15% HCl or NaOH to adjust pH 7.4 Purified water Q.S. to volume/100%
Twice daily application to plaques on the right arm only of a commercially available 0.1% triamcinolone acetonide cream.
[0160] The chlorite/peroxide treated psoriatic plaques on the right arm began to become less severe within 24 hours of beginning treatment and had substantially disappeared within one week of beginning treatment. However, the triamcinolone acetonide treated psoriatic plaques present on the left arm remained unchanged and inflamed during the two week treatment period.
[0161] Beginning the day after the end of the initial two week treatment period, and continuing for a second two week treatment period, the patient was treated as follows:
Twice daily application to plaques on the left arm only of the same commercially available 0.1% triamcinolone acetonide cream described hereabove in this example. Twice daily application to plaques on the right arm only, of the same chlorite/peroxide sustained release gel described hereabove in this example.
[0164] Within 24 hours of commencing the second treatment period, the psoriatic lesions on the right arm began to subside. By day three and continuing through the end of the second two week treatment period, the psoriatic lesions on the right arm had substantially disappeared.
[0165] iii. Example 3: Treatment of Cold Sores
[0166] A patient with painful, fluid-containing cold sores (i.e., chancre sores) on his lips was treated twice daily by application to the lips of a chlorite/peroxide preparation prepared in accordance with Formula 1 above.
[0167] Within 6 to 12 hours of the first application of the chlorite/peroxide preparation, the patient reported that the pain had subsided. Within 24 hours of the first application of the chlorite/peroxide preparation, the fluid contained within the cold sores had substantially dissipated and the cold sores appeared dry. Within six days of the first application of the chlorite/peroxide preparation the cold sores had substantially disappeared and the lips appeared normal, whereas cold sores of such severity typically require substantially longer than six days to completely disappear and heal.
[0168] iv. Example 4: Treatment of Venous Ulcer
[0169] A patient with a venous ulcer on the right leg of 3-4 cm diameter which had been present for 9-12 months was treated by twice daily application to the ulcer of gauze soaked with a chlorite/peroxide liquid solution prepared in accordance with Formula 1 above.
[0170] Within three days after commencement of treatment the ulcer appeared clean and dry. Within 14 days of the commencement of treatment the ulcer began to decrease in size and healthy new tissue was observed about its periphery. At 35 days after commencement of treatment, the ulcer had completely healed, without scarring, and the area where the ulcer had been located was free of pain.
[0171] v. Example 5: Treatment of Diabetic Decubitus Ulcer
[0172] A non-ambulatory, diabetic patient with decubitus ulcers on both legs and some toes, of 12-18 month duration, was treated by daily application of clean, sterile gauze to the ulcers and saturation of each gauze, three times each day, with a liquid chlorite/peroxide solution prepared in accordance with Formula 1 above. Within four to seven days of commencing the chlorite/hydrogen peroxide treatments the ulcers began to appear less inflamed, clean and dry. About seven to ten days after commencement of the chlorite/hydrogen peroxide treatment, granulation tissue began to form within the ulcers. Within 12 to 14 days, re-epithelialization was observed to have begun within the ulcerated areas except for one toe ulcer which had been particularly severe and had permeated to the bone of the toe. Within 30 to 45 days of the commencement of treatment, all of the ulcers except for the severe toe ulcer had completely closed and re-epithelialized, without irregular scar formation. Also, at 30 to 45 days after the commencement of treatment, the toe ulcer had also become substantially smaller (but was not completely closed) and the patient was able to walk. The liquid and or gel formulations of the present invention, such as Formulas 1 and 2 above, may also be applied topically to prevent scar formation due to wounds, burns, acne, infections, trauma, surgical incision, or any other scar-forming lesion or disorder.
[0173] vi. Example 6:
[0174] a. Treatment of Dry Eye Conditions
[0175] Subjects with dry eye conditions have itchy and scratchy eyes. In extreme cases, the subjects have more serious problems that can interfere with health maintenance. Subjects were treated with a preferred tear product of the following formulation:
Sodium Chlorite 0.005%-0.02% Hydrogen Peroxide 0.01% Methylcellulose A4M 0.075% Hyaluronic Acid 0.10%-0.125% Boric Acid 0.15% Sodium Chloride, USP 0.75% Pluronic 127 0.10% HCl or NaOH Adjust pH to 7.4 Purified Water Q.S. to Volume
[0176] Testing of dry eye subjects with rose bengal stain or fluorescein gives a good indication regarding the condition of the corneal epithelial health, while rose bengal staining provides a good indication of the number of dead epithelial cells on the cornea as well as conjunctiva.
[0177] Two subjects with dry eye condition were tested with rose bengal stain, and the quantitative staining to the cornea and conjunctiva was documented by photographs. The subjects started using the above preferred tear product at a dosage of two drops three times per day. At the end of two weeks, the two subjects were tested with rose bengal stain and the level of staining was quantitatively documented by photography. The results showed a 50% to 70% reduction in rose bengal staining, which clearly indicates that the preferred tear formulation was ameliorating the corneal and conjunctival cells from dying.
[0178] In addition to an objective determination of the health of the epithelial cells, the two subjects were tested subjectively regarding the safety and efficacy of the preferred tear product. First of all, slit-lamp biomicroscopy of the subjects during the two-week treatment period did not show any redness, irritation, inflammation, or other signs of discomfort. Second, the subjects indicated that the application of the tear product completely removed symptoms of redness, itching, scratching, pain, and dryness due to dry eye while providing lubrication that lasted for several hours. It is therefore evident that the tear product exhibits both safety and efficacy in the treatment of dry eye. As is further recognized in view of the foregoing antimicrobial activity of such compositions, the tear product will also have efficacy in enhancing wound healing within the eye such as after surgery where bacterial infections are to be avoided.
[0179] b. Treatment of Allergic Conjunctivitis
[0180] In addition to treating dry eye condition with the above preferred tear product, the product was also tested in the treatment of conditions from allergic conjunctivitis. In particular, two subjects suffering from allergic conjunctivitis including itchy, scratchy eyes with constant tearing applied two drops of the product three times per day. This dosage resulted in the disappearance of the symptoms.
[0181] c. Examples of Contact Leans Cleansing
[0182] i. Example 1: Soaking, Cleaning and Disinfecting
[0183] The following formulation is a preferred disinfecting solution applicable to the cleaning of contact lenses by conventional soaking.
Sodium Chlorite 0.05% Hydrogen Peroxide 0.01% Methylcellulose A4M 0.075% Hyaluronic Acid 0.05%-0.10% Boric Acid 0.15% Pluronic 127 0.25%-0.50% Sodium Chloride USP 0.75% HCl or NaOH Adjust pH to 7.4 Purified Water Q.S. to Volume
[0184] Six subjects using soft hydrophilic contact lenses soaked the lenses in the above disinfecting solution and then placed the lenses directly into the eyes. Soaking was performed nightly or on an as-needed basis. All six subjects reported that the lenses felt very comfortable, and that no adverse effects (e.g., burning, stinging, redness, pain) were experienced. Additionally, the solution extended the comfort and clean condition of the lenses for several weeks beyond such extension experienced with other commercially available disinfecting solutions.
[0185] The disinfecting solution can be used with soft hydrophilic lenses of varying water content (e.g., 38% to 75%), as well as with silicone acrylate rigid gas permeable lenses. Cycling studies of soft lenses soaked daily in the solution for 30 days showed no damage or change in the physical and chemical characteristics of the lenses. Eye comfort, as earlier noted, is achieved through non-binding and non-accumulating of preservative in soft or rigid gas permeable lenses, while such binding and accumulation can be found in certain currently commercially available formulations to cause irritation and discomfort.
[0186] ii. Example 2: Cleaning While Wearing
[0187] The following formulation is a preferred disinfecting in-eye solution applicable to the cleaning of contact lenses while they are being worn by introducing the solution into the eye:
Sodium Chlorite 0.02% Hydrogen Peroxide 0.01% Methylcellulose A4M 0.075% Hyaluronic Acid 0.075%-0.10% Boric Acid 0.15% Sodium Chloride USP 0.75% Pluronic 127 0.75% HCl or NaOH Adjust pH to 7.4 Purified Water Q.S. to Volume
[0188] Four subjects applied two drops of the above in-eye solution three times per day for 30 days to contact lenses while being worn. Examinations of all of the subjects showed no irritation, burning, stinging, or adverse effects of any kind. These subjects further reported that the solution felt soothing and lubricating.
[0189] Two subjects were involved in a comparative study where, first of all, they wore ACUVUE disposable lenses continuously for two weeks with occasional removal and cleaning with commercially available cleaning solutions followed with a saline rinse. After 14 days, the lenses became very gritty and uncomfortable, and were discarded. Second, the two subjects started with new ACUVUE lenses and practiced daily application of the present in-eye solution three times per day without removing or touching the lenses. These subjects were able to wear the lenses for three to four weeks before replacement. Additionally, the inconvenience of cleaning the lenses outside the eye was completely eliminated, as was the risk of lens loss, tearing, or contamination. It is therefore evident that the present in-eye cleaning solution provides cleansing efficacy as well as convenience.
[0190] d. In-Vitro and In-Vivo Antimicrobial Efficacy
[0191] i. Synergistic Activity
[0192] Tables I and II compare the antimicrobial effects of (a) 400 ppm sodium chlorite alone; (b) 200 ppm hydrogen peroxide alone; and (c) 400 ppm sodium chlorite and 200 ppm hydrogen peroxide in combination against antibiotic-resistant strains of staphylococcus haemolyticus (Table I) and pseudomonas aeruginosa (Table II) both isolated from human infected eyes. Tables I and II summarize the antimicrobial effects observed at time points one and two hours after introduction of the test solutions.
TABLE I ( staphylococcus haemolyticus : Initial inoculum = 1.01 × 10 7 : Log 7.03) Log Log Reduction Reduction NaClO 2 & H 2 0 2 Time NaClO 2 alone H 2 0 2 alone (400 ppm & (hours) (400 ppm) (200 ppm) 200 ppm) 1 0.11 0.20 0.69 2 1.01 0.23 2.43
[0193]
TABLE II
( pseudomonas aeruginosa : Initial
inoculum = 2.22 × 10 6 : Log 6.35)
Log
Log Reduction
Reduction
NaClO 2 & H 2 0 2
Time
NaClO 2 alone
H 2 0 2 alone
(400 ppm &
(hours)
(400 ppm)
(200 ppm)
200 ppm)
1
0.351
0.01
0.04
2
1.35
0.54
6.35
[0194] In the experiment summarized in Table I, sodium chlorite alone caused a Log reduction in staphylococcus haemolyticus bacteria of 0.11 at 1 hour and 1.01 at 2 hours. Hydrogen peroxide alone caused a Log reduction in staphylococcus haemolyticus bacteria of 0.20 at 1 hour and 0.23 at 2 hours and the combination of sodium chlorite and hydrogen peroxide caused a Log reduction in staphylococcus haemolyticus bacteria of 0.69 at 1 hour and 2.43 at 2 hours. Thus, in this experiment, the antimicrobial effect of the sodium chlorite-hydrogen peroxide combination was significantly greater than the sums of the effects of the sodium chlorite and hydrogen peroxide alone, at least at the 2 hour time point. Accordingly, it is concluded that the sodium chlorite-hydrogen peroxide combination exhibited a supra-additive effect against the strain of staphylococcus haemolyticus used in this experiment.
[0195] In the experiment summarized in Table II, sodium chlorite along caused a Log reduction in pseudomonas aeruginosa bacteria of 0.35 at 1 hour and 1.35 at 2 hours. Hydrogen peroxide alone caused a Log reduction in pseudomonas aeruginosa bacteria of 0.01 at 1 hour and 0.54 at 2 hours and the combination of sodium chlorite and hydrogen peroxide caused a Log reduction in pseudomonas aeruginosa bacteria 0.04 at 1 hour and 6.35 at 2 hours. Thus, in this experiment, the antimicrobial effect of the sodium chlorite-hydrogen peroxide combination was significantly greater than the sums of the effects of the sodium chlorite and hydrogen peroxide alone, at least in the 2 hour time point. Accordingly, it is concluded that the sodium chlorite-hydrogen peroxide combination exhibited a supra-additive effect against the strain of pseudomonas aeruginosa used in this experiment.
[0196] ii. Animal Testing
[0197] S. haemolyticus keratitus was induced in respective right eyes of 12 rabbits by dropping broth containing 50,000 CFU/ml of S. haemolyticus onto abraded corneas of these eyes. After 24 hours, all corneas were likewise infected, and the rabbits were divided randomly into three groups. The rabbits (five) of Group I then were treated with the chlorite-hydrogen peroxide formulation defined above as cleaning while wearing contact lenses (here termed “Bactericide”); the rabbits (five) of Group II were treated with commercially available 0.3% ofloxacin antibiotic ophthalmic solution; and the rabbits (two) of Group III were untreated to serve as a control.
[0198] At 24 and 48 hours post infection, the rabbits underwent visual eye examination, photographic documentation and biomicroscopy. After 24 hours of treatment, three animals each from Groups I and II and one animal from Group III were sacrificed. The eyes were enucleated and an 8 mm disc of cornea was homogenized and plated onto growth media for microbial isolation and quantification. After 48 hours of treatment, the same procedure was followed for the remaining animals.
[0199] Tables III, IV and V summarize the results of this experimentation. As is there apparent, the Bactericide of the present invention exhibited superior overall results as compared to the competing commercially available regimens. The results therefore confirm that the clinical efficacy of the Bactericide is better than the antibiotic treatment. In addition to having excellent bactericidal properties, it is demonstrated that bactericide superiority is probably attributable to inactivation of bacterial proteolytic enzymes (thus decreasing bacterial virulence) and inactivation of bacterial toxins responsible for inflammation and hyperemia.
TABLE III IN-VIVO ANTIMICROBIAL EFFICACY IN INFECTIOUS S. HAEMOLYTICUS KERATITIS IN RABBITS Post Group II Group III Treatment Group I 0.3% Untreated Time Bactericide Ofloxacin Control 24 hours i) 0 CFU i) 23,000 CFU 39,000 CFU ii) 18,000 CFU ii) 5,000 CFU iii) 0 CFU iii) 11,000 CFU Average 6,000 CFU 13,000 CFU 39,000 CFU 48 hours i) 0 CFU i) 5,000 CFU 231,000 CFU ii) 0 CFU ii) 5,200 CFU Average 0 CFU 5,100 CFU 231,000 CFU
[0200]
TABLE IV
IN-VIVO CLINICAL EFFICACY IN INFECTIOUS
S. HAEMOLYTICUS KERATITIS IN RABBITS
Group I
Group II
Group III
Time
Bactericide
0.3% Ofloxacin
Untreated Control
24 hours
inflammation (+2)
inflammation (+2)
inflammation (+2)
after
hyperemia (+2)
hyperemia (+2)
hyperemia (+2)
infection
corneal edema
corneal edema
corneal edema
(+2)
(+2)
(+2)
24 hours
inflammation (0)
inflammation (+2)
inflammation (+3)
after
hyperemia (0)
hyperemia (+2)
hyperemia (+3)
treatment
corneal edema (0)
corneal edema
corneal edema
(+2)
(+3)
48 hours
inflammation (0)
inflammation (+1)
inflammation (+3)
after
hyperemia (0)
hyperemia (+1)
hyperemia (+3)
treatment
corneal edema (0)
corneal edema
corneal edema
(+1)
(+3)
[0201]
TABLE V
IN-VITRO INHIBITION OF PROTEOLYTIC ENZYME ACTIVITY
Inhibition of proteolytic enzyme activity of
Trypsin and porcine pancreatic Elastase
Concentration
% Inhibition of
Enzyme
of Bactericide
Enzyme activity
Elastase (porcine)
0.18 ppm
46%
Trypsin
0.12 ppm
28%
[0202] It will be appreciated by those skilled in the art, that the invention has been described hereabove with reference to certain examples and specific embodiments. However, these are not the only examples and embodiments in which the invention may be practiced. Indeed, various modifications may be made to the above-described examples and embodiments without departing from the intended spirit and scope of the present invention, and it is intended that all such modifications be included within the scope of the following claims. | An anti-microbial composition for providing a therapeutic application onto a living being. The composition includes from about 0.001 wt. % to about 0.20 wt. % chlorite compound and from about 0.001 wt. % to about 0.05 wt. % peroxy compound. The anti-microbial composition of the present invention is composed to remain intact without being degraded to generate chlorine dioxide during storage at about a room temperature. The anti-microbial composition of the present invention is at a pH range between about 6.0 and about 8.8. | 0 |
This is a Divisional of application Ser. No. 11/117,425 (now abandoned) filed Apr. 29, 2005, which is a non provisional application which claims the benefit of French Application No. 04 04674 filed on Apr. 30, 2004 and U.S. Provisional Application No. 60/572,482 filed on May 20, 2004. The disclosure of the prior applications are hereby incorporated by reference herein in its entirety.
BACKGROUND
The present invention relates to packaging and applicator devices, particularly but not exclusively for making up the skin, the mucous membranes, the nails, or hair.
Known devices for packaging and dispensing lipsticks or deodorants comprise a body housing a stick of substance and a mechanism for displacing it relative to the body to compensate for wear as it is used up. The drive mechanism is relatively expensive and, furthermore, the applicator surface never regains its original shape.
Makeup pencils are also known that comprise a wood or plastics body into which the substance is cast to form the “lead”. During use, the “lead” becomes worn and the user must resort to a pencil sharpener to reshape it, which risks breaking the “lead” or weakening it in subsequent use.
Known blushers, lip colors, or eye shadows that are slightly domed for direct application to the skin suffer from the disadvantage of losing their initial shape relatively rapidly; once shape has been lost, application can no longer be as accurate as desired.
SUMMARY
The invention aims to overcome the above disadvantages.
In one of its aspects, the invention provides a packaging and applicator device comprising:
a body;
a block of fluidizable substance that is stationary relative to the body while the substance is in the solid state, said block of substance projecting beyond the body to define at least one surface serving as an applicator surface; and
a reshaper member for reshaping the applicator surface, said reshaper member being positionable on the body to co-operate therewith to define at least one cavity into which the substance can flow when fluidized by supplying heat, the substance being capable of retaining the shape of the cavity when it returns to the solid state after cooling.
The term “fluidizable” should not be construed in its narrow sense, and encompasses any possibility of softening a substance under the effect of heat which is sufficient to allow it to flow into said cavity to reshape its applicator surface.
The term “solid state” means the state of the substance at ambient temperature (about 20° C.) under normal conditions of use.
The term “stationary relative to the body” means that the device has no drive mechanism for displacing the block of substance axially relative to the body when the substance is at ambient temperature such as, for example, known screw mechanisms in certain deodorants or lipsticks.
Advantageously, the reshaper member is arranged to allow the body of the device to remain vertical while the substance is flowing into the cavity. In particular, the reshaper member may be arranged to be capable of resting in a stable manner on a horizontal flat surface.
In an exemplary embodiment, the reshaper member is arranged to engage on the outside of the body. As an example, the reshaper member may also act as a member for closing the body, at its applicator surface end, to protect it when not in use. The reshaper member may optionally be configured to be fastened on the body on its end opposite from the applicator surface which can, for example, reduce the risk of losing the reshaper member while the substance is being applied.
The body has an inside surface in contact with the substance and said inside surface may comprise at least one portion in relief which opposes slipping of the solid substance inside the body. Said portion in relief may comprise a constriction or serration, for example.
The body may also have an inside cross section that tapers or flares towards the applicator surface.
The reshaper member may comprise at least two housings configured to form applicator surfaces having different shapes, depending on which housing the user selects to receive the body of the device. This may afford the user the opportunity to choose between a plurality of applicator surfaces, depending on the type of makeup being applied.
The reshaper member may comprise one housing to reshape the applicator surface and another housing to receive the body in a closed configuration thereof, said other housing not acting to reshape the applicator surface.
If appropriate, the body may include more than one opening through which the substance can flow during reshaping of the applicator surface.
The body may also include at least one eccentric opening through which the substance can flow during reshaping of the applicator surface.
If necessary, the body of the device may be packaged in a package such as a case having a portion that can act as the reshaper member.
Preferably, the quantity of substance contained in the body of the device is sufficient to allow at least one reshaping operation, and preferably at least two reshaping operations.
The temperature to which the substance is heated for reshaping its applicator surface may in particular depend on the nature of the substance and the rate at which its missing portion can be filled in in the cavity of the reshaper member.
As an example, the substance may have an anhydrous formulation, which behaves reversibly as a function of temperature and it may contain at least one compound which can coagulate, plasticize, or harden on returning to ambient temperature.
As an example, the substance may be a blusher, a lipstick, or an eye makeup substance, this list being non-limiting; the invention is applicable to any cosmetic or dermatological care product.
The body of the device and the reshaper member can withstand the rise in temperature necessary to fluidize the substance and reshape the applicator surface; for example, they may withstand a temperature of about 120° C. in the absence of mechanical stresses.
Preferably, the reshaper member is made so as to facilitate unmolding of the applicator surface. The material from which the reshaper member is made may be provided to this end. The reshaper member may, for example, be made of polypropylene (filled or otherwise), polystyrene, polyamide, in particular Nylon®, polyethylene terephthalate (PET), elastomers, or silicones, this list being non-limiting.
It may also be made of at least two different materials, one of which may be elastically deformable. The reshaper member may, for example, be made with a bottom formed from an elastically deformable material, for example silicone, to facilitate unmolding, with the remainder being formed from a non elastomeric material, for example polypropylene.
The reshaper member may include a vent to facilitate filling the cavity.
Advantageously, opposite the reshaper member, the body includes an opening to allow pressure equalization.
In a further aspect, the invention provides a method of reshaping an applicator surface in a device comprising:
a body;
a block of liquefiable substance contained in the solid state in the body, said block of substance projecting beyond the body to define at least one surface serving for application; and
a reshaper member for reshaping the applicator surface, said reshaper member being positionable on the body to co-operate therewith to define at least one cavity;
in which method, after the block of substance has been used at least once, the reshaper member is positioned on the body and is heated to allow the substance to flow into the cavity, the substance being capable of retaining the shape of the cavity on resuming the solid state after cooling.
The substance may be heated by exposing it to microwave radiation, for example for a period in the range 10 seconds to 5 minutes, or to the heat released by an electrical resistance. The substance may be heated to a temperature of more than 80° C., for example.
The cavity into which the substance is cast may be selected from a number of cavities as a function of the desired shape with which the applicator surface is to be endowed.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will be better understood from the following detailed description of non limiting embodiments thereof and from the accompanying drawing in which:
FIG. 1 is a diagrammatic perspective view showing an example of a packaging and applicator device in accordance with the invention;
FIGS. 2 to 4 show reshaping of the applicator surface of the device of FIG. 1 ;
FIGS. 5 to 7 are diagrammatic longitudinal section views showing variations of the device body;
FIG. 8 is a diagrammatic longitudinal section view showing a device in which the reshaper member may also act as the closure cap;
FIG. 9 shows, in isolation, a reshaper member for reshaping the applicator surface into two predetermined shapes, as selected by the user;
FIG. 10 is a diagram showing a package that allows the applicator surface to be reshaped;
FIG. 11 is a diagram of the package in section on XI-XI of FIG. 10 ;
FIG. 12 shows another example of a packaging and applicator device in accordance with the invention;
FIG. 13 illustrates wear on the applicator surface;
FIG. 14 shows the device before reshaping its applicator surface;
FIG. 15 shows the device of FIG. 14 after reshaping its applicator surface;
FIGS. 16 to 18 are diagrams showing other examples of packaging and applicator devices in accordance with the invention;
FIG. 19 shows the possibility of making the body of the device with an eccentric opening for substance outflow;
FIG. 20 shows the possibility of making the body of the device with a plurality of openings for substance outflow;
FIG. 21 shows the possibility of making the reshaper member in at least two different materials; and
FIGS. 22 to 24 show the portions in relief for retaining substance in the body, respectively in the form of a screen, a helical thread, and a porous structure.
DETAILED DESCRIPTION OF EMBODIMENTS
The packaging and applicator device 1 shown in FIG. 1 comprises an applicator member 10 and a reshaper member 20 . The applicator member 10 comprises a body 12 which is elongate along a longitudinal axis X in the example under consideration, and a block of fluidizable substance 13 extending beyond one end of the body 12 to define an applicator surface 14 .
In the example under consideration, the applicator member 10 constitutes a pencil, and prior to its first use, the applicator surface 14 has a generally pointed shape.
The end 15 of the body 12 adjacent to the applicator surface 14 is substantially conical, converging towards the tip. The body 12 in the example under consideration is open at its opposite end 16 . As an example, the substance may be cast into the body 12 via this end 16 during manufacture of the device.
In the example under consideration, the reshaper member 20 is in the general shape of a cap comprising a tubular skirt 21 which connects at its lower end to a bottom portion 22 .
In the example under consideration, the skirt 21 is cylindrical and centered about the axis X, its inside diameter being adapted to the outside diameter of the body 12 so that it fits thereon with a small amount of interference.
The reshaper member 20 defines a cavity 24 defined radially by the skirt 21 and has a bottom 25 with a shape corresponding to that with which the applicator surface 14 is to be endowed when reshaped.
Before first use, the applicator member 10 may have an applicator surface 14 the shape of which corresponds to that of the bottom 25 of the cavity 24 , the substance 13 advantageously being cast into the body 12 while the reshaper member 20 was in position thereon.
After being used one or more times, the applicator surface becomes worn due to transfer of substance onto the treated surface and may, for example, have the flattened shape shown in FIG. 3 . To reshape the applicator surface 14 , the user inserts the applicator member 10 into the reshaper member 20 until the end 15 axially abuts against it, as shown in FIG. 3 . A void remains above the bottom 25 of the cavity 24 .
The user then heats the assembly, disposed vertically with the reshaper member lowermost, for example by placing it in a microwave oven. The duration of heating depends on a several of factors such as the power of the oven, and the natures of the body of the device, and of the substance.
The substance may then be heated to a temperature higher than about 80° C., for example. The body 12 of the applicator member and the reshaper member 20 are capable of withstanding the temperature to which the substance is heated.
The applicator member 10 and the reshaper member 20 may be made so as to be compatible with use in a microwave oven, and should then not include any metal or metallization which could deteriorate or damage the oven used.
The properties of the substance are such that, when heated to a sufficient temperature, it can fluidize and flow under gravity into the cavity to match the shape of its bottom 25 , as shown in FIG. 4 .
The user then allows the substance 13 to cool, to allow it to solidify. Cooling may, for example, be accomplished in air or by placing the assembly in a refrigerator or freezer. It can be seen in FIG. 4 that the level of the substance inside the body 12 drops due to outflow thereof into the cavity 24 during reshaping of the applicator surface 14 , outflow being facilitated by the air pressure equalization made possible by the body 12 because its end 16 is open.
Once the substance has resumed its solid state, the user can once again use the applicator member 10 , the applicator surface 14 having regained a suitable shape, corresponding to that of the bottom 25 .
The operation may be repeated as many times as allowed by the quantity of substance contained in the body 12 . The maximum volume of substance that flows out on each reshaping of the applicator surface 14 into the cavity 24 may, for example, correspond to less than half of the initial volume of the block of substance 13 , preferably less than a third, a quarter, a fifth, or a tenth thereof.
Each time the applicator surface 14 is reshaped, the heating of the substance, if sufficient, may exert a germicidal or bactericidal action on the applicator surface 14 , which may serve to reduce or even dispense with preservatives in the substance.
To reduce the risk of the block of substance 13 slipping relative to the body 12 when the substance is in the solid state, the inside surface of the body 12 may be provided with at least one portion in relief, which may be a hollow or a projection, as shown in FIGS. 5 and 6 and 22 to 24 .
In FIG. 5 , the inside surface 17 is provided with serrations 18 extending across the longitudinal axis X; in FIG. 6 , the inside surface 17 includes a constriction 19 constituted, for example, by an annular bead 31 which projects radially inwards. Clearly, the scope of the invention encompasses making other portions in portion in relief. As an example, at least one screen 61 may be made, as shown in FIG. 22 , or a helical thread 62 , as shown in FIG. 23 , or a porous structure 62 may be fitted in the body, as shown in FIG. 24 . For example, this porous structure which may be a foam or a sponge, and it may occupy a greater or lesser amount of space inside the body, depending, for example, on the viscosity of the substance. The inside surface may also be made with suitable roughness.
It is also possible to give the inside surface 17 a cross section that is not constant, for example a cross section that decreases towards the end 15 , as shown in FIG. 7 , or conversely, increases towards the end 15 (variation not shown).
If appropriate, the inside surface 17 may be made with a cross section that increases or decreases towards one end of the body 12 , and that is also provided with at least one portion in relief to encourage retention of the substance.
The reshaper member 20 may act as a closure cap to protect the applicator surface 14 when not in use, as applies to the example shown in FIGS. 1 to 4 . In a variation, the reshaper member 20 may include a second housing 32 that differs from the housing defining the cavity 24 and that serves only to receive the body 12 when not in use, the cavity 24 being the only cavity suitable for reshaping the applicator surface 14 . In this case, the housing 32 may, for example, be sufficiently wide for the reshaper member 20 not to come into contact with the applicator surface 14 , as shown in FIG. 8 , the end 15 of the body 12 bearing axially, for example, against a shoulder 33 of the housing 32 .
If appropriate, as shown in FIG. 9 , the reshaper member 20 may define two cavities 24 and 24 ′ having respective bottoms 25 and 25 ′ that are arranged to reshape the applicator surface 14 into different shapes, for example one shape which is more pointed than the other. The user can then select which cavity 24 or 24 ′ which is suitable for the desired application in order, for example, to deposit substance on a broad surface or, in contrast, to make an outline.
In the example of FIG. 9 , the cavities 24 and 24 ′ open in opposite directions, but such a configuration is not the only possibility.
FIG. 9 also shows that the reshaper member may be made with at least one vent facilitating evacuation of air contained in the cavity while it is being filled. That vent may, for example, be in the form of a groove 60 .
The reshaper member 20 may then, if appropriate, and as shown in FIGS. 10 and 11 , be in the form of a package comprising a closing lid 37 and a bottom portion 36 with, for example, a housing 35 to receive the applicator member 10 horizontally when not in use and defining at least one cavity, for example three cavities 24 , 24 ′ and 24 ″ in the example shown, to receive the applicator member 10 vertically during reshaping of the applicator surface 14 .
The cavities 24 , 24 ′ and 24 ″ have respective bottoms 25 , 25 ′ and 25 ″ having different shapes, to allow different applicator surfaces to be formed, for example points with different tapers at the end of the applicator member.
The applicator member 10 may differ from that of a pencil; FIG. 12 shows a variation in which the applicator member 10 has a broader applicator surface 14 than in the example of FIG. 1 .
The body 12 of the applicator member 10 in this example comprises a tubular portion 40 that is connected at its bottom to a flange 41 which is directed radially outwardly. In the example under consideration, the flange 41 is provided with an edge 42 which is directed towards the end 16 of the applicator member remote from the applicator surface 14 .
In the example shown, the shape of the applicator surface is substantially part spherical with a periphery which is, for example, substantially half the width of the flange 41 . A rib 43 extends the flange 41 radially inwards from the skirt 40 and forms a portion in relief which improves the grip of the block of substance 13 in the solid state in the body 12 .
The body 12 is shown as it is when obtained as a one-piece plastics molding. Clearly, the scope of the present invention encompasses the body 12 being made by assembling a plurality of elements which have been made independently.
The reshaper member 20 comprises a wall 46 in the form of a cup, defining the cavity 24 having a bottom 25 of the shape that is to be restored to the applicator surface 14 .
The periphery of the wall 46 is connected to a tubular skirt 47 via which the reshaper member may rest on a horizontal surface, with the axis of the cavity 24 vertical. The skirt 47 is extended upwards by a rib 48 which, by cooperating with the edge 42 , can center the applicator member 10 on the reshaper member 20 , as shown in FIG. 14 .
During use, the applicator surface 14 loses its initial shape, as shown in FIG. 13 . To reshape the applicator surface 14 , the applicator member 10 is positioned over the reshaper member 20 , as shown in FIG. 14 , then the assembly is heated, for example in a microwave oven, to allow the substance 13 to fluidize and flow into the bottom of the cavity 24 . The applicator surface 14 may become reshaped in contact with the bottom 25 of the cavity 24 , as shown in FIG. 15 . It can be seen in this figure that the level of substance in the body 12 is reduced following reshaping. The block of substance 13 then sets on cooling and thus retains the shape of the bottom 25 of the cavity 24 .
Contact between the flange 41 and the wall 46 may contribute to preventing substance from leaking out while it is in the fluid state. Clearly, specific sealing means could be provided, such as at least one sealing lip or gasket formed of a particular material, for example an elastomer.
The applicator member 10 may be made in a variety of manners within the scope of the invention, as can the reshaper member 20 .
As an example, FIG. 16 shows an applicator member 10 intended for application to a broad surface, for example to the body, the applicator surface 14 possibly having a domed oblong shape, for example.
In the example shown in FIG. 17 , the body 12 of the applicator member 10 may be relatively short, if the substance is a blusher, for example.
In the example shown in FIG. 18 , the substance is, for example, intended for application to the lips.
The body 12 may include a single opening 45 through which the substance 13 can flow out when it is in the fluid state, to allow the applicator surface 14 to be reshaped. Said opening 45 may be centered on a longitudinal axis of the applicator member, said axis possibly being an axis of symmetry. In a variation, as shown in FIG. 19 , the opening 45 may be eccentric with respect to the longitudinal axis of the body 12 .
The applicator member 10 may also include a plurality of openings 45 through which the substance 13 may flow out during reshaping of the applicator surface 14 , as shown in FIG. 20 .
As shown in FIG. 21 , the reshaper member may also be made of at least two materials with different hardnesses, for example an elastomer and a non elastomer, to facilitate unmolding.
One of the materials may define at least the bottom of the cavity, while the other material constitutes the remainder of the reshaper member.
Clearly, the invention is not limited to the embodiments described above; in particular, the characteristics of the various embodiments described may be combined together.
The substance may be heated to fluidize it in a manner other than placing the applicator member in a microwave oven, for example by exposing the substance to the heat released by an electrical resistance. Such an electrical resistance may be external to the applicator member or, if appropriate, may be integrated in the applicator member. The reshaper member may then comprise a source of electrical energy and means for establishing electrical contact with the resistance carried by the applicator member, so that positioning the applicator member on the reshaper member automatically causes an electric current to flow in the resistance, heating the substance and reshaping the applicator surface.
Throughout the description, the expression “comprising a” should be understood to be synonymous with “comprising at least one”, unless otherwise indicated.
Although the present invention herein has been described with reference to particular embodiments, it is to be understood that these embodiments are merely illustrative of the principles and applications of the present invention. It is therefore to be understood that numerous modifications may be made to the illustrative embodiments and that other arrangements may be devised without departing from the spirit and scope of the present invention as defined by the appended claims. | A packaging and applicator device comprising: a body; a block of fluidizable substance that is stationary relative to the body while the substance is in the solid state, said block of substance projecting beyond the body to define at least one surface serving as an applicator surface; and a reshaper member for reshaping the applicator surface, said reshaper member being positionable on the body to co-operate therewith to define at least one cavity into which the substance can flow when fluidized by supplying heat, the substance retaining the shape of the cavity when it returns to the solid state after cooling. | 0 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present disclosure relates to a method for the diagnosis and treatment of certain types of cancer, especially various types of malignant brain tumors.
2. Description of the Related Art
Glial cell tumors are the most common types of primary brain cancers. They are classified by grade and cell type. The main cell types involved are astrocytes, ependymal cells, and oliodendrocytes. There are four grades of astrocytomas. Grade I and II are “low-grade” gliomas and Grade III and IV are “high-grade” gliomas. While low-grade gliomas are characterized by differentiated cells and are benign, high-grade gliomas are characterized by undifferentiated cells and are malignant.
Glioblastoma multiforme (GBM), or Grade IV astrocytoma, constitutes the most commonly diagnosed and most malignant type of primary brain tumor, affecting 8,000-12,000 new patients per year, or roughly 40% of all patients newly diagnosed with primary brain tumors. GBM is a progressive disease such that even after diagnosis and resection of the cancer cells in the early grades of the disease, degradation to its higher grades has heretofore proven unavoidable and local treatment options have proven unsatisfactory. Computed tomographic (CT) scans and magnetic resonance imaging (MRI) are the primary non-invasive tools for diagnosing GBM.
The median life expectancy for patients with GBM is three to six months without treatment. Current treatment options include the surgical resection of the bulk of the tumor, radiotherapy with involved-field radiation therapy (IFXRT), and chemotherapy. While resection can delay the spread of low-grade gliomas, some GBM cells typically remain undetected outside the treatment area and survive the procedure. As these cells multiply and spread, new tumors typically appear about a centimeter outside the resection cavity. With radiation therapy, the median life expectancy of GBM patients is about a year. Photon radiation augmented with temozolomide chemotherapy is known to add two to three months to the median life expectancy. Given the dismal prognosis associated with GBM, there is clearly a need for more effective means of treating this illness.
SUMMARY OF THE INVENTION
Disclosed herein is a method of treating various types of cancer, specifically the use of targeted radiotherapy directed at likely pathways of migration for cancer cells. Some embodiments herein disclosed are particularly useful for the treatment various types of brain cancers such as GMB. In some embodiments, the bulk of the tumor, or nidus, is detected radiographically. Likely pathways of migration for the cancer cells are then determined based on the location of the nidus. These pathways are further analyzed to determine if cancer cells have already migrated thereto. In addition to surgically excising and/or irradiating known areas of tumor infiltration, treatments can also be directed toward these likely pathways ahead of the leading edge of verified cancer cell migration. In this manner, those cancer cells that have migrated the farthest from the nidus, yet still remain undetectable because of their small number, can be inactivated or destroyed by specifically directing radiation treatments to their suspected location. This technique enables the practitioner to maximize the number of tumor cells eliminated using the lowest possible dosage of radiation, thereby minimizing the iatrogenic destruction of healthy brain tissue. This enables the practitioner to eliminate suspected, yet undetectable cancer cells that would otherwise multiply and spread to other parts of the brain.
In some embodiments, the present disclosure can comprise a kit further comprising a data processing and storage device, one or more imaging devices, and one or more treatment devices. Said data processing and storage device can further comprise software or other executable code capable of determining likely areas of cancer cell migration based on an analysis of the tumor nidus and direct additional radiological analysis thereto. These areas of likely cancer cell infiltration can be determined through an analysis of established areas of cancer cell infiltration and a determination of those pathways along which cancer cells preferentially migrate. Once the verified leading edge of cancer cell migration is determined, the likely location of yet undetected cells can be determined with reference to known migratory patterns as well as other information about the patient's type of cancer. In some embodiments, the kit can further comprise an executable code capable of directing treatments at the known and likely areas of cancer cell infiltration based on previously gathered radiological data. In many cases, the executable code can comprise various commands for delivering appropriate treatments in the areas of likely cancer cell infiltration so as to maximize treatment effect.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an illustration of the transformation of a healthy cell into a cancer cell.
FIG. 2 is an illustration of a cancer cell developing actin and signaling proteins that enable it to interact with the extracellular matrix.
FIG. 3 is an illustration of the spread of cancer cells from a nidus to other parts of the brain.
FIGS. 4A to 4H are a series of eight radiographic images of a brain during treatment for GBM.
FIG. 4J shows a radiographic image of the same brain after treatment.
FIG. 5 is shows magnetic resonance spectrograms of tissues.
FIGS. 6A and 6B are an example of a single voxel-array with the corresponding magnetic resonance spectrogram.
FIGS. 7A and 7B are an example of a multi voxel-array.
FIG. 8 is an illustration of various white matter pathways in the brain.
FIGS. 9-15 depict various radiation treatment profiles in accord with the present disclosure.
FIGS. 16 and 17 each show a series two dimensional tomographic images of a brain that collectively provide the viewer with a three dimensional representation of the treatment area.
FIG. 18 is a flowchart depicting some of the steps involved in planning and executing leading-edge cancer treatment.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
The present disclosure relates to methods of diagnosing and treating various types of cancer. Some embodiments are specifically directed to the treatment of patients with primary brain cancers such as GBM. Some embodiments arise from a recognition that cancer cells from the nidus can migrate to other portions of the brain as a result of the loss of normal inhibitory controls and changes in cell morphology. As depicted in FIGS. 1 and 2 , cancer cells 100 undergo a number of changes resulting in the development of a motile phenotype 110 . These mutated cells are characterized by the polarization of the cell and the development of pseudopodia and/or invadopodia 101 that the cancer cell 110 can use for mobility. In addition, said cancer cells 110 can deploy actin and various signaling proteins 102 on their surface membranes that enable them to interact with the extracellular matrix 103 so as to facilitate their ability to migrate. As illustrated in FIG. 3 , cancer cells migrate from a central nidus 104 to other parts of the brain in predictable patterns following various defined pathways 105 . These pathways comprise various white matter tracts in the brain on which cancer cells preferentially migrate. Some known pathways are depicted in FIG. 8 . Treatment by applying a dose or doses of stereotactic radiation to the tissue most likely to migrate and/or the path along which such migration is most likely to take place (“leading-edge” surgery) is effective. FIGS. 4A through 4H shows a series of radiographic images of the brain of a 39 year-old patient with GBM taken during treatment with involved field radiotherapy (IFXRT) using this technique. FIG. 4J is a radiographic image of the same patient's brain seven years after treatment was completed. Given that the American Cancer Society estimates the five year survival rate of a GBM patient of this age is about 13% with conventional treatment, the treatment in this case was clearly effective.
Some disclosed embodiments relate to methods for gathering data to identify an optimal treatment area or areas in portions of the brain such that a command or series of commands can be formulated, generated, and input into a treatment device or a control element thereof. These commands can then direct radiotherapy or other treatments to specific locations along the likely pathways of cancer cell migration based on the location of the location of the nidus.
Some embodiments relate to methods of treatment planning whereby brain tissue regions are identified for treatment. Such regions can correspond to what are believed to be the leading-edges of cancer cell migration. This is sometimes referred to herein as a “leading-edge target.” In some embodiments, Fluid-Attenuated Inversion-Recovery (FLAIR) sequences provide data that indicate the location or regions of potentially cancerous tissue. This can be used to identify the leading-edge migration of cancer cells could arise and/or to identify a leading-edge target. FLAIR images are advantageous because their enhanced image quality over other methods allows detection of smaller regions of cancer cells remote from the nidus, however it is conceivable that other techniques could result in suitable images.
In some embodiments, Magnetic Resonance Spectroscopy (MRS) can be used to determine the leading-edge target by providing data on the composition of brain tissue that lies outside a region of documented tumor spread. MRS spectra can differentiate between non-target regions (e.g., unaffected tissue or necrotic regions) and areas infiltrated by cancer cells. FIG. 5 shows how MRS spectra vary depending on whether the examined brain cells are normal or cancerous.
FIG. 8 illustrates some of the white matter pathways in the brain along which cancer cells preferentially migrate. A partial list of the depicted pathways includes the perpendicular fasciculus 111 , uncinate fasciculus 113 , superior longitudinal fasciculus 115 , and cingulum 116 . However, a variety of other white matter tracts that can facilitate cancer cell migration including the corona radiata, internal capsule, arcuate and occipito-temporal fasciculi, etc. Based on the location of the nidus in relation to these pathways, MRS can be applied to create spectra corresponding to a voxel, or three dimensional region, near the perimeter of the nidus, focusing on those pathways wherein malignant cells are understood to migrate. FIG. 6A shows an example of a single voxel on a CT scan. FIG. 6B shows the corresponding MRS data for the voxel. In many embodiments, a series of voxel-arrays, or multiple-voxel-arrays with the corresponding MRS analysis can be performed. FIGS. 7A and 7B show an example of such a multiple-voxel-array. One, two, or multiple-voxel-arrays can be employed separately or in combination. MRS can also be used on a second or expanded first voxel-array to further analyze one or more leading-edge pathways along which the cells could potentially migrate. MRS spectra fitting a profile corresponding to cancer cells can be used to identify leading-edge targets.
Stereotactic radiosurgery constitutes one way in which brain cancers can be treated. This technique employs the use of an array of radiation beams targeted to converge on a single point or region within the body. This technique allows minimally-invasive intervention because it is not necessary to cut or otherwise damage a pathway through healthy tissue in order to apply treatment to site of the tumor. While the individual beams of radiation may travel through tissue, the dosage of radiation is insignificant except in the immediate region of convergence wherein radiation levels are sufficiently intense to damage the DNA and constituent proteins of the target tissue. The damaged cells in the targeted area may die or be sufficiently injured so that they are unable to replicate. However, the surrounding tissue is largely unaffected by the minimal amounts of radiation passing through in route to the site of convergence.
Gamma Knife radiosurgery (GKRS) is a method of stereotactic radiosurgery that utilizes a Gamma Knife. In some embodiments, GKRS is performed on tumor regions. In some embodiments, tumor regions are identified with MRS and/or FLAIR techniques as described herein. In some embodiments, treatment isodose plans based on MRS data can be prescribed to treat tissue regions that correspond to MRS and/or FLAIR signal abnormalities. In some embodiments, IFXRT is administered before leading-edge GKRS treatment. In some embodiments, leading-edge treatment is administered in conjunction with chemotherapy and/or immunotherapy. Stereotactic radiosurgery may be administered by other radiation tools such as the Cyberknife, Tomotherapy, linear accelerator (linac) machines, or other devices for which this technique would also be applicable.
Some embodiments of leading-edge cancer treatment can be used in the treatment of GBM or other primary brain cancers. The method can involve planning a treatment of brain tissue that is remote from a concentration of cancer cells, e.g., a nidus. A representation of the steps involved in this treatment method is depicted in FIG. 18 . First, an area that is infiltrated or highly concentrated with cancer cells is identified 200 . Cancer cells are also located that are remote from the identified area of highly-concentrated cancer cells 200 . As discussed below, any suitable method or device for identifying or locating cancer cells, including remote cancer cells, can be used. In some embodiments, such methods include conventional devices such as CT or MRI imaging can be used. One technique for locating remote cancer cells comprises first obtaining one or more FLAIR images of the brain to detect areas containing cancer cells. In some embodiments, upon locating brain tissue that is likely to contain cancer cells 202 , a further confirmation of the nature of the cells is performed 204 . For example, an array of MRS spectra is collected along potential routes of migration, e.g., white matter pathways and/or in regions surrounding the areas identified with reference to the FLAIR images. The MRS spectra can be analyzed to determine the extent of cancer cell migration beyond the cancerous region detected in the FLAIR images. The MRS spectra also can be analyzed to determine the nature of the cells detected in the FLAIR images. In some embodiments, Voxels in the MRS-array that indicate tumor cells are used as reference to guide a trajectory for targeted radiation into the probably location of undetectable cancerous cells 206 . In some embodiments, FIGS. 6 and 7 depict the use of voxels in this manner. In some embodiments, the specific areas selected for MRS analysis can include the white matter pathways depicted in FIG. 8 and other likely routes of likely cancer cell migration 208 .
Once the treatment targets have been identified, these areas may be treated and the cancer cells therein destroyed 208 . In some embodiments, this can involve the use of stereotactic radiotherapy delivered using a Gamma Knife or similar device. This device can be programmed to trace out a particular trajectory and deliver specified doses of radiation along this trajectory. Such trajectories can have irregular or regular three dimensional shapes within the brain tissue. This treatment can be directed at the nidus or other known areas to which the cancer cells have spread. However, in some embodiments, the treatment can also be along one or more preferred cancer cell migration pathways such as the white matter tracts depicted in FIG. 8 . In some cases, this treatment can be directed at sites of likely, but yet undetected cancer cell migration along these or other tracts.
Some embodiments of the present disclosure further comprise a kit comprising a processing device configured to analyze data from medical imaging devices, formulate treatment protocols based on said data, as well as control and monitor various stereotactic treatment devices to execute an appropriate treatment plan. This kit can further comprise software or other executable code provided on a computer-readable medium of data-storage device. In some embodiments, the commands are provided on a computer-readable medium that can be updated and/or supplemented based on experimental or diagnostic findings or history. In some embodiments, the commands are stored on a device and broadcast as signals from that device or another device.
In some embodiments, said kit comprises a computer processor or other device capable of executing algorithms or commanding a separate device to execute algorithms that identify for an operator or help an operator identify potential target tissue based on imaging data. As discussed in greater detail herein, any source of imaging data that can identify a target for leading-edge treatment can be used. Some examples include FLAIR sequences and/or single or multiple voxel MRS.
In some embodiments, a kit includes software of an executable code loaded onto at least one computer-readable medium and/or devices. The executable code can include modules that can be operated by a computer processor to instruct imaging and/or treatment devices to perform methods of some embodiments. The computer readable storage medium can be any suitable permanent or temporary storage medium. For example, a compact disc, a CD-ROM, RAM, a flash drive, a hard drive, one or more hard drives stored at a remote location, etc.
The executable code can take any suitable form, but preferably includes modules that facilitate at least one of the methods discussed herein. For example, the executable code can include a module for controlling the imaging of tissues. The control provided by the imaging control module can include complete control of a device that generates an image showing or representing tissue or can include just high level commands as to specific image to capture. For example, the imaging control module can be configured with a plurality of commands to obtain images of the nidus or other region or regions of origin of cancer and a plurality of pathways of potential cancer cell migration.
The executable code can also include a module for confirming the nature of the cells in any of the images captured by the imaging control module. The tissue confirmation module can, for example, include one or more commands for controlling a tissue characterizing device, such as a command to operate a spectroscopic instrument, for example, an instrument for generating FLAIR images, a command to load an image or to load signal data corresponding to an image into a device capable of executing an algorithm for analyzing that data, a command to export the results of that analysis to a microprocessor which determines based on preset criteria whether further images should be gathered or whether a proper characterization has been made with the already available images. Thus, for example, the tissue confirmation module can be configured to collect and analyze data useful in distinguishing areas of non-cancerous tissue from areas of cancerous tissue.
In some embodiments, the executable code can include a leading-edge pathway identification module adapted to locate areas of potential or actual propagation of cancer cells. For example, the leading-edge pathway identification module could perform all of the steps discussed above with respect to the imaging control module. Additionally, the leading-edge pathway identification module could perform similar steps of collecting and evaluating image or signal data corresponding to an image as discussed above with respect to spectral or voxel-arrays.
In some embodiments, a kit includes an atlas or other indication showing, listing, or describing a set of brain regions known or believed to be particularly suitable for or susceptible to migration of cancer cells. For example, in one embodiment a kit includes an atlas of potential pathways along which cancer cells (e.g., GBM) could move. As discussed in greater detail herein, such potential pathways could be exploited by such cancer cells as they migrate from the nidus. The inventor has discovered that focusing a suitable treatment based on knowledge and imaging of these pathways can prevent or minimize propagation of cancer cells along these “leading-edge” pathways, thereby preventing or minimizing spread of such cells within the brain. The potential pathway can include white matter pathways, which are regions along which tumors preferentially migrate. In some embodiments, the set of regions (e.g., an atlas) can be manually or automatically updated with additional information. In some embodiments, an atlas can be manually updated with additional information. In some embodiments, an atlas can be automatically updated with additional information. In some embodiments, an atlas is self-updating based on single or multiple patient or patient-group histories. This data can include information specific to the patient's cancer and/or general data on the patient's type of cancer based on various research or statistical data. The patient or patient-group histories may include data obtained in various places throughout the world and transferred to a device, which is included in some embodiments, for storage or further transfer or information processing including data integration.
In some embodiments, the kit includes a device capable of analyzing FLAIR and MRS images, through, for example, pattern recognition, to prescribe a treatment, such as a region to be radiated or an amount of radiation to be applied or both. One or more aspects of the embodiments disclosed herein can be performed or located remotely from other aspects of the embodiments, such that analysis and treatment can be performed in locations that are remote from each other. Communication between components can be by any suitable means, e.g., wired communication, secured- or unsecured-wireless communication, over the Internet or private network, etc.
In some embodiments, the executable code can include a module for prescribing a treatment for a tissue region remote from an area of cancer cell concentration. The treatment prescription module can take any suitable form, such as defining a stereotactic treatment regimen for applying a suitable dose of radiation to an area remote from an area of initial cancer cell concentration or formation.
In some embodiments, a kit includes a device adapted to provide commands for directing a Gamma Knife or other stereotactic device capable of administering treatments. These commands can include treatment coordinates and/or radiation dosing instructions. In some embodiments, the kit further includes one or more devices capable of administering isodoses of radiation.
In some embodiments, the treatment prescription module is also adapted to actually control a radiation delivery apparatus, such as a Gamma Knife or other stereotactic apparatus. In other embodiments, the treatment prescription module provides inputs to a controller of such a device. For example, the treatment prescription module can be configured to generate a plurality of coordinates defining a region for treatment at a tissue location, e.g., at a region of tissue remote from a nidus. The coordinates can define a complex geometry of tissue and, thus, can circumscribe complex multi-dimensional structures, such as masses of tumor and/or pathways of cancer cell migration.
The treatment prescription module also can include one or more components related to the strength and profile of radiation to be applied at the remote region. In some embodiments, the dosage is defined to be at least an amount capable of providing an effective cancer treatment to, for example, provide enhanced life expectancy. In some embodiments, dosage is determined with reference to a known dose/volume histogram, e.g., a Flickinger Curve. For example, the treatment prescription module can output commands for treatment devices to apply one isodose of radiation along one trajectory or region and another isodose of radiation along another trajectory or region. In this way dosage can be calibrated to the likelihood of tumor cell migration to a given area. Examples of such dosages and target volumes include 14 Gy at 50% at 21 cc volume and 15 Gy and 50% at 17 cc volume; however persons skilled in the art will recognize that there are a wide variety of possible treatment regimens. Some examples of target sites for such treatment are shown in FIGS. 9-17 . FIGS. 9 through 15 show images of radiation treatment profiles superimposed on a two dimensional tomographic image of a brain. FIGS. 16 and 17 each show a series two dimensional tomographic images of a brain that collectively provide the viewer with a three dimensional representation of the treatment area.
In some embodiments, the kit can further comprise one or more treatment devices. Such treatment devices can take any suitable form. In some cases, the treatment device is configured to deliver an amount of radiation that will prevent or minimize propagation of cancer cells, such as from an area of concentration of such cells to a remote area. As described herein, such migration is believed to occur along anatomical structures of the brain that exhibit relatively low resistance to cell migration. Such structures include leading-edge pathways of preferred migration. In some embodiments, the device is configured to collect spectral data and/or image data useful for planning spectroscopic treatment by determining composition of brain tissue at specified regions or the entire brain and/or determining what regions of brain tissue contain cancer cells that are either migrating or likely to migrate. In some embodiments, the device is further configured to analyze spectral data and/or image data to identify paths along which cancer cells likely will migrate. In some embodiments, the device is configured to execute a series of commands to administer leading-edge surgery based on an output based on spectral data and/or image data. In some embodiments, the device includes a Gamma Knife, or similar apparatus capable of executing leading-edge radiosurgery.
A prescribed treatment profile, for example a trajectory to be traced by a Gamma Knife, can be determined either functionally or based on known effective trajectories. For example, in some embodiments, the trajectory traced by stereotactic instrument that is closest to a cancer cell bulk is traced along a tissue region that is separated from the bulk by a sufficient distance to ensure that any cancer cells have not migrated beyond that distance. As a result, the treatment will be directed to a region that is farther from the bulk of cancer cells than are cells that are migrating from the bulk. This approach would radiate tissue in front of the leading edge of spreading cells to provide an effective leading-edge treatment. Such a treatment can kill latent cancer cells in these areas and thus provide a life expectancy for the patient that is greater than a median life expectancy based on the status of the patient's cancer. In some embodiments, the separation between the trajectory and the bulk is based on experimental results. In some embodiments, the separation between the trajectory and the bulk is based on a patient's history. In some embodiments a trajectory is selected or predicted based on an algorithm. In some embodiments, the trajectory traced can describe a regular or an irregular shape having a minimum separation from a cancer cell bulk of up to but not greater than about 1 cm. In some embodiments, this separation is from about 0.10 to about 0.35 cm. In some embodiments, this separation is from about 0.45 to about 0.75 cm. In some embodiments, this separation is from 0.9 to about 1.0 centimeters away. In some embodiments this separation is from about 1.0 cm to about 1.5 cm. Several exemplary treatment profiles are illustrated in FIGS. 9 through 17 ; however, persons skilled in the art will recognize that a wide variety of treatment profiles are possible.
In some embodiments, multiple trajectories are traced up to but not greater than a distance from one another and/or from known-cancerous regions. In some embodiments, multiple trajectories are traced on regions predicted to provide effective cancer treatment. In some embodiments, these regions are predicted based on experimental results. In some embodiments these regions are predicted based on an algorithm. In some embodiments, these regions are determined with reference to a patient's history. In some embodiments, the trajectories traced can describe regular or irregular shapes and can be spaced from each other by a minimum separation of up to but not greater than about 1 cm. In some embodiments, this separation is from about 0.10 to about 0.35 cm. In some embodiments, this separation is from about 0.45 to about 0.75 centimeters. In some embodiments, this separation is from about 0.9 to about 1.0 centimeters. In some embodiments this separation is from about 1.0 centimeters to about 1.5 centimeters.
Some embodiments provide a method of planning one or multiple leading-edge GKRS treatments in whole and/or in part. Some embodiments provide a method of executing one or multiple leading-edge GKRS treatments in whole and/or in part. Some embodiments provide a method of determining the efficacy of one or multiple leading-edge GKRS treatments. Some embodiments provide a method of determining a follow-up plan for executing or suggesting subsequent GKRS treatments after an initial GKRS treatment or series of GKRS treatments.
In some embodiments, a method is provided for reducing the cost to treat primary brain tumors. In some embodiments, a method is provided for reducing the amount of radiation needed to enhance survival time after a leading-edge procedure, e.g., a GKRS procedure. In some embodiments, a method and/or kit is provided to reduce the amount of expertise and/or time-in-surgery necessary to successfully treat a patient with a leading-edge procedure, e.g., a GKRS procedure.
Although this invention has been disclosed in the context of certain preferred embodiments and examples, it will be understood by those skilled in the art that the present invention extends beyond the specifically disclosed embodiments to other alternative embodiments and/or uses of the invention and obvious modifications and equivalents thereof. In particular, while the present devices, systems, kits, and methods have been described in the context of particularly preferred embodiments, the skilled artisan will appreciate, in view of the present disclosure, that certain advantages, features and aspects of the system may be realized in a variety of other applications. Additionally, it is contemplated that various aspects and features of the invention described can be practiced separately, combined together, or substituted for one another, and that a variety of combination and subcombinations of the features and aspects can be made and still fall within the scope of the invention. Thus, it is intended that the scope of the present invention herein disclosed should not be limited by the particular disclosed embodiments described above. | Kits and methods for the treatment of certain types of cancers, specifically various primary brain cancers. In some embodiments, treatment is directed toward the known areas of cancer cell infiltration and along pathways of likely migration ahead of established areas of cancer cell infiltration. In some embodiments, cancer cells are targeted where they have likely spread, but yet remain undetected. Some embodiments relate to a means of automatically directing radiological analysis along likely pathways of cancer cell migration to precisely determine the extent of detectable cancer spread. In some embodiments, treatments are directed to a predetermined distance along such pathways. | 0 |
TECHNICAL FIELD
The present disclosure relates to controlling a motor while engaging or disengaging a disconnect clutch in a hybrid vehicle.
BACKGROUND
Hybrid electric vehicles include both engines and traction motors. One method of improving the fuel economy in an HEV is to shut down the engine during times that the engine operates inefficiently, and is not otherwise needed to propel the vehicle. In these situations, the electric motor is used in an electric drive mode to provide all of the power needed to propel the vehicle. Some hybrid electric vehicle powertrain configurations include a disconnect clutch configured to selectively disengage the engine from the motor and transmission while operating in electric drive mode.
SUMMARY
A method of controlling a vehicle according to the present disclosure, in which the vehicle includes an engine, a transmission, and an electric machine capable of providing drive torque, selectively coupled to the engine via a clutch, and selectively coupled to the transmission, includes commanding the electric machine to provide drive torque. The command to the electric machine is in response to a driver torque request and the engine being off. The method additionally includes, in response to an engine start request, commanding the clutch to shift from an open position through a slipping position to a locked position. The method further includes, in response to the clutch being in the slipping position, commanding the electric machine to provide a total torque corresponding to a sum of the drive torque and an incremental torque, the incremental torque being based on a clutch torque capacity.
In one embodiment, the clutch torque capacity is based on a clutch pressure, a radius of a friction surface, a number of friction surfaces, and a clutch friction coefficient. In another embodiment, the incremental torque is further in response to a difference between an engine speed and a motor speed. This may include a hyperbolic tangent function of the difference between the engine speed and the motor speed.
A vehicle according to the present disclosure includes an engine, a traction motor, a disconnect clutch configured to selectively couple the engine and motor; and a controller. The controller is configured to, in response to the clutch slipping, command the traction motor to provide an incremental torque. The magnitude of the incremental torque is based on the lesser of a first torque corresponding to an engine torque and a second torque corresponding to a clutch torque capacity.
In one embodiment, the incremental torque is further based on a difference between an engine speed and a motor speed. This may include a hyperbolic tangent function of the difference between the engine speed and the motor speed. In some embodiments, the clutch torque capacity is a function of a clutch pressure, a radius of a friction surface, a number of friction surfaces, and a clutch friction coefficient. In a further embodiment, the controller is additionally configured to, in response to a driver torque request, command the traction motor to provide a total torque corresponding to a sum of a drive torque based on the driver torque request and the incremental torque.
A method of controlling a vehicle according to the present disclosure, where the vehicle includes an engine, a traction motor, and a clutch configured to selectively couple the engine to the motor, includes commanding the traction motor to provide an incremental torque. The motor is commanded to provide the incremental torque in response to the clutch being in a slipping condition and further in response to a current engine torque. The magnitude of the commanded incremental torque is based on the lesser of first and second torques. The first torque corresponds to the engine torque, and the second torque corresponds to a clutch torque capacity. Drive torque provided by the motor is thus generally uninterrupted.
In one embodiment, the incremental torque is further based on a difference between an engine speed and a motor speed. This may include a hyperbolic tangent function of the difference between the engine speed and the motor speed. In some embodiments, the clutch torque capacity is based on a clutch pressure, a radius of a friction surface, a number of friction surfaces, and a clutch friction coefficient. An additional embodiment additionally includes, in response to the clutch being in a slipping condition and a current engine torque being unavailable, commanding the traction motor to provide an incremental torque based on the second torque corresponding to the clutch torque capacity. A further embodiment additionally includes, in response to a driver torque request, commanding the traction motor to provide a total torque corresponding to a sum of a drive torque corresponding to the driver torque request and the incremental torque.
Embodiments according to the present disclosure provide a number of advantages. For example, the present disclosure provides a robust, reliable method for controlling a motor to compensate for torque across a disconnect clutch, thus reducing noise, vibration, and harshness (“NVH”).
The above advantage and other advantages and features of the present disclosure will be apparent from the following detailed description of the preferred embodiments when taken in connection with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic illustration of a hybrid electric vehicle having a modular powertrain configuration;
FIG. 2 illustrates engine and motor speeds and torques during a sample engine start;
FIG. 3 illustrates a method of calculating torque in a disconnect clutch in flowchart form;
FIG. 4 illustrates a method of calculating torque in a disconnect clutch in block diagram form; and
FIG. 5 illustrates a method of controlling a motor in a hybrid electric vehicle having a modular powertrain configuration in flowchart form.
DETAILED DESCRIPTION
Embodiments of the present disclosure are described herein. It is to be understood, however, that the disclosed embodiments are merely examples and other embodiments can take various and alternative forms. The figures are not necessarily to scale; some features could be exaggerated or minimized to show details of particular components. Therefore, specific structural and functional details disclosed herein are not to be interpreted as limiting, but merely as a representative basis for teaching one skilled in the art to variously employ the embodiments. As those of ordinary skill in the art will understand, various features illustrated and described with reference to any one of the figures can be combined with features illustrated in one or more other figures to produce embodiments that are not explicitly illustrated or described. The combinations of features illustrated provide representative embodiments for typical applications. Various combinations and modifications of the features consistent with the teachings of this disclosure, however, could be desired for particular applications or implementations.
Referring to FIG. 1 , a schematic diagram of a hybrid electric vehicle (HEV) 10 is illustrated according to an embodiment of the present disclosure. FIG. 1 illustrates representative relationships among the components. Physical placement and orientation of the components within the vehicle may vary. The HEV 10 includes a powertrain 12 . The powertrain 12 includes an engine 14 that drives a transmission 16 , which may be referred to as a modular hybrid transmission (MHT). As will be described in further detail below, transmission 16 includes an electric machine such as an electric motor/generator (M/G) 18 , an associated traction battery 20 , a torque converter 22 , and a multiple step-ratio automatic transmission, or gearbox 24 .
The engine 14 and the M/G 18 are both drive sources for the HEV 10 . The engine 14 generally represents a power source that may include an internal combustion engine such as a gasoline, diesel, or natural gas powered engine, or a fuel cell. The engine 14 generates an engine power and corresponding engine torque that is supplied to the M/G 18 when a disconnect clutch 26 between the engine 14 and the M/G 18 is at least partially engaged. The M/G 18 may be implemented by any one of a plurality of types of electric machines. For example, M/G 18 may be a permanent magnet synchronous motor. Power electronics 56 condition direct current (DC) power provided by the battery 20 to the requirements of the M/G 18 , as will be described below. For example, power electronics may provide three phase alternating current (AC) to the M/G 18 .
When the disconnect clutch 26 is at least partially engaged, power flow from the engine 14 to the M/G 18 or from the M/G 18 to the engine 14 is possible. For example, the disconnect clutch 26 may be engaged and M/G 18 may operate as a generator to convert rotational energy provided by a crankshaft 28 and M/G shaft 30 into electrical energy to be stored in the battery 20 . The disconnect clutch 26 can also be disengaged to isolate the engine 14 from the remainder of the powertrain 12 such that the M/G 18 can act as the sole drive source for the HEV 10 . Shaft 30 extends through the M/G 18 . The M/G 18 is continuously drivably connected to the shaft 30 , whereas the engine 14 is drivably connected to the shaft 30 only when the disconnect clutch 26 is at least partially engaged. When the disconnect clutch 26 is engaged, a fixed speed relationship exists between the speed of the engine 14 and the speed of the M/G 18 .
The M/G 18 is connected to the torque converter 22 via shaft 30 . The torque converter 22 is therefore connected to the engine 14 when the disconnect clutch 26 is at least partially engaged. The torque converter 22 includes an impeller fixed to M/G shaft 30 and a turbine fixed to a transmission input shaft 32 . The torque converter 22 thus provides a hydraulic coupling between shaft 30 and transmission input shaft 32 . The torque converter 22 transmits power from the impeller to the turbine when the impeller rotates faster than the turbine. The magnitude of the turbine torque and impeller torque generally depend upon the relative speeds. When the ratio of impeller speed to turbine speed is sufficiently high, the turbine torque is a multiple of the impeller torque. A torque converter bypass clutch 34 may also be provided that, when engaged, frictionally or mechanically couples the impeller and the turbine of the torque converter 22 , permitting more efficient power transfer. The torque converter bypass clutch 34 may be operated as a launch clutch to provide smooth vehicle launch. Alternatively, or in combination, a launch clutch similar to disconnect clutch 26 may be provided between the M/G 18 and gearbox 24 for applications that do not include a torque converter 22 or a torque converter bypass clutch 34 . In some applications, disconnect clutch 26 is generally referred to as an upstream clutch and launch clutch 34 (which may be a torque converter bypass clutch) is generally referred to as a downstream clutch.
The gearbox 24 may include gear sets (not shown) that are selectively placed in different gear ratios by selective engagement of friction elements such as clutches and brakes (not shown) to establish the desired multiple discrete or step drive ratios. The friction elements are controllable through a shift schedule that connects and disconnects certain elements of the gear sets to control the ratio between a transmission output shaft 36 and the transmission input shaft 32 . The gearbox 24 is automatically shifted from one ratio to another based on various vehicle and ambient operating conditions by an associated controller, such as a powertrain control unit (PCU) 50 . The gearbox 24 then provides powertrain output torque to output shaft 36 . The gearbox 24 may be understood to provide a selectable fixed speed relationship between the speed of M/G 18 and the speed of vehicle traction wheels 42 .
It should be understood that the hydraulically controlled gearbox 24 used with a torque converter 22 is but one example of a gearbox or transmission arrangement; any multiple ratio gearbox that accepts input torque(s) from an engine and/or a motor and then provides torque to an output shaft at the different ratios is acceptable for use with embodiments of the present disclosure. For example, gearbox 24 may be implemented by an automated mechanical (or manual) transmission (AMT) that includes one or more servo motors to translate/rotate shift forks along a shift rail to select a desired gear ratio. As generally understood by those of ordinary skill in the art, an AMT may be used in applications with higher torque requirements, for example.
As shown in the representative embodiment of FIG. 1 , the output shaft 36 is connected to a differential 40 . The differential 40 drives a pair of wheels 42 via respective axles 44 connected to the differential 40 . The differential transmits approximately equal torque to each wheel 42 while permitting slight speed differences such as when the vehicle turns a corner. Different types of differentials or similar devices may be used to distribute torque from the powertrain to one or more wheels. In some applications, torque distribution may vary depending on the particular operating mode or condition, for example.
The powertrain 12 further includes an associated powertrain control unit (PCU) 50 . While illustrated as one controller, the PCU 50 may be part of a larger control system and may be controlled by various other controllers throughout the vehicle 10 , such as a vehicle system controller (VSC). It should therefore be understood that the powertrain control unit 50 and one or more other controllers can collectively be referred to as a “controller” that controls various actuators in response to signals from various sensors to control functions such as starting/stopping engine 14 , operating M/G 18 to provide wheel torque or charge battery 20 , select or schedule transmission shifts, etc. Controller 50 may include a microprocessor or central processing unit (CPU) in communication with various types of computer readable storage devices or media. Computer readable storage devices or media may include volatile and nonvolatile storage in read-only memory (ROM), random-access memory (RAM), and keep-alive memory (KAM), for example. KAM is a persistent or non-volatile memory that may be used to store various operating variables while the CPU is powered down. Computer-readable storage devices or media may be implemented using any of a number of known memory devices such as PROMs (programmable read-only memory), EPROMs (electrically PROM), EEPROMs (electrically erasable PROM), flash memory, or any other electric, magnetic, optical, or combination memory devices capable of storing data, some of which represent executable instructions, used by the controller in controlling the engine or vehicle.
The controller communicates with various engine/vehicle sensors and actuators via an input/output (I/O) interface that may be implemented as a single integrated interface that provides various raw data or signal conditioning, processing, and/or conversion, short-circuit protection, and the like. Alternatively, one or more dedicated hardware or firmware chips may be used to condition and process particular signals before being supplied to the CPU. As generally illustrated in the representative embodiment of FIG. 1 , PCU 50 may communicate signals to and/or from engine 14 , disconnect clutch 26 , M/G 18 , launch clutch 34 , transmission gearbox 24 , and power electronics 56 . Although not explicitly illustrated, those of ordinary skill in the art will recognize various functions or components that may be controlled by PCU 50 within each of the subsystems identified above. Representative examples of parameters, systems, and/or components that may be directly or indirectly actuated using control logic executed by the controller include fuel injection timing, rate, and duration, throttle valve position, spark plug ignition timing (for spark-ignition engines), intake/exhaust valve timing and duration, front-end accessory drive (FEAD) components such as an alternator, air conditioning compressor, battery charging, regenerative braking, M/G operation, clutch pressures for disconnect clutch 26 , launch clutch 34 , and transmission gearbox 24 , and the like. Sensors communicating input through the I/O interface may be used to indicate turbocharger boost pressure, crankshaft position (PIP), engine rotational speed (RPM), wheel speeds (WS 1 , WS 2 ), vehicle speed (VSS), coolant temperature (ECT), intake manifold pressure (MAP), accelerator pedal position (PPS), ignition switch position (IGN), throttle valve position (TP), air temperature (TMP), exhaust gas oxygen (EGO) or other exhaust gas component concentration or presence, intake air flow (MAF), transmission gear, ratio, or mode, transmission oil temperature (TOT), transmission turbine speed (TS), torque converter bypass clutch 34 status (TCC), deceleration or shift mode (MDE), for example.
Control logic or functions performed by PCU 50 may be represented by flow charts or similar diagrams in one or more figures. These figures provide representative control strategies and/or logic that may be implemented using one or more processing strategies such as event-driven, interrupt-driven, multi-tasking, multi-threading, and the like. As such, various steps or functions illustrated may be performed in the sequence illustrated, in parallel, or in some cases omitted. Although not always explicitly illustrated, one of ordinary skill in the art will recognize that one or more of the illustrated steps or functions may be repeatedly performed depending upon the particular processing strategy being used. Similarly, the order of processing is not necessarily required to achieve the features and advantages described herein, but is provided for ease of illustration and description. The control logic may be implemented primarily in software executed by a microprocessor-based vehicle, engine, and/or powertrain controller, such as PCU 50 . Of course, the control logic may be implemented in software, hardware, or a combination of software and hardware in one or more controllers depending upon the particular application. When implemented in software, the control logic may be provided in one or more computer-readable storage devices or media having stored data representing code or instructions executed by a computer to control the vehicle or its subsystems. The computer-readable storage devices or media may include one or more of a number of known physical devices which utilize electric, magnetic, and/or optical storage to keep executable instructions and associated calibration information, operating variables, and the like.
An accelerator pedal 52 is used by the driver of the vehicle to provide a demanded torque, power, or drive command to propel the vehicle. In general, depressing and releasing the pedal 52 generates an accelerator pedal position signal that may be interpreted by the controller 50 as a demand for increased power or decreased power, respectively. Based at least upon input from the pedal, the controller 50 commands torque from the engine 14 and/or the M/G 18 . The controller 50 also controls the timing of gear shifts within the gearbox 24 , as well as engagement or disengagement of the disconnect clutch 26 and the torque converter bypass clutch 34 . Like the disconnect clutch 26 , the torque converter bypass clutch 34 can be modulated across a range between the engaged and disengaged positions. This produces a variable slip in the torque converter 22 in addition to the variable slip produced by the hydrodynamic coupling between the impeller and the turbine. Alternatively, the torque converter bypass clutch 34 may be operated as locked or open without using a modulated operating mode depending on the particular application.
To drive the vehicle with the engine 14 , the disconnect clutch 26 is at least partially engaged to transfer at least a portion of the engine torque through the disconnect clutch 26 to the M/G 18 , and then from the M/G 18 through the torque converter 22 and gearbox 24 . The M/G 18 may assist the engine 14 by providing additional power to turn the shaft 30 . This operation mode may be referred to as a “hybrid mode” or an “electric assist mode.”
To drive the vehicle with the M/G 18 as the sole power source, the power flow remains the same except the disconnect clutch 26 isolates the engine 14 from the remainder of the powertrain 12 . Combustion in the engine 14 may be disabled or otherwise OFF during this time to conserve fuel. The traction battery 20 transmits stored electrical energy through wiring 54 to power electronics 56 that may include an inverter, for example. The power electronics 56 convert DC voltage from the battery 20 into AC voltage to be used by the M/G 18 . The PCU 50 commands the power electronics 56 to convert voltage from the battery 20 to an AC voltage provided to the M/G 18 to provide positive or negative torque to the shaft 30 . This operation mode may be referred to as an “electric only” operation mode.
In any mode of operation, the M/G 18 may act as a motor and provide a driving force for the powertrain 12 . Alternatively, the M/G 18 may act as a generator and convert kinetic energy from the powertrain 12 into electric energy to be stored in the battery 20 . The M/G 18 may act as a generator while the engine 14 is providing propulsion power for the vehicle 10 , for example. The M/G 18 may additionally act as a generator during times of regenerative braking in which rotational energy from spinning wheels 42 is transferred back through the gearbox 24 and is converted into electrical energy for storage in the battery 20 .
It should be understood that the schematic illustrated in FIG. 1 is merely exemplary and is not intended to be limited. Other configurations are contemplated that utilize selective engagement of both an engine and a motor to transmit through the transmission. For example, the M/G 18 may be offset from the crankshaft 28 , an additional motor may be provided to start the engine 14 , and/or the M/G 18 may be provided between the torque converter 22 and the gearbox 24 . Other configurations are contemplated without deviating from the scope of the present disclosure.
When operating in electric only mode (i.e. the internal combustion engine is turned off), an engine start may be requested in response to various inputs. As an example, an engine start may be requested in response to a driver torque request exceeding a motor torque capacity, to a battery state of charge falling below a predefined threshold, or in response to a high electric accessory load. In response to an engine start request, the engine may be started according to various control strategies. According to one control strategy, the engine is started using a low voltage electric starter. In an alternative control strategy, the engine is started by engaging the disconnect clutch and controlling the traction motor to start the engine.
When starting the engine using the traction motor, torque is transferred from the motor through the disconnect clutch to the engine. The traction motor torque must overcome compression and friction forces within the engine before the engine starts. The torque transferred through the disconnect clutch to the engine may reduce the motor torque available for other purposes, such as drive torque. If the traction motor is providing drive torque as the clutch is engaged, the torque transfer to the engine may thus cause NVH or other undesirable drivetrain effects.
Referring to FIG. 2 , a graph illustrating engagement of a disconnect clutch in a hybrid vehicle during engine start is shown. From t 0 to t 1 , the clutch is open, and disconnect clutch torque is zero. Beyond t 2 , the clutch is closed, and the clutch torque is equal to the engine torque. From t 1 to t 2 , the clutch is closing, and the torque capacity is variable. Disturbances in motor speed and torque, as illustrated between t 1 and t 2 , may result in NVH.
NVH caused by slippage in the clutch may be avoided by controlling the traction motor torque to compensate for the torque disturbance arising from engaging the clutch. However, this requires an accurate calculation of the torque across the disconnect clutch. When the clutch is locked, the torque is equal to the engine torque. When the clutch is open, there is no torque transferred. When the clutch is slipping, i.e. neither locked nor open, the torque may be estimated based on the lesser of a clutch capacity τ pres and engine torque τ eng :
τ cap =min(τ pres ,τ eng )
During normal engine operation, the engine torque τ eng may be available from a controller, such as the PCU or an engine control module (“ECM”). However, during some situations, such as during an engine start, the engine torque calculation may be unavailable or otherwise unreliable. During such situations, the disconnect clutch torque may be estimated based on the clutch capacity τ pres :
τ cap =τ pres
The clutch capacity may be calculated based on a commanded/actual clutch pressure P, a mean radius of friction surface r, a number of friction surface N and a clutch friction coefficient μ:
τ pres =μNrP
This calculation may be performed by a controller such as the PCU or a transmission control module (“TCM”).
The torque across a slipping clutch may then be calculated according to:
τ cl =α*τ cap
The modifier α is calculated based on a speed differential across the clutch, between the engine speed and the motor speed, to account for the direction of torque transfer across the clutch:
α= sgn (ω motor −ω eng )
According to a conventional usage, a positive torque corresponds to the engine delivering torque across the clutch to the drivetrain. In a preferred embodiment, the modifier is calculated based on the hyperbolic tangent function of the speed differential:
α=tan h (ω motor −ω eng )
By using the hyperbolic tangent function, the method avoids rapid changes from positive to negative torque based on relatively small changes in motor and/or engine speeds. A similar effect may be obtained by, for example, providing a hysteresis range near a zero speed differential.
Referring to FIG. 3 , a flowchart illustrates a method of calculating torque in a disconnect clutch. A determination is made of whether the disconnect clutch is open, as illustrated at operation 60 . If yes, then there is no torque across the clutch, as illustrated at block 62 , and so the calculated torque is set equal to zero. If no, a determination is made of whether the disconnect clutch is in a slipping condition, as illustrated at operation 64 . If no, then the disconnect clutch is closed, as illustrated at block 66 , and so the clutch torque is set equal to the engine torque, as illustrated at block 68 . If yes, then a determination is made of whether the engine is starting, as illustrated at operation 70 . If yes, then the calculated clutch capacity τ pres is used in the torque calculation, as illustrated at block 72 . If no, then the lesser of the calculated clutch capacity τ pres and the engine torque is used in the torque calculation, as illustrated at block 74 . In either case, a modifier is then calculated based on the engine speed and motor speed, as illustrated at block 76 . Finally, the torque across the clutch is calculated, as illustrated at block 78 .
Referring to FIG. 4 , a method of calculating torque across a disconnect clutch is illustrated in block diagram form. A current engine speed is subtracted from a current motor speed at block 80 . The modifier α is calculated at block 82 , as discussed above. In a parallel operation, a minimum value of a clutch capacity and an engine torque is determined at block 84 . The result is multiplied by the modifier α at block 86 . At block 88 , a determination is made of whether the disconnect clutch is in a slipping condition. If yes, then the calculated clutch torque is fed forward to block 90 . If no, then the engine torque is fed forward to block 90 . At block 90 , a determination is made of whether the clutch is open. If yes, then the clutch torque is set equal to zero. If no, then the clutch torque is set equal to the output of block 88 .
In one embodiment, the above-described clutch torque calculation is performed repeatedly during the duration of a drive cycle. In such an embodiment, the motor may be controlled to compensate for any torque disturbances that give arise to slippage in the clutch, in addition to compensating for clutch torque during an engine start event.
Referring now to FIG. 5 , a method for controlling a traction motor in a hybrid vehicle is illustrated in flowchart form. The traction motor is providing drive torque, as illustrated at block 92 . A determination is then made that a disconnect clutch is in a slipping condition, as illustrated at block 94 . This may occur, for example, when the clutch is engaging to transmit motor torque to an engine for an engine start event, as illustrated at block 96 . The torque across the disconnect clutch is then calculated, as illustrated at block 98 . The calculated torque may be based on a clutch capacity, engine torque, motor speed, and engine speed, as illustrated at block 100 and discussed above. The motor is then commanded to provide an additional incremental torque to compensate the calculated torque across the disconnect clutch, as illustrated at block 102 . The motor thus provides a total torque to both satisfy a driver requested drive torque and to compensate the torque across the disconnect clutch.
As can be seen from the various embodiments, the present disclosure provides a robust method for calculating torque across a disconnect clutch in a hybrid vehicle. The calculated torque may be used to control a motor to compensate for the torque across the clutch, reducing NVH.
While exemplary embodiments are described above, it is not intended that these embodiments describe all possible forms of the invention. Rather, the words used in the specification are words of description rather than limitation, and it is understood that various changes may be made without departing from the spirit and scope of the invention. Additionally, the features of various implementing embodiments may be combined to form further embodiments of the invention. | A method of controlling a vehicle, in which the vehicle includes an engine, a traction motor, and a clutch configured to selectively couple the engine to the motor, includes commanding the traction motor to provide an incremental torque. The motor is commanded to provide the incremental torque in response to the clutch being in a slipping condition. The magnitude of the commanded incremental torque is in response to the lesser of first and second torques. The first torque corresponds to an engine torque, and the second torque corresponds to a clutch torque capacity. | 1 |
This application is a continuation of application Ser. No. 08/661,132, filed Jun. 10, 1996 now abandoned.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to the control of steering and propulsion on marine vehicles in general, and more particularly to the control of trolling motors used for fishing.
2. Description of the Relevant Art
Trolling motors are small motors which are primarily used to propel a boat during fishing. They are generally suitable for maneuvering a boat quietly, at relatively low speeds. A typical trolling motor includes a small fractional-horsepower electric motor mounted on the end of a shaft such that it can be lowered into the water. The electric motor turns a propeller which is the source of propulsion for the boat during trolling operation. The electric motor is usually powered by batteries on board the boat, with electric current transmitted by power cables which run through the hollow center of the shaft and connect to the motor. Steering is accomplished directly by turning the shaft, such that the direction of the thrust from the propeller changes.
Small internal combustion outboard motors are sometimes used as trolling motors, but the desire for quiet operation has led many fishermen to prefer the electric powered trolling motor. Electric powered trolling motors can be attached to either the bow, or the stern of the boat depending primarily on the preference of the operator. Stern mounted manual control electric trolling motors are usually the least expensive option, and typically have a control handle which can be twisted to vary the speed of the motor, or turned, to vary the thrust angle, thereby steering the boat. A primary disadvantage to stern mounted, manual control electric trolling motors is that the operator of the trolling motor is required to sit or stand in the back of the boat with one hand on the trolling motor control--a position not conducive to fishing.
Bow mounted electric trolling motors are typically mounted on a special folding mount which allows the trolling motor to be retracted when not in use. When a bow mounted electric trolling motor is in use, it operates in tractor fashion, pulling the boat through the water. Some bow mounted electric trolling motors have simple hand controls similar to the stern mounted motors, while many have a remote foot operated pedal which is used to steer the motor and change its speed. The steering mechanism of some foot controlled electric trolling motors is a mechanical linkage having a system of cables and gears. However, some foot operated trolling motors have a small electric steering motor which is capable of steering the trolling motor through various arrangements, and consequently the remote control foot pedal includes a number of electrical switches which are used to control the direction and speed of the trolling motor. Disadvantages to these previous trolling motor control methods is that they either require the operator to use a free hand to control the motor (manual control), or they require the operator to maintain one position in the boat (foot control). The use of a hand usually precludes fishing at the same time, while not being free to move about the boat may result in a snagged line when a hooked fish attempts to run under the boat.
There have therefore been numerous attempts to devise sophisticated trolling motor control systems to allow the operator to concentrate on fishing. Some such systems automatically maintain the set heading, regardless of wind or current. Others use acoustic depth finders along with a steering computer to automatically follow a given depth profile. Still others use a distance measuring method to maintain a fixed distance from the shore. A disadvantage to all of these systems is that often the boat must be maneuvered along a curved bank where the water depth changes abruptly, and where there are numerous obstructions such as partially or fully submerged trees. Operation in these conditions requires constant operator intervention to avoid obstacles and maintain the boat along a desired course.
SUMMARY OF THE INVENTION
The problems outlined above are in large part solved by a trolling motor with a voice-controlled control system in accordance with the present invention. In one embodiment, a trolling motor is equipped with a voice-controlled remote control system which utilizes a speech recognition computer to allow the operator to control the speed and direction of an electrically steered trolling motor by voice commands, thereby allowing the operator to freely move about the boat. The speech recognition computer may be contained within a remote unit such as a beltpack unit worn by the operator. The remote unit may include keys which can be used to manually control the trolling motor, providing another way to control when conditions are too noisy for reliable voice control. The beltpack control unit may provide electronic commands to the trolling motor using a radio or other wireless link.
The voice-controlled control system may further utilize a software gain control function wherein the average and/or peak signal levels associated with a spoken command by the operator are compared to the average and/or peak signal levels associated with a record stored in a recognizer memory. In response to detecting a difference between the signal levels of the spoken command and those of the record, a control computer calculates a new gain setting for the preamplifier which amplifies the spoken commands.
The voice-controlled control system may further be equipped with one or more power control circuits for controlling the application of power to selected components of the remote unit and/or of the trolling motor control circuitry. The power control circuitry advantageously reduces overall power consumption of the system.
The voice-controlled control system may still further employ a voice command vocabulary which provides reliable speech recognition capabilities and which provides ease of use for the operator. In one embodiment, the command set includes: "left", "right", "hard left", "hard right", "stop", "faster", "slower", "reverse", and "forward".
BRIEF DESCRIPTION OF THE DRAWINGS
Other objects and advantages of the invention will become apparent upon reading the following detailed description and upon reference to the accompanying drawings in which:
FIG. 1 is a side view of the bow of a fishing boat with a bow-mounted electric trolling motor attached.
FIG. 2 is a drawing of an exemplary speaker dependent beltpack unit.
FIG. 3 is a system block diagram for an exemplary remote beltpack printed circuit.
FIG. 4 is an electrical schematic of an audio preamplifier/filter circuit.
FIG. 5 is an electrical schematic of an audio encode/decode circuit.
FIG. 6 is an electrical schematic of a speech detect interrupt generation circuit.
FIG. 7 is a system block diagram of an exemplary trolling motor control circuit.
FIG. 8 is a list of exemplary voice commands and their functions.
FIG. 9 is a flow diagram illustrating operation of the speaker dependent beltpack unit in "Key only" mode.
FIG. 10 is a flow diagram illustrating operation of the speaker dependent beltpack unit in "Voice" mode.
FIG. 11 is a flow diagram illustrating operation of the speaker dependent beltpack unit in "Voice" mode.
FIG. 12 is a flow diagram illustrating command training in "Learn" mode.
FIG. 13a is a flow diagram illustrating individual command training.
FIG. 13b is a flow diagram illustrating software gain control.
FIG. 14 is a drawing of an exemplary speaker independent beltpack unit.
FIG. 15 is a flow diagram illustrating operation of the speaker independent beltpack unit in "Key only" mode.
FIG. 16 is a flow diagram showing key actions in "Voice" mode.
FIG. 17 is a flow diagram for showing voice commands in "Voice" mode.
FIG. 18 is a block diagram of an exemplary beltpack unit wherein the audio output is provided from a control computer via an audio output circuit.
FIG. 19 is a block diagram of an exemplary beltpack unit wherein the speech recognition functionality is performed by a control computer.
While the invention is susceptible to various modifications and alternative forms, specific embodiments thereof are shown by way of example in the drawings and will herein be described in detail It should be understood, however, that the drawings and detailed description thereto are not intended to limit the invention to the particular form disclosed, but on the contrary, the intention is to cover all modifications, equivalents and alternatives falling within the spirit and scope of the present invention as defined by the appended claims.
DETAILED DESCRIPTION
Turning now to the drawings, FIG. 1 shows an exemplary electric trolling motor mounted securely to the bow of a fishing boat in a manner which has become popular in the industry. The trolling motor has a submerged housing unit 1a that contains an electric thrust motor 1b which drives a propeller 2. The submerged housing unit is securely attached to a lower shaft 3 which extends up through an upper shaft 4 to the upper housing 9. The upper shaft 4 is held securely by a mounting block 5 which is attached to a folding deck mount 7 mounted on the deck of a fishing boat 6. The trolling motor is steered by turning the lower shaft by means of an electric steering motor 11a which is contained within the upper housing 9. A direction pointer 10 is also attached to the lower shaft 3, and turns along with it, providing visual feedback to the operator about the direction that the submerged housing unit 1a is pointing. Electric power is provided to the trolling motor by a power cable 8 which is connected to 12 V batteries on board the boat 6. A trolling motor control circuit 11b enclosed within the upper housing 9 controls the electric steering motor 11a and the electric thrust motor 1b.
FIG. 2 shows a remote control beltpack unit 50 which can be used to remotely control the speed and direction of the trolling motor. A beltpack unit printed circuit board 51 is contained within an external waterproof housing 48 and 49. The external housing 48 and 49 has an external microphone connector 33, an external earphone connector 34 and a belt clip 32 for attaching it to the operator's belt.
Remote control beltpack unit 50 further includes a front keypad with individual keys for controlling various remote control system features. Several of the keys on the remote control beltpack unit 50 allow manual operation of the trolling motor, while still other keys are provided to control certain functionality related to voice control of the trolling motor. More specifically, for the implementation of FIG. 2, the PWR key 35 turns the beltpack unit power on or off. The RIGHT key 38 causes the steering motor 11a to turn the submerged housing unit 1a to the right. The LEFT key 37 causes the steering motor 11a to turn the submerged housing unit 1a to the left. The THRUST ON/OFF key 39a is used to turn the thrust motor 1b manually on or off. The THRUST JOG key 39b causes the thrust motor 1b to spin while it is held down. The ONE key 46 is used to set the speed of the thrust motor 1b to one-quarter of maximum thrust. The TWO key 45 is used to set the speed of the thrust motor 1b to one-half of maximum thrust. The THREE key 44 is used to set the speed of the thrust motor 1b to three-quarters of maximum thrust. The FOUR key 43 is used to set the speed of the thrust motor 1b to maximum thrust. The FASTER key 42 increases the speed of the thrust motor 1b by one-sixteenth of maximum thrust. The SLOWER key 47 key decreases the speed of the thrust motor 1b by one-sixteenth of maximum thrust. The STOP key 41 causes the thrust motor 1b to stop spinning. The VOICE REC key 36a is a toggle key which enables or disables voice commands. The LEARN key 36b is a toggle key which is used for training voice commands in a speaker dependent mode. As will be described further below, the speaker dependent mode allows circuitry within remote control beltpack unit 50 to "learn" the specific voice pattern of the operator for certain voice commands which control the trolling motor. More specifically, pressing the LEARN key once causes the unit to enter a "learn mode". In learn mode, the pressing of an additional key will cause the command corresponding to that key to be trained as will be explained in greater detail below in conjunction with the description of FIG. 10, FIG. 12, and FIG. 13a. If the ALL key 36c is pressed, all of the available voice commands are trained sequentially. This combination of keys allows the operator to train all commands at once, or to train an individual command by itself. The option of training a single command is useful when one of the trained commands is not being recognized reliably.
FIG. 3 shows a system block diagram for components mounted upon the beltpack unit printed circuit board 51. The beltpack keypad 19 is scanned by a control computer 23 which interprets key presses and sends appropriate command codes to the wireless transmitter 20. As will be explained further below, the wireless transmitter 20 transmits the command codes to a wireless receiver 25 (shown in FIG. 7) which makes them available to a motor control computer 31 (also shown FIG. 7).
When operating in voice control mode, sound pressure patterns from the operator's voice are received by a microphone 12 which converts them to a voice analog signal. The microphone 12 in one embodiment is a lapel microphone which may be attached to the operators clothing, or to a cord worn around the operators neck. The voice analog signal is input to an analog interface unit 14. Generally speaking, analog interface unit 14 provides an analog interface between microphone 12, earphone 13, speech recognition computer 16, and control computer 23.
For one specific implementation, analog interface unit 14 includes an analog preamp/filter 100 coupled to a speech detect interrupt unit 101 and an audio encode/decode and digital gain adjust circuit 102. These circuits perform a variety of functions including supplying power to the microphone element, adjusting the amplitude and offset of the voice analog signal, filtering out unwanted frequency components of the voice analog signal, detecting when speech is present, and conversion between analog and digital signals. It is specifically contemplated that a variety of additional or alternative circuits may be employed to implement analog interface unit 14.
FIG. 4 shows one suitable implementation of audio preamplifier/filter circuit 100. The circuit supplies power to the microphone 12 through transistor Q1 and jumper J1. In this implementation, microphone 12 is an electret microphone which requires a bias voltage of approximately 5 volts. Transistor Q1 is a PMOS Field Effect Transistor (FET) which is controlled by the digital signal "MIC -- ENX" from the control computer 23. The voice analog signal from the microphone 12 is AC coupled into the preamplifier/filter circuit through series capacitor C3. Diodes D1 and D2 are protection "clamping" diodes which protect the input of amplifier U1A from static discharge which may occur when the microphone is plugged into the circuit. The remainder of the circuit is a three op-amp adjustable-gain differential amplifier with a bandpass filter function. Gain adjustment is performed by changing potentiometer R4. It is noted that it is not necessary to use a differential amplifier design, although this design has been shown to perform well in practice. Also, the circuit may optionally contain a variable filter which may be controlled by control computer 23 to reduce unwanted noise such as wind noise which is associated with operating in an outdoor environment.
FIG. 5 shows one suitable implementation of audio encode/decode circuit 102. The circuit performs final gain adjustment of the input voice analog signal under the control of the control computer 23. A gain adjustment range of 12 dB is provided by a digital potentiometer U2, which in this example is a Dallas Semiconductor DS1267. Other suitable digital potentiometers exist and may be used at the circuit designers discretion. The digital gain adjustment provides a way for the control computer to adjust for changes in the position of the microphone on the operator's clothing or other voice amplitude variations. The audio encode/decode circuit also contains a CODEC U3, which digitizes the amplified and filtered voice analog signal into a serial voice digital signal acceptable to the speech recognition computer 16. The CODEC used in this example is an AT&T T7513B, which is an 8-bit serial companding (u-law) CODEC. It is noted that other CODECs and methods for converting between analog and digital signals are available and may be used at the circuit designers discretion. The CODEC is also used to convert the synthesized voice digital signals from the speech recognition computer 16 into a synthesized voice analog signal which is applied to the earphone 13 for operator feedback. Digital potentiometer U2 contains two separately controllable potentiometers, and is thus also used to control the volume of the synthesized voice at the earphone.
FIG. 6 shows one suitable implementation of speech detect interrupt generation circuit 101 which supplies an interrupt to the control computer 23 when speech is detected. A primary use of this circuit is to allow the control computer 23 to shut down unnecessary circuitry when no speech is present, and power up the circuitry when speech is detected. This results in a considerable power savings.
Referring again to FIG. 3, in one embodiment the speech recognition computer 16 examines the voice digital signal from the CODEC (FIG. 5, U3) to determine the starting and ending point of each word said by the operator, and then compares specific parameters calculated from the voice digital signal during the time a word was detected to records stored in the recognizer memory 17. When the parameters calculated from a specific word match one of the records from the recognizer memory closely enough, the speech recognition computer 16 sends a signal to the control computer 23, notifying the control computer 23 which command word was recognized. The control computer 23 then takes the appropriate action which depends on the command word which was recognized Examples of some command words, and their functions are shown in FIG. 8.
The speech recognition computer 16 may include a digital signal processor, a microcontroller, or other appropriate computer which is programmed with speech recognition software. The control computer 23 may include a digital signal processor, a microcontroller, or other appropriate computer which is programmed with appropriate control software. In addition, the speech recognition computer 16 and the control computer 23 may be the same physical unit, with functional partitioning performed in the software programming. Furthermore, many of the functions shown separately in the unit block diagram may be integrated into a single integrated circuit. An example of this type of circuit integration is the OKI Semiconductor MSM6679 which contains a speech recognition computer, recognizer memory, and CODEC on a single silicon chip.
For the embodiment of FIG. 3, the speech recognition software running in the speech recognition computer 16 is speaker dependent, and the command word records stored in the recognizer memory 17 are stored in a separate Random Access Memory (RAM). An example of a suitable speech recognition computer is the AT&T DSP16A Digital Signal Processor. Suitable Speech Recognition software is also available from AT&T. Another example of a suitable speech recognition computer is the OKI Semiconductor MSM6679, which can provide either speaker-dependent, or speaker-independent speech recognition using software provided by Voice Control Systems Inc. As noted above, the use of the MSM6679 provides opportunities for reduction in the number of separate system components since it integrates the recognizer memory, CODEC, and speech recognition processor. A disadvantage to the MSM 6679 is that it is a little slower than the DSP16A which may result in a perceptible lag between when the operator gives a voice command and when the trolling motor responds.
In one embodiment, remote control system beltpack unit 50 may implement a speech audio output function which can be used to communicate with the operator. Error messages and other audio feedback are stored digitally in the audio memory 18. The control computer 23 may command the speech recognition computer 16 to output an audio message by sending a control code with the number of the message which is to be output. When this occurs, the speech recognition computer 16 reads the digitized audio message out of the audio memory 18 and converts it into a stream of digital words which are sent to the analog interface circuit 14. The analog interface circuit 14 converts the digital words into an electrical analog signal which is amplified, filtered, and sent to a speaker 13 which converts the electrical analog signal into a sound pressure signal which the operator can hear. The speaker in one embodiment is a small earphone 13 which is inserted directly into the operators ear.
The power control circuit 22 is configured to selectively power down portions of the remote beltpack circuitry under the control of the control computer 23. For example, when the unit is not in voice control mode, the speech recognition computer 16, recognizer memory 17, and analog interface unit 14 may be powered down resulting in a considerable power savings and extended battery life. In addition, the control computer 23 may be placed in a low-power "stop" condition while waiting for a keypress. This feature can be activated by the software in the control computer 23.
FIG. 7 shows a system block diagram for an embodiment of the trolling motor control circuit 11b. An antenna 24 and wireless receiver 25 are connected to a motor control computer 31. The antenna 24 and wireless receiver 25 receive control commands transmitted from remote beltpack unit 50 which may be carried by the operator or attached to the operator's belt. The motor control computer 31 may be implemented using a Motorola Inc. MC68HC05 microcontroller or the Microchip Technology Inc. PIC16C55 microcontroller or other suitable microprocessor. In this embodiment, the motor control computer 31 controls a thrust control circuit 26 which adjusts the speed of the thrust motor 1b by pulse width modulation of the voltage attached to the terminals of the thrust motor 1b. The motor control computer 31 also controls a steering control circuit 29 which adjusts the polarity and voltage applied to the terminals of the electric steering motor 11a, thereby causing the submerged housing unit 1a to rotate in the desired direction, or maintain direction. Additionally, the motor control computer 31 may control a power control circuit 30 which can selectively power down portions of the trolling motor control circuit 11b to save power when the unit is not in use.
FIG. 8 shows a sample list of commands which can be used by the operator to remotely control the trolling motor by voice command. Careful selection of voice commands is important for best voice recognizer performance, and for ease of use. It is important that the voice command set include words that do not sound alike to the voice recognizer, and it is equally important that they are reasonably intuitive to the operator. In one embodiment, the voice command "LEFT" causes the trolling motor to turn left 22.5 degrees when viewed by an operator who is standing facing forward in the boat. The voice command "RIGHT" causes the trolling motor to turn right 22.5 degrees. The voice commands "HARD LEFT" and "HARD RIGHT" cause the trolling motor to turn 90 degrees to the left or right respectively. "HARD LEFT" and "HARD RIGHT" are useful for turning the boat around, or for avoiding obstacles, or for turning the boat away from the bank when a fish is hooked while trolling parallel to the bank.
The voice commands "REVERSE" and "FORWARD" cause the trolling motor to turn 180 degrees to the left or right respectively. The purpose of these commands is to reverse the thrust direction of the trolling motor. It is also possible to reverse the rotation of the propeller to achieve the same effect, however this may not be advisable due to the design of the propeller, and subsequent cavitation noise. Commands which affect the speed of the thrust motor are "STOP", "ONE", "TWO", "THREE", "FOUR", "FASTER", and "SLOWER". In one embodiment, the thrust control circuit 26 is capable of fifteen individual speed settings in addition to stopped. The voice command "STOP" causes the thrust motor to stop, while the voice command "FOUR" or "MAX" causes the thrust motor to set to speed fifteen (highest). The voice commands "ONE", "TWO", and "THREE" cause the speed to be set to one-quarter, one-half, and three-quarter speed respectively. The voice commands "FASTER" and "SLOWER" cause the current speed setting to be incremented or decremented by one setting. This results in an acceptable tradeoff between fine control of speed, and large numbers of voice commands.
The voice commands "THRUST" and "NO THRUST" cause the thrust motor to start or stop respectively. When a "THRUST" command is voiced after a previous "NO THRUST" command, the thrust motor restarts at the speed at which it was operating when the "NO THRUST" command was detected. The voice command "VOICE OFF" is used to cause the remote control unit to stop processing voice commands This command may be used when the operator wishes to carry on a conversation with another boat passenger without the risk of unintended remote control operation. Once a "VOICE OFF" command has been recognized, the operator must use the "VOICE REC" key to restart voice command mode.
It is noted that while the list of voice commands as illustrated in FIG. 8 are believed to work well, other or alternative voice commands are contemplated in other embodiments.
FIG. 9 shows one implementation of software flow for the speaker-dependent embodiment described above. After the insertion of batteries into the remote beltpack unit 50, or when the beltpack unit has been reset, the system starts at the Initialize block in the upper left-hand corner of FIG. 9. When the PWR key 35 is pressed, the system alerts the operator that the power has been turned on through an audible beep, or visual indication (LED), and waits for another key to be pressed. This condition is referred to as a "Key Only" mode, because the speech recognition is not enabled. Motor control keys such as LEFT 37, RIGHT 38, etc. are handled directly by the control program. Pressing VOICE REC 36a or LEARN 36b places the unit in "Voice Mode" or "Learn Mode" respectively. Voice Mode enables the use of voice commands to control the trolling motor, while Learn Mode allows the speaker-dependent training of individual voice commands.
FIG. 10 is a flow diagram which illustrates exemplary functions of the beltpack unit system software in Voice Mode. When the operator presses the VOICE REC key 36a while in Key Only mode, the unit enters Voice Mode, and an audible indication is made to the operator such as a synthesized voice saying "Voice Mode". This indication could also be a special audible beep, or a visual indication such as an LED. Once in Voice Mode, the motor control keys continue to function as in Key Only mode, however the speech recognition is enabled, and the unit will also respond to voice commands. FIG. 11 shows the software flow which handles voice commands when they are recognized. Learn Mode can be entered from Voice Mode by pressing the LEARN key 36b, and the speech recognition can be disabled by pressing the VOICE REC key 36a a second time.
FIG. 12 is a flow diagram which illustrates exemplary functions of the beltpack unit system software in Learn Mode. The operator can train individual voice commands by pressing motor control keys to indicate which command to train. In Learn Mode, the motor control keys only function to select commands to train, and keyboard control of the trolling motor is disabled. Pressing the ALL key 36c causes the beltpack unit to train all of the voice commands sequentially. FIG. 13a shows the training sequence for an individual command The unit first prompts the operator to say the command by playing the synthesized voice sequence "Please Say <cmd>" where <cmd> is replaced by the synthesized sequence for the voice command which is being trained. Once the operator has responded, the speech recognition computer 16 determines the start and endpoint of the utterance and calculates the peak signal level (in dB), average signal level (in dB), and background noise level (in dB). It then calculates specific parameters used by the speech recognition software, and prompts the operator to repeat the command by playing the synthesized voice sequence "Please Repeat <cmd>". When the operator responds, the speech recognition computer 16 once again determines the start and endpoint of the utterance, and calculates the signal levels, and speech recognition parameters. It then compares the parameters with the parameters calculated from the first utterance, and determines if the two utterances are similar enough to use. If the two utterances are not similar enough, the system issues an error message to the operator. However, if the utterances are similar enough, the speech recognition computer 16 combines the parameters from the two utterances to form a single command record used for recognizing that particular voice command. The peak signal level, average signal level, and background noise level are stored in a memory location of recognizer memory 17 which is associated with the particular command which was trained. These levels are used during voice command recognition to enable the use of a software controlled gain function which compensates for variation in microphone placement, wind noise, the volume of the operators voice, etc. An exemplary software flow diagram for the software controlled gain function is shown in FIG. 13b. It is noted that other training methodologies may be used with the remote control system at the system designers discretion.
FIG. 13b illustrates an exemplary software flow during recognition of a voice command, and particularly an exemplary software gain control function for the audio encode/decode block (FIG. 5). When a voice command is detected, the speech recognition computer 16 first determines the start and endpoints of the utterance, and then calculates a peak and average signal level in dB. The speech recognition parameters are then calculated and compared individually to each of the command records previously stored in the recognizer memory 17. The speech recognition parameters calculated and the method of comparison will depend on the speech recognition algorithm used, and may involve dynamic time warping and/or Markov Models etc. If none of the command records matches the utterance closely enough, the command is ignored. However, if there is a match, the speech recognition computer 16 communicates with the control computer 23, identifying which command has been recognized, and passing the peak and average signal levels from the utterance, and the peak and average signal levels stored with the command record. The control computer 23 performs the command function indicated by the voice command, and then compares the peak and average signal levels from the utterance and command record. If the peak and average signal levels from the command record and the utterance match closely enough (within one or two dB), there is no further action. However, if the signal level difference is more significant, the control computer 26 calculates a new gain setting. The control computer 26 then adjusts the preamplifier gain setting by writing a new value to the digital potentiometer U2. In addition, the control computer may adjust a digital scale factor which is used to scale the digital input to the speech recognition computer 16. The exemplary software gain control function as illustrated in FIG. 13b is equally useful in speaker-independent, and speaker adaptive embodiments as discussed below.
FIGS. 14-17 illustrate another embodiment of a voice controlled trolling motor system which employs a speaker-independent speech recognition algorithm such as that of the OKI MSM6679 speech recognition processor. Speaker-independent speech recognition command records are derived from several hundred utterances of a particular voice command, all by different speakers, and are typically stored in read-only memory (ROM) instead of random access memory (RAM). The primary differences in the outward appearance of the remote beltpack unit 50 for this embodiment are the removal of the LEARN key (36b FIG. 2) and ALL key (36c FIG. 2). Exemplary software flow diagrams for the speaker independent embodiment of FIGS. 14-17 are shown in FIGS. 15-17, and are identical to those of the previous embodiment, with the exception that the Learn Mode has been removed. Speaker-independence can be more convenient for the operator since it does not recognize training of voice commands. However, this convenience may be at the cost of reduced reliability for certain operators, and in addition, the operator cannot retrain an individual command if there is one command with which he/she is having difficulty.
Yet another embodiment incorporates a speaker-adaptive speech recognition algorithm. In such an embodiment, the speech recognition command records have been derived from the utterances of hundreds of different speakers similar to the embodiment of FIGS. 14-17. However, the Learn Mode functions are retained, and a particular voice command may be re-trained by the operator similar to the first embodiment. In addition, as the unit is used, the speech recognition algorithm may update the speech recognition command records for individual voice commands as needed to assure maximum performance by the speech recognition algorithm.
Turning next to FIG. 18, a block diagram of another embodiment of a remote beltpack unit printed circuit board 51 is shown. Circuit portions that correspond to those of FIG. 3 are numbered identically for simplicity and clarity. In this embodiment, the control computer 23 controls an audio output circuit 15 directly. The control computer 23 reads digitized voice from an audio memory 18 and outputs it to the audio output circuit 14 in order to produce the synthesized speech passages or audio sounds used for operator feedback. Audio output circuit 15 may convert digital voice signals to analog voice signals, and may amplify the audio voice signals for conveyance to earphone 13.
FIG. 19 shows an embodiment that includes a remote beltpack unit printed circuit board 51 where the control computer 23 and the speech recognition computer 16 are implemented using the same physical microcontroller. In addition, it is possible to integrate the recognizer memory 17 and audio memory 18 along with the combined voice recognition/control computer 23,16 to form a highly integrated unit. The OKI MSM6679 is an example of this type of integration. The MSM6679 also performs certain analog interface functions performed by analog interface circuit 14 and audio output circuit 15, resulting in a significant savings on printed circuit board real estate. However, as previously noted, the MSM6679 also has some performance drawbacks which may adversely affect overall system performance. It is noted that the particular speech recognition computer or voice recognition algorithm may be varied from the embodiments described above.
Still another embodiment of a voice controlled trolling motor system incorporates all of the electronics circuitry into a single printed circuit board mounted inside the trolling motor upper housing 9 (FIG. 1). In such an embodiment, a microphone and acoustic speaker are mounted inside the trolling motor upper housing 9, and are acoustically coupled to the outside of the housing. The operator controls the trolling motor by speaking voice commands in the general direction of the trolling motor. An advantage of this embodiment is that there is no external remote control necessary, resulting in a possible cost savings. In addition, the speech recognition and control processors 16 and 32 can be powered by the large batteries which power the trolling motor itself, instead of the batteries in a remote beltpack unit. Software speech recognition algorithms which may accommodate the large dynamic range input signal associated with recognizing speech from a varying distance are available from Voice Control Systems (Dallas Tex.), as well as other vendors.
In yet another embodiment, rather than incorporating the speech recognition circuitry within a remote unit (e.g., with remote beltpack unit 50), the voice recognition circuitry is incorporated within the trolling motor upper housing 9, while a remote unit is utilized to receive voice commands of the user and to convey the voice commands via a wireless transmission. Such an embodiment may include a remote unit having keys similar to those of the beltpack unit of FIGS. 2 and 14 and that function similarly. Instead of performing local speech recognition within the beltpack, the remote unit. may utilize an RF (radio frequency) transceiver with a full-duplex audio channel to communicate with the printed circuit board in the trolling motor upper housing 9. Voice commands picked up by the operator's microphone 12 are sent directly via radio frequency transmission to the printed circuit board in the trolling motor upper housing 9, where the voice commands are recognized and performed. In addition, key presses are encoded and sent over the same RF channel. Audio feedback for the user is sent back via an RF channel to the beltpack unit where it is transmitted to the operators earphone 13. An advantage of this embodiment is that it reduces the amount of circuitry incorporated in the remote beltpack unit 50, and consequently the power drain on the batteries.
The above described embodiments are intended to illustrate a variety of possible implementations of the invention, and not by way of limitation. Other possible configurations will be apparent to one skilled in the art. | A device for controlling the speed and direction of a watercraft using voice commands. The device includes a voice recognition computer, which recognizes spoken commands, and a motor control computer which causes the speed and steering direction of the watercraft to change in response to the spoken commands. A remote control beltpack unit with a radio or infrared link allows free movement of the operator while controlling the watercraft. | 1 |
CROSS-REFERENCE TO RELATED APPLICATIONS
This application claims priority to commonly owned U.S. provisional application Ser. No. 60/804,236 filed Jun. 8, 2006, incorporated by reference in its entirety.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
Not applicable.
BACKGROUND OF THE INVENTION
Portable electronic devices, such as laptop computers, PDAs, and the like, are used in modern clinical settings in the delivery of patient care. These devices allow clinicians to perform a variety of care-related tasks, examples of which include viewing a patient's electronic medical record (EMR) or collaborating with other clinicians about a particular patient's plan of care, all without having to be at a fixed location. By providing clinicians with tools that enable faster access to the information they need to make informed care delivery decisions, treatment outcomes and patient satisfaction may be improved.
Clinical organizations often have a number of portable electronic devices that are shared amongst numerous individuals performing clinical tasks. For example, a team of anesthesiologists in a hospital may share use of the same set of laptop computers or PDAs that are loaded with software relevant to the tasks that they commonly perform. These devices, however, are often the subject of theft due to their high value and portability. Not only is it expensive to replace these devices, but sensitive patient information may also be stored on them. Additionally, these items are easy to misplace in clinical settings where many other electronic devices are present. Each clinician that shares use of a device may also choose to store the device at a secure location that they will remember, but other clinicians may not be familiar with, causing confusion and wasted time searching for the device. Portable electronic devices also typically have a power supply, also called a “power converter”, for drawing A/C power during normal operation or recharging batteries within the device. In a clinical setting, these power supplies are also easy to misplace and difficult to distinguish from one another when many devices are present. Clinicians, therefore, have found elusive a solution for the organized storage and recharging of portable electronic devices.
SUMMARY OF THE INVENTION
A storage unit provides for the organized and secure retention of portable electronic devices. The storage unit is configured to allow access to the electronic devices within the unit only by authorized clinicians. By aggregating a number of electronic devices together in a centralized location, clinicians can more easily locate a needed device that is shared with other individuals.
In one aspect, the storage unit is formed with an enclosure for housing portable electronic devices and associated power supplies. A plurality of shelves are disposed within the enclosure, each being sized for supporting a portable electronic device. One or more access doors are mounted onto the enclosure and moved between a closed position preventing access to housed electronic devices and an open position where the electronic devices may be viewed and accessed. Each access door has a locking mechanism coupled therewith to selectively maintain the access door in the closed position. A chamber is also formed within the enclosure where power supplies associated with the portable electronic devices may be stored.
The storage unit may optionally have casters so that the unit may be easily moved to another location within a clinical environment, such as a hospital. Additionally, the locking mechanism may receive input regarding a request for access to the enclosure and automatically unlock each access door when the input received is associated with an authorized request for access to the storage unit. Sensors may also be provided on the plurality of shelves to detect where electronic devices are currently present, as well as when devices are removed and return to specific shelves.
In another aspect, the storage unit is formed as an enclosure that houses portable electronic devices that are supported by a plurality of shelves disposed within the enclosure. One or more access doors are mounted onto the enclosure and moved between a closed position preventing access to housed electronic devices and an open position where the electronic devices may be viewed and accessed. A locking mechanism is coupled with and selectively maintains each access door in the closed position. Each locking mechanism receives input regarding a request for access to the enclosure and automatically unlocks the associated access door when the input received is associated with an authorized request for access to the storage unit.
A method for regulating access to an enclosure is provided in another aspect. The enclosure contains a plurality of shelves that are each sized for supporting a portable electronic device, and access to the enclosure is gained through one or more access doors mounted on the enclosure. According to the method, input is received regarding a request for access to the enclosure while the one or more access doors are secured in a closed position. The input is processed to determine if an authorized request for access to the enclosure has been made. If so, then a locking mechanism that secures the one or more access doors in the closed position moves to an unlocked position to allow the doors to be moved from the closed position to the open position, allowing access and removal from the enclosure of portable electronic devices positioned on the plurality of shelves.
Additional advantages and features of the invention will be set forth in part in a description which follows, 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.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
In the accompanying drawings, which form a part of the specification and are to be read in conjunction therewith and in which like reference numerals are employed to indicate like parts in the various views:
FIG. 1 is a perspective view of an embodiment of a storage unit holding portable electronic devices and with access doors in the closed position;
FIG. 2 is a front elevational view of the storage unit of FIG. 1 with the access doors in the open position;
FIG. 3 is a side elevational view of the storage unit of FIG. 1 with the side wall partially removed and one divider wall removed to show an extended shelf supporting a portable electronic device with an associated power supply;
FIG. 4 is a perspective view of one shelf having a resilient clip and a pressure sensor;
FIG. 5 is a schematic block diagram of an embodiment of circuital architecture of the storage unit;
FIG. 6 is a flow chart illustrating one process for regulating access to the portable electronic devices within the storage unit; and
FIG. 7 is a fragmentary view, partially in section, showing the contact switch mounted with the enclosure and one access door to indicate when the access door in the closed position.
DETAILED DESCRIPTION OF THE INVENTION
One embodiment of a storage unit 100 having regulated access to contents housed within the unit, such as portable electronic devices, is shown generally in FIGS. 1 and 2 . The storage unit 100 is particularly well suited for use in clinical settings where a group of authorized clinicians may share use of various portable electronic devices. As one example, the portable electronic devices may include laptop computers, PDAs, tablet PC's, cellular phones, and the like, which may display various types of clinical information (e.g., electronic medical records (EMR) or other documentation, diagnostic images, etc.) and facilitate communication with other portable electronic devices, computing devices or networks. The storage unit 100 provides a centralized location where a number of shared devices may be stored while ensuring that only authorized clinicians may access the devices. Additionally, the storage unit 100 is configured to provide an organized layout where specific devices can be easily located and differentiated from other devices within the unit 100 .
The storage unit 100 is formed generally by an enclosure 102 with a ceiling 104 , a floor 106 , a pair of sidewalls 108 , a back wall 110 and a pair of front access doors 112 . Locking mechanisms 114 regulate the opening of the access doors 112 for obtaining access to the enclosure 102 . An exterior shelf 116 extends from each sidewall 108 , and set of casters 118 are mounted onto the floor 106 of the enclosure 102 for portability of the storage unit 100 in a clinical environment (e.g., hospital, physician's office, etc.). It should be understood that the overall shape of the enclosure 102 shown in FIGS. 1 and 2 is exemplary. Additionally, the enclosure 102 may one, two, or any number of access doors 112 mounted onto the enclosure 102 as a matter of design choice.
In the embodiment illustrated in FIG. 2 , the pair of access doors 112 are pivoted to a fully opened position to reveal a plurality of shelves 120 onto which may be placed portable electronic devices 122 of a particular size. The shelves 120 are preferably mounted upon drawer slides 124 (e.g., roller or ball bearing) as seen in further detail in FIG. 3 . The drawer slides 124 are fixedly positioned within the enclosure 102 to allow for extension of the shelves 120 laterally outward. This facilitates removal of electronic devices 122 from specific shelves 120 without disturbing electronic devices 122 on other shelves 120 . The shelves 120 may have uniform vertical spacing between one another of a limited dimension in order to limit the sizes of specific portable electronic device 122 that may be stored on certain shelves 120 within the storage unit 100 . For instance, the shelf spacing may limit the storage of items larger than a full-size laptop computer on most shelves 120 . Furthermore, specifically dimensioned bays 126 may be formed on particular shelves 120 to provide a storage region for small electronic devices 122 (e.g., PDAs) while preventing larger electronic devices 122 from being placed on such shelves 120 . Those of skill in the art will appreciate, however, that other shelf sizes and configurations may be selected based on the types of portable electronic device 122 desired to be stored within the unit 100 .
A pair of divider walls 128 extend vertically through the enclosure 102 between first and second columns of shelves 120 . The divider walls 128 define a central chamber 130 therebetween into which a power supply 132 (i.e., a AC-to-DC power converter) for each of the portable electronic devices 122 may be stored. A multi-outlet power strip 134 is mounted onto the back wall 110 of the enclosure 102 and may be plugged into a standard wall A/C outlet of a building. Each power supply 132 plugs into the power strip 134 to provide power (converted to D/C) to a specific electronic device 122 . The divider walls 128 also have cutouts (not shown) to allow power supply cords 136 to extend therethrough to reach the electronic devices 122 stored on the shelves 120 . A plurality of horizontally flanges 138 extend from the divider walls 128 within the central chamber 130 and are each generally positioned adjacent to one of the shelves 120 to support a power supply 132 that is associated with one particular electronic device 122 that is to be placed on the adjacent shelf 120 . For instance, each shelf could be designated with a particular position (e.g., Column 1, Shelf 5) and a particular electronic device 122 associated with that position by placing a label on the exterior of the electronic device 122 denoting the assigned position for the device 122 . This ensures that when the electronic device 122 is placed on a shelf, the power supply 132 associated with that particular electronic device 122 is conveniently located in an adjacent position and may be easily plugged in to recharge the battery within the electronic device 122 .
As seen in further detail in FIG. 4 , a resilient clip 140 is attached to the upper surface 142 of each shelf 120 and serves to retain an end connector 144 of the power supply cord 136 on the shelf 120 through extension and retraction of the shelves 120 . This allows a clinician to easily plug the end connector 144 into a electronic device 122 without having to search for the end connector 144 within the enclosure 102 . Adjacent to the clip 140 on each shelf 120 is a pressure sensor 146 , which may be in the form of a thin membrane. Exemplary pressure sensors 146 that are suitable include piezoelectric pressure sensors or pressure transducers. The pressure sensor 146 detects the presence of an electronic device 122 on the shelf 120 by the weight of the electronic device 122 pressing on the pressure sensor 146 . When a pressure change is detected, either by a electronic device 122 being placed on or removed from the pressure sensor 146 surface, a signal is transmitted to circuitry 500 disposed within a housing 148 mounted to the enclosure 102 , and seen in further detail in FIG. 5 . Circuitry 500 processes the signal received from the pressure sensor 146 to determine if an increase or decrease of pressure has occurred from the last signal received from the particular pressure sensor 146 transmitting the signal. Additionally, circuitry 500 registers the time at which the signal is received from the particular pressure sensor 146 , which allows for logging of the amount of time a particular electronic device 122 has been “checked out” of the storage unit 100 . As an alternative to the pressure sensor, an optical sensor (e.g., an infrared sensor) or other type of sensor may be provided for sensing the presence of an electronic device 122 upon a particular shelf 120 . The functionality of circuitry 500 will be explained in further detail herein.
Returning to FIGS. 1 and 2 , and with reference to FIG. 5 , one locking mechanism 114 is mounted onto each of the access doors 112 . Each locking mechanism 114 has an actuator 150 , for example, a solenoid, operating on electrical current regulated by the circuitry 500 . The actuator 150 turns a hub 152 having a pair of opposed locking rods 154 pivotably mounted thereto. When one of the access doors 112 is in the closed position shown in FIG. 1 , the rotation of the hub 152 extends the locking rods 154 through apertures 156 in top and bottom sections 158 and 160 of each access door 112 and into the slots 162 and 164 in the ceiling 104 and floor 106 , respectively, of the enclosure 102 to lock the door 112 in place.
Clinicians may be provided by a clinical organization with an access card (not shown) having a readable magnetic strip that stores information regarding authorization for access to the electronic devices 122 within the storage unit 100 . Such an access card would thus function in a similar way to known cards having a readable magnetic strip, such as a consumer credit or debit card. Accordingly, the storage unit 100 has an electronic card reader 166 mounted on the external surface 160 of one of the doors 112 . The electronic card reader 166 scans the magnetic strip present on an access card to verify whether the clinician associated with the card is authorized to access the devices 122 within the storage unit 100 . Upon scanning, the card reader 166 sends a signal to the circuitry 500 to verify whether the access card should grant storage unit access. If so, then the circuitry 500 allows a flow of electrical current to energize the actuator 150 and cause hub 152 rotation and retraction of the locking rods 154 from the slots 162 and 164 , thereby allowing the doors 112 to be fully opened to the position depicted in FIG. 2 . In an alternative embodiment, the card reader 166 may be replaced with a touch keypad (not shown) or other device allowing a clinician to enter certain information (e.g., a confidential alphanumerical passcode) confirming authorization to access electronic devices 122 within the storage unit 100 .
It should be understood that other types of locking mechanisms 114 may be implemented with the storage unit 100 . For example, mechanisms may be mounted directly onto the enclosure 102 instead of on the access doors 112 . Such a locking mechanism may extend locking rods 154 or the like through either or both of the apertures 156 in the top and bottom sections 158 and 160 of each access door 112 to maintain the doors 112 in the closed position.
With reference to FIGS. 2 and 7 , an magnetic contact switch 168 may be provided, in one embodiment, with each access door 112 . Each contact switch 168 includes a wired magnetic component 170 mounted to the underside 176 of the ceiling 104 of the enclosure 102 and an unwired magnetic component 172 mounted onto an inside surface 174 of one of the access doors 112 . When one access door 112 is moved to the closed position, the wired magnetic component 170 and unwired magnetic component 172 are in close proximity to one another to form a completed circuit, as seen in FIG. 7 . Circuitry 500 detects the completed circuit and controls the electrical current flow to the actuator 150 of the associated access door 112 to enable locking of the door 112 . Thus, when one of the access doors 112 is moved to the closed position, it is automatically locked without requiring further action from the clinician accessing the storage unit 100 .
In accordance with one embodiment, the circuitry 500 includes a processing unit 502 , such as a microprocessor, microcontroller or application-specific integrated circuit, along with associated memory 504 . By way of example, the processing unit 502 handles control signals and/or data signals of various types. For instance, one or more pressure sensors 146 generate a signal that is transmitted to the processing unit 502 . The memory 504 stores embedded software that is used by the processing unit 502 to determine pressure values based on the signal received from a specific pressure sensor 146 and also causes the processing unit 502 to note the time when the signal was received and the specific sensor 146 from which the signal originated. The embedded software is also used in the verification of authorization information (e.g., retrieved from the scanned access card) for accessing the storage unit 100 . Circuitry 500 optionally includes a digital-to-analog (D/A) converter 506 connected with a speaker 508 . When the locking mechanisms 114 move to the unlocked position, so that either or both of the access doors 112 may be opened, the circuitry 500 notes the time. If the circuitry 500 does not detect a completed circuit or “closed access door” condition from each of the magnetic contact switches 168 within predetermined period of time (e.g., 60 seconds), the circuitry 500 generates an alarm signal that is transmitted to the D/A converter 506 , which forces the speaker 508 to produce an audible alarm to remind the clinician to close all of the access doors 112 to the storage unit 100 . Circuitry 500 may also include a transmitter 510 for communication with a clinical network via a remote receiver (not shown), so that information logged and stored by the circuitry 500 regarding storage unit 100 access, an alarm situation, or electronic device 122 inventory, return to and/or retrieval from the unit 100 may be monitored by a clinical organization. Furthermore, the exemplary architecture of the circuitry 500 ensures that if the main power input to the storage unit 100 is not provided, then access to the enclosure 102 is forbidden. More specifically, if the storage unit 100 is simply unplugged, the electronic card reader 166 will not be able to scan access cards, and no electrical current will flow to the actuators 150 , both steps being necessary to unlock the access doors 112 .
One exemplary process 600 for regulating access to the electronic devices 122 within the storage unit 100 is illustrated in FIG. 6 . A clinician will swipe an assigned access card through the electronic card reader 166 , in step 602 . Based on information detected on the card, a decision is made in step 604 regarding whether an authorized request for access has been made. If the request for access is not authorized, then the access doors 112 of the storage unit 100 remained locked in step 606 and thereafter the process 600 ends. Otherwise, in step 608 , an authorized request for access causes the locking mechanisms 114 to unlock each of the access doors 112 . Each pressure sensors 146 then detects the presence of electronic devices 122 and transmits representative signals to the circuitry 500 , in step 610 , allowing the circuitry 500 to register the positions (i.e., particular column and shelves 120 ) where electronic devices 112 are presently located while also logging the time of the access doors 112 unlocking. Thereafter, the pressure sensors 146 detect the removal from and return of electronic devices 122 to the shelves 120 while one or more of the access doors 112 are opened, as will be explained herein.
In step 612 , a determination is made as to whether electronic device 122 removal is detected by any particular pressure sensors 146 . If none of the pressure sensors detect the removal of electronic devices 122 , the process continues at step 616 . Otherwise, if electronic device removal is detected, then in step 614 , the circuitry 500 registers the position and time of removal for each electronic device 122 removed. Then, in step 616 , a determination is made as to whether electronic device 122 return is detected by any particular pressure sensors 146 . If none of the pressure sensors detect the return of electronic devices 122 , the process continues at step 620 . Otherwise, if electronic device return is detected, then in step 618 , the circuitry 500 registers the position and time of return for each electronic device 122 returned.
During the process 600 , the circuitry 500 is detecting for a closed circuit condition with each magnetic contact switch 168 , which signals that the access doors 112 are closed and the contents of the enclosure 102 are secure. Based on the time noted for when the locking mechanisms 114 unlock the access doors 112 (in step 608 ), the circuitry 500 determines, in step 620 , whether a excessive period of time has elapsed since the access doors 112 were unlocked based on a predetermined time limit. If the predetermined time limit is exceeded before the circuitry detects the closed circuit condition for the magnetic contact switches 168 , an alarm signal is generated by the circuitry 500 and an audible alert provided by the speaker 508 in step 622 . Otherwise, detection of the closed circuit condition for each of the magnetic contact switches 168 before the predetermined time limit is exceeded causes the process to move directly to step 624 . Returning to step 622 , the audible alarm will cease once the closed circuit condition for each of the magnetic contact switches 168 is detected. At the point where the circuitry 500 detects the closed circuit condition for each switch 168 , then in step 624 , the closing of the doors is registered. Circuitry 500 then controls the electrical current flow to the actuator 150 of each locking mechanism 114 to enable locking of the access doors 112 , in step 626 . Thereafter, the process 600 ends.
As can be seen, the storage unit 100 and associated methods of operation thereof provide for controlled and shared access to portable electronic devices in a clinical environment. Since certain changes may be made in the above invention without departing from the scope hereof, it is intended that all matter contained in the above description or shown in the accompanying drawing be interpreted as illustrative and not in a limiting sense. It is also to be understood that the following claims are to cover certain generic and specific features described herein. | A storage unit and associated methods of use enable clinicians to store portable electronic devices in a centralized location while ensuring that proper authorization is needed to access the devices. The storage unit is formed with an enclosure for housing portable electronic devices. A plurality of shelves are disposed within the enclosure, each being sized for supporting a portable electronic device. One or more access doors are mounted onto the enclosure and moved between a closed position preventing access to housed electronic devices and an open position where the electronic devices may be viewed and accessed. Each access door has a locking mechanism coupled therewith to selectively maintain the access door in the closed position. Optionally, the locking mechanism receives input regarding a request for access to the enclosure and automatically unlocks the associated access door when the input received is associated with an authorized request for access. | 0 |
TECHNICAL FIELD OF THE INVENTION
The present invention relates to methods for corneal reformation, specifically, to a method for corneal reformation that permits faster recovery with improved visual acuity and surgical instruments for performing such methods.
BACKGROUND OF THE INVENTION
The human eye includes a specialized structure referred to as the cornea. The cornea is a multi-layered structure, however, the three most superficial layers—the corneal epithelium, Bowman's Membrane, and the stromal bed—are the layers that are primarily implicated in corneal reformation surgery. The epithelium, which comprises the delicate covering of the human cornea and is only five or six cells thick, is the protective barrier against infection of the cornea. The cornea, being avascular, has unique immune requirements and an infection in this part of the eye is problematic since systemic antibiotics are relatively ineffective. Therefore, preservation of the epithelial integrity is critical in surgery as well as for general eye care.
The epithelium is adherent to the stromal surface along Bowman's Membrane which is a cell-free zone approximately 7 to 12 microns thick and defines the Basement Membrane. Bowman's Membrane is the most anterior structure of the stromal tissue which is the major lamellar structure of the corneal anatomy. In most surgeries of the cornea, efforts are made to prevent the tearing of the epithelium from Bowman's Membrane because such tearing causes pain, slow visual recovery, and predisposes to corneal infiltrates (precursors to infection).
Some corneal reformation techniques, such as LASIK, require the creation of a flap of corneal epithelium which may result in significant destruction of the stromal bed leading to trauma or even permanent damage to the eyes and compromise eyesight. PRK, on the other hand, removes the upper most layer(s) of corneal epithelium without danger to the underlying stromal bed but requires a long recovery period for the patient.
In LASIK, in order to create a useable flap, the flap must be relatively thick. A thick flap, however, requires corneal reformation by ablating underlying tissue that extends into the stromal bed of the cornea. Ablating this tissue has severe consequences. Unless sufficient tissue remains in the stromal bed, the cornea can destabilize resulting in keratoectasia. A patient's long recovery time after PRK surgery is disadvantageous for multiple reasons, such as lengthier vulnerability to infection, discomfort, and inability to return to daily routine quickly.
Accordingly, there is a need for a method of corneal reformation that reduces the risk of trauma and permanent damages to the eye while permitting quick recovery.
SUMMARY OF THE INVENTION
In accordance with the present invention, a method for reforming the cornea to alter visual acuity is presented whereby a shallow incision of less than about 85 microns is made into the corneal epithelium to create a sheet of epithelium. The sheet of epithelium is separated from the Bowman's Membrane using an epithelial separator or cannula and then is lifted from of the cornea to permit ablation of the underlying membrane followed by return of the epithelial sheet.
BRIEF DESCRIPTION OF THE DRAWINGS
For a more complete understanding of the present invention and for further advantages thereof, reference is now made to the following Description of the Preferred Embodiments taken in conjunction with the accompanying Drawings in which:
FIG. 1 a is a block diagram illustrating the present method;
FIGS. 1 b – 1 g are pictorial representations illustrating steps of the present method;
FIG. 2 is a perspective view of a trephine used in practicing the present method;
FIG. 3 is a side elevational view of the trephine cutting band illustrated in FIG. 2 ;
FIG. 4 is a bottom plan view of the trephine cutting band shown in FIG. 3 ;
FIG. 5 is a sectional view taken generally along sectional lines 5 — 5 of FIG. 3 of the trephine cutting band;
FIG. 6 is a perspective view of an embodiment of a surgical instrument used in the practice of the present method;
FIG. 7 is an enlarged side elevational view of the cannula shown in FIG. 6 ;
FIG. 8 is sectional view taken generally along sectional lines 8 — 8 of FIG. 7 of the cannula of the present invention;
FIG. 9 is a front elevation view taken generally at lines 9 — 9 of FIG. 7 of the distal tip of the cannula of the present invention;
FIG. 10 is a side elevational view of another embodiment of a cannula used in the practice of the present method;
FIG. 11 is a sectional view taken generally along sectional lines 11 — 11 of FIG. 10 of the cannula of the present invention;
FIG. 12 is a side elevational view of another embodiment of a cannula used in the practice of the present method;
FIG. 13 is a sectional view taken generally along sectional lines 13 — 13 of FIG. 12 of the cannula of the present invention;
FIG. 14 is a perspective view of an embodiment of an epithelial separator used in the practice of the present method;
FIG. 15 is an enlarged side elevational view of the spatula-like portion of the epithelial separator shown in FIG. 14 ;
FIG. 16 is a sectional view taken generally along sectional lines 16 — 16 of FIG. 15 of the spatula-like portion of the epithelial separator of FIG. 14 ;
FIG. 17 is a front elevational view taken generally along lines 17 — 17 of FIG. 15 of the distal tip of the epithelial separator of the present invention shown in FIG. 14 ;
FIG. 18 is a perspective view of a further embodiment of an epithelial separator used in the practice of the present method;
FIG. 19 is a side elevational view of the spatula-like portion of the epithelial separator shown in FIG. 18 ;
FIG. 20 is a sectional view taken generally along sectional lines 20 — 20 of FIG. 19 of the spatula-like portion of the epithelial separator shown in FIG. 18 ;
FIG. 21 is a front elevational view taken generally along lines 21 — 21 of FIG. 19 of the distal tip of the spatula-like portion of the epithelial separator of FIG. 18 ;
FIG. 22 is a perspective view of a further embodiment of an epithelial separator used in the practice of the present method;
FIG. 23 is a side elevational view of the spatula-like portion of the epithelial separator of FIG. 22 ;
FIG. 24 is a sectional view taken generally along sectional lines 24 — 24 of FIG. 23 of the spatula-like portion of the separator shown in FIG. 22 ; and
FIG. 25 is a front elevational front view taken generally along lines 25 — 25 of FIG. 23 of the distal tip of the spatula-like portion of the epithelial separator of FIG. 22 .
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The present method for reforming the corneal surface of the mammalian eye has advantages of LASIK surgery while avoiding the disadvantages of PRK surgery. The present method is termed LASEK. Briefly, in practicing LASEK a gossamer thin sheet of no more than about 85 microns of the corneal epithelium is lifted from the corneal surface to permit corneal reformation of the underlying epithelium and is then replaced. The present method permits rapid recovery like LASIK. With the present method, the corneal bed is mostly maintained which prevents thickening or other indications of trauma. Another advantage of the present invention is that, unlike PRK, the eye is not treated with harsh chemicals that are used in PRK to remove the corneal epithelium and long recovery periods are avoided. Again, by reducing the cornea's exposure to irritants, damage to the cornea is avoided and recovery time is enhanced.
Referring to FIGS. 1 a – 1 g , a block diagram of the present method is illustrated together with pictorial representations of steps of the present method. At step 10 , a full or partial thickness epithelial cut 12 is made in the epithelial layer 14 of cornea 16 of an eye. This incision 12 is no deeper than about 85 microns. The incision 12 forms a sheet 18 ( FIG. 1 f ) that can be lifted from the underlying Bowman's Membrane 20 . The area 22 of the cornea 16 and surrounding area that remains attached to the underlying corneal epithelium 14 is termed the “hinged region” as this region functionally serves as a hinge whereby the sheet 18 is maintained attached to the epithelium 14 . In a preferred embodiment of the invention, a curved, “C”-shaped, partial or full depth epithelial incision 12 is made to form an arc of between about 250 and 330 degrees. This incision 12 is preferably made using a guarded trephine, to be subsequently described with respect to FIG. 2 which may be vibrated at step 24 . An example of a trephine is illustrated in FIG. 2 for making an incision 12 of about 300 degrees. The incision 12 can alternatively be made by a variety of surgical tools such as a scalpel or knife.
In step 26 , an incision 28 using a scalpel or similar cutting instrument, preferably with a rounded blade, is made near the hinge 22 of the partial thickness epithelial cut 12 . This incision 28 is about 1 to about 2 millimeters long and is sufficiently deep to reach the corneal bed, stromal layer, or Bowman's Membrane 20 and is about 1 to about 2 millimeters long. A cutting instrument 30 a for performing step 26 is illustrated in FIG. 3 a . Cut 28 may be made using a fluid 38 expelled from the tip of instrument 30 a.
In step 32 of the present invention, the epithelial cells are stiffened by adding several drops of sodium chloride in a concentration ranging from about 3% to about 7% (such as Muro 128 ) for 10 seconds followed by rinsing with buffered saline solution. Stiffening of the epithelial cells makes them easier to handle.
After the incision 28 is made in step 26 , the epithelium layers remain firmly affixed to each other. To separate the corneal epithelium from the underlying epithelium an epithelial separator, such as instrument 30 b , is inserted under the layer 14 near its hinge region 22 at step 34 ( FIG. 1 c ). This insertion is done by entering the incision 28 made in step 26 and is preferably done by applying suction to the eye and using an epithelial separator 30 b which may vibrate. Suction should last for no longer than about 45 seconds and, if necessary, should only be tried a second time after about 15 seconds has elapsed since the first attempt. Suction may not be necessary, however, when vibration is used at step 36 . Instead of using an epithelial separator, a cannula capable of ejecting media 38 may be used to enter the incision 28 created at step 26 . A more detailed description instruments 30 a–c and manners of use are described in more detail below. An epithelial separator is contemplated to be no greater than about one-half millimeter in diameter which permits its entry under the epithelium without tearing what will become the sheet. The epithelial separator is inserted parallel to hinge 22 connecting the ends of the incision line or lines, whereby hinge 22 substantially marks the attachment boundary or hinge 22 of the sheet 18 after the epithelium 14 is lifted.
Once the epithelial separator 30 b is inserted at or near the hinge region, the separator 30 b is slid away from the hinge region 22 while being held substantially perpendicularly to the direction of movement and parallel to the uncut line at step 40 ( FIG. 1 d ). During step 40 the epithelial layers are teased apart by a gentle sawing, “window washing” motion. Alternatively, a cannula having an internal cavity and having one side having a plurality of apertures is contemplated whereby a medium such as gel, liquid, or gas (including air) 38 , hereinafter collectively referred to by the term “fluid”, can be used to tease the epithelial layers apart and to raise the epithelial layer. A more detailed description of this embodiment of the cannula will be also discussed below.
After the epithelial separator or cannula 30 b is slid along under the corneal surface within the incision area created by cut 12 the epithelium layers are separated to form sheet 18 at step 42 . If the corneal area to be altered is relatively large, the sheet 18 may be bisected ( FIG. 1 e ) by making an incision 44 in the epithelium sheet to form two halves 18 a and 18 b , or leafs, which may be more easily moved out of the ablation zone. Additional leafs may be created depending on the size of the corneal area to be altered.
At step 46 , the sheet 18 is lifted from the underlying surface to expose the Bowman's Membrane 20 or bare stoma in a re-treatment case and the corneal bed is ablated or altered by any of a variety of methods commonly known to one of ordinary skill in the art such as by excimer laser and refractive technology.
After ablating the corneal bed, as needed the sheet 18 is replaced over the underlying cornea at step 48 ( FIG. 1 g ) using an instrument 30 c to refloat sheet 18 back into position. An instrument 30 c is subsequently described with respect to FIGS. 14–25 .
Several instruments are used in the practice of the present invention. To make the initial incision 12 (step 10 , FIG. 1 b ) a guarded trephine is preferable such as the one shown in FIG. 2 . Guarded trephine generally identified by the numeral 50 includes a cutting member 52 , a shaft 54 , and a handle 56 . Cutting member 52 is shown in greater detail in FIGS. 3–5 . Cutting member 52 includes a support band 58 , a cutting band 60 , cutting teeth 62 , spaced apart by gaps 64 , an outer surface 66 , an inner surface 68 , and an edge 70 . Cutting teeth 62 may protrude, for example, from cutting band 60 along the innermost about 90 microns leaving the remaining thickness of the outer surface 66 of cutting band 60 to form edge 70 . Cutting teeth 62 cut from about 250 to about 330 degrees along the circular cutting band 60 to form hinge region 22 ( FIG. 1 b ), or an uncut arc of the epithelium, of about 110 to about 30 degrees. FIG. 4 illustrates trephine 50 for forming an uncut arc or hinge of about 60 degrees. FIG. 5 is a cross-sectional view of cutting member 52 through the a gap 64 along sectional lines 5 — 5 in FIG. 3 . Shown is inner surface 68 , bottom edge 70 , and beveled edge 72 of outer surface 66 . In a preferred embodiment, beveled edge 72 is angled towards inner surface 68 at about 30 degrees. Additionally, cutting band 60 may include a continuous cutting surface in which gaps 64 have been eliminated.
In a preferred embodiment of trephine 50 , cutting member 52 is connected to a vibration source 73 . Vibration source 73 may comprise, for example, a mechanical vibrator on an ultra sound vibration source. Vibration is in the range of 20 kHz to 200 kHz. As noted above, the incision made by trephine 50 , if approximately circular, and is about 250 to 330 degrees. Trephines for creating cuts of other dimensions are acceptable so long as the cut is partial to leave an area of attachment between the corneal epithelium its surrounding epithelium to form the hinge 22 ( FIG. 1 b ).
To accomplish steps 34 and 40 ( FIG. 1 a ), the separation of the corneal surface epithelium from the underlying cornea several embodiments of a cannula as described above may be used with the present method and are shown generally in FIGS. 6–13 . The present cannula is hollow and is in fluid communication with a connector that can be received by a standard syringe which may contain a variety of fluid usable to separate the epithelial layers. One embodiment of a cannulas connected to a syringe, generally identified by the numeral 74 , or other pumping systems providing a fluid source is shown in FIG. 6 . Syringe 74 includes a cannula 76 , a connector 78 , and a syringe body 80 , which further includes a plunger 82 . Cannula 76 includes a proximal end 84 , a distal section 86 , a distal tip 88 , a contact surface 90 , an upper surface 91 , and a plurality of apertures 92 as shown in FIG. 7 . The length of the cannula 76 may range from about 10 millimeters to about 15 millimeters. Apertures 92 are disposed on one lateral surface, relative to contact surface 90 and upper surface 91 of distal section 86 of cannula 76 . Preferably, 15 to 25 apertures 92 are utilized for ejection of syringe media. Distal section 86 includes a channel 93 in fluid communication with apertures 92 and syringe body 80 for delivery of fluid to apertures 92 . The diameters of apertures 92 range from about 0.05 to about 0.10 millimeter and are spaced about 0.4 millimeter apart along the side of cannula 76 . The radius of curvature of cannula 76 is contemplated to range from about 8 millimeters to about 12 millimeters. Distal tip 88 is preferably tapered as shown in FIG. 9 to allow cannula 76 to enter under the epithelium after an incision 28 is made as shown in FIG. 1 c . During separation of the epithelial sheet, the syringe plunger 82 may be depressed to eject various media through the plurality of apertures 92 as mentioned above such as air, gel, liquid, to aid in the separation of the epithelial sheet. Distal tip 88 may also include an aperture as illustrated in FIG. 1 b for expelling media to create cut 28 in which case cannula 76 will have no apertures 92 .
Various embodiments of distal section 86 include multiple cross-sectional geometries; such as, for example, circular, trapezoidal, and oval as shown in FIGS. 8–13 . FIG. 8 illustrates a circular embodiment.
An embodiment of a trapezoidal geometry of the present cannula is shown in FIGS. 10 and 11 . A trapezoidal cannula, generally identified by the numeral 94 , includes a proximal end 96 , a distal section 98 , a distal tip 100 , a contact surface 102 , an upper surface 104 , a plurality of apertures 106 , sides 108 a and 108 b , and a channel 110 . The width of upper surface 104 , for example, in the range from about 0.5 millimeters to about 1.0 millimeters and the width of contact surface 102 to range from 0.75 millimeter to about 1.25 millimeter. The height of the trapezoid, i.e. the distance between contact surface 102 and upper surface 104 is to range from about 0.25 millimeters to about 0.5 millimeters. The length of the cannula 94 may range from about 10 millimeters to about 15 millimeters. The plurality of apertures 106 are disposed on one lateral surface, relative to contact surface 102 , of distal section 98 of cannula 94 . Preferably, 15 to 25 apertures 106 are utilized for ejection of syringe media. The diameter of apertures 106 ranges from about 0.05 to about 0.10 millimeter and are spaced about 0.4 millimeter apart along the side 108 a of cannula 94 . The radius of curvature of cannula 94 is contemplated to range from about 8 millimeters to about 12 millimeters. Proximal end 84 is oriented with respect to distal section 86 to form a vertical angle that is in the range of about 40 degrees to about 60 degrees.
An embodiment of an oval geometry of the present cannula is shown in FIGS. 12 and 13 . An oval cannula generally identified by the numeral 112 includes a proximal end 114 , a distal section 116 , a distal tip 118 , a contact surface 120 , an upper surface 122 , a plurality of apertures 124 , and a channel 126 . The short axis of the oval ranges in length from about 0.27 millimeters to about 0.5 millimeters and the long axis ranges in length from about 0.75 millimeters to about 1.25 millimeters. During use the short axis is perpendicular to the corneal surface. The length of oval cannula 112 ranges, for example, from about 10 millimeters to about 15 millimeters. The plurality of apertures 124 are disposed on one lateral surface, relative to contact surface 120 , of distal section 116 of cannula 112 . Preferably, 15 to 25 apertures 124 are utilized for ejection of syringe media. The diameter of apertures 124 ranges from about 0.05 to about 0.10 millimeter and are spaced about 0.4 millimeter apart along the side of cannula 112 . The radius of curvature of cannula 112 , for example, in the range from about 8 millimeters to about 12 millimeters. Proximal end 114 is oriented with respect to distal section 116 to form a vertical angle that is in the range of about 40 degrees to about 60 degrees.
To accomplish step 40 ( FIG. 1 a ), the separation of the corneal surface epithelium from the underlying epithelium, several embodiments of an epithelial separator as described above may be used with the present method, and are shown generally in FIGS. 14–25 . An epithelial separator, generally identified by the numeral 128 , includes a slender spatula-like portion 130 connected to a handle 132 by a shaft 134 . Shaft 134 is oriented with respect to spatula-like portion 130 so that a vertical angle is formed that ranges from about 40 to about 60 degrees.
Spatula-like portion 130 includes a proximal end 136 , a distal section 138 , a distal tip 140 , a contact surface 142 , and an upper surface 144 . The height of the spatula-like portion 130 is no greater than about 0.5 millimeter and is preferably less than 0.4 millimeter. Various embodiments of distal section 138 include various cross-sectional geometries such as, for example, circular, triangular, and oval, as shown in FIGS. 16–25 . A circular embodiment of spatula-like portion 130 is shown in FIG. 16 . The circular embodiment of the spatula-like portion has a length between about 10 millimeters to about 15 millimeters and has a radius of curvature of about 8 millimeters to about 12 millimeters. Distal tip 106 is preferably tapered as shown in FIG. 17 to form a leading edge that can enter under the incision into the epithelium in order to separate the epithelium from the corneal bed. Proximal end 136 is oriented with respect to distal section 138 to form a vertical angle that is in the range of about 40 degrees to about 60 degrees.
Another embodiment of a separator 128 is shown in FIGS. 18–21 . A spatula-like portion 146 includes a proximal end 148 , a distal section 150 , a distal tip 152 , a contact surface 154 , and an upper surface 156 . Spatula-like portion 146 includes a triangular cross-sectional shape and is shown in FIG. 20 , which is a section through sectional lines 20 — 20 of FIG. 19 . Spatula-like portion 146 is triangular in cross-section having a height, generally, of no more than about 0.5 millimeter, and a base of about 1 millimeter, and with the base angles being acute and equal, each preferably less than about 30 degrees. The base, in reference to the triangular cross-section, lies substantially adjacent to the underlying cornea during separation of the epithelium from the corneal bed. The triangular embodiment of the spatula-like portion 146 has a length between about 10 millimeters to about 15 millimeters having a radius of curvature of about 10 millimeters to about 40 millimeters. Shown in FIG. 21 , distal tip 152 of the triangular embodiment tapers to contact surface 154 to form leading edge 158 . The tip 152 of the spatula-like portion 146 is preferably angled having a chisel-like appearance so that the height of the spatula-like portion 146 tapers forward to the base to form leading edge 158 that has a narrower profile than the rearward section of the spatula. Such leading zone permits the spatula-like portion 146 to be inserted between the layers so that the rest of the spatula 146 can further separate the epithelial layers as the spatula-like portion 146 is moved further under the sheet of epithelium. Proximal end 148 is oriented with respect to distal section 150 to form a vertical angle that is in the range of about 40 degrees to about 60 degrees.
Another embodiment of a separator 128 is shown in FIGS. 22–25 . A spatula-like portion 160 includes a proximal end 162 , a distal section 164 , a distal tip 166 , a contact surface 168 , and an upper surface 170 . Spatula-like portion 160 is shown in FIG. 24 , which is a section through sectional lines 24 — 24 of FIG. 23 . In the oval embodiment of spatula-like portion 160 the short-axis ranges in length from about 0.27 millimeters to about 0.5 millimeters and the long-axis ranges in length from about 0.75 millimeters to about 1.25 millimeters. The short axis is perpendicular to contact surface 168 and the long-axis is parallel to the contact surface 168 . As shown in FIG. 25 , distal tip 166 tapers to form leading edge 172 so that the leading edge may enter into under the epithelium and be used to separate the epithelium from the underlying corneal bed. Proximal end 162 is oriented with respect to distal section 164 to form a vertical angle that is in the range of about 40 degrees to about 60 degrees.
Therefore, it can be seen that the present invention provides for a method and surgical instruments for creating and lifting a sheet of epithelium without killing the tissue or exposing the cornea and eye to dangerous toxins.
Whereas it is intended that the description of the present invention includes several embodiments for implementing the invention. Variations in the description likely to be conceived by those skilled in the art still fall within the breadth and scope of the disclosure of the present invention. It is also understood that additional applications of the present invention will be apparent to those skilled in the art upon a reading of the description and a consideration of the appended claims and drawings. | A surgical method of corneal reformation reduces the risk of trauma and shortens overall recovery while yielding improved visual acuity includes making a relatively shallow incision of no more than about 85 microns deep into the corneal epithelium, separating the corneal epithelial sheet from the underlying Bowman's Membrane using an epithelial separator or a specialized cannula, and lifting the epithelial sheet away from the ablation zone so that the Bowman's Membrane and underlying stromal bed can be reformed. Multiple surgical instruments include the optional use of vibration with an epithelial separator or cannula to separate an epithelial sheet from the cornea of no more than about 85 microns thick. | 0 |
BACKGROUND OF THE INVENTION
This invention pertains to an improved casket having a single press formed base or body, and a stamped top or cap.
In the manufacture of metal caskets, and particularly casket made of various grades of sheet steel or paneling, a relatively large number of manipulative steps are required, many of which necessitate the intervention of considerable manual labor. Consequently, the manufacturing cost of metal caskets is relatively high. Accordingly, it would be of extreme benefit to the industry to reduce the cost of casket manufacture by minimizing the various steps in the manufacturing process, and, of course, the intervention of manual labor.
Normally, when manufacturing metal caskets of steel sheets or paneling, the component parts will be subject to a number of stamping operations requiring various tooling configurations. The stamped casket parts include a top cap or lid, the side and end panels, and the bottom. The side and end panels will be initially tack welded to one another and squared. After squaring, the bottom, sides, and ends will be welded to one another. If the casket is what is termed in the trade an "non-sealer", only the top and bottom rails of the side and end panels will be completely welded to one another to provide a hermetic joint or juncture at this location. Later assembly process decorative hardware will be applied to the corners over the sections that are merely tack welded to one another. Then a corner piece may be added or a "Hammond-type" metal strip applied to the corners between the top and bottom rails. In the event a "sealer" casket is being manufactured, the entire corner including the top and bottom rails and the section therebetween will be completely welded.
The welded corners will be subjected to a grinding opearation followed by buffing and fine finishing to obtain the desired aesthetic appearance. An alternative to grinding and finishing is the addition of a casket corner piece. The top or cap is then assembled. Following assembly the entire casket is passed through a cleaning operation followed by an application of primer and paint to obtain the appropriate decorative appearance. Selected hardware for both the exterior and interior is applied and the interior is suitably trimmed with liners, cloth and other materials.
As can be seen, the above described method of casket manufacture is both complicated, labor intensive coupled with lengthy production times resulting in costly caskets.
SUMMARY OF THE INVENTION
The primary object of the present invention is to achieve ultimate simplicity in casket manufacture. Accordingly, it is an object of the present invention to minimize the steps involved and the resources needed in the casket manufacturing process by utilizing a one-piece casket base or body formed by stamping or pressing operation of a forming stamp, and a one-piece casket top cap, or lid also formed by a stamping process. In this manner, separate stamping processes and dies for side panels, end panels, casket bottom, and top cap or lid are eliminated with considerable savings in production time and labor costs. Additionally, equipment and skilled labor requirements are reduced. The tooling used in forming the top or cap and the base or body may be of substantially identical configuration, or of non-identical configurations. If substantially identical tooling is used in forming the top and base, the resulting casket will consist of a stamped cap or lid as the casket top, and an inverted stamped cap or lid as the casket base.
Another object of this invention is to minimize the steps involved and the manual labor needed for squaring, welding and sealing at joints or junctions of the casket body components, including: the side panels, the end panels, and the casket bottom. This is accomplished by utilizing the aforementioned casket body, produced by a single stamping die, as a casket base. The result is a joined, watertight, airtight casket base with considerable savings in production time and manual labor costs.
It is another object of the present invention to provide a casket which is especially suitable to use for mass disaster victims, quarantine diseases, drowned, mutilated, burned or decomposed corpses. Additionally the stamped casket is particularly apt in use for; transfer and shipping, autopsy, disinterment, immersion and placement in a holding vault.
A further object is to provide a functional, economical affordable casket.
A still further object is to provide a casket which requires less space, with consequent advantages in shipping or storing that is stream-lined and aesthetically pleasing and acceptable.
These and other objects and advantages will become apparent from the following detailed description which is to be taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of the casket incorporating the teachings of the present invention;
FIG. 2 is a perspective view of the casket with the cap in an open position;
FIG. 3 is an end longitudinal view of the casket; and
FIG. 4 is a partial bottom view of the casket shown along the lines 4--4 of FIG. 3.
FIG. 5 is a perspective view of an embodiment of the present invention incorporating two three sided casket end stands, one end stand shown in phantom.
FIG. 6 is perspective view of a three sided end stand disconnected from the casket base.
FIG. 7 is an end longitudinal view of an embodiment of the present invention incorporating elongated handles for support and carrying of the casket.
FIG. 8 is a bottom view of the casket base illustrating the elongated handles affixed to the casket base.
FIG. 9 is a bottom view of an embodiment of the present invention showing three base stand pieces to support the casket.
FIG. 10 is a perspective view of a base stand piece.
FIG. 11 is a perspective view showing the "half couch" casket.
FIG. 12 is an enlarged section of the top and bottom showing a gasket therebetween.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
In the drawings, a casket 10 incorporating the present invention, is shown.
The casket may be made of any suitable materials, e.g., various grades of steel, zinc coated steel, copper, bronze etc.
The casket consists of a top or cap 12 and a base 14. To minimize production steps the same forming stamp may be used to make casket top 12 and the casket base 14.
The top or cap is comprised of a rectangular frame and a hollowed out inner shell. The hollow inner shell has the form of a half oval or half capsule, as shown in FIG. 3, which shape is maintained for the length of the casket top. The top is composed of an integral material throughout. The base or body 14, is comprised of a rectangular frame and a hollowed out inner shell. The inner shell may have a substantially identical form as the top or cap. The hollowed out inner shell of the base or body may take an alternate form (e.g., right parallelepiped) by the use of non-identical tooling. The base or body is composed of an integral material throughout. The top and base section have integral generally horizontal flanges extending inwardly from the edges of the top and bottom to form opposing generally parallel surfaces when the top is lowered.
Connecting casket top 12 to casket base 14 are conventional hinges 16 and 18, and arm supports 20 and 22. Outside pin hinges 16 and 18 may be used, or alternatively, internal concealed hinge(s) may be applied to the casket. It may be found necessary, in order to accomodate the hinge and closing means, to make the lateral size of the casket top 72 slightly larger than that of the casket base (see FIG. 12). Typical lever locks 24 and 26 are mounted on casket top 12 and aligned with lever lock receptacles 28 and 30 on casket base 14. Alternately, snap locks, which are readily adapted to use on a non-sealer casket, may be used. A crank lock means may be used including an end crank or an internal crank lock. Base stands 32 and 34 are mechanically fixed to the casket base 14. Base stands 32 and 34 may be affixed permanently or so as to be removable from casket base 14 if desired.
Base stands 32 and 34 have a front section, extending below the front (viewing) side of the casket, each section of the base stand having a front portion, 36, extending away from the casket base, a second bar portion, 38, which is bent, and a third bar portion, 40, extending to, and mechanically affixed to the casket base. This may be accomplished by spot welding, nuts and bolts, or other conventional affixing means. A selected lining 35 is then set into casket base 14.
A "half couch" casket allowing viewing, as illuminated in FIG. 11, may be made by cutting casket top 12 into two parts, 66 and 68, which may be independently opened, or alternatively by affixing a casket top having two parts, 66 and 68, to casket base 14. Headers and/or bridges are normally associated with the perfection type of lid. A perfection type of lid having headers and/or bridges may be used on both the foot end and the head end in FIG. 11. Slight redesign to allow desired levels of viewing of the deceased and to allow proper fit of the deceased into the casket will be required when the perfection type of lid having headers and/or bridges are used.
An alternate casket support means, as illustrated in FIGS. 5 and 6, includes a three sided casket end stand, 44 mechanically affixed to casket base 14 at the head end 46 of the casket and one three sided end stand 42 mechanically affixed to casket base 14 at the foot end 48 of the casket. Each end stand has three sections, end stand 44 having section 50 affixed adjacent to, and supporting, the front side of the casket base toward the head end 46 of the casket, a second section, 52, is affixed adjacent to and supporting the head end 46 of casket base 14, and a third section, 54, of the end stand is affixed adjacent to and supporting the back side of casket base 14 toward the head end 46 of the casket. In this embodiment handles may be affixed to the sides of end stands 42 and 44, or alternately, to the sides of the casket itself.
An additional alternative support means is illustrated in FIGS. 7 and 8 comprising six elongated handles, 56, mechanically affixed to the underside of casket base 14. The elongated handles 56 extend below casket base 14 to a point on a common plane so as to support the casket when it is on a flat, level surface.
FIG. 9 illustrates a casket support means comprising three base stand pieces, 58, mechanically affixed to the underside of the casket base, transversely to the length of the casket, having a top 60 curved to fit the curved underside of casket base 14, a solid body portion 62, and a flat bottom part 64 to support the casket.
The present invention contemplates the addition of other conventional, decorative, or functional hardware if so desired. A finish, to obtain the desired aesthetic appearance may also be applied to the casket.
A casket sealing gasket device 70 (FIG. 12) may be used. The gasket means may be composed of rubber or other suitable material. A casket sealing gasket comprising a continuously sealed joint about the entire casket periphery and achieving an airtight/watertight seal when the lid is closed may be desired.
Thus it will be evident that the present invention realizes the object of ultimate simplicity in casket manufacture consisting of an affordable, economical, functional casket which eliminates many of the steps required in traditional casket manufacture. Thus the several aforenoted objects and advantages are more effectively attained. Although a preferred embodiment of the invention has been disclosed and described in detail herein, it should be understood that this invention is in no sense limited thereby and its scope is to be determined by that of the appended claims. | A casket having a base or body produced by a single press of a forming stamp, and a top or cap also formed by a single press of a forming stamp. The base or body may be formed by the same tooling as the top or cap reducing the equipment necessary, time of production and labor costs in manufacture of the casket shell. | 0 |
CROSS REFERENCE TO RELATED APPLICATIONS
This application claims priority to GB 0524887.7, filed Dec. 6, 2005 and PCT/SE2006/001339, filed Nov. 28, 2006.
FIELD OF THE INVENTION
The present invention relates to an arrangement for detecting a crash, and more particularly relates to an arrangement, to be installed in a motor vehicle, for detecting a crash and evaluating the severity of the crash, and for providing a signal to actuate a safety device to protect an occupant of the vehicle in the event that a crash situation occurs.
BACKGROUND OF THE INVENTION
Conventional crash detection arrangements typically comprise a crash sensor and a control unit. The crash sensor is usually an accelerometer which is connected to a processor within the control unit to provide a signal to the processor which is indicative of the acceleration applied to the vehicle, for instance by forces arising during a crash situation. The control unit is usually provided with a first comparator which compares the signal from the accelerometer with a predetermined acceleration value, which is set at a level such that values of acceleration higher than the predetermined value would indicate that the vehicle is involved in a crash situation. The processor is configured to process the signal from the accelerometer when the first comparator indicates that the signal from the accelerometer is in excess of the predetermined acceleration value. The processor processes the signal for a predetermined length of time (as explained in more detail below) following a determination that the acceleration has first risen above the predetermined acceleration value, and this processing generally determines an amount by which the velocity of the vehicle changes during the predetermined length of time.
A second comparator compares the result of the processing of the signal with a predetermined threshold. If the second comparator finds the result of the signal processing to be in excess of the predetermined threshold (i.e. the velocity has changed by more than a pre-set amount), the second comparator generates a trigger signal which is indicative of the occurrence of a crash situation which is severe enough to warrant activation of a safety device, such as an air-bag. The trigger signal is then transmitted to a safety device to actuate the safety device to protect an occupant of the vehicle.
Referring now to FIG. 1 of the accompanying drawings, the variation in the acceleration a of a vehicle is plotted against time during a crash, with a first curve a 1 which corresponds to a high speed crash (e.g., a crash at 37 mph) and a second curve a 2 which corresponds to a relatively low speed crash (e.g., a crash at 9 mph).
If a conventional crash detection arrangement, such as the arrangement described above, is installed in a vehicle which is involved in either the high speed crash or the low speed crash, the processor will begin to process the acceleration signal a 1 or a 2 when first comparator indicates that the acceleration signal a 1 or a 2 is in excess of a predetermined acceleration value a 0 . The times at which the processor starts to process the acceleration signal a 1 or a 2 , are indicated respectively at times t 01 and t 02 on FIG. 1 .
The processor processes the signal a 1 or a 2 by integrating the signal a 1 or a 2 over a set length of time to determine the change in velocity Δv of the vehicle, according to the following equation:
Δ v =(∫( a−a 0 ) dt )
The resultant value indicative of the change in velocity Δv is then compared, by the second comparator, with a predetermined threshold Δv T .
If the second comparator detects the change in velocity Δv to be in excess of the predetermined threshold Δv T , (i.e. Δv>Δv T ) the second comparator generates a trigger signal which is transmitted to the safety device to actuate the safety device to protect an occupant of the vehicle.
Referring now to FIG. 2 , the change in velocity Δv is plotted against time, with a first curve Δv 1 corresponding to the integral of the first curve a 1 of FIG. 1 , (i.e. the high speed crash) and a second curve Δv 2 corresponding to the integral of the second curve a 2 of FIG. 1 (i.e. the low speed crash). It can be seen, from FIG. 2 , that the curves Δv 1 and Δv 2 each start at the respective times t 01 and t 02 , which each correspond to the times at which the acceleration a 1 or a 2 first exceeds the predetermined acceleration value a 0 , and hence the time at which the processor starts processing the signal a 1 or a 2 .
A determination must be made within an appropriate period of time (e.g. 30 ms) following the time at which the acceleration rises above a 0 as to whether the crash situation requires the actuation of a safety device. If the actuation of the safety device is not triggered within an appropriately short period of time, the benefit of the safety device may be lost and the actuation thereof may be positively harmful to a vehicle occupant.
As can be seen from FIG. 2 , the changes in velocity Δv 1 and Δv 2 exceed the predetermined threshold Δv T for respectively the high speed crash and the low speed crash at respective trigger times t T1 and t T2 , which correspond to approximately 30 ms after t 01 and t 02 respectively.
The actuation of the safety device is desirable in the case of the high speed crash, represented by the first curves a 1 and Δv 1 , as the forces (proportional to a 1 ) arising from such a high speed crash will become large, at the end of the crash event meaning that it is likely that an occupant will need protection. However, it may not be desirable to trigger the safety device as a result of the low speed crash represented by the second curves a 2 and Δv 2 , as it is unlikely that an occupant will need the protection provided by the safety device since the forces arising from the low speed crash are likely to be minimal.
Unfortunately, as can be seen from FIGS. 1 and 2 , the acceleration in a 30 ms time period following the moment at which the acceleration rises above the threshold is largely dependent on the stiffness of parts of the vehicle, and is not heavily dependent upon the severity of the impact. In a severe impact, such as a high speed crash, the acceleration will continue to rise after the 30 ms interval has passed (following a short “plateau” phase) but, as discussed above, it is not desirable to wait longer than the 30 ms interval this before a decision must be taken as to whether to actuate the safety device.
In the case of a high speed crash, therefore, it is important to actuate the safety device very soon after the crash has occurred, so that the safety device may be fully deployed to protect an occupant of the vehicle from forces arising from the crash. In order to provide early actuation of the safety device, the predetermined threshold Δv T can be set at a relatively low level so that the time taken for the change in velocity Δv to rise to the low predetermined threshold Δv T is relatively short. However, if a low value of the predetermined threshold Δv T is chosen, the change in velocity Δv 2 in the case of a low speed crash will also rise to the level of the predetermined threshold Δv T during the 30 ms processing period. Thus, selecting a low value for the predetermined threshold Δv T can result in the safety device being unnecessarily actuated in the event of a low speed crash.
One way to prevent the safety device from being actuated in the event of a low speed crash would be to raise the predetermined threshold Δv T to a level which the change in velocity Δv 2 in a low speed crash will not reach. In this case, the safety device would only be actuated by the relatively large change in velocity Δv 1 , arising from a high speed crash, which reaches the higher predetermined threshold Δv T . However, the raising of the predetermined threshold Δv T means that the length of time until which the change in velocity Δv takes to reach the threshold is increased, thus increasing the length of time after which the crash occurs when the safety device is actuated.
Therefore, the need arises for a crash detection arrangement which can actuate a safety device swiftly to protect an occupant of a vehicle during a high speed crash, but which will not actuate the safety device unnecessarily in response to a relatively low speed crash.
The present invention seeks to provide an improved arrangement for determining the severity of a crash at an early stage.
According to one aspect of the present invention, there is provided a crash detection arrangement, to be installed in a motor vehicle, for detecting a crash and providing a control signal for controlling a safety device in the event that a crash is detected, the arrangement comprising an accelerometer and a control unit, the accelerometer being arranged to supply a signal to the control unit which is indicative of the acceleration of the vehicle, characterised by the control unit being adapted to: calculate a classification parameter based on the value of the signal from the accelerometer during a classification time period, which includes an interval of time before an initiation criterion was fulfilled; modify a crash evaluation algorithm in dependence upon the classification parameter; and perform the crash evaluation algorithm upon fulfillment of the initiation criterion to produce the control signal.
Advantageously, the control unit is adapted to compare the signal from the accelerometer with a predetermined acceleration value, and the initiation criterion is fulfilled when the signal from the accelerometer first exceeds the predetermined acceleration value.
Preferably, the crash evaluation algorithm comprises processing of the signal from the accelerometer for an evaluation time period which follows the time at which the initiation criterion is fulfilled.
Conveniently, the control signal comprises an actuation signal, an evaluation parameter is calculated by the crash evaluation algorithm, the step of modifying the crash evaluation algorithm comprises the steps of setting a threshold value in dependence upon the value of the classification parameter, and the crash evaluation algorithm comprises comparing the evaluation parameter with the threshold value to provide an actuation signal in dependence upon the result of the comparison.
Advantageously, the crash evaluation algorithm comprises integration of the sensed value of acceleration, and an actuation signal is provided if the result of the integration is greater than the threshold value.
Conveniently, the control unit is configured to set the threshold value to be equal to a low threshold value when the classification parameter indicates that the rise in acceleration before fulfillment of the initiation criterion is relatively fast, and to be equal to a high threshold value when the classification parameter indicates that the rise in acceleration before fulfillment of the initiation criterion is relatively slow.
Advantageously, the classification parameter is based at least partly on an integration of the sensed value of acceleration during the classification time period, or on an average of the sensed value of acceleration during the classification time period.
Preferably, the control unit is configured to set the threshold value to be equal to the high threshold value when the classification parameter is relatively high and to be equal to the low threshold value when the classification parameter is relatively low.
Alternatively, the classification parameter is based partly on an average of a derivative of the sensed value of acceleration during the classification time period.
Conveniently, the control unit is configured to set the threshold value to be equal to the high threshold value when the classification parameter is relatively low and to be equal to the low threshold value when the classification parameter is relatively high.
Advantageously, the determination as to whether the classification parameter is relatively high or relatively low is made by comparing the classification parameter with a predetermined constant.
Preferably, the threshold value is proportional to the classification parameter.
Conveniently, the classification parameter provides an indication of the rapidity of the rise in acceleration before fulfillment of the initiation criterion.
Advantageously, the control unit is configured to set the threshold value according to a formula which is dependent upon the classification parameter.
Preferably, the control signal comprises a variable output value.
Conveniently, the control unit repeatedly re-calculates the classification parameter.
Advantageously, the classification parameter is re-calculated at regular intervals.
Preferably, the classification parameter is calculated in response to the fulfillment of the initiation criterion.
Conveniently, the arrangement comprises a memory which is configured to store sensed values of acceleration.
Advantageously, the memory is configured to store, at a given moment, values of acceleration that were sensed during a predetermined length of time preceding the given moment.
Preferably, upon fulfillment of the initiation criterion, the predetermined length of time corresponds to the classification time period.
Conveniently, the classification parameter is calculated using values of acceleration stored in the memory.
Advantageously, the classification time period falls entirely before the fulfillment of the initiation criterion.
Preferably, the classification time period has a length of approximately 8 ms.
Another aspect of the present invention provides a crash detection method for detecting whether a vehicle is involved in a crash and providing a control signal for controlling of a safety device in the event that a crash is detected, the method comprising the step of: providing an accelerometer which supplies a signal which is indicative of the acceleration of the vehicle; and being characterised by the steps of calculating a classification parameter based on the value of the signal from the accelerometer during a classification time period, which includes an interval of time before an initiation criterion was fulfilled; modifying a crash evaluation algorithm in dependence upon the classification parameter; and upon fulfillment of the initiation criterion, performing the crash evaluation algorithm to produce the control signal.
BRIEF DESCRIPTION OF THE DRAWINGS
In order that the invention may be more readily understood, and so that further features thereof may be appreciated, the invention will now be described, by way of example, with reference to the accompanying drawings in which:
FIG. 1 is a graphical representation of the acceleration of a vehicle against time in a high speed crash and in a low speed crash,
FIG. 2 is a graphical representation of the calculated change in velocity against time in a high speed crash and a low speed crash,
FIG. 3 is a diagrammatic view of an arrangement for detecting a crash in accordance with a preferred embodiment of the invention installed in a motor vehicle,
FIG. 4 is a block diagram of a control arrangement in accordance with the preferred embodiment of the invention,
FIG. 5 is a graphical representation of the acceleration of the vehicle against time, during an initial stage after a collision, in the case of a high speed crash and a low speed crash, and
FIG. 6 is a graphical representation corresponding to FIG. 2 , but including a high predetermined threshold and a low predetermined threshold.
DETAILED DESCRIPTION OF THE INVENTION
Referring now to FIG. 3 , a crash detection arrangement 1 embodying the present invention is installed in a motor vehicle 2 for detecting a crash situation. The arrangement 1 incorporates an accelerometer 3 which is configured to measure the acceleration of the vehicle 2 . The accelerometer 3 is connected to supply a signal which is indicative of the acceleration of the vehicle 2 to a control unit 4 . The control unit 4 processes the signal from the accelerometer 3 (in a manner which will be discussed below) to determine whether a crash situation is occurring. The control unit 4 is connected to a safety device 5 to provide a control to the safety device 5 in the event that a crash situation is detected, to control the operation of the safety device 5 to protect an occupant of the vehicle. The safety device 5 shown here is in the form of a front air-bag unit which may be actuated to inflate an air-bag, but it is to be appreciated that the safety device 5 may be any other type of safety device, for instance a safety belt pretensioner or a side air-bag unit.
The control unit 4 incorporates a first processing arrangement 6 which is configured to integrate the signal a from the accelerometer 3 . The first processing arrangement 6 is provided with an input to receive a start signal from a comparator 7 . The comparator 7 is configured to provide the start signal when the acceleration signal a first exceeds the predetermined acceleration value a 0 . When the sensed value of acceleration rises above the acceleration value a 0 , the processing arrangement 6 processes the acceleration signal a for an evaluation time period to determine the change in velocity Δv of the vehicle 2 over a period of time, as discussed above. The length of the classification time period may vary in dependence upon the manner in which the result of the processing of the acceleration signal is to be used, as will be discussed below.
Thus, the first processing arrangement 6 processes the acceleration signal a for the evaluation time period to generate a value which is indicative of the change in velocity Δv during that period of time. As discussed above, this may be achieved by integrating the sensed value of the increase in acceleration during the evaluation time period. In preferred embodiments of the invention, the first processing arrangement 6 then compares the calculated change in velocity Δv with a predetermined threshold Δv T . If the change in velocity Δv is greater than the predetermined threshold Δv T , it has been determined that the vehicle 2 is involved in a crash which is sufficiently severe to warrant activation of the safety device 5 , and the first processing arrangement 6 transmits an actuation signal to the safety device 5 . These embodiments are particularly applicable to use of the invention with safety devices that require an actuation signal, for instance an air-bag unit. Other safety devices may require a control signal which may take several different values, or indeed be continuously variable, as will be discussed below.
In preferred embodiments of the invention, the sensed acceleration of the vehicle exceeding a 0 comprises an initiation criterion, which indicates that the vehicle is involved in a crash situation. Once the initiation criterion is fulfilled, the first processing arrangement 6 performs a crash evaluation algorithm to provide an evaluation parameter, and in the above-described embodiment the evaluation parameter comprises a result of integrating the sensed value of acceleration during the evaluation time period. This evaluation parameter may, as discussed above, then the compared with a threshold value to determine whether an actuation signal should be provided to the safety device 5 .
The control unit 4 further incorporates a second processing arrangement 8 which is configured to process the signal a from the accelerometer 3 over a classification time period, which in preferred embodiments has a length of around 8 ms. In such embodiments, at any given moment, the classification time period corresponds at least approximately to the 8 ms preceding that moment. This calculation is continuously updated, and for instance could be updated for each new sample of acceleration that is taken. A typical interval between samples is around 0.5 ms.
In embodiments of the present invention, the second processing arrangement 8 is configured to integrate the signal a from the accelerometer 3 for consecutive and successive periods of time corresponding to the classification time period. The second processing arrangement 8 once again integrates the signal a from the accelerometer 3 over the classification time period, which in these embodiments may be at least approximately 8 ms, to determine a value k to be used as a classification parameter. The second processing arrangement 8 therefore continually calculates values of k for successive time periods even when the sensed value of acceleration a is below the predetermined acceleration value a 0 . Thus, at any moment in time, irrespective of the acceleration of the vehicle, the second processing arrangement 8 will recently have calculated a value of k for the preceding 8 ms, and it will be appreciated that the second processing arrangement 8 thus operates on data relating to a “sliding window” of time which falls just before the present time.
After the second processing arrangement 8 has generated the value k the second processing arrangement 8 passes the value k to a second comparator 9 . The second comparator 9 has an output connected to a memory unit 10 which is adapted to store a value which corresponds to the predetermined threshold Δv T .
In embodiments of the invention in which the control signal comprises an actuation signal, the second comparator 9 compares the value k with a predetermined constant k T , and if the second comparator 9 determines that the value k is less than the constant k T , the second comparator 9 passes a value to the memory unit 10 which corresponds to a low predetermined threshold Δv T1 . The memory unit 10 stores the low predetermined threshold Δv T1 until a further value is sent from the second comparator 9 . If the second comparator 9 determines that the value k from the second processing arrangement 8 is greater than the constant k T , the second comparator 9 passes a value to the memory unit 10 which corresponds to a high predetermined threshold value Δv T2 .
Alternatively, the threshold Δv T may be set in accordance with a formula which is dependent upon the value k, and thus may take more values than a high predetermined threshold Δv T2 or a low predetermined threshold Δv T1 . For instance, the threshold Δv T may be set to be proportional to k, or include a component which is proportional to k (for instance comprising a constant to which a factor is added, the factor being proportional to k). Alternatively, the threshold Δv T may be proportional to the √k, to k 2 , or be dependent in any other way upon k, as a skilled person will appreciate.
In these embodiments, the threshold Δv T that is set may be continuously variable, and hence may be set to be appropriate for any type of crash situation.
The memory unit 10 is also connected to the first processing arrangement 6 to provide the stored value of the predetermined threshold Δv T to the first processing arrangement 6 . Thus, it is to be appreciated that the threshold Δv T is set to either a low threshold Δv T1 or a high threshold Δv 2 in dependence upon the most recent value of k produced by the second processing arrangement 8 .
Referring now to FIG. 5 , the curves a 1 and a 2 representing respectively the acceleration of the vehicle in a high speed crash and a relatively low speed crash, have been plotted so that the curves a 1 and a 2 first intersect at a time t 01 or t 02 when each of the curves a 1 or a 2 first exceeds the predetermined acceleration value a 0 and the initiation criterion is thus fulfilled. The “sliding window” of 8 ms is indicated as being a period of 8 ms before the times t 01 and t 02 when the curves a 1 and a 2 first exceed the predetermined acceleration value a 0 . The values of the acceleration a of the vehicle during this 8 ms “sliding window” are the values of acceleration a which are processed by the second processing arrangement 8 . It is to be appreciated that as the second processing arrangement 8 carries out an integrating calculation over the classification time period to calculate the value k, the value k will correspond to the area beneath each of the curves a 1 and a 2 during the classification time period. It can be seen that, as the acceleration a of the vehicle rises more rapidly during the initial stages of a high speed crash situation represented by curve a 1 , as opposed to a low speed crash situation represented by curve a 2 , the area beneath the high speed crash curve a 1 is less than the area beneath the low speed crash curve a 2 over the classification time period. Thus, the value k calculated by the second processing arrangement 8 is less in the case of a high speed crash than the value k calculated during a low speed crash.
This difference in the calculated value of k relating to the classification time period preceding the rise of the acceleration a above the predetermined acceleration value a 0 can be used to differentiate, at an early stage, between a high speed crash and a low speed crash. The constant k T which is compared by the second comparator 9 with the value k is chosen so that when the value k is less than the constant k T , indicating that the sensed acceleration value rose quickly towards the end of the classification time period and thus that a high speed crash is occurring, the second comparator 9 passes a low threshold value Δv T1 to the memory unit 10 . Conversely if the value k is greater than the constant k T , indicating a rapidity in the rise in acceleration which is below the predetermined value, and thus a low speed crash, the second comparator passes a high predetermined threshold Δv T2 to the memory unit 10 .
Thus, the calculated value k is lower when it has been determined that the vehicle is involved in a high speed crash, thereby helping to ensure that a safety device is triggered effectively in this situation.
In the above description, the value k is generated by integrating the sensed acceleration over the classification time period. However, in alternative embodiments, the second processing arrangement may calculate a value for k by taking an average of values of acceleration during the classification time period. In these embodiments, a low value of k is indicative of a more severe crash.
A further alternative approach is to take an averages of the derivative of these acceleration values. In these embodiments, a shorter classification time period will generally be appropriate, and for instance a classification time period of around 4 ms may be used. This is because, over an 8 ms classification time period, the averages of the derivatives of the second acceleration for gentle and severe crashes are likely to be similar, because at the start of the 8 ms classification time period the sensed acceleration will be close to zero in both cases, and at the end of the 8 ms classification time period the sensed value of acceleration will have risen in both cases, but by a similar amount. Since the derivative of the sensed acceleration is effectively equal to the slope of the acceleration/time graph, it will be understood that the average slope over 8 ms will be similar or identical over 8 ms for severe and gentle crashes. In effect, the fact that, for a more severe crash, the sensed acceleration would have remained low for the first part of the classification time period and then risen relatively rapidly would not be detected.
If, however, a shorter classification time period, for example of 4 ms, is used, this distinction can be detected far more readily. In the case of a more gentle crash, the sensed acceleration will begin to rise before the start of the 4 ms classification time period, and will already have risen by a certain amount at the start of the 4 ms classification period and continue to rise relatively gently throughout the 4 ms classification time period.
By contrast, in the case of a more severe crash, the sensed acceleration is likely to be around zero at the start of the 4 ms classification period, and rise sharply during this period. The average of the derivative of the acceleration value will therefore be higher in the case of a more severe crash when a shorter classification time period such as this is used. In this embodiment, therefore, a high value of k is indicative of a more severe crash.
A skilled person will understand how the above-described method may be adapted to accommodate these alternative methods of generating the value of k.
Referring now to FIG. 6 , the change in velocity Δv can be seen against time for the case of a high speed crash and a low speed crash, indicated respectively by curves Δv 1 and Δv 2 . The high and low predetermined thresholds Δv T1 and Δv T2 are also indicated. It is to be appreciated that a high speed crash curve Δv 1 intersects the low predetermined threshold Δv T1 at a trigger time t T1 which is relatively soon after the start time t 01 . If the second comparator 9 sets the high predetermined threshold Δv T2 , it can be seen that the high predetermined threshold Δv T2 only intersects with the high speed crash curve Δv 1 and not the low speed crash curve Δv 2 . Thus, if the second processing arrangement 8 and the second comparator 9 determine that the crash is a low speed crash, with the value k being greater than the constant k T , the high predetermined threshold Δv T2 is selected to avoid the trigger signal being generated by the low predetermined threshold Δv T2 being exceeded. However, it is to be appreciated that the high predetermined threshold Δv T2 may be exceeded if a low speed crash subsequently changes in severity to become a severe or high speed crash. The arrangement 1 can thus be used to trigger the safety device 5 in the event of a low speed crash which subsequently develops into a severe or high speed crash.
Although the preferred embodiment described thus far only incorporates two predetermined threshold Δv T1 and Δv T2 , it is to be appreciated that other embodiments may utilise a greater number of predetermined thresholds, to distinguish more finely between different types of crash.
It will be noted that both Δv T1 and Δv T2 are “stepped” in shape on the graph of FIG. 6 , and hence vary with time. These thresholds may vary with time in order to increase the number of dangerous types of crash that are correctly detected, while correctly classifying less dangerous crashes, and a skilled person will appreciate how this may be achieved. In the example shown Δv T1 and Δv T2 are stepped, but part or all of either of these thresholds may vary continuously with time.
Whilst the preferred embodiment utilises a classification time period which is around 8 ms in length, it is to be understood that the classification time period may be any other length of time, which is greater or less than 8 ms (in particular, see the discussion above relating to the use of a shorter time period in certain embodiments). Also, although the second processing arrangement 8 of the preferred embodiment calculates the value k every 0.5 ms, in other embodiments the value k may be calculated after successive time intervals which are greater or less than 0.5 ms.
Indeed, the second processing arrangement 8 may calculate a value for k only when the sensed value of acceleration first rises above a 0 . Thus, in this embodiment a sliding window of data is stored, but this data is only processed as and when it is detected that a crash situation has arisen.
In the above, it is described that the crash evaluation algorithm decides whether or not an actuation is signal is provided to a safety device, and an example of a safety device that may receive an actuation signal is an air-bag, the actuation signal simply dictates whether or not the air-bag is inflated. However, the output of the crash evaluation algorithm could also control a continuous parameter, such as the force level of a seat belt force limiter, or the pressure of air which is introduced into an air-bag. Therefore, the crash evaluation algorithm need not simply output a parameter which is compared with a threshold, but may output an appropriate and continuously variable value which may be used by the control unit 4 to control a safety-device, as will be appreciated by a skilled person. Even if a threshold is used, the triggering of the safety device could be adjusted in response to the detected crash severity by changing parameters in the crash evaluation algorithm.
Although the preferred embodiment described above utilises a control unit 4 which has two processing arrangements 6 , 8 and two comparators 7 , 9 and a memory unit 10 , the invention is not limited to such an arrangement. Indeed, it is to be understood that other embodiments of the invention may have any suitable control unit which can carry out equivalent steps to the control unit 4 of the preferred embodiment, for instance with the steps being carried out by a single processor or other unit.
While the above description constitutes the preferred embodiment of the present invention, it will be appreciated that the invention is susceptible to modification, variation and change without departing from the proper scope and fair meaning of the accompanying claims. | A crash detection arrangement, to be installed in a motor vehicle, for detecting a crash and providing a control signal for controlling a safety device in the event that a crash is detected, the arrangement comprising an accelerometer and a control unit, the accelerometer being arranged to supply a signal to the control unit which is indicative of the acceleration of the vehicle, the control unit being adapted to: calculate a classification parameter based on the value of the signal from the accelerometer during a classification time period, which includes an interval of time before an initiation criterion was fulfilled; modify a crash evaluation algorithm in dependence upon the classification parameter; and perform the crash evaluation algorithm upon fulfillment of the initiation criterion to produce the control signal. | 1 |
This application claims benefit of provisional appln 60/220,327 filed Jul. 29, 2000.
TECHNICAL FIELD OF THE INVENTION
This invention generally relates to blow molding methods and machines for producing heat set plastic containers. More specifically, this invention relates to a mechanism which stabilizes a blow molded plastic container in the blow mold cavity.
BACKGROUND OF THE INVENTION
Stretch blow molding processes are performed in automatic machines which sequence preforms and containers through several stations to complete the bottle fabrication process. The blow molding operation is performed with a plastic preform which is inflated with a gas to form a container. If the container becomes unstable or hung up in the mold during demolding, the machine must be shut down and the operator must remove the obstructing container from the machine. This results in costly lost production time and an increase in the overall machine cycle time for each container. This is economically undesirable. The trend is to reduce the cycle time of each operation in the cycle. By increasing the speed of the operation, there is a greater possibility of losing control of a container during extraction from the mold because of the high acceleration rates of the various machine components.
When the container is in the finish portion down orientation, there is a tendency for some types of containers to hang up or jam in the stretch blow molding station because of a loss of control of the container during the demolding process.
Containers with a complex sidewall geometry or a high aspect ratio are particularly prone to adhering to one side of the mold as the mold is opened. The result is that the container can cock relative to the mandrel while the container is being removed from the mold. The mandrel is part of the core assembly which passes through the finish portion and into the container. When a container cocks on the mandrel, it can jam in the mold due to the loss of control of the orientation of the bottle. Another aspect of the problem relates to containers with dimensional variations in the inside diameter of the finish portion. If the inside diameter of the finish portion is too large, the container can fall off the mandrel as a result of being jostled by the mold opening which can result in the container being jammed in the mold.
On many rotary type blow molding machines, a mechanism integral with the machine grips and stabilizes the container during demolding, preventing the problems described above. On linear type machines, a bottle stabilizer is not integral with the molding machine. Thus, there is a need for a container stabilizing device applicable to linear molding machines, with preforms in a threads or finish portion down orientation, which prevents the mold opening action from destabilizing the container relative to the mandrel thus preventing the container from getting hung up or jamming in the mold.
SUMMARY OF THE INVENTION
The present invention provides a blow molding device which is adapted for stabilizing a container formed from a preform. The container and preform each have a portion defining a finish. The device includes a mold having a first mold section, a second mold section and a cavity therebetween. The first mold section is movable toward and away from the second mold section. A mandrel is adjacent to the mold. The mandrel has one of the preform and the container disposed thereon. The first mold section and the second mold section is adapted to open and close about the mandrel in order to permit the mandrel to move into and out of the cavity in the mold. At least one jaw is adjacent to one of the first mold section and the second mold section. The at least one jaw conforms to the finish and moves transversely of the finish. The at least one jaw is biased by a resilient member to compress the finish of the preform and the bottle to the mandrel to stabilize the container when the first mold section and the second mold section move away from one another.
No complex controls or actuators are required for the operation of the present invention. When the mold is fully opened, the at least one jaw disengages from the finish of the container and allows for the passage of the incoming mandrel and clamping device, the preform, the outgoing mandrel and clamping device, and finally the molded container. As the mold closes, each jaw comes into contact with the preform finish. Upon further closing of the mold, the jaws travel on guides to compress springs and grip the preform finish. After mold closure and the blow molding process, the spring loaded jaws continue to grip the container finish and retain the container's position relative to the mandrel as the mold initially opens. As the mold further opens, the jaws continue to contact the container finish by the bias of the springs until the jaws reach the end of their travel on the guide rods, and move with each of the mold sections during the remainder of the mold opening travel. Thus, the operation of the present invention is mechanically sequenced with the normal mold opening and closing procedure.
Further features and advantages of the invention will become apparent from the following discussion and accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a sectional side view of a preform in a mold cavity used to form a blow molded container in accordance with the present invention;
FIG. 1 a is a side view of a blow molded container formed in the mold cavity shown in FIG. 1;
FIG. 1 b is a side view of the preform shown in FIG. 1;
FIG. 2 is a simplified plan view in the direction of arrows 2 — 2 labeled in FIG. 1 showing the container finish and the container stabilizer device of the present invention with the mold sections in a fully open position;
FIG. 3 is the same view as FIG. 2 with the mold sections in a partially closed position; and
FIG. 4 is the same view as FIG. 2 with the mold sections in a fully closed position.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
The container stabilizer device according to the invention is shown in FIGS. 1 through 4 and is designated by the numeral 100 . The container stabilizer device 100 includes a blow mold 12 , a mandrel 34 and an integral clamping device 36 . The container stabilizer device 100 is adapted to work in conjunction with a plastic preform 5 and a container 10 .
As illustrated in FIGS. 1 and 1 b , the preform 5 having a finish 18 and threads 22 is provided. The preform 5 is inflated with gas or fluid to form the container 10 as shown in FIG. 1 a.
In FIG. 1, the preform 5 is oriented in a mold cavity 11 of the blow mold 12 in a threads down orientation. A thread down orientation is defined as a condition wherein the preform 5 is positioned in the mold cavity 11 of the blow mold 12 with the threads 22 below the plastic body of the preform 5 . In FIG. 1 b , the preform 5 is shown in a threads up orientation.
With continued reference to FIGS. 1, 1 a and 1 b , the blow mold 12 includes a first mold section 14 , a second mold section 16 and the mold cavity 11 therebetween. The container 10 , is processed from the preform 5 which includes a finish 18 having a bore 17 and threads 22 adapted to receive a screw on cap (not shown). A flat region known as an A band 24 is located on the finish 18 . The A band 24 is located on the finish 18 between a tamper ring 26 and a support ring 28 . Other container 10 features include a sidewall 30 and a base 32 to enclose the bottom of the container 10 . The mandrel 34 is adapted to pass through an inner diameter 19 of the finish 18 of the container 10 .
The mandrel 34 includes a top portion 31 and an inner projecting portion 35 . The mandrel 34 has a passage 33 extending through both the top portion 31 and the inner projecting portion 35 . The inner projecting portion 35 has an outer diameter 37 which is less than the inner diameter 19 of the finish 18 . Thus, the inner projection portion 35 of the mandrel 34 is capable of being disposed within the finish 18 of the preform 5 . The passage 33 provides a flow path for the introduction of gas or fluid into the bore 17 of the preform 5 as is conventional. The mandrel 34 is axially related to the top of the blow mold 12 .
The inner projecting portion 35 of the mandrel 34 has a top flange 39 , a smaller flange 41 adjacent to the top flange 39 and an undercut 43 between the top flange 39 and the smaller flange 41 . The top flange 39 of the inner projecting portion 35 has ball detents on its outer periphery to assist in its retention in a cavity extending through the top portion 31 of the mandrel 34 .
The top portion 31 of the mandrel 34 also has an outer peripheral portion 45 and an undercut 47 on its inner diameter. The inner projecting portion 35 of the mandrel 34 is connected to the top portion 31 of the mandrel 34 by means of a conventional retainer such as a snap ring 49 which fits into the undercut 47 of the top portion 31 and the undercut 43 of the inner projecting portion 35 to lock the two portions together, as is conventional.
The outer diameter 37 of the inner projecting portion 35 is smaller than the inner diameter 19 of the finish 18 of the preform 5 so as to accommodate for dimensional fluctuations in the inner diameter 19 . An annular seal member 7 is disposed in a counterbore in the mandrel 34 . The seal member 7 abuts the end of the finish 18 . Alternatively, the seal member 7 is disposed about the outer periphery of the finish 18 . The seal member 7 prevents the blow molding fluid from leaking out of the bore 17 of the plastic preform 5 when the container 10 is being formed. The mandrel 34 extends into the inner diameter 19 of the finish 18 and between a pair of jaws 38 , and is fastened thereto by conventional means.
FIGS. 2 through 4 show the integral clamping device 36 , the finish 18 of the container 10 and the container stabilizer device 100 with the mold sections 14 and 16 of the present invention. Mandrel 34 has been removed for clarity. The integral clamping device 36 is disposed in a cavity 15 formed on top of and between the mold sections 14 and 16 , and is fastened, in any commonly known manner, on each mold section 14 and 16 , respectively. The clamping device 36 has a pair of jaws 38 . Each jaw 38 is mounted on a pair of spaced apart guide bars 40 . Each jaw 38 is preferably semicircular in shape having a contact surface 51 in the plan view which conform to the curved surface of the A band 24 of the preform 5 and the container 10 . The guide bars 40 pass through and glide in bores 42 in the mold sections 14 and 16 , respectively. Each guide bar 40 captures and preloads a biasing member 44 between the jaw 38 and the mold 12 . Each guide bar 40 is threaded on an end opposite the jaw 38 . Nuts 46 are used to attach and compress biasing members 44 . Each bore 42 is counterbored to provide appropriate seats for the biasing members 44 , nuts 46 and any appropriate washers or shims, as is conventional. The free position of each of the jaws 38 and the preload of the biasing members 44 can be adjusted by rotating each nut 46 and appropriate washers and shims as is well known in the art. The biasing members 44 may be helical springs, or any other resilient member that is within the teachings and scope of the present invention.
In the initial open position of the blow mold 12 , as shown in FIG. 2, a clearance is provided between the mold sections 14 and 16 , respectively, to permit the mandrel 34 with an attached preform 5 to be positioned between the mold sections 14 and 16 . The mold 12 is then moved to a partially closed position, as shown in FIG. 3, at which point each of the jaws 38 contact the A band 24 of the preform 5 . As the mold 12 proceeds to a fully closed position, as shown in FIG. 4, each of the opposed jaws 38 continue to contact and press against the A band 24 . The biasing members 44 are compressed as each of the jaws 38 translate into the cavity 15 as the mold sections 14 and 16 are closed. When the mold sections 14 and 16 are in the closed position, the biasing members 44 are fully compressed, and each jaw 38 grips and applies pressure to the finish 18 of the preform 5 .
Once the mold 12 is fully closed, the preform 5 is stretch blow molded as is conventional to form the container 10 . Once the container 10 is formed, the mold 12 is partially opened. During this time, the opposing pair of jaws 38 continue to apply pressure to each side of the A band 24 and, in turn, the mandrel 34 because of the compressed biasing members 44 . The pressure of the jaws 38 captures the container 10 around the circumference of the A band 24 in the horizontal direction, and between the tamper ring 26 and the support ring 28 in the vertical direction. This stabilizes the container 10 and prevents any movement of the container 10 relative to the mandrel 34 as the mold 12 is initially opened.
As the mold sections 14 and 16 continue to open, the jaws 38 continue to apply pressure against the A band 24 , thus maintaining the container 10 in the desired stabilized position until the mold sections 14 and 16 are approximately half open (see FIG. 3 ). At this point, the jaws 38 begin to disengage from the A band 24 since the travel of each jaw 38 is limited by the length of the guide bars 40 . Thereafter, each jaw 38 moves with each respective mold section 14 and 16 to the position shown in FIG. 2 . This position allows the mandrel 34 to be retracted out of the mold 12 and permits the removal of the completed container 10 from the mold 12 . Thereafter, another cycle of the molding process can be repeated.
The foregoing discussion discloses and describes a preferred embodiment of the present invention. One skilled in the art will readily recognize from such discussion, and from the accompanying drawings and claims, that changes and modifications can be made to the invention without departing from the true spirit and fair scope of the invention as defined in the drawings and in the following claims. | A method and apparatus for stabilizing a blow molded plastic preform and container in a blow mold during a demolding operation. The blow mold has a first mold section, a second mold section, and a mandrel. The mandrel cooperates with a pair of spring loaded jaws slidingly coupled to one or both of the mold sections. With the mold sections in their fully open position, the mandrel with an attached preform and/or container travels into the blow mold. During the final stage of closing the mold sections, the jaws contact the finish and restrain the container. As the mold sections begin to open, the jaws prevent any movement of the container relative to the mandrel. | 1 |
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0001] This invention was made in part with government support under grant no. HG00205 awarded by the National Institutes of Health (NIH). The government has certain rights in this invention.
FIELD OF THE INVENTION
[0002] The present invention relates generally to biochemistry. More particularly, the present invention relates chemically cleavable phosphoramidite linkers.
BACKGROUND
[0003] Tandem oligonucleotide synthesis involves stepwise synthesis of two or more oligonucleotides end-to-end in a tandem manner on the surface of a solid-phase support. Cleavage and deprotection of the linked oligos results in two (or more) different oligos in the deprotection solution. Tandem oligonucleotide synthesis is considered especially advantageous for polymerase chain reaction (PCR), in which two oligonucleotides must perform a reaction in the same reaction vessel.
[0004] Several methods have been proposed to accomplish tandem oligonucleotide synthesis, but they all have disadvantages. It was first proposed that enzymatic processes could be used to cleave two primers that were synthesized end-to-end by exploiting the specific recognition of Uracil DNA Glycosylase (UDG) enzyme for uridine residues. UDG recognizes uridine, which is not typically present in synthetic DNA, and catalyzes the removal of the uridine nucleobase from the DNA backbone. The DNA backbone at the abasic site is highly susceptible to breakage if the DNA is heated to about 90° C., if it is treated by Human Apurinic Exonuclease (APE), or if it is treated chemically with N,N′-dimethylethylenediamine (DMED). Unfortunately, it was found that UDG and APE preferred double stranded substrates and thus did not reliably create abasic sites or break the DNA backbone of single-stranded DNA oligonucleotides (ssDNA), and thus these treatments proved unsuccessful in breaking a single stranded oligonucleotide. DMED was very effective in breaking the abasic site's backbone generated by UDG, however it too proved to be less than ideal for producing two PCR primers from a synthetic oligonucleotide because it left a 3′ phosphate or a 3′ ring-opened sugar on the 5′ end of the cut site. Because polymerases and most other DNA acting enzymes require a 3′ hydroxyl in order for the DNA to initiate enzymatic activity, DMED could not be used because it would not reliably leave a 3′ hydroxyl.
[0005] Commercially available chemical methods were also investigated. One method was based on a modified phosphoramidite where each base was chemically separated from the 3′ phosphate by a chemically cleavable linker. Two structures were proposed for separating the phosphate from the 3′ oxygen on the nucleobase. In one case, the phosphate was separated by a sulfone group, which is highly base-labile and cleaves quickly in ammonium hydroxide, a chemical that is already used to deprotect the nucleobases of an oligonucleotide. There are two problems with this approach. First, the sulfone group is sufficiently base-labile so that the phosphoramidite would quickly degrade before it was chemically coupled (incorporated) into the oligonucleotide. Second, degradation may occur during storage, particularly for oligonucleotides containing more basic nucleosides. Another version of this linker cleaved but left a 5′ ethylphosphate, which is incompatible with several biological processes, which require a 5′ phosphate or a 5′ hydroxyl. Accordingly, there is a need in the art to develop a new linkers that produce oligonucleotides that are more stable during storage and synthesis and more suitable for downstream reactions.
SUMMARY OF THE INVENTION
[0006] The present invention provides phosphoramidite linkers that are useful for the production of synthesizing two or more oligonucleotides in tandem. The inventive linkers have the following desirable properties: (i) enhanced stability to alkali conditions versus the linkers previously published, (ii) cleaves to produce 5′ and 3′ ends that are fully biologically compatible, (iii) cleaves completely under conditions that are already used in cleavage/deprotection processes so it is fully compatible with conditions that are common in laboratories and does not require additives that necessitate further purification after cleavage, (iv) integrates easily onto commercially available synthesizers because it is compatible with standard coupling chemistry, and (v) is compatible with DNA, RNA, forward, reverse, and LNA synthesis chemistry. In addition, the inventive linkers may be coupled to a solid support. Thus, the inventive linkers provide a significant advancement in the state of the art.
[0007] In one embodiment, the present invention provides a compound having formula I:
[0000]
[0000] wherein
B is a nucleobase; P 1 is an acyl, an aroyl, a phenoxyacetyl, an isopropylphenoxyacetyl, a t-butylphenoxyacetyl, an acetyl, a benzoyl, an isobutyryl, a levulinoyl, a dialkylformamidino, an fmoc, or a photolabile protecting group; P 2 is a dimethoxytrityl, a monomethoxytrityl, a levulinoyl, an ArCO, a silyl, or a photolabile protecting group; R 1 is a base-labile group; R 2 is a hydrogen, a fluoro, a protected amino, a protected hydroxyl, an O-alkyl, an O-alkylalkoxy, or a secondary amine; R 3 is a phosphorus protecting group; R 4 is an alkyl or (R 4 ) 2 forms a cyclic secondary amine; and O, P, and N have their normal meanings of oxygen, phosphorous and nitrogen.
[0016] In another embodiment, the present invention provides a material having formula II:
[0000]
[0000] wherein
B is a nucleobase; P 1 is an acyl, an aroyl, phenoxyacetyl, an isopropylphenoxyacetyl, a t-butylphenoxyacetyl, an acetyl, a benzoyl, an isobutyryl, a levulinoyl, a dialkylformamidino, an fmoc, or a photolabile protecting group; P 2 is a dimethoxytrityl, a monomethoxytrityl, a levulinoyl, an ArCO, a silyl or a photolabile protecting group; R 1 is a base-labile group; R 2 is a hydrogen, a fluoro, a protected amino, a protected hydroxyl, an O-alkyl, an O-alkylalkoxy, or a secondary amine; R 5 is at least one nucleotide; R 3 is a phosphorous protecting group; X is a solid support; and O, P, and N have their normal meanings of oxygen, phosphorous and nitrogen.
[0026] In yet another embodiment, the present invention provides a method of synthesizing the compound having formula I. According to this method, a compound having formula III:
[0000]
[0000] is provided, wherein
B is a nucleobase; P 1 is an acyl, an aroyl, phenoxyacetyl, an isopropylphenoxyacetyl, a t-butylphenoxyacetyl, an acetyl, a benzoyl, an isobutyryl, a levulinoyl, a dialkylformamidino, an fmoc, or a photolabile protecting group; P 2 is a dimethoxytrityl, a monomethoxytrityl, a levulinoyl, an ArCO, a silyl or a photolabile protecting group; R 1 is a base-labile group; R 2 is a hydrogen, a fluoro, a protected amino, a protected hydroxyl, an O-alkyl, an O-alkylalkoxy, or a secondary amine; and O and H have their normal meanings of oxygen and hydrogen.
[0033] The compound having formula III is reacted with one of two types of compounds. In one aspect of this embodiment, the compound having formula III is reacted with about 1-1.5 equivalents of an O-protected bis-dialkylaminophosphodiamidite, (R′ 1 O—P—(NR′ 2 ) 2 where R′ 2 is a dialkyl or (NR′ 2 ) 2 forms a cyclic secondary amine, and R′ 1 is a protecting group. In another aspect of this embodiment, the compound having formula III is reacted with 1-1.5 equivalents of chloro-β-cyanoethyl-N′N′-diisopropylphosphoramidite in the presence of a tertiary amine.
[0034] In yet another embodiment, the present invention provides a method of synthesizing at least two oligonucleotides in tandem. According to this method, a first nucleotide is synthesized. The compound having formula I is then incorporated into this first oligonucleotide. Next, a second oligonucleotide is synthesized, where the second oligonucleotide is coupled to the compound having formula I. Finally, the first and second oligonucleotides are cleaved from the compound having formula I.
[0035] In a final embodiment, the present invention provides a method of synthesizing an oligonucleotide. According to this method, the material having formula II is provided and a sequence of bases is coupled to this material until the oligonucleotide is synthesized.
BRIEF DESCRIPTION OF THE FIGURES
[0036] The present invention together with its objectives and advantages will be understood by reading the following description in conjunction with the drawings, in which:
[0037] FIG. 1 shows an example of synthesis of tandem oligonucleotides according to the present invention.
[0038] FIG. 2 shows an example of synthesis of oligonucleotides on a solid support according to the present invention.
[0039] FIG. 3 shows an example of synthesis of a phosphoramidite linker according to the present invention.
[0040] FIG. 4 shows an example of cleavage of tandem DNA oligonucleotides according to the present invention.
[0041] FIG. 5 shows an example of functionality of a cleaved tandem oligonucleotide primer pair in a PCR reaction according to the present invention.
[0042] FIG. 6 shows an example of quality of DNA synthesized from a phosphoramidite linker coupled to either a polystyrene or glass support.
[0043] FIG. 7 shows an example of synthesis and cleavage of tandem RNA oligonucleotides according to the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0044] In one embodiment, the present invention provides a compound having formula I (hereafter referred to as the phosphoramidite linker:
[0000]
[0000] wherein:
B is a nucleobase; P 1 is an acyl, an aroyl, a phenoxyacetyl, an isopropylphenoxyacetyl, a t-butylphenoxyacetyl, an acetyl, a benzoyl, an isobutyryl, a levulinoyl, a dialkylformamidino, an fmoc, or a photolabile protecting group; P 2 is a dimethoxytrityl, a monomethoxytrityl, a levulinoyl, an ArCO, a silyl or a photolabile protecting group; R 1 is a base-labile group; R 2 is a hydrogen, a fluoro, a protected amino, a protected hydroxyl, an O-alkyl, an O-alkylalkoxy, a secondary amine, or a phosphorous protecting group; and R 3 is a phosphorus protecting group; R 4 is an alkyl or (R 4 ) 2 forms a cyclic secondary amine; and O, P, and N have their normal meanings of oxygen, phosphorous and nitrogen.
[0053] In a preferred aspect of this embodiment, R 1 is
[0000]
[0000] where x is an alkyl, an alkoxyalkyl, an aryl aralkyl, or an ether. In a particularly preferred aspect of this embodiment, R 1 is a succinate, a malonate, a glutarate, an adipate, a diglycolate, a catechol, or an analog or derivative thereof. A key quality of R 1 is that it be a bi-functional group in which both functions are base labile. Preferably, the hydroxyl in R 2 is protected by 2′TBDMS (t-butyldimethylsilyl), 2′TOM (triisopropylsilyloxymethyl), or 2′ACE (bis-acetoxyethylorthoformate). In a particularly preferred aspect of this embodiment, the hydroxyl in R 2 is protected by a silyl group. In another preferred aspect of this embodiment, the photolabile protecting group is 2-(2-nitrophenyl)-propoxycarbonyl, 2-(2-nitrophenyl) propoxycarbonyl piperidine (NPPOC-pip), 2-(2-nitrophenyl)-propoxycarbonyl hydrazine (NPPOC-Hz), or MeNPOC (3,4-methylenedioxy-6-nitro-phenylethyloxycarbonyl). The nucleobase according to this embodiment of the invention may be any type of nucleobase, including but not limited to a deoxyribonucleobase, a ribonucleobase, or analogs or derivatives thereof.
[0054] In another embodiment, the present invention provides a material having formula II (hereafter referred to as the phosphoramidite linker material):
[0000]
[0000] wherein:
B is a nucleobase; P 1 is an acyl, an aroyl, a phenoxyacetyl, an isopropylphenoxyacetyl, a t-butylphenoxyacetyl, an acetyl, a benzoyl, an isobutyryl, a levulinoyl, a dialkylformamidino, an fmoc, or a photolabile protecting group; P 2 is a dimethoxytrityl, a monomethoxytrityl, a levulinoyl, an ArCO, a silyl or a photolabile protecting group; R 1 is a base-labile group; R 2 is a hydrogen, a fluoro, a protected amino, a protected hydroxyl, an O-alkyl, an O-alkylalkoxy, or a secondary amine; R 5 is at least one nucleotide; R 3 is a phosphorous protecting group; X is a solid support; and O, P, and N have their normal meanings of oxygen, phosphorous and nitrogen.
[0064] In a preferred aspect of this embodiment, R 1 is
[0000]
[0000] where x is an alkyl, an alkoxyalkyl, an aryl aralkyl, or an ether. In a particularly preferred aspect of this embodiment, R 1 is a succinate, a malonate, a glutarate, an adipate, a diglycolate, a catechol, or an analog or derivative thereof. Preferably, the hydroxyl in R 2 is protected by 2′TBDMS, 2′TOM, or 2′ACE. In a particularly preferred aspect of this embodiment, the hydroxyl in R 2 is protected by a silyl group. In another preferred aspect of this embodiment, the photolabile protecting group is 2-(2-nitropheynyl)-propoxycarbonyl, 2-(2-nitrophenyl) propoxycarbonyl piperidine (NPPOC-pip), 2-(2-nitrophenyl)-propoxycarbonyl hydrazine (NPPOC-Hz), or MeNPOC. The nucleobase according to this embodiment of the invention may be any type of nucleobase, including but not limited to a deoxyribonucleobase, a ribonucleobase, or analogs or derivatives thereof. Also preferably, the solid support is a solid support matrix. The solid support may be, but is not limited to, controlled pore glass, polystyrene, or an oligonucleotide array.
[0065] In another embodiment, the present invention provides a method of synthesizing at least two oligonucleotides in tandem. According to this method, a first oligonucleotide is synthesized. Next, the phosphoramidite linker is incorporated into the first oligonucleotide. Next, a second oligonucleotide is synthesized, where the second oligonucleotide is coupled to the phosphoramidite linker. Finally, the first and second oligonucleotides are cleaved from the phosphoramidite linker. Importantly, once the second oligonucleotide is cleaved from the phosphoramidite linker, the 3′ end of the second oligonucleotide ends up as —OH (after deprotection), the succinate linker is lost, and the phosphorous becomes part of the 5′-phosphate of the first oligo, as shown in FIG. 1 .
[0066] The second oligonucleotide may be coupled to the phosphoramidite linker using any coupling chemistry, including any standard coupling chemistry known in the art. In an exemplary embodiment, the second oligonucleotide is coupled to the phosphoramidite linker using the following method, called the phosphoramidite method. According to this method, coupling reactions are catalyzed by a weakly acidic compound, which protonates the amidite nitrogen; the conjugate base of the compound serves as a nucleophile to activate the phosphorus atom. The electropositive phosphorous subsequently attacks the electronegative oxygen (on the 5′ end of the support-bound nucleoside/oligomer). This chemical attack results in a phosphite triester, which is stabilized by oxidation to the pentavalent phosphate triester during a subsequent step. Activators typically used for this reaction include, but are not limited to, 1-H-Tetrazole, 5-ethylthio-1H-tetrazole (ETT), 5-benzylthio-1H-tetrazole (BTT), dicyanoimidazole (DCI), a pyridinium salt and a trifluomethanesulfonate salt.
[0067] The inventive method may further include deprotecting the oligonucleotides, using techniques known in the art. These deprotected oligonucleotides may be used directly in, e.g., PCR reactions, sequencing reactions, or ligation reactions. As such, the oligonucleotides may be, but are not limited to, PCR primers, synthetic genes, DNA oligonucleotides, or RNA oligonucleotides.
[0068] In another embodiment, the present invention provides a method of synthesizing an oligonucleotide, as shown in FIG. 2 . This method includes providing a phosphoramidite linker material and coupling a sequence of bases to the material until the oligonucleotide is synthesized. The oligonucleotide may then be cleaved from the phosphoramidite linker material. Any oligonucleotides may by synthesized according to the present invention, including but not limited to PCR primers, synthetic genes, DNA oligonucleotides, or RNA oligonucleotides. The inventive method may further include deprotecting the oligonucleotides, using techniques known in the art. These deprotected oligonucleotides may be used directly in, e.g., PCR reactions, sequencing reactions, or ligation reactions.
[0069] The present invention also provides a method of synthesizing the phosphoramidite linker. According to this method, one first provides a compound having formula III:
[0000]
[0000] wherein
B is a nucleobase; P 1 is an acyl, an aroyl, phenoxyacetyl, an isopropylphenoxyacetyl, a t-butylphenoxyacetyl, an acetyl, a benzoyl, an isobutyryl, a levulinoyl, a dialkylformamidino, an fmoc, or a photolabile protecting group; P 2 is a dimethoxytrityl, a monomethoxytrityl, a levulinoyl, an ArCO, a silyl or a photolabile protecting group; R 1 is a base-labile group; R 2 is a hydrogen, a fluoro, a protected amino, a protected hydroxyl, an O-alkyl, an O-alkylalkoxy, or a secondary amine; and O and H have their normal meanings of oxygen and hydrogen.
[0076] In this embodiment, the compound having formula III is then reacted with about 1-1.5 equivalents of an O-protected bis-dialkylaminophosphodiamidite, (R′ 1 O—P—(NR′ 2 ) 2 wherein R′ 2 is a dialkyl or (NR′ 2 ) 2 forms a cyclic secondary amine, and R′ 1 is a protecting group. (NR′ 2 ) 2 may be, but is not limited to, piperidine, morpholine, or pyrrolidine. R′ 1 may be, but is not limited to, methyl, β-cyanoethyl, allyl, or nitrophenethyl. In a preferred aspect of this embodiment, the O-protected bis-dialkylaminophosphodiamidite is β-cyanoethyl-N,N,N′,N′-tetraisopropylphosphordiamidite. Also preferably, 0.05-1.5 equivalents of an activator is added to the O-protected bis-dialkylaminophosphodiamidite. The activator may be, but is not limited to, 1H-tetrazole, S-ethylthiotetrazole, 5-benzylthio-1H-tetrazole, 4,5-dicyanoimidiazole, a trifluoromethylsulfonic acid salt, or a pyridinium salt.
[0077] In another embodiment, the compound having formula III is reacted with about 1-1.5 equivalents of chloro-β-cyanoethyl-N′N′-diisopropylphosphoramidite in the presence of a tertiary amine.
[0078] In either embodiment, the reaction is preferably accomplished at room temperature for between about 1 and about 5 hours. Also preferably, dichloromethane is added when the reaction is complete in order to form a solution and facilitate the wash step. The solution is then preferably washed with a 5% aqueous NaHCO 3 solution and a saturated NaCl solution. The organic phase of the solution, which contains the phosphoramidite linker, may then be isolated using standard techniques known in the art. Preferably, the organic phase is isolated a pH in the range of between about 7.5 and about 9.5. Preferably, the organic phase is then dried with Na 2 SO 4 , filtered, and evaporated until no further solvent is distilled over, using techniques known in the art. Preferably, the organic phase is also evaporated, where the evaporating dries the organic phase Phosphoramidite linker prepared according to the present invention is stable for at least 2.5 years at −40° C. and at least two days at ambient temperature.
[0079] The inventive method may further include coupling the phosphoramidite linker to a solid support, using chemistries known in the art. The solid support may be, for example, a solid support matrix, a controlled pore glass, a polystyrene, or an oligonucleotide array.
[0080] The present invention may be used for numerous applications. The following is a list of exemplary, but non-limiting examples of applications.
[0081] One important example is the use of the inventive linker to produce PCR primers. In this way, both primers could be prepared in a single well of a multi-well plate, reducing errors and volumes and cost.
[0082] Another important example is synthesis of oligonucleotides on microarrays. Following coupling of the phosphoramidite linker to a microarray using standard phosphoramidite coupling procedures, further coupling of phosphoramidite bases can proceed until full length oligonucleotides are built on the solid support. In the case of a microarray, this will enable the production of tens of thousands of unique oligonucleotides in parallel on the array. As the phosphoramidite linker used to tether the first base on the 3′ end of the oligonucleotide is cleavable, all of the synthesized oligos may then be released into solution and used. An application for the large scale production of thousands of oligonucleotides could be the synthesis of whole genes or genomes from the oligos produced on a single microarray.
[0083] The inventive linker could be also used for synthesizing RNA oligonucleotides. An application receiving particular attention recently is the use of RNA duplexes for RNA interference (RNAi) studies. RNA duplexes, when designed properly, have been shown to reduce the expression of target genes in vivo, effectively “knocking down” the level of gene expression. Since the RNA oligonucleotides are synthesized in the single stranded form and then pooled with their compliment to form a duplex, time and money could be saved by synthesizing both strands of an RNA duplex in the same reaction vessel.
[0084] Another application includes the construction and assembly of synthetic genes where the sense and anti-sense strands are synthesized in tandem. Upon cleavages of the two strands (lengths dependent upon complimentary melting temperatures (Tm) of overlapping regions of homology), the downstream oligonucleotide will hybridize with the upstream strand, still support-bound, creating a double stranded fragment of DNA. This technique also utilizes the presence of the 5′ phosphate inherent upon complete cleavage and removal of the carboxylic-phosphoric acid mixed anhydride. Furthermore, this saves on the cost of additional phosphorylation reagent ordinarily needed to modify the 5′ region of the upstream strand.
EXAMPLES
[0085] Synthesis of the Phosphoramidite Linker
[0086] In this example, shown in FIG. 3 , succinate phosphoramidite linkers were synthesized. A similar procedure would be used for other phosphoramidite linkers. Nucleoside-3′-O-succinate (1a-1d, Thermo Fisher Scientific (Milwaukee)) was dissolved in dichloromethane in a flask under an argon atmosphere. β-Cyanoethyl-N,N,N′N′-tetraisopropylphosphordiamidite (1 eqv.) was added followed by 1H-tetrazole (1.2 eqv.). The reaction was stirred at room temperature for 1-5 hrs. When complete, dichloromethane was added to the reaction mixture and the resulting solution was washed with 5% aq. NaHCO 3 and saturated NaCl solutions. The organic phase was dried (Na 2 SO 4 ), filtered, and evaporated to dryness. The phosphoramidite (2a-2d) was obtained as white foam with 91-97% HPLC purity. The succinate phosphoramidite linkers (2a-2d) were very stable under common storage conditions.
[0087] To determine the stability of succinate phosphoramidite linkers, the products were stored at −40° C. under argon. The linker was then left at room temperature for one hour prior to analysis. Product purity was tested by HPLC and, in some cases, 31 PNMR (CDCl 3 ). Results for Bz-dC succinate amidite are shown in Table 1.
[0000]
TABLE I
Date
Timepoint
HPLC (%)
31 P NMR* (%)
(Dec. 24, 2004)
0
95
94
Jan. 25, 2005
1-Month
95
93
Mar. 16, 2005
3-Month
95
93
Jul. 12, 2005
6-Month
95
95
Mar. 27, 2006
15-Month
93
99
Jan. 17, 2007
>2 Years
95
—
[0088] Coupling of Tandem DNA Oligonucleotides from the Phosphoramidite Linker
[0089] This experiment was carried out to show proof of concept that the inventive phosphoramidite linkers cleaved from the 3′ region of the upstream DNA strand and the 5′ region of the downstream DNA strand of both oligonucleotides in tandem. Analysis was carried out using reverse-phase high performance liquid chromatography (HPLC).
[0000]
(SEQ ID NO: 1)
5′-TTTTTTTTTTTTTTTTTTT_Linker-T_TTTTTTTTTT-3′
[0090] Poly T Oligomers Adjoined with T-Succinyl Phosphoramidite Linker
[0091] Starting from the 3′ end, the downstream Poly T 10 mer was synthesized DMT-ON using a 0.2 μmol scale. Afterwards, the T succinate phosphoramidite linker was added using a 1 μmol scale synthesis cycle.
[0092] The overall coupling efficiency (CE) of the upstream oligo was ˜99.3 percent. After linker addition, the CE dropped to 79 percent. During its detritylation a light orange color was observed within the synthesis column suggesting the linker had been coupled to the 5′ region of the downstream oligo. The final CE of the two oligos in tandem was ˜85 percent.
[0093] Cleavage and Deprotection of Tandem Oligos from the Phosphoramidite Linker
[0094] The coupled oligonucleotides were cleaved from their support using 28-30% ammonium hydroxide in solution (NH 4 OH). One mL NH 4 OH was passed through each sample 3 times with a hold time of fifteen minutes using Norm-Ject 1 mL syringes (4010.200V0). Following cleavage from the solid support, the tandem T 10 and T 20 oligos were deprotected over night (O/N) at 55° C. Though the thymidine phosphoramidite has no base protection, exposure to NH 4 OH will remove any residual cyanoethyl groups from the oligonucleotide. All samples were normalized to 100 μM in water. FIG. 4 shows LC-MS data for T 30 (SEQ ID NO:1) cleaved into T 10 and T 20 oligos.
[0095] Biological Functionality of Cleaved and Deprotected Tandem Oligos in PCR Reactions
[0096] pUC19 primers (56.3/55.8 T m s, respectively) were synthesized in tandem as described above.
[0000]
5′-GATACGGGAGGGCTTACCA(linker-
(SEQ ID NO: 2)
T)GATAACACTGCGGCCAACTT-3′
[0097] When cleaved and deprotected, as described above, the resulting primers are:
[0000]
(Forward)
5′-GATACGGGAGGGCTTACCAT-3′
(SEQ ID NO: 3)
(Reverse)
5′-PO4-GATAACACTGCGGCCAACTT-3′
(SEQ ID NO: 4)
[0098] PCR was carried out on a GeneAmp PCR System 9700 (Applied Biosystems) using the following PCR cycle:
1. 94° C., 10 min 2. 94° C., 0:30 sec 3. 55° C., 0:45 sec 4. 73° C., 2:00 min 5. Repeat steps 2-4, 30× 6. 72° C., 7 min 7. 4° C., ∞
[0106] Reagents purchased from Applied Biosystems included PCR Buffer II 10×, 25 mM MgCl 2 , 125 mM dNTPs, 3.2 pmol forward and reverse primers, and 5 U AmpliTaq Gold enzyme. After PCR, the samples were analyzed on a 0.9% Agarose gel with EtBr. Fermentas O'Generuler 50 pb DNA Ladder (0.1 μg/μL) was used to measure amplicon size.
[0107] FIG. 5 shows a gel image comparing control primers and NH 4 OH(l) cleaved T-succinyl Linker primers in Tandem. Based on data obtained from MS and HPLC, the cleavage between upstream and downstream poly T oligonucleotides is not 50:50 (see FIG. 4 ). For the application of PCR, having more of one primer than the other in solution could have an effect on the amplification. The target [c] for each of the control primers is 3.2 pmol. To calculate the initial [c] of the primers in tandem, an average of both extinction coefficients was taken. The final [c] value apparently was an overestimation, hence the lighter band intensity of the custom linker sample compared with the control.
[0108] Synthesis of a DNA Oligonucleotide Using the Inventive Phosphoramidite Linker Material
[0109] As shown in FIG. 6 , the utility of a succinate (tandem) linker phosphoramidite as a universal support was tested by synthesizing a thymidine 10 mer homopolymer (T 10 ) (SEQ ID NO:5) on a standard polystyrene support ( 610 ) and on bare glass ( 620 ). Use of the phosphoramidite in this manner shows that high quality oligonucleotides may be synthesized directly from a glass surface, such as the SiO 2 layer of a silicon chip or microarray, or on underivitized glass supports. The quality of the two oligonucleotides, one synthesized on a standard support and the other synthesized directly on bare glass, are virtually indistinguishable, suggesting further that this linker is suitable for microarray work.
[0110] The two oligonucleotides were synthesized on an Applied Biosystems 394 synthesizer. The control oligo ( 610 ) was produced using a polystyrene flow-through column with the first nucleoside (thymidine) attached to the support. The control oligo, after synthesis was completed, was removed from the solid support by treatment in 28% ammonium hydroxide solution, a standard cleavage reagent. The oligo was heated to 55° C. for 30 min to remove cyanoethyl groups from the oligomer. The same T 10 homopolymer was also synthesized on an aminated glass support from CPG, Inc., using the same synthesizer cycle as the control oligo with two exceptions: 1) since the first oligonucleotide is not pre-attached to the bare support, the tandem oligo linker was coupled to the support in the same manner as all other bases were coupled (BTT activator plus amidite) except the first coupling step was performed for 15 minutes instead of 30 seconds, which is adequate for subsequent additions. The need for the longer coupling time is two-fold: the tandem oligo linker has a higher molecular weight than standard phosphoramidites and therefore is expected to react more slowly than standard phosphoramidites, and 2) the primary amine on the CPG support is less reactive than the hydroxyl that is normally present on a standard RNA/DNA synthesis support. Subsequent nucleosides were attached in the same manner for each oligonucleotide.
[0111] This proof-of-concept reaction proves that DNA may also be synthesized in situ directly on a DNA chip (microarray). The utility of this concept is straightforward, because it will allow synthesis of oligonucleotides on a highly parallel microarray platform, and allows the oligonucleotides to be removed from the microarray for use in assays. The most obvious applications for collecting oligonucleotides from a microarray synthesis are: 1) synthesis of synthetic genes from the oligos, and 2) use of the oligos in large pools for genotyping applications such as MIP (molecular inversion probe) genotyping.
[0112] Synthesis and Cleavage of Tandem RNA Oligonucleotides Using the Inventive Phosphoramidite Linker
[0113] The utility of the inventive phosphoramidite linker material was also tested for use in RNA synthesis. Although RNA and DNA phosphoramidites each have the same reactive groups to facilitate coupling reactions, proof of the ability to synthesis two RNA fragments in a single reaction vessel is desirable. With a clear application in siRNA research, the most common application is where two complementary ssRNA fragments are pooled and hybridized to form an siRNA cassette. Synthesis of two RNA fragments in a single reaction vessel so that errors associated with incorrect pooling of the two ssRNA strands is avoided. The chromatogram shown in FIG. 7 is of a 40 mer deoxyuridine (dU) with two thymidine (dT) nucleosides in the sequence (SEQ ID NO:6), linked in tandem and then cleaved into two shorter RNA fragments. A control ribooligomer (SEQ ID NO:7) is 40 nt in length but lacks the internal succinate linker amidite, and thus should not cleave under treatment with alkali solution. After treatment of both RNA oligos with 28% ammonium hydroxide, the 40 mer synthesized with an internal tandem oligo linker fragments into two smaller RNA oligonucleotides ( 720 ). The control 40 nt ribooligomer that was synthesized without a tandem linker did not cleave when treated with ammonium hydroxide. The fragments were both analyzed on RP-HPLC to show that the uncleaved control fragment migrates slower on the column ( 710 ) relative to the shorter cleaved fragments.
[0114] As one of ordinary skill in the art will appreciate, various changes, substitutions, and alterations could be made or otherwise implemented without departing from the principles of the present invention. Accordingly, the scope of the invention should be determined by the following claims and their legal equivalents. | The present invention provides phosphoramidite linkers that are useful for the production of synthesizing two or more oligonucleotides in tandem. The inventive linkers have the following desirable properties: (i) enhanced stability to alkali conditions versus the linkers previously published, (ii) cleave to produce 5′ and 3′ ends that are fully biologically compatible, (iii) cleave completely under conditions that are already used in cleavage/deprotection processes so they are fully compatible with conditions that are common in laboratories and do not require additives that necessitate further purification after cleavage, (iv) integrate easily onto commercially available synthesizers because they are compatible with standard coupling chemistry, and (v) are compatible with DNA, RNA, forward, reverse, and synthesis chemistries. In addition, the inventive linkers may be coupled to a solid support. Thus, the inventive linkers provide a significant advancement in the state of the art. | 2 |
FIELD OF THE INVENTION
The present invention relates to an apparatus for aiding in the preparation of an injection serum and more particularly pertains to an apparatus adapted to facilitate the preparation of an injectable medicament wherein the preparation operation requires the use of multiple syringes and/or multiple medicine vials.
DESCRIPTION OF THE PRIOR ART
Many patients who are on a daily self-injection regime either have impaired eyesight or lack the dexterity required to accurately perform the syringe filling operation. The use of syringe filling devices has therefore been contemplated by the prior art. More specifically, syringe filling devices heretofore devised and utilized for the purpose of assisting a user in filling a syringe with a desired quantity of medicine which is extracted from a sealed vial are known to consist basically of familiar, expected, and obvious structural configurations. These types of devices are designed primarily for patients who are required to give themselves regular injections at home over an extended period of time.
By way of example, the prior art discloses in U.S. Pat. No. 2,677,372, to Barish, Jr., U.S. Pat. No. 3,875,979, to Hults, U.S. Pat. No. 4,489,766, to Montada, and U.S. Pat. No. 3,853,158 to Whitty devices which include means for supporting a vial such that its contents may be withdrawn by a syringe.
However, many patients who must self-administer drugs at home often times must actually prepare the serum which must be injected. This is accomplished by extracting a specific quantity of a diluent from a sterile vial into a syringe. The extracted quantity in the syringe is then injected into a second vial which contains a powdered or concentrated form of a medication which must be mixed with the diluent, thus forming the drug to be administered. The secondary dilution operation requires the user to perforate the central portion of the rubber seal of the vial with the needle of a syringe and evacuate the previously extracted quantity of diluent into the vial. This operation has proven to be difficult for many persons who are afflicted with poor eyesight or suffering from spasticity in their hands.
The injection dose aids of the prior art are only adapted to assist a user with the initial extraction operation. If a person's treatment requires the secondary dilution in order to prepare the injection serum, the user must physically remove the filled syringe from the dosing aid and perform the dilution operation without the assistance of the device.
Therefore, it can be appreciated that there exists a continuing need for an improved injection dosing apparatus which can be used for aiding a user in both filling a syringe with a quantity of liquid medication or diluent from a first vial and subsequently evacuating that quantity of liquid from the syringe into a second vial. In this regard, the present invention substantially fulfills this need.
In this respect, the injection dosing apparatus according to the present invention substantially departs from the conventional concepts and designs of the prior art, and in doing so provides an apparatus primarily developed for the purpose of facilitating both the extraction and the dilution operations which are required in the preparation of an injection serum for self-administration.
SUMMARY OF THE INVENTION
The general object of the present invention, which will be described subsequently in greater detail, is to provide an improved apparatus for aiding in the preparation of an injectable serum and a method associated therewith.
In particular, it is an object of the present invention to provide an apparatus adapted to facilitate the preparation of an injectable medicament wherein the preparation operation requires the use of multiple syringes and/or multiple medicine vials.
It is a further object of the present invention to provide an apparatus which is capable of facilitating both filling a syringe with liquid which is withdrawn from a sealed vial and also transferring liquid contained within a syringe into a sealed vial.
It is another object of the present invention to provide an apparatus which can be utilized by persons who are on a medical treatment regime which requires self-administration of injections.
It is a further object of the present invention to provide an apparatus which allows persons suffering from poor eyesight or an affliction which causes hand tremors or shakiness to easily and accurately prepare and administer injections at home without any assistance from medical personnel.
An even further object of the present invention is to provide an apparatus which would be beneficial in assisting a person in filling a syringe with medication wherein the medication being administered is either in a premixed form or in a form which requires a subsequent mixing operation.
Even still another object of the present invention is to provide an apparatus for aiding in the preparation and administration of an injection serum wherein the preparation thereof requires the use of multiple syringes and medicine vials.
Accomplishing these and other objects, the present invention provides an apparatus for aiding in the preparation of an injectable serum which comprises a two-part assembly including a stabilizing base and a framed support. The apparatus includes a means for receiving one or more conventional medicine vials, which is rotatable about a horizontal axis. The apparatus further includes a means for receiving one or more conventional syringes which is disposed horizontally and in substantially parallel relationship with respect to the vial receiving means. This arrangement facilitates accurate alignment of the syringes and vials when liquid is being transferred from a vial to a syringe.
If a treatment regimen requires a subsequent mixing operation before injection, a patient may have to transfer the liquid which has been filled in the syringe into a second vial which contains a powdered or concentrated form of a medication. In order to aid in the transfer of liquid from a syringe to a vial, the stabilizing base is provided with a plurality of wells which are formed in the outer surface of the base. The second vial may be placed within one of the wells in the base which will hold the vial steady while the needle of the previously filled syringe is inserted. The liquid may then be easily ejected into the second vial to form the injection serum.
Therefore, various combinations of syringe to vial or vial to syringe operations are possible to accomplish using the apparatus of the present invention, thus making the apparatus of the present invention adaptable to different treatment regimens.
For a better understanding of the invention, its operating advantages and the specific objects attained by its uses, reference should be had to the accompanying drawings and descriptive matter in which there is illustrated preferred embodiments of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will be better understood and objects other than those set forth above will become apparent when consideration is given to the following detailed description of a preferred embodiment thereof. Such description makes reference to the annexed drawings wherein:
FIG. 1 is a perspective view of the preferred embodiment of the apparatus for aiding in the preparation of an injection serum constructed in accordance with the principles of the present invention.
FIG. 2 is a perspective view of the support section of the apparatus showing a vial and syringe housed therein.
FIG. 3 is a perspective view of the support section after the vial has been inverted to allow its contents to be transferred into the syringe.
FIG. 4 is a side elevational view in taken in cross-section.
The same reference numerals refer to the same parts through the various Figures.
DESCRIPTION OF THE PREFERRED EMBODIMENT
With reference now to the drawings, and in particular to FIG. 1 thereof, the preferred embodiment of the apparatus embodying the principles and concepts of the present invention and generally designated by the reference numeral 10 will be described.
More specifically, it will be noted in the various Figures that there is shown an apparatus 10 for aiding in the preparation of an injectable serum. The apparatus 10 includes two independent components, a stabilizing base 12, and an upstanding frame member 14. Although each of the components 12,14 could function independently with respect to specific uses, in the preferred embodiment of the present invention, the base 12 and frame member 14 are utilized together. Thus, in the operative assembled configuration as shown in FIGS. 1 and 4, the stabilizing base 12 is positioned on a planar portion 34 of the platform 30 of the frame member 14.
The stabilizing base 12 is preferably of solid construction and formed of wood, metal, plastic or resin, or other suitable material. The stabilizing base 12 is generally rectangular in shape, thus having six exterior faces. Each of the exterior faces is consistent with a rectangular prism with the exception that one face 16, instead of being oriented perpendicularly with respect to its adjacent faces is angled outwardly at approximately a 45° angle so as to form a sloped surface 16.
The sloped surface 16 is provided with multiple wells 18 formed thereon. The first wells 18 are adapted so as to accommodate the receipt of a conventional medicine vial 26 therein.
The upper surface 20 of the stabilizing base has attached thereto a sloped triangular projection 22. The projection may be either integrally formed with the base 12 or may be fabricated separately and attached to the base 12 by an adhesive, a mechanical fastener, or any conventional means.
The projection 22 is provided with at least one well 24 formed therein. The wells 24 are also sized so as to accommodate a conventional medicine vial 26. It is contemplated that due to the solid construction of the stabilizing base 12, when a vial 26 is placed within any of the wells 18,24 of the base 12, a person can easily insert the needle of a syringe 28 into the rubber seal portion of the vial 26. When utilizing the base 12 as a stabilizer for the vial 26, the needle placement operation may be accomplished using only one hand. Therefore, a person suffering from a physical affliction which causes reduced dexterity will be considerably aided in that when placing a needle into a vial 26, the person can concentrate on accurately puncturing the sealed portion of the vial 26 without worrying about holding the vial 26 steady.
It is additionally contemplated that by the design of the present invention, the stabilizing base 12 may be used for holding vials either for storage or when evacuating a liquid medication or diluent from a syringe 28 into a vial 26 which contains a powdered or concentrated form of a medication in order to form a serum to be injected.
To transfer liquid from a vial to a syringe, the design of the frame member 14 allows the vial 26 to be oriented at a level above that of the syringe 28 as shown in FIG. 3 so as to accomplish complete removal of the liquid contents from the vial 26. The frame member 14 in its preferred embodiment, is fabricated from metal but it is additionally contemplated that any material displaying sufficient rigidity, such as many plastics and resins, could be substituted for metal without departing from the invention.
The frame member 14 includes a U-shaped platform base 30. Two vertical upstanding arms 32 are attached in perpendicular orientation with respect to the planar portion 34 of the platform 30. The arms 32 are attached to the platform 30 by rivets, screws, or any other mechanical fastening design expedient.
In use, the stabilizing base 12 is positioned on the flat portion 34 of the platform 30 as shown in FIGS. 1 and 4. The interior dimensions of the frame member 14 are designed to be substantially identical to the exterior dimensions of the base 12. Therefore, when the frame member 14 and base 12 are in an assembled position, the base 12, being of solid construction, acts to stabilize the frame member 14 and ensure the frame member 14 is held steady and remains in vertical, upstanding orientation. In the preferred embodiment, the base 12 and frame member 14 do not include any separate fastening means but are held together merely due to the dimensional specifications set forth above so as to allow ease in assembly of the apparatus. However, it is contemplated that fasteners could be employed without departing from the spirit of the invention.
The frame member 14 further includes a vial support 36 and a syringe support 38. The vial and syringe supports 36,38 are disposed horizontally between the two upstanding arms 32 and parallel with respect to each other.
The syringe support 38 is fixedly attached to the upstanding arms 32 by rivets, screws, or other mechanical fastener. The vial support 36 is rotatably mounted about a horizontal axis A between the arms 32 and above the syringe support 38. The mounting mechanism 40 for the vial support 36 may include pins (not shown) which extend through each arm 32 and are seated within the vial support 36 at each distal end thereof. The length of the pin provides an axis of rotation to allow for rotational movement of the vial support 36. The mounting should include such frictional resistance so as to prevent uncontrolled movement of the support 36. Thus, the support 36 will not turn or rotate until force is applied by the user. The above described mounting mechanism 40 is merely illustrative and it is contemplated that the mounting mechanism could consist of any other known means which would impart the desired rotation to the vial support 36.
In order to accommodate one or more conventional medicine vials, the vial support 36 is provided with at least one aperture 42. Within the aperture 42, there is provided a bushing 41 formed of rubber or other such resilient material so that upon placement of the vial 26 therein, the vial will be held in frictional engagement therewith. The syringe support 38 is provided with at least one arcuate cut-out 44. Each of the cut-outs 44 is positioned in direct alignment with an aperture 42 of the vial support 36. The arcuate cut-out 44 is configured so as to allow the barrel portion of the syringe 28 to be removably inserted therein. The arcuate design allows for a clamping-like engagement of the barrel when it is introduced within the cut-out 44 and thus allows for ease in insertion and removal of the syringe within the confines of the cut-out 44.
The direct vertical or axial alignment between an aperture 42 and its complementary arcuate cut-out 44 provides for simultaneous engagement of both a vial 26 and a syringe 28 during a filling operation. When it is desired to fill a syringe with the liquid contents of a medicine vial, the vial 26 is placed within an aperture 42 of the vial support 36 and the needle of the syringe 28 is inserted within the rubber diaphragm seal (not shown) of the vial 26. With the syringe in place, the vial support 36 is rotated 180°, so as to invert both the vial 26 and syringe 28. At this point, the syringe 28 is juxtaposed adjacent to the aligned arcuate cut-out 44. The barrel of the syringe 28 is accordingly snapped within the cut-out 44 which will effectively hold the syringe 28 and the vial 26 in a fixed position. The plunger of the syringe may then be withdrawn so as to allow the liquid to flow downwardly from the vial 26 into the syringe 28. Therefore, it can be appreciated that the present invention is completely capable of aiding in dosing a single component medication such as insulin, which is purchased in a ready-to-use form.
The present invention is further adapted to accommodate and assist in the preparation of any type of injectable serum which requires two or more components to be mixed or diluted. The vial containing the first component is positioned within an aperture 42 of said vial support 36. The needle of the syringe 28 is then inserted within the rubber seal of the vial 26. The liquid is then extracted from the vial into the syringe in the same manner by rotating the vial support 36 as described above.
The second vial which may contain a powdered or concentrated form of a second component is then placed within one of the wells 24 of the base. The well 24 which is utilized will at that point in time be positioned directly below the now filled syringe. The filled syringe is then removed from the arcuate cut-out 44 and inverted 180 degrees so that the needle of the syringe is pointing downwardly toward the second vial. The needle of the syringe filled with the liquid obtained from the first vial is then inserted within the second vial which is being held in the well 24. The barrel of the syringe may be repositioned within the arcuate cut-out 44 so as to hold the syringe steady.
The plunger of the syringe is then slowly pushed downwardly to evacuate the liquid from the syringe into the second vial. The second vial is then agitated so as to adequately mix the two components to form an injectable serum of uniform consistency. It is contemplated that additional components could added or mixed as well using the same above described technique.
The second vial which contains the serum to be injected may then and probably is placed in an aperture 42 of the vial support 36 and the serum transferred to an injection syringe. The syringe containing the serum is then removed from the apparatus 10 and injected into a human body according to conventional techniques.
As to the manner of usage and operation of the present invention, the same should be apparent from the above description. Accordingly, no further discussion relating to the manner of usage and operation will be provided.
Once given the above disclosure may other features, modifications and improvements will become apparent to the skilled artisan. Such other features, modifications and improvements are therefore considered to be a part of this invention, the scope of which is to be determined by the following claims. | An apparatus for aiding in the preparation of an injectable serum is provided which comprises a two-part assembly including a stabilizing base and a framed support. The apparatus includes a support arm for receiving one or more conventional medicine vials which is rotatable about a horizontal axis. The apparatus further includes a support arm for receiving one or more conventional syringes which is disposed horizontally and in substantially parallel relationship with respect to the vial receiving support arm. This arrangement facilitates accurate alignment of syringes and vials which are being utilized in the preparation of the injection serum. | 0 |
FIELD OF THE INVENTION
The present invention pertains to liquid preparations containing cyclosporin, especially cyclosporin A, for oral or parenteral administration, and to a process for preparing same.
BACKGROUND OF THE INVENTION
Cyclosporins are cyclic oligopeptides of microbiological origin, which are used especially as immunosuppressives.
Cyclosporins, especially cyclosporin A, are used in connection with organ transplantation to prevent the rejection of the transplanted organ.
It has also been known that cyclosporins have anti-inflammatory and antiparasitic actions.
Therefore, the use of cyclosporins is not limited to immunosuppressives, but it also includes various autoimmune diseases and inflammatory conditions, especially inflammatory conditions in which autoimmune processes are involved. They include arthritic diseases, e.g., rheumatoid arthritis and rheumatic diseases.
Cyclosporins can be used as antiparasitic agents for the treatment of protozoal infections, e.g., malaria.
However, severe side effects, especially nephrotoxic effects, must be accepted with the cyclosporin formulations currently used in practice.
Cyclosporins are substances of a highly hydrophobic nature. Due to their poor solubility in water, it is difficult to process cyclosporins with the usual pharmaceutical carriers to prepare preparations of sufficient bioavailability.
The cyclosporin-containing pharmaceutical preparations disclosed in the prior art are based on the use of an alcohol and/or oils or similar vehicles in conjunction with a surface-active agent.
U.S. Pat. No. 4,388,307 discloses the solution of cyclosporin in a mixture of transesterification products of various oils formed with polyethylene glycol (e.g., Labrafil M 1499 CS a product of Gattefosse, France), as well as ethanol and a vegetable oil. However, the products thus obtained are unsuitable for intravenous administration because they contain oil. They can be administered only subcutaneously or intramuscularly.
According to product information on the Sandimmun drinking solution sold by Sandoz Pharmeceutical (Chapter XII, Sandoz-Pharma, Basel, 1984), cyclosporin is dissolved in a solution of polyoxyethylated castor oil (e.g., Cremophor EL, available from BASF) and ethanol. The disadvantage of these preparations is the fact that they are poorly tolerated by the patients, because anaphylactic reactions frequently develop (KAHAN et al., Lancet, 1984, I:52; LEUNISSEN, K. M. et al., Lancet, 1985, I:636).
PCT Application WO 92/09299 discloses oral liquid pharmaceutical preparations which contain a cyclosporin in a mixture of a hydrophilic solvent and a surface-active agent. Polyoxyethylene-polyoxypropylene block polymers (polyoxamers) with molecular weights of 1,000 to 15,500 are used as surface-active agents. The disadvantage of this formulation is the precipitation of the active ingredient in contact with aqueous solutions. These formulations are unsuitable for parenteral administration because of the solubilizing ability of the polyoxamers.
SUMMARY OF THE INVENTION
The goal of the present invention is to provide liquid preparations containing cyclosporin or cyclosporins, which are poorly soluble or insoluble in water, which can be diluted with water in any quantity ratio and form clear, stable solutions.
Another goal of the present invention is to provide formulations which lead to better bioavailability of the active ingredient and thus make it possible to reduce the amount of active ingredient to be administered.
The applicant has surprisingly found that the above-described goals can be accomplished with a solution which contains cyclosporin dissolved in a mixture of a nonionics emulsifying agent such as polyoxyethylene glycerol fatty acid monoester and monohydric and/or polyhydric alcohols, wherein the solutions are stable, well tolerated, have improved bioavailability, and can be administered either orally or parenterally.
More specifically, the present invention pertains to liquid pharmaceutical preparations for oral or parenteral administration, which contain cyclosporin as the active ingredient in combination with a polyoxyethylene glycerol fatty acid monoester and monohydric and/or polyhydric alcohol(s).
DETAILED DESCRIPTION OF THE INVENTION
Polyoxyethylene glycerol fatty acid monoesters (PGFME) are nonionic emulsifying agents, especially those commercially available under the name Tagat from Th. Goldschmidt AG, Germany. Preferred compounds among them are the monoesters of lauric, stearic, oleic and isostearic acids. Especially preferred are the monoesters of oleic acid and lauric acid, which are commercially available under the names Tagat O and Tagat L. The HLB value of the emulsifying agent used is in the range of 10 to 20 and preferably 14 to 17.
The solution concentrations according to the present invention contain 1 to 20 parts by weight of PGFME and 0.5 to 20 parts by weight of the monohydric and/or polyhydric alcohols, preferably 10 to 20 parts PGFME and 2 to 10 parts alcohol and especially 12 to 18 parts of PGFME and 3 to 6 parts of alcohol relative to one part by weight of active ingredient.
All the known natural and synthetic cyclosporins, including their analogs and derivatives, are suitable for use in the preparations according to the present invention. Examples of such cyclosporins are described in, e.g., German Offenlegungsschriften Nos. DE-OS 40,03,844 and DE-OS 40,05,190. Cyclosporin A is preferred.
The active ingredient concentrations in the solutions concentrates according to the present invention are in the range of 20 to 200 mg/mL and preferably 50 to 100 mg/mL.
The alcohol components are monohydric and/or polyhydric alcohols used as individual substances or in random mixtures, e.g., ethanol, propylene glycol and/or polyethylene glycols with a molecular weight of up to 600. Ethanol and/or propylene glycol are preferably used.
In addition, the preparations according to the present invention may optionally also contain other carrier and/or auxiliary substances suitable for intravenous administration, and the preparations intended for oral administration may contain usual pharmaceutical additives, e.g., taste-improving agents, diluents, preservatives, isotonizing agents, etc.
The present invention is explained in greater detail by the following examples, without being limited to them.
EXAMPLE 1
Seventy g of polyoxyethylene glycerol monooleate (Tagat O) were mixed with 30 g of propylene glycol. Five g of cyclosporin A were dissolved in the resulting mixture at room temperature. The volume of the solution was increased to 100 mL with propylene glycol, and was homogenized by stirring. Depending on the intended use, the solution thus prepared was put into bottles or ampules, or subjected to further processing into soft gelatin capsules. For parenteral preparations, the preparation and the filling must be performed under sterile conditions. The active ingredient concentration is adjusted to the desired content by dilution with water or aqueous solutions before therapeutic use.
EXAMPLE 2
Eighty g of polyoxyethylene glycerol monolaurate (Tagat L2) were mixed with 10 g of 96-vol. % ethanol. Five g of cyclosporin A were dissolved in this solution at room temperature while stirring. The solution thus obtained was made up to 100 mL with 96-vol. % ethanol, and it was homogenized by stirring. Further processing is as described in Example 1.
EXAMPLE 3
Thirty g of polyoxyethylene glycerol monolaurate (Tagat L2) were mixed with 65 g of propylene glycol. Five g of cyclosporin A were dissolved in this mixture.
The preparation thus obtained was subjected to further processing as described in Example 1.
EXAMPLE 4
Seventy g of polyoxyethylene glycerol monostearate (Tagat S) were mixed with 30 g of 96-vol. % ethanol, and 5 g of cyclosporin A were dissolved in this [mixture] while stirring. The preparation thus obtained was subjected to further processing as in Example 1.
EXAMPLE 5
Seventy-five g of polyoxyethylene glycerol monostearate (Tagat S) were mixed with 10 g of 96-vol. % ethanol and 10 g of propylene glycol, and 5 g of cyclosporin A were dissolved in this mixture while stirring. The solution was made up to 100 mL with 96-vol. % ethanol, and it was homogenized by stirring. Further processing is as described in Example 1.
EXAMPLE 6
Sixty g of polyoxyethylene glycerol monooleate (Tagat O) were mixed with 20 g of 96-vol. % ethanol, and 5 g of cyclosporin A were dissolved in this [mixture] while stirring. The solution was made up to 100 mL with 96-vol. % ethanol. Further processing is as described in Example 1.
EXAMPLE 7
Eighty-eight g of polyoxyethylene glycerol monooleate (Tagat O) were mixed with 10 g of propylene glycol, and 10 g of cyclosporin A were dissolved in this mixture while stirring. The solution was made up to 100 mL with propylene glycol, and it was subjected to further processing as described in Example 1.
The solution concentrate prepared according to the present invention are filled into bottles or ampules, and they are diluted to the desired active ingredient content before the therapeutic use. Depending on the desired active ingredient content, the solution and concentrate are diluted at weight ratios ranging from 1:10 to 1:100. Water or aqueous solutions, e.g., physiological saline solutions, glucose, dextran, fructose, or mannitol solutions, may be used as the diluents.
Solution concentrate for oral administration may also be filled into soft gelatin capsules.
The preparations according to the present invention showed no precipitation, decomposition or other changes after storage for 6 months at temperatures ranging from -18° C. to 60° C. (stress test).
Bioavailability
A group of beagle dogs was used for the bioavailability studies on the compositions according to the present invention. The preparations to be tested were administered orally to fasting animals by means of a stomach tube. Blood was taken from the saphenous veins of the animals at defined time intervals, and were collected in corresponding plastic tubes with added EDTA. The blood samples were stored at -18° C. until time for the determination. Cyclosporin was determined in the whole blood by fluorescence polarization immunoassay (FPIA).
The areas under the curves (AUC), on which the concentrations of the drug in the blood were plotted as a function of time, were calculated according to the trapezoidal rule. The average AUC values of the composition according to the present invention are substantially higher than those of the commercially available Sandimmun drinking solution, which were determined in the same manner, at the same dosage, in the same dogs. The data from the curve is set forth in Table I.
TABLE I______________________________________Sample AUC (0-12 h) ng/ml______________________________________1 13.600 ± 1.5422 10.277 ± 2.1964 12.092 ± 3.1285 12.153 ± 2.352Cyclosporin 7.452 ± 2.452DrinkingSolution______________________________________
From Table I it is apparent the preparations according to the invention yield a higher degree of bioavailability for cyclosporin than cyclosporin in a known drinking solution.
Depending on the composition, the bioavailabilities of the pharmaceutical preparations according to the present invention are surprisingly, i.e. 40 to 70%, higher than that of the formulation that is currently commercially available.
Due to this surprising result, it is possible to reduce the dose of the active ingredient and thus to drastically reduce the severe side effects of the currently available formulations, especially the nephrotoxic side effects.
Having thus described our invention, what is desired to be secured by Letters Patent of the United States is set forth in the appended claims. | The present invention pertains to cyclosporin-containing liquid preparations for oral or parenteral administration, as well as to a process for preparing same. Besides the active ingredient cyclosporin, the preparations contain a polyoxyethylene glycerol fatty acid monoester and a monohydric and/or polyhydric alcohol(s). The preparations are stable and well tolerated, and they have higher bioavailability than the preparations known currently. | 0 |
BACKGROUND OF THE INVENTION
This invention relates generally to a golf swing training apparatus and, more particularly, to an apparatus which can be used repeatedly by a user to develop a functional golf swing.
Many training devices have been proposed for improving the golf swing. Most such devices are intended for repeated use to introduce "muscle memory" that will lead to a proper swing without the aid of the device. The devices include, for example, coded mats which show you how to place your feet and the recommended path of the club as it approaches the ball; a golf club which is half rope to teach "rhythm"; golf clubs with bent shafts to train the forearms to rotate properly; weighted clubs to develop strength; clubs which click to indicate a proper timing and "release"; devices which click when you shift your weight improperly; attachments for golf club and the wall which force the club to trace a proper plane; a stationary helmet which keeps the head in a fixed position; inclined planes or tracks to guide a club; etc. However, all of these prior devices can be used improperly and can lead to frustration, lack of confidence, and ultimate abandonment.
The object of this invention is to provide an apparatus which controls the angle of the spine and the rotary and lateral motion of the hips and groin area rather than restricting or influencing the perimeter area of the body as prior devices have done.
SUMMARY OF THE INVENTION
The invention encompassed in one embodiment is a golf swing training apparatus including a base; a strut having one end supported by the base; a support retained by a portion of the strut opposite to the one end, the support adapted to project between a golfer's legs and to engage the groin regions thereof; and a rotational coupling allowing rotation of the support means in response to rotational movement of the golfer's hips. This structural combination desirably provides a steady base, allows the hips to pivot around a near vertical axis and keeps the groin area fixed in space.
The invention further encompasses in another embodiment a golf swing training apparatus including a strut having one end adapted for support by a support surface; a support retained by a portion of the strut opposite to the one end, the support adapted to project between a golfer's legs and to engage the groin regions thereof; a rotational coupling allowing rotation of the support in response to rotational movement of the golfer's hips; and a translational coupling adapted during rotation of the support to allow reciprocating movement thereof in directions substantially transverse to the strut. The translational coupling desirably allows a slight forward movement of the golfer's body during a forward swing.
The invention additionally encompasses in another embodiment a golf swing training apparatus including a strut having one end adapted for support by a support surface; a support retained by a portion of the strut opposite to the one end, the support adapted to project between a golfer's legs and to engage the groin regions thereof; a rotational coupling allowing rotation of the support in response to rotational movement of the golfer's hips; and a restraint supported by the strut and extending upwardly from the support, the restraint adapted to engage and substantially restrain the golfer's spine in a given orientation during rotation of the support. The restraint desirably prevents lifting of the upper body during a backswing.
According to one feature, the invention includes a release mechanism for automatically deactivating the restraint in response to motion of the support into a predetermined position and to thereby allow movement of the golfer's spine into an orientation different than the given orientation. The release allows the golfer to relax and straighten his body in the later portion of a forward swing.
According to another feature of the invention, the motion of the support is rotation and the predetermined position is a predetermined angular position. Use of support rotation to activate restraint release facilitates desirable operation of the apparatus.
According to another feature, the invention includes a latch latching the restraint in an active position, a means biasing the restraint in that position and a latch adjustment means for selectively adjusting the predetermined position in which the restraint is released. These structural features allow the apparatus to be tailored to a particular golfer.
According to yet another feature, the invention includes a restraint adjustment means for selectively adjusting the height of the restraint relative to the support. The restraint adjustment means facilitates use of the apparatus by golfers of different size.
According to still another feature, the invention includes a support adjustment means for selectively adjusting the height of the support above the base. This feature further adapts the apparatus for use by different golfers.
According to another feature, the invention includes an inclination adjustment means for selectively adjusting the vertical inclination of the strut. The inclination adjustment means allows the apparatus to be tailored to the style of a particular golfer.
According to additional features, the translational coupling permits pivotal movement of the strut to provide reciprocating movement, and includes a stop means for limiting the reciprocating movement of the support means between predetermined first and second pivotal positions thereof, and a stop adjustment means for selectively adjusting the distance between the first and second positions. The stop and stop adjustment permit selection of a selected degree of forward body movement during a forward swing as desired by an individual golfer.
DESCRIPTION OF THE DRAWINGS
These and other objects and features of the invention will become more apparent upon a perusal of the following description taken in conjunction with the accompanying drawings wherein:
FIG. 1 is a front perspective view of a golf training apparatus according to the invention;
FIG. 2 is a rear perspective view of the apparatus shown in FIG. 1;
FIG. 3 is a detailed view of a rotational adjustment mechanism employed in the apparatus shown in FIGS. 1 and 2;
FIG. 4 is a cross-sectional view of the mechanism shown in FIG. 3;
FIG. 5 is a partial view illustrating a release mechanism of the apparatus shown in FIGS. 1 and 2;
FIGS. 6-8 are cross sectional views of the mechanism shown in FIG. 5;
FIG. 9 is an exploded perspective view of a rotational coupling employed with the apparatus shown in FIGS. 1 and 2;
FIG. 10 is a plan view of a translational coupling assembly used with the device shown in FIGS. 1 and 2;
FIG. 11 is a side view of the coupling assembly shown in FIG. 10;
FIG. 12 is a left end view of the coupling assembly shown in FIGS. 10 and 11;
FIG. 13 is a cross sectional view taken along lines 13--13 of FIG. 10; and
FIGS. 14-17 are schematic views illustrating use of the training apparatus shown in FIGS. 1 and 2 by a golf trainee.
DESCRIPTION OF THE PREFERRED EMBODIMENT
A golf swing training apparatus 21 according to the invention is illustrated in FIGS. 1 and 2 The training apparatus 21 includes an elongated strut assembly 22 supported at one end by a base 23, a support seat 24 retained at an opposite end of the strut assembly 22, and a rotational coupling 25 between the strut assembly 22 and the support seat 24 for providing rotational motion thereof. Also included in the apparatus 21 is a spinal restraint 26 supported by the strut assembly 22 above the support seat 24 and a translational coupling mechanism 27 connected between the base 23 and the strut assembly 22.
The strut assembly 22 includes an upper tubular member 31 telescopically received by a lower tubular member 32. Positioned at the upper end of the lower tubular member 32 is a releaseable clamp 33 that can be tightened to prevent relative movement between the upper member 31 and the lower member 32 or released to permit either longitudinal or rotational movement of the upper member 31 in the lower member 32. A rotational adjustment mechanism 35 (FIG. 3) attaches a lower end of the lower tubular member 32 to the base 23. Included in the rotational adjustment mechanism 35 is a yoke 36 having spaced apart arms 37, 38 projecting upwardly from a circular plate 39, a bolt 41 extending through the base 23 and the plate 39, and a nut 42 engaging the threaded bolt 41 and having a handle 43. After loosening of the nut 42, the strut assembly 22 can be rotated into a desired angular position relative to the base 23.
The rotational coupling 25 and the release mechanism 28 are shown most clearly in FIGS. 5-8. Forming the rotational coupling 25 is a mounting member 45 and a tubular member 46 that is telescopically received by the outer surface of the upper tubular member 31. The mounting member 45 includes an upper shaft portion 47 and a lower shaft portion 48 straddling an increased diameter mid-portion 49. Receiving an upper end of the tubular member 46 and pinned thereto by a pin 51 is the lower shaft portion 48. The bicycle type support seat 24 is attached to the upper shaft portion 47 in a conventional manner that permits selective tilting. After a predetermined degree of rotational movement by the seat 24 in a forward direction further movement is prevented by engagement between a tab stop 44 on the tubular member 46 and a clamp stop 50 on the tubular member 31.
Included in the release mechanism 28 (FIGS. 5-8) is a projection portion 53 of the mounting member 45. The portion 53 projects downwardly from the lower shaft portion 48 and is terminated by a knob portion 54. A latch arm 55 is received by a slot 56 through the projection portion 53. One end of the latch arm 55 is retained by a pivot pin 57 while an opposite end forms a hook portion 58. An additional portion of the release mechanism 28 is formed by a cam surface 59 (FIG. 9 ) formed on the upper edge of the upper tubular member 31 by a portion more elevated than the remaining portion 60 thereof. In response to simultaneous rotational movement of the support seat 24, the mounting member 45 and the projection portion 53, the cam surface 59 moves into engagement with an intermediate portion of the latch arm 55 so as to produce upward movement of the hook portion 58 as shown in FIG. 8.
Engaged by the knob 54 is a complementary knob 61 on an insert 62 that is received by the upper tubular member 31 and fixed thereto by a pin 63. A pair of arcuate collars 66 have inwardly projecting upper and lower flange portions 67, 68 that engage the knobs 54, 61 so as to prevent relative longitudinal movement between the insert 62 and the mounting member 45 while permitting relative rotational movement therebetween. The outer surfaces of the arcuate sleeves 66 are retained by the inner surface of the upper tubular member 31.
The spine restraint 26 includes a back rest 71 (FIG. 1) attached to one end of an elongated support 72, the opposite end of which is secured to a U-shaped angle iron 73. Pivotally attaching a lower end of the iron 73 to the upper tubular member 31 of the strut assembly 22 is a pivot pin 74 (FIG. 2). The support 72 is retained by a fastener assembly 75 (FIGS. 7 and 8) including a threaded bolt 76 that extends through a vertically extending slot 77 in the iron 73 and a vertically extending slot 78 in a curved lower portion 79 of the support 72. Received by the bolt 76 are a nut 81 and a block 80 disposed between the iron 73 and the curved portion 79 and geometrically conforming thereto. After loosening of the nut 81, the bolt 76 can be adjusted vertically within the slot 77 to establish a desired height for the back rest 71 relative to the support seat 24. Similarly, vertical movement of the curved portion 79 of the support 76 as permitted by the vertical slot 78 permits adjustment in the inclination of the support 72 so as to provide a desired orientation therefor.
Another slot 83 in the angle iron 73 above the fastener assembly 75 receives and engages the hook portion 58 of the latch arm 55 so as to establish a predetermined orientation for the spinal restraint 26. However, in response to upward movement of the latch arm 55 in response to engagement by the cam surface 59, the hook portion 58 is unlatched to release the restraint assembly 26 and allow movement thereof on the pivot pin 74. A bias leaf spring 84 has one end attached by rivets to the angle iron 73 and an opposite end engaged with the tubular member 46. Exerted by the leaf spring 84 is a force that biases the spinal restraint 26 into a position engaged with the hook portion 58 of the latch arm 55.
The translational coupling mechanism 27 (FIGS. 10-13) includes a translational assembly 91 and pin 92 and bearing 90 (FIG. 2) that retain the lower end of the lower tubular member 32 between the arms 37, 38 (FIG. 3) and permits pivotal movement thereof. Included in the assembly 91 (FIGS. 10-13) is a bed 93 secured to the base 23, a clamp 94 (FIG. 2) secured to the lower tubular member 32 and a connecting rod 95 therebetween. An upper end of the connecting rod 95 is pivotally connected to the clamp 94 by a pin 97 and a lower end is secured to a cross shaft 98 by a universal joint 99. The cross shaft 98 is retained within horizontally extending slots 101 in bifurcated appendages 102, 103 projecting upwardly from the bed 93. Attached to the appendage 102 at opposite ends of the slot 101 are nut and bolt assemblies 105. The assemblies 105 retain cam shaped stops 106, 107 having outer surfaces 108, 109 that alternately engage the cross shaft 98 in response to reciprocating motion thereof between first and second positions. By rotationally adjusting the cam shaped stops 106, 107 the length of travel of the cross shaft 98 between the first and second positions within the slots 101 can be adjusted to provide a predetermined resultant translational movement of the strut assembly 22. Translational movement of the assembly 22 is biased in a forward direction by a spring 110 having ends secured by bolt assemblies 111, 112, respectively, to the bed 93 and a slide member 113 supporting the shaft 98. If desired, the orientation of the bed 93 on the base 23 can be reversed to establish a rearward bias for the assembly 22.
OPERATION
Prior to use of the training apparatus 21, the clamp 33 is released to permit movement of the tubular member 31 and therewith the seat 24 into a position comfortable for a trainee 121 (FIGS. 14-17). The tilt of the seat 24 then is adjusted to suit the trainee. In addition, a desired inclination and height for the backrest 71 is obtained by adjustment of the fastener assembly 75 as described above. With the cross shaft 98 engaging the rear cam surface 108, the clamp 94 can be vertically adjusted on the lower tubular member 32 to establish a desired vertical orientation for the strut assembly 22. Similarly, a desired rotational position for the strut assembly 22 relative to the base 23 can be obtained by suitable adjustment of the rotational adjustment mechanism 35. This adjustment establishes the direction of translational motion. The degree of translational movement of the seat 24 made possible by pivotal movement of the strut assembly 22 also can be selected by suitable adjustment of the cam surfaces 108, 109 to establish a predetermined length of travel by the cross shaft 98 within the slots 101. Finally, the precise angular position at which the spinal restraint 26 is released by the release mechanism 28 can be determined by loosening the clamp 33 and utilizing a handle 115 to rotate the upper tubular member 31 and the cam surface 59 thereon into a predetermined angular position with respect to the base 23. In that way, the degree of pivot seat 24 movement required to unlatch the arm 55 and release the spinal restraint 26 can be adjusted.
After all manual adjustments have been completed, a golf trainee 121 assumes a position on the base 23 with the seat 24 positioned between his groin regions and lightly touching his buttocks as illustrated in FIG. 14. A belt 117 then can be secured about the trainees waist to retain him in position on the support seat 24 and with his spine resting on the backrest 71. The vertical strut, is then set into the biased position established by the spring 110. During both the backswing depicted in FIG. 15 and the forward swing depicted in FIGS. 16 and 17, the apparatus 21 allows the hips to rotate around a near vertical axis while the slight weight of the body on the seat 24 above this axis keeps the groin area fixed in space. This encourages a rotary motion of the hips in a near-horizontal plane. During the backswing, the spinal restraint 26 prevents lifting of the upper body which rotates in a space about the base of the spine. The proper coiling of the body is aided by the seat 24 which allows the mid section of the body to turn but not sway. During the forward swing shown in FIGS. 16 and 17, the coupling mechanism 27 allows the seat 24 to translate slightly foward while rotating and continuing along with the restraint 26 to properly constrain and guide motion of the hips and lower spine. In addition, at a predetermined point in the forward swing, the release mechanism 28 is activated to release the spinal restraint 26 and allow the upper body to raise into an unstressed, upright position as shown in FIG. 17. This allows the shoulders and arms to turn and swing freely about a supporting body which is moving properly.
When using the apparatus 21, the golfer 121 will be guided through an effective motion of the mid and lower body. The presence of the vertical axis established by the strut 22, the seat 24 and spinal restraint 26 encourages a very smooth rotary motion which prevents lunging, falling back, swaying, and a reverse pivot. On the forward swing, this rotary motion whips the arms past the vertical axis and throws the weight onto the forward foot. However, because the vertical and spinal axes retain the body, there is little change of "spinning out" with the upper body.
Obviously, many modifications and variations of the present invention are possible in light of the above teachings. For example, release mechanisms for the spinal restraint 26 other than the one preferred type disclosed can be employed. It is to be understood, therefore, that the invention can be constructed and practiced otherwise than as specifically described. | A golf swing training apparatus including a base; a strut having one end supported by the base; a support retained by a portion of the strut opposite to the one end, the support adapted to project between a golfer's legs and to engage the groin regions thereof; and a rotational coupling allowing rotation of the support means in response to rotational movement of the golfer's hips. This structural combination desirably provides a steady base, allows the hips to pivot around a near vertical axis and keeps the groin area fixed in space. | 0 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to an Fe--Cr alloy, exhibiting excellent ridging resistance, corrosion resistance and workability, for steel sheet having excellent surface characteristics.
2. Description of the Related Art
Fe--Cr alloys, such as ferrite stainless steels, having excellent characteristics, e.g. high corrosion resistance and thermal resistance, are widely used in various industrial fields, such as household articles and automobile parts. Because such alloys, however, have drawbacks in workability, and in detail, ridging, in other words, a surface defect like rough dry skin readily forms during press working of the thin steel plate, for example, such alloys are not suitable for the usage in which heavy working, such as deep drawing, are applied.
Many attempts have been proposed to solve the drawbacks set forth above. For example, Japanese Unexamined Patent Publication No. 52-24913 discloses the improvement in ridging resistance by a specified composition, i.e., a ferrite stainless steel exhibiting excellent workability which comprises 0.03 to 0.08% by weight of C (hereinafter "% by weight" is expressed as merely "%"), 0.01% or less of N, 0.008% or less of S, 0.03% or less of P, 0.4% or less of Si, 0.5% or less of Mn, 0.3% or less of Ni, 15 to 20% of Cr, 2×N to 0.2% of Al, and the balance Fe and inevitable impurities. Further, Japanese Unexamined Patent Publication No. 7-18385 discloses an Fe--Cr alloy exhibiting excellent ridging resistance which comprises 3 to 60% of Cr, decreased amounts of C, S and O, 0.003 to 0.5% of N, and the balance Fe and inevitable impurities. In such prior art, although the ridging resistance is improved by specifying the components, characteristics other than the ridging resistance are unsatisfactory.
Additionally, Japanese Unexamined Patent Publication No. 55-141522 discloses a method for making a ferrite stainless steel with decreased ridging by performing hot rolling in which the slab heating temperature is limited to the range of 950° to 1,100° C. Although the prior art intends to decrease ridging by fining crystal grains at a lower slab heating temperature, defects at the steel surface significantly increase since the heating temperature is lower than the rolling temperature.
In the prior art, although ridging resistance has been improved to some extent as set forth above, such an improvement is not satisfactory in practical uses. Further, no material exhibiting excellent characteristics, e.g. workability, such as elongation and r value, and surface characteristics, such as corrosion resistance and packed scab, has been proposed.
SUMMARY OF THE INVENTION
It is an object of the present invention to provide an Fe--Cr alloy, exhibiting a significantly improved ridging resistance and excellent corrosion resistance and workability, for steel sheet having excellent surface characteristics.
An Fe--Cr alloy in accordance with the present invention, exhibiting an excellent ridging resistance and surface characteristics, comprises:
0.01% (percent by weight; the same as below) or less of C;
1.0% or less of Si;
1.0% or less of Mn;
0.01 or less of S;
9% or more to 50% or less of Cr;
0.07% or less of Al;
0.02% or less of N;
0.01% or less of O; and
the balance being Fe and inevitable impurities;
wherein the C and N contents satisfy the following equations:
N(%)/C(%)≧2,
and
0.006≦[C(%)+N(%)]≦0.025;
and
the Ti content satisfies the following equations:
{Ti(%)-2×S(%)-3×O(%)}/[C(%)+N(%)]≦4,
and
[Ti(%)]×[N(%)]≦30×10.sup.-4.
The Fe--Cr alloy in accordance with the present invention preferably further contains at least one element selected from the group consisting of Ca, Mg, and B in an amount of 0.0003 to 0.005 weight percent.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a graph showing the correlation between the ridging resistance and the {Ti(%)-2×S(%)-3×O(%)}/[C(%)+N(%)] value;
FIG. 2 is a graph showing the correlation between the ridging resistance and the N/C ratio; and
FIG. 3 is a graph showing the correlation between the ridging resistance and the (C+N) content.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The present inventors have intensively investigated the achievement of the objects set forth above, and in particular, the improvement in ridging resistance. First, experiments which have led to the present invention will be explained.
The ridging resistance was evaluated with various thin sheets in which the Ti content is varied in the base composition comprising 16.4% of Cr--Fe alloy containing 0.0032% of C, 0.38% of Si, 027% of Mn, 0.003% of S, 0.005% of O and 0.017% of Al. A JIS No. 5 tensile test piece was prepared from each thin sheet, 20% of tensile strain was added to the test piece, each maximum roughness (R max ) in the direction perpendicular to the tensile direction was measured by a surface coarseness meter. The evaluation of ridging resistance was based on the following standard:
Ridging grade 0.5: R max<5 μm
Ridging grade 1.0:5 μm≦Rmax<10 μm
Ridging grade 1.5:10 μm≦Rmax<15 μm
Ridging grade 2.0:15 μm≦Rmax<30 μm
Ridging grade 2.5:30 μm≦Rmax
The smaller ridging grade means smaller ridging size.
The results are shown in FIG. 1. FIG. 1 demonstrates that the ridging resistance significantly improves, i.e., the ridging grade is 1.0 or less when the value of {Ti(%)-2×S(%)-3×O(%)}/[C(%)+N(%)] is 4 or more. The improvement in ridging resistance is due to the carbonitride formed by adding Ti in response to the C+N content.
Next, the ridging resistance was evaluated with thin sheets each comprising either of 17.1 to 17.3% of Cr--Fe alloy (Alloy A) containing 0.41 to 0.55% of Si, 0.15 to 0.30% of Mn, 0.001 to 0.003% of S, 0.003 to 0.005% of O, and 0.011 to 0.015% of Al, or 22.5 to 22.7 % of Cr--Fe alloy (Alloy B) containing 0.35 to 0.45% of Si, 0.50 to 0.65% of Mn, 0.002 to 0.004% of S, 0.004 to 0.006% of O, and 0.011 to 0.015% of Al. Further, the C and N contents are controlled so that {Ti(%)-2×S(%)-3×O(%)}/[C(%)+N(%)] ranges within 4 to 10. Results are shown in FIG. 2. FIG. 2 demonstrates that ridging resistance is not satisfactory at a N/C ratio of less than 2 even if the Ti content is controlled, and is improved up to a ridging grade of 1 or less at a N/C ratio of 2 or more.
Additionally, the ridging resistance is evaluated with various thin sheets which comprise a 17.8% Cr--Fe base alloy containing 0.41% of Si, 0.37% of Mn, 0.004% of S, 0.005% of O, and 0.011% of Al, the Ti content is controlled so that {Ti(%)-2×S(%)-3×O(%)}/[C(%)+N(%)] ranges within 6.5 to 7.5, the N/C ratio is 2 or more, and the C+N content is varied. The results are shown in FIG. 3. FIG. 3 demonstrates that the ridging resistance is improved when the N/C ratio is 2 or more and the C+N content is 0.006% or more with a controlled Ti content.
The improvement in the ridging resistance can be achieved only when all of the Ti content, the C+N content and the N/C ratio satisfy the conditions set forth above. The present invention is achieved based on the experiments set forth above.
The reason of the limitation of the contents of various elements in the present invention will now be explained.
C: 0.01% or less
The carbon (C) content is an important factor in the present invention. A lower carbon content is preferable in consideration of workability, e.g. elongation and r-value, and corrosion resistance. When the C content exceeds 0.01%, the above characteristics are deteriorated. Thus, the upper limit of the C content is set to be 0.01%.
Si: 1.0% or less
Silicon acts as a deoxidizer and increases the strength, whereas a Si content exceeding 1% causes a decrease in ductility. Thus, the upper limit of the Si content is set to be 1.0%, and the Si content is more preferably 0.05 to 0.7% in consideration of strength and ductility.
Mn: 1.0% or less
Manganese (Mn) acts as a deoxidizer and increases the strength, whereas a Mn content exceeding 1% causes a decrease in ductility and corrosion resistance. Thus, the upper limit of the Mn content is set to be 1.0%, and the Mn content is more preferably 0.05 to 0.7% in consideration of strength and corrosion resistance.
S: 0.01% or less
Sulfur (S) generally forms inclusions adversely affecting the material quality and decreasing corrosion resistance, in particular, pitting corrosion resistance. Further, S reacts with the added Ti to form TiS, and thus decreases the amount of Ti effectively reacting with C and N. Thus, a lower S content is preferable. The upper limit is set to be 0.01% and more preferably 0.006%, because the effects set forth above are noticeable when the S content exceeds the limit.
Cr: 9% or more to 50% or less
Chromium (Cr) is an element for effectively improving the corrosion resistance and heat resistance of the alloy and is required in an amount of at least 9%. On the other hand, a Cr content exceeding 50% causes difficulty in production by rolling. Thus, the Cr content is set to be 9% to 50%.
Al: 0.07% or less
Aluminum (Al) acts as a deoxidizer, and forms large inclusions when Al is added in an amount exceeding 0.07%, resulting in a decrease in corrosion resistance and the formation of scabs on the sheet surface. Thus, the upper limit is set to be 0.07%, and more preferably 0.05% in consideration of slag spot (slag inclusion) formation during welding.
N: 0.02% or less
The nitrogen (N) content is an important factor, and a lower N content is preferable for workability, e.g. elongation and r-value, and corrosion resistance. The upper limit is set to be 0.02%, because a content exceeding the upper limit causes the deterioration of such characteristics.
O: 0.01% or less
Because oxygen (O) is an impurity, it is preferred that the O content is as low as possible. Much oxygen forms inclusions to decrease corrosion resistance and to cause scabs on the sheet surface. Thus, the upper limit of the O content is set to be 0.01%.
N(%)/C(%)≧2,
and
0.006≧[C(%)+N(%)]≧0.025
The correlation between the C and N contents must be limited for improving the ridging resistance as the primary object of the present invention. The ridging resistance significantly improves when the ratio of the N content to the C content is 2 or more. Thus, the N/C ratio is set to be 2 or more. Further, when the C+N content is less than 0.006%, the ridging resistance does not noticeably improve even if the N/C ratio is 2 or more. On the other hand, a C+N content exceeding 0.025% causes a decrease in elongation and r-value. Thus, the lower and upper limits of the C+N content are set to be 0.006% and 0.025%, respectively.
{Ti(%)-2×S(%)-3×O(%)}/[C(%)+N(%)]≧4,
and
[Ti(%)]×[N(%)]≧30×10.sup.-4
Titanium (Ti) is a primary element in the present invention and forms carbonitride to enhance the ridging resistance. At the same time, Since Ti readily reacts with S and O, the Ti content must be set in consideration of the formation of TiS and TiO 2 . As set forth in FIG. 1, the ridging grade is 1.0 or less, when {Ti(%)-2×S(%)-3×O(%)}/[C(%)+N(%)] is 4 or more. When the value is less than 4, the ridging grade is more than 1.0, i.e., the ridging resistance does not noticeably improve. The lower limit of the Ti content depends on the C, N, S and O contents, and is preferably 0.05% in consideration of the ridging resistance. By adding a large amount of Ti, stringer-type defects form on the sheet surface probably due to the precipitation of coarse TiN grains. Thus, the ripper limit of the Ti content is set so as to satisfy the equation:
[Ti(%)]×[N(%)]≧30×10.sup.-4.
At least one element of Ca, Mg and B: 0.0003 to 0.005%
A trace amount of the addition of Ca, Mg and/or B can effectively prevent clogging of the immersion nozzle due to the precipitation of Ti inclusions which readily form in a continuous casting step of Ti-containing steel. Such an effect is noticeable when at least one element is added in an amount exceeding 0.0003%. On the other hand, a content exceeding 0.005% significantly decreases corrosion resistance and, in particular, pitting corrosion resistance. Thus, the lower and upper limits of the content of at least one element of Ca, Mg and B are set to be 0.0003% and 0.005%, respectively.
The balance is Fe and inevitable impurities. Ni, V, Mo, Nb, and Cu can be included as inevitable impurities within their respective allowable ranges, i.e., Ni≦0.3%, V≦0.3%, Mo≦0.3%, Nb≦0.02%, and Cu≦0.3%.
The P content must be suppressed as much as possible, and preferably to be 0.05% or less, because P causes the embrittlement of the alloy.
The Fe--Cr alloy in accordance with the present invention can be produced by any process described below for exemplification, but not for limitation. Steel making processes include RH degassing and VOD (vacuum oxygen decarburization) processes, casting processes preferably include continuous casting in consideration of productivity and quality. Any hot rolling and cold rolling processes may be employed to obtain a desired sheet thickness. Various products, such as hot rolling sheets, cold rolling sheets, welding pipes, seamless pipes, and their surface treated products, are available with the present invention.
EXAMPLES
The Fe--Cr alloy in accordance with the present invention will now be explained based on Examples.
Example 1
From Fe--Cr alloys each having a composition as given in Table 1, approximately 200-mm thick slabs were prepared by RH degassing and/or VOD processes, and a continuous casting process. Each slab was heated to 1,120° to 1,240° C. and then was subjected to hot rolling to form a hot-rolled sheet having a thickness of 4 mm at a finishing rolling temperature of 770° to 900° C. Each hot-rolled sheet was annealed for recrystallization at 800° to 1,000° C., descaled with an acid, and subjected to cold rolling to obtain a cold-rolled sheet having a thickness of 1.0 mm. The cold-rolled sheet was again annealed for recrystallization at 800° to 1,000° C., descaled with an acid, and subjected to various tests. The test results are shown in Table 1. The surface finishing was based on 2B specified in JIS. Each test was based on the following procedures:
(1) Ridging Resistance
A JIS No. 5 tensile strength test piece of each sample was prepared from its respective sheet for ridging resistance evaluation. The ridging resistance was evaluated in terms of the ridging point as set forth above. A smaller ridging point means a smaller ridging (or higher ridging resistance).
(2) r-Value
Three test pieces for JIS No. 13B tensile strength test were prepared by cutting the sheet in L, C, and 45 degree directions, respectively. The r-values in three directions of each test piece were measured with 15% tensile strain. The r-value in Table 1 is the average of r-values in three directions.
(3) Surface Characteristics
Stringer-type defects on the sheet surface were visually observed. The evaluation was base on the following standard:
A: No defect (Good surface characteristic)
B: Slight defect (Slightly impaired surface characteristics)
C: Many defects (Poor surface characteristics)
Results in Table 1 demonstrate that each sample in accordance with the present invention exhibits an excellent ridging resistance and surface characteristics, as well as a higher r-value.
TABLE 1__________________________________________________________________________Unit: weight %No. C Si Mn S Cr Al N O Ti Remarks__________________________________________________________________________1 0.0074 0.45 0.33 0.004 10.8 0.015 0.0153 0.007 0.14 Present2 0.0028 0.18 0.28 0.006 15.6 0.038 0.088 0.003 0.19 Invention3 0.0038 0.66 0.40 0.002 16.3 0.004 0.0097 0.002 0.214 0.0022 0.52 0.32 0.001 16.8 0.055 0.0133 0.004 0.165 0.0051 0.38 0.19 0.003 17.2 0.007 0.0144 0.005 0.196 0.0047 0.09 0.58 0.005 21.4 0.014 0.0129 0.004 0.167 0.0026 0.12 0.22 0.004 30.3 0.028 0.0061 0.006 0.098 0.0038 0.57 0.39 0.007 16.4 0.015 0.0041 0.004 0.18 Comparative9 0.0014 0.44 0.28 0.004 16.9 0.011 0.0037 0.004 0.13 Examples10 0.0033 0.51 0.48 0.004 16.9 0.007 0.0084 0.006 0.0611 0.0079 0.15 0.22 0.003 17.4 0.018 0.0188 0.004 0.2412 0.0039 0.44 0.09 0.004 21.6 0.011 0.0094 0.006 0.43__________________________________________________________________________ Ridging SurfaceNo. N/C C + N Y-value* Ti × N Grade r-value defect Remarks__________________________________________________________________________1 2.07 0.0227 4.89 0.002142 0.5 1.9 A Present2 3.14 0.0116 14.6 0.001672 0.5 1.8 A Invention3 2.55 0.0135 14.8 0.002037 0.5 1.8 A4 6.05 0.0155 9.42 0.002128 0.5 1.8 A5 2.82 0.0195 8.67 0.002736 0.5 1.8 A6 2.74 0.0176 7.84 0.002064 0.5 1.6 A7 2.35 0.0087 7.36 0.000549 0.5 1.5 A8 1.08 0.0079 19.5 0.000738 2.0 1.5 A Comparative9 2.64 0.0051 21.6 0.000481 1.25 1.8 A Examples10 2.55 0.0117 2.91 0.000504 1.5 1.3 A11 2.38 0.0267 8.31 0.004512 1.25 1.3 C12 2.41 0.0133 30.4 0.004042 0.5 1.3 B__________________________________________________________________________ *Y-value = {Ti(%) -2 × S(%) -3 × O(%)}/{C(%) + N(%)
Example 2
From Fe--Cr alloys each having a composition as given in Table 2, approximately 200-mm thick slabs were prepared by RH degassing and/or VOD processes, and a continuous casting process. Clogging of the immersion nozzle in the continuous casting was evaluated with the K-value [=1-(inner diameter of immersion nozzle after casting)/(inner diameter of immersion nozzle before casting)] at a casting weight of 50 ton. Each slab was subjected to hot rolling, annealing, descaling with acid, cold rolling and then descaling With acid to obtain a cold-rolled sheet having a thickness of 1.0 mm. Surface finishing was 2B.
Each cold-rolled sheet was subjected to SST (salt solution spraying test according to JIS-Z-2371) at 50° C. for 50 hours using a 5% aqueous NaCl solution. Corrosion formed on the sheet surface was visually observed. The evaluation was based on the number of corrosion points formed in 100 cm 2 according to the following ranking:
A: Corrosion points 2 or less
B: Corrosion points 3 to 15
C: Corrosion points 16 or more
Results are shown in Table 2.
In Example 2, clogging of the immersion nozzle is not substantially observed and corrosion resistance is excellent.
As set forth above, the present invention can provide an Fe--Cr alloy which exhibits excellent ridging resistance compared with prior art alloys, and excellent corrosion resistance, workability, and surface characteristics. Thus, the alloy is applicable to working parts which cannot be made of prior art alloys.
TABLE 2__________________________________________________________________________Unit: weight %No. C Si Mn S Cr Al N O Ti Ca B Mg Remarks__________________________________________________________________________13 0.0061 0.27 0.19 0.004 11.2 0.022 0.0153 0.005 0.17 0.0011 -- -- Present14 0.0028 0.07 0.18 0.005 16.1 0.034 0.0091 0.003 0.19 -- 0.0007 -- Invention15 0.0038 0.58 0.33 0.002 16.4 0.005 0.0097 0.002 0.21 -- -- 0.001816 0.0028 0.44 0.60 0.006 18.5 0.044 0.0133 0.004 0.16 0.0007 -- 0.000617 0.0048 0.31 0.19 0.003 20.5 0.007 0.0144 0.005 0.17 0.0019 0.0005 --18 0.0045 0.23 0.22 0.005 16.5 0.018 0.0102 0.006 0.19 -- 0.0058 -- Compara-19 0.0038 0.29 0.19 0.003 16.8 0.026 0.0112 0.004 0.18 0.0058 -- -- tive20 0.0021 0.24 0.27 0.004 16.3 0.022 0.0094 0.003 0.20 -- -- 0.0058 Examples21 0.0038 0.57 0.39 0.007 16.4 0.015 0.0041 0.004 0.18 -- -- --22 0.0014 0.44 0.28 0.004 16.9 0.011 0.0037 0.004 0.13 0.0058 -- --23 0.0033 0.51 0.48 0.004 16.9 0.007 0.0084 0.006 0.06 -- 0.0001 --__________________________________________________________________________ Ridging CorrosionNo. N/C C + N Y-value* Ti × N Grade K-value Resistance Remarks__________________________________________________________________________13 2.51 0.0214 6.87 0.002601 0.5 0.05 A Present14 3.25 0.0119 14.4 0.001729 0.5 0.04 A Invention15 2.55 0.0135 14.8 0.002037 0.5 0.04 A16 4.75 0.0161 8.45 0.002128 0.5 0.05 A17 3.00 0.0192 7.76 0.002448 0.5 0.07 A18 2.27 0.0147 11.0 0.001938 0.5 0.06 C Comparative19 2.95 0.0150 10.8 0.002016 0.5 0.04 C Examples20 4.48 0.0115 15.9 0.000188 0.5 0.05 C21 1.08 0.0079 19.5 0.000738 2.0 0.7 A22 2.64 0.0051 21.6 0.000481 1.25 0.04 C23 2.55 0.0117 2.91 0.000504 1.5 0.38 B__________________________________________________________________________ *Y-value = {Ti(%) -2 × S(%) -3 × O(%)}/{C(%) + N(%) | It is directed to provide an Fe--Cr alloy exhibiting an excellent ridging resistance and surface characteristic, comprising:
0.01% (percent by weight; the same as below) or less of C;
1.0% or less of Si;
1.0% or less of Mn;
0.01 or less of S;
9% or more to 50% or less of Cr;
0.07% or less of A1;
0.02% or less of N;
0.01% or less of O; and
the balance being Fe and inevitable impurities;
wherein the C and N contents satisfy the following equations:
N(%)/C(%)≧2,
and
0.006≦[C(%)+N(%)]≦0.025;
and
the Ti content satisfy the following equations:
{Ti(%)-2×S(%)-3×O(%)}/[C(%)+N(%)]≦4,
and
[Ti(%)]×[N(%)]≦30×10.sup.-4. | 2 |
RELATED APPLICATION
[0001] This application is a Divisional of U.S. patent application Ser. No. 10/696,046, filed on Oct. 29, 2003, which is a Continuation-In-Part of U.S. patent application Ser. No. 10/011,187, filed on Nov. 13, 2001 now U.S. Pat. No. 6,648,473 entitled HIGH-RESOLUTION RETINA IMAGING AND EYE ABERRATION DIAGNOSTICS USING STOCHASTIC PARALLEL PERTURBATION GRADIENT DESCENT OPTIMIZATION ADAPTIVE OPTICS, the entire disclosures of which are incorporated by reference herein in their entireties.
BACKGROUND OF THE INVENTION
[0002] 1. Field of Invention
[0003] This invention relates to a method and a system for high-resolution retinal imaging, eye aberration compensation, and diagnostics based on adaptive optics with direct optimization of an image quality metric using a stochastic parallel perturbative gradient descent technique.
[0004] Adaptive optics is a promising technique for both diagnostics of optical aberrations of the eye and substantially aberration-free high-resolution imaging of the retina. In existing adaptive optics techniques adaptive correction is based on illumination of the retina by a collimated laser beam to create a small size laser location on the retina surface with consequent measurement of phase aberrations of the wave scattered by the retina tissue. Correction of eye optical aberrations is then performed using the conventional phase conjugation technique.
[0005] This traditional approach has several important drawbacks. One important drawback is the danger due to an invasive use of the laser beam focused onto the retina. Other drawbacks include overall system complexity and the high cost of the necessary adaptive optics elements such as a wavefront sensor and wavefront reconstruction hardware. More importantly, due to aberrations the laser beam location size on the retina is not small enough to use it as a reference point-type light source and hence conjugation of the measured wavefront does not result in optimal optical aberration correction. Additionally, the traditional approach can produce a turbid image that can make performing an operation with a microscope difficult.
[0006] One prior art method using a laser is taught in U.S. Pat. No. 6,095,651 entitled “Method and Apparatus for Improving Vision and the Resolution of Retinal Images”, issued to Williams, et al. on Aug. 1, 2000. In Williams, et al. teaches a method and apparatus for improving resolution of retinal images. In this method, a point source of light is produced on the retina by a laser beam. The source is reflected from the retina and received at a lenslet array of a Hartman-Shack wavefront sensor. Thus, higher order aberrations of the eye can be measured and data can be obtained for compensating the aberrations using a system including a laser. U.S. Pat. Nos. 5,777,719 and 5,949,521 provide essentially the same teachings. While these references teach satisfactory methods for compensating aberrations, there is some small risk of damaging the retina since these methods require applying laser beams to the retina.
[0007] U.S. Pat. No. 5,912,731, entitled “Hartmann-type Optical Wavefront Sensor” issued to DeLong, et al. on Jun. 5, 1999 teaches an adaptive optics system using adjustable optical elements to compensate for aberrations in an optical beam. The aberrations may be caused, for example, by propagation of the beam through the atmosphere. The aberrated beam can be reflected from a deformable mirror having many small elements, each having an associated separate actuator.
[0008] Part of the reflected beam taught by DeLong can be split off and directed to impinge on a sensor array which provides measurements indicative of the wavefront distortion in the reflected beam. The wavefront distortion measurements can then be fed back to the deformable mirror to provide continuous corrections by appropriately moving the mirror elements. Configurations such as this, wherein the array of small lenses as referred to as a lenslet array, can be referred to as Shack-Hartmann wavefront sensors.
[0009] Additionally, DeLong teaches a wavefront sensor for use in measuring local phase tilt in two dimensions over an optical beam cross section, using only one lenslet arrangement and one camera sensor array. The measurements of DeLong are made with respect to first and second orthogonal sets of grid lines intersecting at points of interest corresponding to positions of optical device actuators. While this method does teach the way to correct aberrations in a non-laser light system, it cannot be used in cases where lasers are required.
[0010] U.S. Pat. No. 6,007,204 issued to Fahrenkrug, et al. entitled “Compact Ocular Measuring System”, issued on Dec. 28, 1999, teaches a method for determining refractive aberrations of the eye. In the system taught by Fahrenkrug, et al. a beam of light is focused at the back of the eye of the patient so that a return light path from the eye impinges upon a sensor having a light detecting surface. A micro optics array is disposed between the sensor and the eye along the light path. The lenslets of the micro optics array focus incremental portions of the outgoing wavefront onto the light detecting surface so that the deviations and the positions of the focused portions can be measured. A pair of conjugate lenses having differing focal lengths is also disposed along the light path between the eye and the micro optics array.
[0011] U.S. Pat. No. 6,019,472, issued to Koester, et al. entitled “Contact Lens Element For Examination or Treatment of Ocular Tissues” issued on Feb. 1, 2000 teaches a multi-layered contact lens element including a plurality of lens elements wherein a first lens element has a recess capable of holding a volume of liquid against a cornea of the eye. A microscope is connected to the contact lens element to assist in the examination or treatment of ocular tissues.
[0012] U.S. Pat. No. 6,086,204, issued to Magnante entitled “Methods and Devices To Design and Fabricate Surfaces on Contact Lenses and On Corneal Tissue That Correct the Eyes Optical Aberrations” on Jul. 11, 2000. Magnante teaches a method for measuring the optical aberrations of an eye either with or without a contact lens in place on the cornea. A mathematical analysis is performed on the optical aberrations of the eye to design a modified shape for the original contact lens or cornea that will correct the optical aberrations. An aberration correcting surface is fabricated on the contact lense by a process that includes laser ablation and thermal molding. The source of light can be coherent or incoherent.
[0013] U.S. Pat. No. 6,143,011, issued to Hood, et al. entitled “Hydrokeratome For Refractive Surgery” issued on Nov. 7, 2000 teaches a high speed liquid jet for forming an ophthalmic incisions. The Hood, et al. system is adapted for high precision positioning of the jet carrier. An airway beam may be provided by a collimated LED or laser diode. The laser beam can be used to align the system.
[0014] U.S. Pat. No. 6,155,684, issued to Billie, et al. entitled “Method and Apparatus for Precompensating The Refractive Properties of the Human Eye With Adaptive Optical Feedback Control” issued on Dec. 5, 2000. Billie, et al. teaches a system for directing a beam of light through the eye and reflecting the light from the retina. A lenslet array is used to obtain a digitized acuity map from the reflected light for generating a signal that programs an active mirror. In accordance with the signal the optical paths of individuals beams in and the beam of light are made to appear to be substantially equal to each other. Thus, the incoming beam can be precompensated to allow for the refractive aberrations of the eyes that are evidenced by the acuity map.
[0015] Additional methods for using adaptive optics to compensate for aberrations of the human eye are taught in J. Liang, D. Williams and D. Miller, “Supernormal Vision and High-Resolution Retinal Imaging Through Adaptive Optics,” J. Opt. Soc. Am. A, Vol. 14, No. 11, pp. 2884-2891, 1997 and F. Vargas-Martin, P. Prieto, and P. Artal, “Correction of the Aberrations in the Human Eye with a Liquid-Crystal Spatial Light Modulator: Limits to Performance,” J. Opt. Soc. Am. A, Vol. 15, No. 9, pp. 2552-2561, 1998. Additionally, J. Liang, B. Grimm, S. Goelz, and J. Bille, “Objective Measurement of Wave Aberrations of the Human Eye with the Use of a Hartmann-Shack Wave-Front Sensor,” J. Opt. Soc. Am. A, Vol. 11, No. 7, pp. 1949-1957, 1994 teaches such a use of adaptive optics.
[0016] Furthermore, it is known in the art to use a PSPGD optimization algorithm in different applications. For example, see M. Vorontsov, and V. Sivokon. “Stochastic Parallel-Gradient-Descent Technique for High-Resolution Wave-Front Phase-Distortion Correction,” J. Opt. Soc. Am. A, Vol. 15, No. 10, pp. 2745-2758, 1998. Also see M. Vorontsov, G. Carhart, and J. Ricklin, “Adaptive Phase-Distortion Correction Based on Parallel Gradient-Descent Optimization,” Optics Letters, Vol. 22, No. 12, pp. 907-909, 1997.
[0017] It is well known in the art to scan an iris and obtain an iris biometric image. See, for example, U.S. Pat. Nos. 4,641,349, 5,291,560, 5,359,669, 5,719,950, 6,289,113, 6,377,699, 6,526,160, 6,532,298, 6,539,100, 6,542,624, 6,546,121, 6,549,118, 6,556,699, 6,594,377, 6,614,919, and U.S. Patent Application Nos. 20010026632A1, 20020080256A1, 20030095689A1, 20030120934A1, 20020057438A1, 20020132663A1, 20030018522A1, 20020158750A1. However, such images were often not optimal and their applicability was somewhat limited.
[0018] 2. Description of Related Art
[0019] All references cited herein are incorporated herein by reference in their entireties.
BRIEF SUMMARY OF THE INVENTION
[0020] The invention includes a method for clarifying an optical/digital image of an object to perform a procedure on an object having the steps of applying to the object a light beam formed of incoherent light and reflecting the applied incoherent light beam from the object to provide a reflected light beam and providing electrical signals representative of the reflected light beam. An image quality metric is determined in accordance with the electrical signals and an image is determined in accordance with the image quality metric. The procedure is performed in accordance with the image quality metric.
[0021] In a further method of the invention a procedure is performed on an eye having an iris. An iris biometric image representative of the iris is obtained and the procedure is performed on an eye in accordance with the iris biometric image.
[0022] Additionally a method for optimizing electromagnetic energy in a system for processing an image of an object in order to perform a procedure on an object is provided. The method includes applying to the object a plurality of light beams formed of incoherent light at a plurality of differing frequencies and reflecting the plurality of applied incoherent light beams from the object to provide a plurality of reflected light beams. The method also includes providing a corresponding plurality of electrical signals representative of the reflected light beams of the plurality of reflected light beams and determining a corresponding plurality of image quality metrics in accordance with the plurality of electrical signals. A corresponding plurality of images is determined in accordance with the plurality of image quality metrics and an image of the plurality of images is selected in accordance with a predetermined image criterion to provide a selected image. The method also includes determining a frequency of the plurality of differing frequencies in accordance with the selected image to provide a determined frequency and performing the procedure on an object in accordance with the determined frequency.
[0023] The inventions also deals with new methods of high-resolution imaging and construction of images of the retina, and adaptive correction and diagnostics of eye optical aberrations, as well as such imaging of articles of manufacture, identifying articles and controlling a manufacturing process. Additionally, the method is applicable to identifying individuals in accordance with such images for medical purposes and for security purposes, such as a verification of an identity of an individual. These applications can be performed using adaptive optics techniques based on parallel stochastic perturbative gradient descent (PSPGD) optimization. This method of optimization is also known as simultaneous perturbation stochastic approximation (SPSA) optimization. Compensation of optical aberrations of the eye and improvement of retina image resolution can be accomplished using an electronically controlled phase spatial light modulator (SLM) as a wavefront aberration correction interfaced with an imaging sensor and a feedback controller that implements the PSPGD control algorithm.
[0024] Examples of the electronically-controlled phase SLMs include a pixelized liquid-crystal device, micro mechanical mirror array, and deformable, piston or tip-tilt mirrors. Wavefront sensing can be performed at the SLM and the wavefront aberration compensation is performed using retina image data obtained with an imaging camera (CCD, CMOS etc.) or with a specially designed very large scale integration imaging chip (VLSI imager). The retina imaging data are processed to obtain a signal characterizing the quality of the retinal image (image quality metric) used to control the wavefront correction and compensate the eye aberrations.
[0025] The image quality computation can be performed externally using an imaging sensor connected with a computer or internally directly on an imaging chip. The image quality metric signal is used as an input signal for the feedback controller. The controller computes control voltages applied to the wavefront aberration correction. The controller can be implemented as a computer module, a field programmable gate array (FPGA) or a VLSI micro-electronic system performing computations required for optimization of image quality metrics based on the PSPGD algorithm.
[0026] The use of the PSPGD optimization technique for adaptive compensation of eye aberration provides considerable performance improvement if compared with the existing techniques for retina imaging and eye aberration compensation and diagnostics, and therapeutic applications. The first advantage is that the PSPGD algorithm does not require the use of laser illumination of the retina and consequently significantly reduces the risk of retina damage caused by a focused coherent laser beam. A further advantage is that the PSPGD algorithm does not require the use of a wavefront sensor or wavefront aberration reconstruction computation. This makes the entire system low-cost and compact if compared with the existing adaptive optics systems for retina imaging. Additionally, the PSPGD algorithm can be implemented using a parallel analog, mix-mode analog-digital or parallel digital controller because of its parallel nature. This significantly speeds up the operations of the PSPGD algorithm, providing continuous retina image improvement, eye aberration compensation and diagnostics.
[0027] Thus, in the adaptive correction technique of the present invention neither laser illumination nor wavefront sensing are required. Optical aberration correction is based on direct optimization of the quality of an retina image obtained using a white light, incoherent, partially coherent imaging system. The novel imaging system includes a multi-electrode phase spatial light modulator, or an adaptive mirror controlled with a computer or with a specially designed FPGA or VLSI system. The calculated image quality metric is optimized using a parallel stochastic gradient descent algorithm. The adaptive optical system is used in order to compensate severe optical aberrations of the eye and thus provide a high-resolution image and/or of the retina tissue and the eye aberration diagnostic.
BRIEF DESCRIPTION OF SEVERAL VIEWS OF THE DRAWINGS
[0028] The invention will be described in conjunction with the following drawings in which like reference numerals designate like elements and wherein:
[0029] FIGS. 1 A,B show a schematic representation of system suitable for practicing the eye aberration correcting method of the present invention.
[0030] FIG. 2 shows a flow chart representation of control algorithm suitable for use in the system of FIG. 1 when practicing the method of the present invention.
[0031] FIGS. 3 A,B show images of an artificial retina before and after correction of an aberration
[0032] FIG. 4 A,B show an eye and a biometric image of the iris of the eye.
[0033] FIG. 5 shows a block diagram representation of an iris biometric image comparison system which can be used with the aberration correcting system of FIG. 1 .
[0034] FIG. 6 shows a block diagram representation of an iris positioning system which can be used in cooperation with the aberration correcting system of FIG. 1 .
[0035] FIG. 7 shows an illumination frequency optimization system which can be used in cooperation with the aberration correcting system of FIG. 1 .
[0036] FIG. 8 shows an image superpositioning system which can be used with the aberration correcting system of FIG. 1 .
DETAILED DESCRIPTION OF THE INVENTION
[0037] Referring now to FIGS. 1 A,B there are shown schematic representations of the aberration correcting system 10 of the present invention. In the aberration correcting system 10 a light beam from a white light source 1 is redirected by a mirror 2 in order to cause it to enter an eye. In accordance with the present invention the white light beam from the light source 1 can be any kind of incoherent light.
[0038] The light from the mirror 2 reaches the retina 4 of the eye and reflected light exits the eye to provide two light beams, one passing in each direction, as indicated by arrow 3 . The exiting light beam then passes through an SLM 5 . The light beam from the SLM 5 enters an image sensor 6 . The image sensor 6 can be a charge coupled capacitor device or any other device capable of sensing and digitizing the light beam from the SLM 5 .
[0039] The imaging sensor 6 can include an imaging chip for performing the calculations required to determine an image quality metric. The image quality metric can thus be computed on the imaging chip directly or it can be calculated using a separate computational device/computer 7 that calculates the image quality metric of the retina image. It is the use of a digitized image in this manner that permits the use of an incoherent light rather than a coherent light for performing the operations of the aberration correction correcting system 10 .
[0040] The computational device 7 sends a measurement signal representative of the image quality metric to a controller 8 . The controller 8 implements a PSPGD algorithm by computing control voltages and applying the computed control voltages to the SLM 5 . The PSPGD algorithm used by the controller 8 can be any conventional PSPGD algorithm known to those of ordinary skill in the art. In the preferred embodiment of the invention, the controller 8 continuously receives digital information about the quality of the image and continuously updates the control voltages applied to the SLM 5 until the quality of the retina image is optimized according to predetermined image quality optimization criteria.
[0041] Referring now to FIGS. 2 and 3 A,B there are shown a flow chart representation of a portion of a PSPGD control algorithm 20 for use in cooperation with the aberration correcting system 10 in order to practice the present invention as well as representations of the corrected image, both before correction ( 3 A) and after correction ( 3 B). In order to simplify the drawing a single iterative step of the PSPGD control algorithm 20 is shown with a loop for repeating the single iterative step until the quality of the compensation is acceptable.
[0042] In step 25 of the PSPGD control algorithm 20 a measurement and calculation of the image quality metric is performed. This step includes the retinal image capture performed by the sensor 5 and the calculation of the image quality metric performed by the computational device 7 within the aberration correcting system 10 . The image captured by the sensor 5 at the beginning of the operation of the PSPGD control algorithm 20 can be substantially as shown in FIG. 3A , as previously described. One can use any relevant metric entity as an image quality metric. For example, in one embodiment of the PSPGD control algorithm 20 the image quality metric can be a sharpness function. A sharpness function suitable for use in the present invention can be defined as
[0000] J=∫|∇ 2 I ( x, y )| dxdy
[0000] where I(x,y) is the intensity distribution in the image, and ∇ 2 is the Laplacian operator over the image. The Laplacian can be calculated by convolving the image with a Laplacian kernel. The convolving of the image can be performed by a special purpose VLSI microchip. Alternately, the convolving of the image can be performed using a computer that receives an image from a digital camera as described in more detail below. In another embodiment different digital high-pass filters can be used rather than the Laplacian operator.
[0043] Additionally, a frequency distribution function can be used rather than a sharpness function when determining the image quality metric. The use of a frequency distribution function allows the system to distinguish tissues of different colors. This is useful where different kinds of tissue, for example, different tumors, have different colors. Locating tumors in this manner also permits the invention to provide tumor location information, such as a grid location on a grid having a pre-determined reference in order to assist in diagnosis and surgery. It also permits the invention to provide tumor size and type information. Additionally, the use of a frequency distribution function permits a surgeon to determine which light frequencies are best for performing diagnosis and surgery.
[0044] The image quality metric J can also be calculated either optically or digitally using the expression introduced in:
[0000] J=∫|F {exp [ iγI ( x, y )]}| 4 dxdy
[0045] Where F is the Fourier transform operator and [[ã]] y is a parameter that is dependent upon the dynamic range of the used image.
[0046] In step 30 of the PSPGD control algorithm 20 random perturbations in the voltages applied to the SLM 5 electrodes are generated. The SLM 5 can be a liquid crystal membrane for modifying the light beam according to the electrical signals from controller 8 in a manner well understood by those skilled in the art.
[0047] In order to generate the perturbations for application to the electrodes for the SLM 5 random numbers with any statistical properties can be used as perturbations. For example, uncorrelated random coin flip perturbations having identical amplitudes|u J and the Bernoulli probability distribution:
[0000] du j =±p, Pr ( du j =+p )=0.5
[0000] for all j=1, . . . , N (N=the number of control channels) and iteration numbers can be used. Note that Non-Bernoulli perturbations are also allowed in the PSPGD control algorithm 20 .
[0048] In step 35 of the PSPGD control algorithm 20 a measurement of the perturbed image quality metric and a computation of the image quality perturbation δJ (m) are performed. Following the determination of the perturbed image quality metric, the gradient estimations
[0000] {tilde over (J)}′ J (m) =δJ (m) π j (m)
[0000] are computed as shown in step 40 .
[0049] The updated control voltages are then determined as shown in step 45 . Therefore, a calculation of:
[0000] u J (m+1) =u J (m) −γδJ (m) π j (m)
[0000] is performed.
[0050] To further improve the accuracy of gradient estimation in the PSPGD control algorithm 20 a two-sided perturbation can be used. In a two-sided perturbation two measurements of the cost function perturbations J + and J − are taken. The two measurements correspond to sequentially applied differential perturbations+u J /2 and −u J /2.
[0000] It follows that:
[0000] dJ=dJ + −dJ − and
[0000]
{tilde over (J)}′
j
=δ J δ u
j
[0000] which can produce a more accurate gradient estimate.
[0051] The process steps 25 - 45 of the PSPGD control algorithm 20 are repeated interactively until the image quality metric has reached an acceptable level as determined in step 50 . The choice of an acceptable level of the image quality metric is a conventional one well known to those skilled in the art. As shown in step 55 the aberration is then corrected and an image of the retina can be taken. The image resulting from the operation of the PSPGD algorithm 20 can be as shown in FIG. 3B .
[0052] The eye aberration function (x,y) can be calculated from known voltages applied to wavefront correction Δu j } at the end of the iterative optimization process and known response functions of {S j (x,y)} wavefront correction.
[0000]
j
(
x
,
y
)
=
∑
j
=
1
N
u
j
S
j
(
x
,
y
)
.
[0053] Referring now to FIGS. 4 A,B, there is shown an eye 80 having an iris 84 with a pupil 88 therein and an iris biometric image 90 . The iris biometric image 90 is a biometric image of the iris 84 , which can be obtained using an iris scanning system, such as the aberration correcting system 10 . In an alternate embodiment of the invention, the iris biometric image 90 can be obtained by any other system (not shown) capable of scanning and digitizing an iris and providing an image that is characteristic of the iris, such as a bar code type output as shown in FIG. 4B . Furthermore, it will be understood that every human eye has an unique iris biometric image when it is scanned and digitized in this manner. Thus, an iris biometric image can be used as a unique identifier of an individual in the manner that fingerprints are used or even to distinguish between the left and right eyes of an individual.
[0054] When the predetermined image quality is obtained, a plurality of locations 92 within the iris 84 can be defined. In one preferred embodiment of the invention, four locations 92 can be selected. The four locations 92 can be disposed on the corners of a rectangle which is concentric with the iris 84 . The locations 92 can thus be easily used to find the center of the iris 84 . The four locations 92 are represented on the iris biometric image 90 in accordance with the mathematical relationships previously described. Thus, the xy coordinates of the locations 92 may be mapped into corresponding xy coordinates within the iris biometric image 90 if a spatial transform such as the sharpness function is used, while they may be convolved over areas of the iris biometric image 90 if a frequency or other transform is used.
[0055] Various features already occurring in the eye 80 also have corresponding representations within the iris biometric image 90 . The location and study of such features can be used to diagnose pathologies, for example, to diagnose tumors and to determine the position of the eye iris 84 . As a further example, a feature can be studied several times over a period of time to determine how its parameters are is changing.
[0056] Referring now to FIG. 5 , there is shown the iris biometric image comparison system 100 . The iris biometric image comparison system 100 receives the previously determined iris biometric image 90 as one of its inputs. Additionally, a new iris biometric image 95 is produced, for example, before or during the performance of a procedure on the eye 80 . The new iris biometric image 95 is received by the image comparison system 100 as a second input. The new iris biometric image 95 can be provided by the aberration correction system 10 . The light beam used to obtain the iris biometric image 95 can be the same light beam being used for other purposes during the procedure.
[0057] When using the aberration correcting system 10 , the image can be optimized by executing additional iterations of the PSPGD control algorithm 20 . The algorithm can be iterated until a predetermined image quality is obtained and computing the image quality metric within the computer 7 as previously described. In addition to performing more iterations of the PSPGD control algorithm 20 , increased image sensitivity quality can be obtained by increasing the number of pixels in the digitized image or increase image sensitivity can be obtained by increasing the number of measuring points in the iris 84 .
[0058] When performing the method of the image comparison system 100 the iris biometric image 90 can be assumed by the image comparison system 100 to be the correct iris biometric image of the iris 84 upon which the procedure is to be performed. Furthermore, it can be assumed that the iris biometric image 90 applied to the image comparison system 100 was obtained when the position and orientation of the eye 80 were correct.
[0059] The iris biometric images 90 , 95 are compared by the image comparison system 100 at decision 104 . A determination is made as to whether the iris biometric image 95 is an image of the same iris 84 that was imaged to produce the enrolled iris biometric image 90 . Any of the well known correlation techniques can be used for the comparison. Substantially similar correlation techniques can be used for the comparison if the locations 92 are used or if other markings within the iris 84 are used. The sensitivity of the comparison can be adjusted by those skilled in the art.
[0060] If the determination of decision 104 is negative, then the procedure being performed on the eye 80 is not continued as shown in block 102 . If the determination of decision 104 is positive, then a determination can be made in decision 106 whether the iris 84 is positioned in the xy directions correctly and oriented or rotated correctly at the time that the iris biometric image 95 was produced. The determination of decision 106 can be used for a number of purposed. For example, it could be used to direct a beam of light to a predetermined location within the eye 80 . Thus, if the determination of decision 106 is negative, the beam can be redirected as shown in block 110 . The position of the iris 84 can be checked again in decision 106 . When the position of the iris 84 is correct, the procedure can begin, as shown in block 112 .
[0061] The determination of decision 106 can be made in accordance with the representations of locations 92 within the iris 84 selected when iris biometric image 90 was obtained. If corresponding locations are found in the iris biometric image 95 in the same positions, the determination of decision 106 is positive. Alternately, the determination of decision 106 can be made in accordance with predetermined features or markings within the iris 84 other than the locations 92 . The method of the image comparison system 100 can be used to determine whether the iris 84 is rotated or translated in the direction of either of the axes orthogonal to the arrow 3 shown in FIGS. 1 A,B.
[0062] Referring now to FIG. 6 , there is shown the iris positioning system 120 . The iris positioning system 120 is adapted to precisely position the iris 84 while performing a procedure on the eye 80 . The iris positioning system 120 differs from the iris biometric image comparison system 100 primarily in the fact that the iris positioning system 120 is provided with a servo 124 . The servo 124 is effective in modifying the relative positions of the iris 84 and the camera 6 of the aberration correcting system 10 which can be coupled to equipment (not shown) used to perform the procedure in the eye.
[0063] In the iris positioning system 120 a determination is made in decision 104 whether the iris biometric images 90 , 95 were made on the same eye as previously described with respect to image comparison system 100 . The procedure is continued only if a positive determination is made. A determination is then made in decision 106 whether the iris 84 is in the correct position. The determination of decision 106 can be made by comparing the iris biometric images 90 , 95 in accordance with the locations 92 or any other markings within the iris 84 as previously described. The determination made can be, for example, whether the iris 84 is rotated or translated in the x or y direction at the time that the iris biometric image 95 is obtained.
[0064] When a determination is made that the iris 84 is in an incorrect position, a correction signal representative of the error is calculated. The error correction signal is applied to the servo 124 . The servo 124 is adapted to receive the error correction signal resulting from the determinations of decision 106 and to adjust the relative positions of the iris 84 and the equipment performing the procedure in accordance with the signal in a manner well understood by those skilled in the art. Servos 124 capable of applying both rotational and multi-axis translational corrections are both provided in the preferred embodiment of the invention. Either the object such as the iris 84 or the equipment can be moved in response to the determination of decision 106 .
[0065] The method of the iris positioning system 120 can be repeatedly performed, or constantly performed, during the performance of a procedure on the eye 80 to re-capture, re-evaluate or refine the process the eye 80 . Thus, the relative positions of the iris 84 and the procedure equipment can be kept correct at all times.
[0066] Referring now to FIG. 7 , there is shown the illumination frequency optimization system 130 . The illumination frequency optimization system 130 is an alternate embodiment of the aberration correcting system 10 . Within the frequency optimization system 130 a variable frequency light source 132 rather than a single frequency light source applies a light beam to the eye 80 . The variable frequency light source 132 can be a tunable laser, a diode, filters in front of a light source, a diffraction grating or any other source of a plurality of frequencies of light. An image quality metric can be obtained and optimized in the manner previously described with respect to system 10 .
[0067] Using the variable frequency light source 132 , it is possible to conveniently adjust the frequency of the light beam used to illuminate the eye 80 or object 80 at a plurality of differing frequencies and to obtain a plurality of corresponding image quality metrics. In order to do this, the frequency of the light applied to the eye 80 by the variable frequency light source 132 can be repeatedly adjusted and a new image quality metric can be obtained at each frequency. Each image quality metric obtained in this manner can be optimized to a predetermined level. The levels of optimization can be equal or they can differ. While the optimizations should be done using the frequency distribution, it is possible to return to images optimized using the frequency distribution and sharpen using the sharpness function.
[0068] It is well understood that differing types of tissue can be visualized best with differing frequencies of light. For example, tumors, lesions, blood and various tissues as well as tissues of varying pathologies can be optimally visualized at different frequencies since their absorption and reflection properties vary. Thus, by adjusting the frequency applied to the eye 80 by the variable frequency light source 132 and viewing the results, the best light for visualizing selected features can be determined. Furthermore, using this method there can be several optimized images for one eye. For example, there can be different optimized images, for a tumor, for a lesion and for blood. The determination of the best frequency for each image can be a subjective judgment made by a skilled practitioner.
[0069] A skilled practitioner can use the illumination frequency optimization system 130 to emphasize and de-emphasize selected features within images of the eye 80 . For example, when obtaining an iris biometric image 95 , the iris 84 may be clouded due to inflamation of the eye 80 or the presence of blood in the eye 80 . It is possible to effectively remove the effects of the inflamation blood with the assistance of the frequency optimization system 130 by varying the frequency of the light provided by the light source 132 until the optimum frequency is found for de-emphasizing the inflammation or blood and permitting the obscured features to be seen. In general, it is often possible to visualize features when another feature is superimposed on them by removing the superimposed feature using system 130 .
[0070] In order to remove the effects of the inflamation or blood, a plurality of images of the eye 80 can be provided and the frequency at which the blood or inflamation is least apparent can be determined. Removing these features from the iris biometric image 95 can facilitate its comparison with the iris biometric image 90 . Furthermore, when the biometric image 95 is obtained from the iris 110 of a person wearing sunglasses, it is possible to remove the effects of the sunglasses in the same manner and identify an eye 80 behind the sunglasses. This feature is useful when identifying people outside of laboratory conditions.
[0071] Referring now to FIG. 8 , there is shown the image superposition system 150 . In many cases it is desirable to perform a procedure on an eye 80 when selected features of the eye 80 are obscured by other features, where different features are visualized best at different frequencies, or where the criteria for emphasizing and de-emphasizing features can change during a procedure. Image superposition 100 can be used to obtain improved feature visualization under these and other circumstances.
[0072] For example, white light is often preferred for illuminating an iris 84 because in many cases white light shows the most features. However, if white light is used to illuminate an iris 84 when the iris 84 is clouded with blood, the blood can block the white light. This can make it difficult, or even impossible, to visualize the features that are obscured by the blood. One solution to this problem is to use red light to illuminate the iris 84 and visualizes the features obscured by the blood.
[0073] However, the red light could fail to optimally visualize the features which are normally visualized best using, for example, white light. The image superposition system 150 can solve this problem by superimposing two images such as the direct image 166 and the projected image 170 , where the images 166 , 170 are obtained using light sources of differing frequencies. The optimum frequencies for obtaining each of the images 166 , 170 can be determined using the illumination frequency optimization system 130 .
[0074] For example, an object 168 to be visualized can be illuminated with incoherent white light to provide the direct image 166 . Illumination of the object 168 by white light to produce the direct image 166 can be provided using any of the known methods for providing such illumination of objects to provide digital images. The direct image 166 can be sensed and digitized using an image sensor 152 which senses light traveling from the object 168 in the direction indicated by the arrows 156 , 164 .
[0075] The image sensor 152 senses the direct image 166 of the object 168 by way of a superposition screen 160 . The superposition screen 160 can be formed of any material capable of transmitting a portion to the light applied to it from the object 168 to the image sensor 152 , and reflecting a portion of the same light. For example, the superposition screen 168 can be formed of glass or plastic. A viewer, a TV screen or a gradient filter can also serve as the superposition screen 160 . The screen 160 can also be a gradient filter. In a preferred embodiment of the invention, the angle 172 of the superposition screen 160 can be adjusted to control the amount of light it transmits and the amount it reflects.
[0076] The projected image 170 of the object 168 can be obtained using, for example, the aberration correcting system 10 as previously described. Illumination with red light or any other frequency of light can be used within the aberration correcting system 10 to obtain the superposition image 178 . The superposition image 178 is applied to an image projector 176 by the aberration correcting system 10 . The image projector 176 transmits the projected image 170 in accordance with the superposition image 178 in the direction indicated by the arrow 174 and applies it to the superposition screen 160 .
[0077] A portion of the projected image 170 applied to the superposition screen 160 by the projector 176 is reflected off of the superposition screen 160 and applied to the image sensor 152 in the direction indicated by the arrow 156 . The amount of the projected image 170 reflected to the image sensor 152 can be adjusted by adjusting the angle 172 of the superposition screen 160 . The image projector 176 is disposed in a location adapted to apply the projected image 170 to the superposition screen 160 in the same region of the superposition screen 160 where the direct image 166 is applied. When the images 166 , 170 are applied to the superposition screen 160 in this manner, they are superimposed and the image sensed by the image sensor 152 is thus the superposition or composite of the images 166 , 170 .
[0078] Adjustment of the angle 172 results in emphasizing and de-emphasizing the images 166 , 170 relative to each other. This is useful, for example, where different features visualized selectively at differing frequencies must be brought in and out of visualization in the composite image for different purposes. Another time where this is useful is when the intensity of one of the images 166 , 170 is too high relative to the other and must be adjusted down or too low and must be adjusted up.
[0079] In various alternate embodiments of the image superposition system 150 , either or both of the images 166 , 170 can be optimized using the PSPGD algorithm 20 within the aberration correction system 10 . Furthermore, the images 166 , 170 can be optimized to differing degrees by the PSPGD algorithm 20 and with differing optimization criteria in order to emphasis one over the other or to selectively visualize selected features within the images 166 , 170 and thus, within the composite image sensed by image sensor 152 . This permits selected features of the eye 80 to be brought into view and brought out of view as convenient at different times during a diagnosis or a procedure.
[0080] Thus, the illumination used to obtain the images 166 , 170 superimposed by the image superposition system 150 does not need to be red and white light. The illumination used can be light of any differing frequencies. The frequencies selected for obtaining the images 166 , 170 can be selected in accordance with the sharpness function on the frequency distribution as previously described.
[0081] The images superimposed by the image superposition system 150 do not need to be obtained by way of a camera, such as the camera 6 of the aberration correction system 10 . A microscope, an endoscope, or any other type of device having an image sensor capable of capturing transmission, absorption or reflection properties of an object or tissue in a normal state or enhancement by such materials as markers and chromophores and thereby providing an optical/digital signal that can be applied to the computer 7 for optimization using the PSPGD algorithm 20 can be used. Thus, for example, an image obtained from an endoscope or a microscope can be superimposed upon an image obtained from an camera using the method of the present invention. Images from endoscopes, microscopes and other devices can be digitized, and superimposed and synthesized with each other. It will be understood that images obtained from such devices and optimized using the PSPGD algorithm 20 can be used in any other way that images obtained from the PSPGD algorithm 20 using camera 6 are used.
[0082] The description herein will so fully illustrate my invention that others may, by applying current or future knowledge, adopt the same for use under various conditions of service. For example, the invention may be used for ophthalmological procedures such as photocoagulation, optical biopsies such as measuring tumors anywhere in the eye, providing therapy, performing surgery, diagnosis or measurements. Additionally, it can be used for performing procedures on eyes outside of laboratory or medical environments. Furthermore, the method of the present invention can be applied to any other objects capable of being imaged in addition to eyes and images of an object provided. In accordance with the method of the invention can be used when performing such procedures on other objects.
[0083] While the invention has been described in detail and with reference to specific examples thereof, it will be apparent to one skilled in the art that various changes and modifications can be made therein without departing from the spirit and scope thereof. | A method for performing a procedure on a patient, includes obtaining a biometric image representative of the patient and performing the procedure on the patient in accordance with the biometric image. The patient has an iris and the biometric image comprises an iris biometric image and the procedure comprises a medical procedure. First and second iris biometric images; are obtained and the first and second iris biometric images arc compared to provide a biometric comparison result. A patient is identified in accordance with the biometric comparison result. The patient has at least one feature and the feature is represented within at least one of the first and second iris biometric images. | 0 |
This is a division of application Ser. No. 07/886,831 , filed May 22, 1992.
BACKGROUND OF THE INVENTION
Corning Incorporated, Corning, N.Y. has marketed tableware products under the trademark CORELLE® for over 20 years. The ware consists of a laminate composed of a relatively thick interior body (the core glass) enveloped within a thin surface layer (the skin glass). The ware is manufactured by means of a continuous hot forming process wherein glass batches are melted for the individual laminae and streams of the molten glasses are brought together such that laminae are essentially simultaneously fused together and shaped into a desired configuration. The individual layers are prepared from compositions exhibiting different thermal expansion and viscosity characteristics such that, upon cooling, the surface layer is placed in a state of compression and the interior body is placed in a state of tension. U.S. Pat. No. 3,673,049 (Giffen et al.) and U.S. Pat. No. 3,737,294 (Dumbaugh, Jr. et al.) provide discussions of the method of forming the laminated articles and properties exhibited by those articles. To avoid repetition here, the disclosures of those patents are expressly incorporated herein by reference.
As is explained in those patents, to secure a surface compression layer, the skin glass will have a lower linear coefficient of thermal expansion than the core glass. And, as the difference in thermal expansion (termed "expansion mismatch") is increased, the mechanical strength, as reflected in unabraded modulus of rupture measurements, the internal and maximum central tensions, the surface compression, and the stored tensile energy all increase. Furthermore, for a specific expansion mismatch the thickness of the skin glass demonstrates the following effects:
(a) the mechanical strength, as represented by unabraded modulus of rupture measurements, decreases essentially linearly with increasing skin thickness;
(b) both the internal tension and the maximum central tension increase essentially linearly with increasing skin thickness;
(c) the depth of the compression layer decreases approximately linearly with increasing skin thickness following air tempering;
(d) the stored tensile energy in the core glass, which factor directly impacts upon product frangibility, increases quadratically with increasing skin thickness; and
(e) the surface compression decreases essentially linearly with increasing skin thickness.
The overall thickness of CORELLE® ware is closely controlled which, in turn, restricts the individual thicknesses of the core and skin glasses. Whereas the tableware is very strong mechanically, the thinness of the glassware subjects it to infrequent breakage. As can be appreciated, it is most desirable that any such breakage be relatively gentle so that the likelihood of injury to the user is reduced to a minimum. Paragraph (d) above notes that the stored tensile energy in the core glass is the prime factor in influencing the force of breakage and that energy increases significantly with increasing skin thickness.
Because the skin glass of CORELLE® ware is very thin, the articles can be subject to delayed breakage; i.e., in usage the ware may become bruised, scuffed, chipped, or otherwise injured, but the impact causing the injury is not sufficient to cause immediate breakage. In further service, however, other small impacts and/or the penetration of water may cause the initial injury to move through the skin to the interface between the skin and core glasses, thereby resulting in breakage. A thicker skin layer would reduce the possibility of such breakage.
Thus, the skin glass must be sufficiently thick to assure complete coverage of the ware surface to provide a compression layer thereon to enhance the mechanical strength of the ware, but not so thick that the central tension and stored tensile energy in the core glass become very high. Accordingly, a balance must be struck between the thickness of the surface skin and the difference in thermal expansion existing between the core glass and the skin glass.
The overall thickness of CORELLE® ware is ˜0.105" (˜2.7 mm) with a skin thickness of about 0.0015"-0.003" (˜0.04-0.08 mm). Spontaneous opal glasses having compositions disclosed in U.S. Pat. No. 3,661,601 (Dumbaugh et al.) have been found to be particularly suitable for use as core or body glasses in laminated glass articles. Those glasses exhibit linear coefficients of thermal expansion (0°-300° C.) of about 60-110×10 -7 /° C. and consist essentially, expressed in terms of weight percent on the oxide basis, of
______________________________________SiO.sub.2 50-75 Na.sub.2 O 0-7Al.sub.2 O.sub.3 3-9 K.sub.2 O 0-7CaO 11-20 N.sub.2 O + K.sub.2 O 3-10B.sub.2 O.sub.3 1-7 F 2-4______________________________________
the sum of those components constituting at least 85% of the total composition.
The opacity present in those glasses results from a non-crystalline opacifying phase consisting of phase separated droplets or opacifying particles which comprise about 10-40% by volume of the total glass volume. The core glass used in CORELLE® ware, viz., Corning Code 1001, has the following approximate composition, expressed in terms of weight percent
______________________________________SiO.sub.2 64.4 Na.sub.2 O 3.05Al.sub.2 O.sub.3 6.2 K.sub.2 O 3.0CaO 15.0 MgO 1.07B.sub.2 O.sub.3 4.75 F 3.4______________________________________
and exhibits an annealing point of 605° C., a strain point of 557° C., and a linear coefficient of thermal expansion (0°-300° C.) of 72×10 -7 /° C. The phase separated droplets crystallize during subsequent thermal tempering of the CORELLE® ware. Compositions found to be especially suitable for preparing transparent skin glasses exhibit linear coefficients of thermal expansion (0°-300° C.) of about 30-80×10 -7 /° C. and consist essentially, expressed in terms of weight percent on the oxide basis, of
______________________________________SiO.sub.2 50-65 MgO 0-12Al.sub.2 O.sub.3 10-20 B.sub.2 O.sub.3 0-10CaO 5-25______________________________________
with, optionally, up to 12% total of at least one oxide selected from the group of BaO, La 2 O 3 , SrO, and ZnO, and up to 5% total of at least one oxide selected from the group of K 2 O, Li 2 O, Na 2 O, TiO 2 and ZrO 2 .
The skin glass used in CORELLE® ware, viz., Corning Code 1002, has the following approximate composition, expressed in terms of weight percent,
______________________________________SiO.sub.2 58.25 B.sub.2 O.sub.3 6.25Al.sub.2 O.sub.3 14.8 MgO 5.7CaO 15.0______________________________________
and demonstrates a linear coefficient of thermal expansion (0°-300° C.) of 48×10 -7 /° C.
The mismatch in thermal expansion existing between the body and skin glasses is directly related to both the strength of the laminate and the frangibility. The term mismatch refers to the difference in thermal expansion between the skin and body glasses, the measurement being computed at the setting temperature of the softer (lower annealing point) body glass and expressed in terms of parts per million (ppm). It can be appreciated that, once defined, this mismatch, for all practical purposes, is not a controllable variable in the manufacturing process; hence, the criticality of selecting the core and skin glass compositions to achieve the desired mismatch.
As was observed above, the overall thickness of CORELLE® tableware is held within straitly-limited values. Accordingly, an increase in thickness of the skin glass requires a compensating decrease in the cross-section of the body glass. As was also explained above, however, an increase in thickness of the skin glass, when the expansion mismatch is held constant, results in a buildup of the central tension in the core glass which leads to more forceful breakage. Therefore, in order to safely increase the thickness of the skin to enhance resistance to bruises and scratches, the level of expansion mismatch must be reduced. Nevertheless, in achieving that goal, the other chemical and physical properties required in the individual core and skin glasses, as well as those displayed by the laminate, must not be sacrificed. For example, the annealing point, the liquidus temperature, the liquidus viscosity, and the chemical durability must closely track present values. Moreover, the mechanical strength of the laminate must not be degraded to any substantial extent.
The linear coefficient of thermal expansion (0°-300° C.) of Corning Code 1001 glass is 72×10 -7 /° C. and that of Corning Code 1002 is 48×10 -7 /° C., resulting in a mismatch of 1733 ppm. It was calculated that an expansion mismatch of about 1200-1400 ppm would not significantly degrade the mechanical strength of the laminate but would permit an increase in skin glass thickness, thereby leading to both improved breakage characteristics and improved resistance to bruises and scratches. Moreover, the use of a thicker skin layer enables the production of deeper drawn ware inasmuch as hazards resulting from the skin becoming too thin at the bottom corners and edges of the ware during vacuum forming are greatly reduced. With continued use of Corning Code 1001 as the body glass, a new skin glass was sought exhibiting a linear coefficient of thermal expansion of 57-59×10 -7 /° C. which would result in an expansion mismatch approximating 1200-1400 ppm.
Accordingly, the primary objective of the instant invention was to devise glass compositions demonstrating linear coefficients of thermal expansion within the interval of about 57-59×10 -7 /° C. and which display chemical and physical properties closely compatible with those exhibited by Code 1001 glass, while maintaining the viscosity characteristics of the current skin glass. Thus, the approximately 30% reduction in expansion mismatch between the body and skin glasses would lead to (a) about 20% lower central tension in the body glass, (b) about 37% lower stored energy in the body glass, with consequent less breakage force, (c) the capability of increasing the thickness of the skin glass to about 0.0045" (˜0.1 mm), and (d) a compression layer about 13-22% deeper, with consequent 13-22% improvement in resistance to bruises and scratches.
SUMMARY OF THE INVENTION
That objective can be achieved utilizing glasses consisting essentially, expressed in terms of weight percent on the oxide basis, of
______________________________________SiO.sub.2 56-60 CaO 19-24.25Al.sub.2 O.sub.3 12-15 Na.sub.2 O 0-3B.sub.2 O.sub.3 5.5-7 K.sub.2 O 0-3Na.sub.2 O + K.sub.2 O 0.5-3.______________________________________
Those glasses demonstrate annealing points of 682°-702° C., linear coefficients of thermal expansion of 57-59×10 -7 /° C., internal liquidus values of ≦1100° C., solubilities in 5% by weight aqueous solutions of HCl at 95° C. for 24 hours of ≦1 mg/cm 2 , and solubilities in 0.02N aqueous solutions of Na 2 CO 3 at 95° C. for 6 hours of ≦0.25 mg/cm 2 .
The preferred compositions consist essentially, in weight percent, of
______________________________________SiO.sub.2 57-59 CaO 20-22Al.sub.2 O.sub.3 13-15 Na.sub.2 O 0-1.5B.sub.2 O.sub.3 5.5-7 K.sub.2 O 0-1.5Na.sub.2 O + K.sub.2 O 0.5-1.5.______________________________________
PRIOR ART
The composition intervals for the calcium alumino-silicate skin glasses disclosed in U.S. Pat. Nos. 3,673,049 and 3,737,294 (supra) overlap the ranges of the instant inventive glasses, but there is no discussion in either patent of glasses exhibiting the chemical, physical, and viscosity characteristics demanded in the subject glasses, and none of the working examples provided in those patents has a composition coming within the ranges of the present glasses.
DESCRIPTION OF PREFERRED EMBODIMENTS
Table I records a group of glass compositions, expressed in terms of parts by weight on the oxide basis, illustrating the criticality of composition control to yield glasses demonstrating the required properties. Because the sum of the components totals or closely approximates 100, for all practical purposes the tabulated value of the individual components can be deemed to represent weight percent. The actual batch ingredients can comprise any materials, either an oxide or another compound, which, when melted together with the other constituents, will be converted into the desired oxide in the proper proportions. For example, CaCO 3 and Na 2 CO 3 can comprise the source of CaO and Na 2 O, respectively. Example 13 comprises Corning Code 1002 glass.
The batch components were compounded, ball-milled together to assist in obtaining homogeneous melt, and charged into platinum crucibles. The crucibles were moved into a furnace operating at about 1550° C. and the batches melted for four hours. The melts were poured onto a steel plate to yield glass slabs having the approximate dimensions of 12"×5"×0.375" (˜30.5×12.7×1 cm), and those slabs were transferred immediately to an annealer operating at about 690°-710° C.
It will be appreciated that the above description of mixing, melting, and forming procedures represents laboratory activity only and that the glass compositions operable in the present invention are capable of being produced employing mixing, melting, and forming practices conventionally employed in commercial glassmaking. That is, it is only necessary that the batch ingredients be thoroughly blended together, melted for a sufficient length of time at a high enough temperature to secure a homogeneous melt, and thereafter formed into a glass article. In most instances the glass article will be subjected to an annealing process. When the batch is melted commercially, the melt may be sulfate fined.
TABLE I______________________________________ 1 2 3 4 5 6 7______________________________________SiO.sub.2 57.9 57.9 58.1 57.0 56.6 56.1 54.4Al.sub.2 O.sub.3 13.8 14.8 14.9 13.9 13.9 12.8 12.9B.sub.2 O.sub.3 6.1 5.69 5.72 6.35 6.31 6.25 7.57CaO 21.1 20.4 19.4 21.5 21.3 24.2 24.4Na.sub.2 O 1.1 1.13 1.7 1.13 -- -- --K.sub.2 O -- -- -- -- 1.71 -- --______________________________________ 8 9 10 11 12 13______________________________________SiO.sub.2 52.7 57.3 56.3 54.6 56.4 58.25Al.sub.2 O.sub.3 13.1 14.7 14.7 14.8 13.8 14.8B.sub.2 O.sub.3 8.91 5.64 6.27 7.59 6.29 6.25CaO 24.6 22.2 22.2 22.4 23.3 15.0MgO -- -- -- -- -- 5.7______________________________________
Table II reports the linear coefficient of thermal expansion (Exp.) over the temperature range of 25°-300° C. expressed in terms of X10 -7 /° C., the softening point (S.P.), annealing point (A.P.), and strain point (St.P.) expressed in terms of ° C., and the density (Den.) expressed in terms of grams/cm 3 as determined in accordance with measuring techniques conventional in the glass art.
The liquidus temperature (Liq.) was established by placing crushed glass in a platinum boat, inserting the filled boat into a furnace having a temperature gradient which spans the conjectured liquidus temperature, maintaining the boat within that furnace for 24 hours, and then withdrawing the boat into the ambient environment. The length of glass was extracted from the boat, thin sections were cut therefrom which were ground thin and polished, and those thinned and polished sections were examined microscopically for the presence of crystals, the temperature in ° C. at the crystal/glass interface being adjudged to be the liquidus temperature.
The chemical durability of the glasses when exposed to acids, as defined in terms of weight loss (W.L.A.), was determined by immersing polished plates of known weight for 24 hours in an aqueous bath of 5% by weight HCl operating at 95° C. After withdrawal from the bath and drying, the plates are reweighed and the weight loss measured in terms of mg/cm 2 .
The chemical durability of the glass when exposed to bases, as defined in terms of weight loss (W.L.B.), was determined by immersing polished plates of known weight for 6 hours in an aqueous bath of 0.02N Na 2 CO 3 operating at 95° C. After withdrawal from the bath and drying, the plates are reweighed and the weight loss measured in terms of mg/cm 2 .
TABLE II__________________________________________________________________________1 2 3 4 5 6 7 8 9 10 11 12 13__________________________________________________________________________Exp. 58.2 58.1 56.3 57.8 57.5 59.3 58.6 59.2 55.6 54.4 55.0 55.8 48.8S.P. 861 853 861 -- -- -- -- -- 876 -- -- -- 872A.P. 685 678 686 686 697 691 685 678 707 697 696 702 692St.P.641 636 642 644 654 646 644 637 667 649 661 660 649Den. 2.593 2.577 2.575 2.593 2.592 -- -- -- 2.605 -- -- 2.618 2.566Liq. 1040 1015 1055 1040 1070 1072 1045 1019 1073 1088 1025 1045 962W.L.A.0.59 0.8 0.6 0.9 1.9 0.9 4.7 4.9 0.7 1.2 5.3 2.1 0.8W.L.B.0.02 0.08 0.09 0.09 0.09 -- -- -- 0.06 -- -- 0.17 0.17__________________________________________________________________________
That strict control of the concentrations of the individual components to produce glasses demonstrating the demanded matrix of properties is evident from an examination of Tables I and II. For example, at levels of B 2 O 3 greater than 7%, the chemical durability of the glass becomes unacceptable. At levels below 5.5% the glass can become too hard as is illustrated in the annealing point of 707° C. in Example 9.
The incorporation of Na 2 O and/or K 2 O raises the thermal expansion of the glass but also can adversely affect the acid durability thereof and lower the annealing point. Therefore, the total alkali metal oxide content will not exceed about 3%, with the preferred glasses containing no more than about 1.5%. K 2 O appears to have less effect upon the annealing point than Na 2 O, but a greater adverse effect upon acid durability.
Al 2 O 3 is present at a level of 12% to impart good chemical durability to the glass. Nevertheless, Al 2 O 3 contents in excess of about 15% may lead to crystallization during the forming process.
Example 1 constitutes the most preferred embodiment of the inventive glasses. Its viscosity characteristics closely track those of Corning Code 1002 glass and its chemical durability is somewhat superior thereto. Its mismatch with Corning Code 1001 glass is 1257 ppm. | The present invention is directed to glasses exhibiting annealing points between 682°-702° C., linear coefficients of thermal expansion (25°-300° C.) between 57-59×10 -7 /° C., and excellent resistance to attack by HCl and Na 2 CO 3 consisting essentially, in weight percent, of
______________________________________
SiO 2 56-60 Na 2 O 0-3Al 2 O 3 12-15 K 2 O 0-3B 2 O 3 5.5-7 Na 2 O + K 2 O 0.5-3.CaO 19-24.25______________________________________ | 2 |
TECHNICAL FIELD
The present invention relates to a method for indicating the cleaning time in teeth cleaning.
BACKGROUND
It is known with electric tooth brushes to provide a time switch, which, starting from switching-on of the electric tooth brush, emits a discernible signal after a predetermined time duration for a user. The signals serve to indicate to the user the end of the cleaning time. The user is made aware of the end of the optimal cleaning time through the use of acoustic or optical signals. From WO 96/14025, it is known to not emit an acoustic or optical timer signal, rather instead to switch the drive motor of the tooth brush on and off rapidly so that the drive motor stutters. This can be done while the device is either in the hand or in the mouth of the user.
In addition, it can be provided that the electric tooth brush is switched off after termination of the target cleaning time automatically. This is inexpedient if the timer-signal merely indicates that a partial region of the teeth, such as, for example, a biting quadrant, has been completely cleaned. In WO 97/19650, it therefore proposed to switch again to regular cleaning operation after the stuttered operation, so that the biting quadrant can be cleaned completely according to the desire of the user. As soon as the user changes to another biting quadrant, he can start anew the timing member by means of a button, in order again to be provided the target cleaning time for this new biting quadrant. This method for indicating the target cleaning time does not fulfill the wishes of all tooth brush users, however.
From DE 197 28 964 A1, a tooth brush with a device is known, which signals to the tooth brush user the beginning and end of the optimal tooth cleaning time. On the tooth brush, a knob or slide switch is mounted, with which at the beginning of the teeth cleaning, an acoustic signal can be released, which is repeated automatically after approximately three minutes. In addition, a signal after approximately three months of using the tooth brush can be emitted, whereby the user is informed that the tooth brush should be replaced with a new tooth brush.
U.S. Pat. No. 6,029,303 discloses a manual tooth brush with an electric circuit, which emits a discernible signal regarding the cleaning time. The beginning of the cleaning time can be determined, for example, by means of a movement sensor, which releases a timing member, whereby, at the end of the time, a signal discernible by the user is emitted from the timing member of an electrical circuit. Also, the possibility exists that with the electronic circuit, the entire cleaning time is added up and a further signal from the electronic circuit is then emitted, which falls below the recommended use time of the tooth brush.
SUMMARY
The present invention is based on the object of producing an improved tooth cleaning device as well as an improved method of the above-disclosed type. Along with deviation of the actual cleaning time from the predetermined target cleaning time in an individual case, a mean value for the actual cleaning time can be reached over multiple, separately successive cleaning processes.
The target cleaning time is variably determined, particularly, when predetermined cleaning times are not obtained from the user. An actual cleaning time of the tooth cleaning process is determined by means of a time determination device. By means of an evaluation device, the deviation of the determined actual cleaning time from a predetermined constant or variable standard cleaning time, depending on parameters, is determined. A control device determines the target time for a subsequent tooth cleaning process. This determination depends on the deviation determined by the evaluation device. After termination of the target time, a timer signal is emitted.
The target cleaning time can be adapted personally to the cleaning environment and/or for example, to the daily rhythm of the user. Behind the variable timer-signal, the consideration exists that a combination of short and longer cleaning processes resulting from the variable timer-signal can lead to a good or satisfactory cleaning result, because a cleaning process that was too short is compensated by a lengthened cleaning time in a subsequent cleaning process. The variable standard cleaning time can adopt different values that are user-specific. For example, the variable standard cleaning time may differ between children and adults. It may also be cleaning-tool specific. For example, the variable standard cleaning time may differ depending on the type of implement used, such as a flat brush, inter-dental brush, floss offset or the like.
In a further embodiment of the invention, a cleaning time account is managed, which takes into consideration the deviations of the actual cleaning time from the predetermined standard cleaning time with multiple, previous tooth cleaning processes. Thus, the sum of deviations over multiple tooth cleaning processes is determined. A cleaning time memory can be provided, which stores the sum of deviations between the actual cleaning time and the standard cleaning time determined from multiple tooth cleaning processes. The control device uses the cleaning time memory with the determination of the target cleaning time for a new tooth cleaning process and determines the target cleaning time based on the determined deviations from one or more previous cleaning processes. With multiple deviations, correspondingly marked changes of the target cleaning time take place. In particular, the target cleaning time relative to the standard cleaning time is markedly lengthened when only one shortened tooth cleaning process was performed. Similarly, the target cleaning time relative to the standard cleaning time may be markedly shortened when only one lengthened tooth cleaning was performed.
Preferably, the deviations between actual cleaning time and standard cleaning time only up to a predetermined amount are taken into consideration. In particular, the deviations between the actual cleaning times and the standard cleaning times can be added up only to a known capping limit and can be stored in the cleaning time memory. Upon exceeding the capping limit, the threshold value can be taken into consideration or the target time change can be considered.
It is likewise possible not only to limit the sum of the deviations, but also to provide a capping limit for the individual deviations. If the actual cleaning time deviates too intensely from the predetermined standard cleaning time, only the provided maximum amount of the deviation is considered for the change of the target cleaning time of the next tooth cleaning process. Such a limitation of the considered deviations is based on the conclusion that a known frame and optimal tooth cleanliness cannot be achieved when the fluctuations are too marked. Thus, only deviations within a predetermined range change the target cleaning time.
In particular, it can be provided that the control device determines the target cleaning time always within a predetermined range. This range basically can be formed differently. Thus, in particular, a maximum lengthening of the target cleaning time can be provided.
The range limit for the target cleaning time can be determined differently. According to an advantageous form of the invention, the standard cleaning time can be provided as the minimal target cleaning time. The control device determines the target cleaning time always as greater or the same as the standard cleaning time. When the user positively fills up his cleaning time ledger by too long of a tooth cleaning over the target cleaning time, the timer is not activated before the standard cleaning time by the control device during the next tooth cleaning process.
According to an alternative embodiment of the invention, it can be provided that the target cleaning time can not only be lengthened, but also shortened relative to the standard cleaning time. For the cleaning time account, then, cleaning times over the target cleaning time are also taken into consideration and referenced for the determination of the next target cleaning time. If the user, for example, cleans his teeth in the evening for a particularly long time over the standard cleaning time, a corresponding credit is placed on the cleaning time account and the target cleaning time on the next morning is correspondingly shortened.
The deviations determined with a previous cleaning process or with multiple previous cleaning processes can be taken into consideration in various ways with the determination of the target cleaning time. Thus, it can be provided that the deviations are passed along only in part with the change of the target cleaning time. For example, a cleaning time that lasts 30 seconds over the standard cleaning time can lead to only a 15-second shortening of the next target cleaning time. According to an advantageous embodiment of the invention, the determined deviation or the sum of the determined deviations between actual cleaning times and standard cleaning times is directly abstracted. Thus, a one-to-one determination of the target time to the standard cleaning time is proposed or abstracted. This takes place preferably only within the determined limits, so that the target cleaning time is changed only within the predetermined capping limits.
In a further embodiment of the invention, only tooth cleaning processes that last longer than a minimum time are taken into consideration for the cleaning time account. If the actual cleaning time of a tooth cleaning process lies below the minimum limit, which are determined by different, for example, user- or cleaning-tool-specific factors, no deviation between the actual cleaning time and the standard cleaning time is determined or this is not taken into consideration with the determination of the target cleaning time of a later tooth cleaning process. The minimum time is preferably 30 seconds.
In order to better signal to the user of the tooth cleaning device the adaptation of the time or his deviation from the standard cleaning time, a corresponding warning signal is emitted, which indicates to the user that the last tooth cleaning process was too short and a correspondingly longer target cleaning time is necessary for the current tooth cleaning process. The warning signal is preferably emitted at the beginning of the respective tooth cleaning process.
In a further embodiment of the present invention, it can be provided that upon termination of a tooth cleaning process before reaching the standard cleaning time, a warning signal is emitted, which indicates to the user that he cleaned his teeth for too short of a time. A further warning signal is preferably provided when the tooth cleaning process is interrupted before reaching the respectively variable target cleaning time. Accordingly, the noted warning signals are different from one another, so that it is clear which change or deviation is made or occurred.
In order to achieve a measured determination and evaluation of the actual cleaning times, a coast down timer can be provided. With the determination of the actual cleaning time, temporary interruptions of the tooth cleaning process can be ignored. This can be particularly sensible with a temporary on/off switching of the tooth cleaning device. This may occur, for example, upon changing from one biting quadrant to the next biting quadrant or when tooth paste is removed from the mouth and the tooth brush is turned off temporarily. If the time determination and the corresponding evaluation were run anew each time, few sensible results would be achieved.
Next, the invention will be described in more detail with reference to a preferred embodiment and associated drawings.
BRIEF DESCRIPTION OF DRAWINGS
FIG. 1 shows a schematic representation of an electric tooth brush according to the present invention;
FIG. 2 is a block diagram of a variable timing member of the electric tooth brush according to FIG. 1 ; and
FIG. 3 is a flow diagram of the variable timing member, which makes clear the changes of a cleaning time account over multiple cleaning processes.
DETAILED DESCRIPTION
In FIG. 1 , an electric tooth brush 1 is shown, in which a housing 2 , an accumulator 3 , a motor 4 , and a drive 5 are accommodated. On a free end of the electric tooth brush 1 , an attachment brush 6 can be inserted, which has a rotary-supported stiff-bristled support 7 with bristles 8 attached thereto. The bristle-support 7 can be rotary driven in an oscillating manner about a rotational axis that is essentially perpendicular to the longitudinal axis of the attachment brush 6 in a known manner by the motor 4 .
In the housing 2 of the tooth brush 1 , a coil 9 as well as a control device 10 in the form of a circuit board are accommodated. The coil 9 is arranged on the end of the housing 2 lying opposite the attachment brush 6 and serves for charging the accumulator 3 . The control device 10 includes various electronic components, which control the operation of the electric tooth brush 1 . Accessible from outside, a switch 11 is arranged in the wall of the housing 2 , with which the motor 4 of the tooth brush can be switched on and off. An output unit 12 is arranged in the wall of the housing 2 , which is connected with the control unit 10 and serves to emit signals, in particular, a timer signal, for indicating the termination of the target cleaning time. The signals emitted by the output unit 12 can be variously formed, for example, optically or acoustically. Also, other output of the signals can be provided. For example, the motor 11 can be placed into a stuttering operation, such as described in WO 97/19650. Regarding the structure of the timer-signal in this connection, specific reference is made to WO 97/19650.
The control device 10 includes, in particular, a timing member or a timer for production of a timer-signal after termination of a target cleaning time. Such a timer is shown in FIG. 2 and is generally designated with reference numeral 13 . In a memory 14 , first cleaning constants are stored, which dictate the boundary conditions of the target cleaning process. In particular, a standard cleaning time and a minimum cleaning time for an effectual cleaning process can be stored in the memory.
In addition, a time determination device 15 is provided, which can be activated by a switch 11 for switching on the motor 4 . Preferably, it includes a coasting down means, so that with temporary interruptions of the motor operation, it continues to run. It determines the time between switching on of the motor 4 and its definite switching off.
A central component of the timer or the timing member for emitting the timer signal is the evaluation device 16 , which has access to the memory 14 and which is connected with the time determination device 15 in order to obtain the actual cleaning time. It determines the deviation of the respectively determined actual cleaning times from the standard cleaning times stored in the memory 14 . It places the determined deviations on a cleaning time account MPK, and determines with reference to the deviations from previous tooth cleaning process the target cleaning time, after whose termination a timer-signal is emitted. The memory 14 and the cleaning time account MPK can be formed from separate storage components, as shown in the drawing. Alternatively, however, they can also be formed as a common memory.
For outputting the timer signal, the evaluation device 16 is connected with the output unit 12 . The output unit 12 can emit a timer-signal 17 , which indicates the termination of the variably determined target cleaning time. In addition, the output unit 12 can emit different warning signals 18 , which indicate to the user different deviations or changes of the time switch. In particular, a sub-minimum warning signal W 1 can be emitted, when a cleaning process is discontinued under the minimum cleaning time. A sub-target warning signal W 2 can be emitted, when the user switches off the apparatus before reaching the timer-signal 17 . The sub-target warning signal W 2 preferably can be distinguished from the first warning signal W 1 . Finally, in order to note a changed target cleaning time, relative to the standard cleaning time, with the next cleaning process, a non-standard warning signal W 3 or advisory signal can be emitted, which is distinguishable from the previous signals and indicates to the user that the timer-time was changed. The named signals can be emitted optically or acoustically. Also, the previously described stuttered-motor can be provided. Other signal output forms are possible.
Next, the function of the tooth brush 1 and in particular, the timing member 13 , will be explained in greater detail with reference to different cleaning processes in connection with FIG. 3 .
First, the cleaning time account MPK guided by the evaluation device 16 is empty. For the cleaning time account, a capping limit of 90 seconds is provided, that is, deviations between actual cleaning time and standard cleaning time up to merely a total of 90 seconds can be added up. The cleaning time account has a capacity of 90 seconds. The standard cleaning time stored in the memory 14 amounts to 120 seconds in the shown embodiment. The minimum cleaning time likewise stored in the memory 14 for an effectual cleaning process is determined with 30 seconds.
With a first cleaning process, the user terminates his cleaning process after 15 seconds, without waiting for a signal from the timing member 13 . The sub-minimum warning signal W 1 indicates that the cleaning process was too short and is not valued for the time balance. Accordingly, the cleaning time account remains empty.
With a second cleaning process, the user terminates his cleaning process after 105 seconds, again without emission of the timer-signal. The warning signal W 2 indicates that the recommended standard cleaning time has not been reached. The evaluation device 16 determines the deviation between the actual cleaning time and the stored standard cleaning time. The difference of 105 seconds and 120 seconds, namely, 15 seconds less time, is added to the cleaning time account. The cleaning time account obtains therewith the value of 15 seconds less time.
With a third cleaning process, the timer is reconfigured. The target cleaning time is placed to a value differing from the standard cleaning time. The target cleaning time is set up to the sum of the standard time of 120 seconds and the stored value of 15 seconds, namely, to 135 seconds. In order to make noticeable the now-lengthened cleaning time, this non-standard warning signal W 3 sounds directly after the switching on of the tooth brush, in order to indicate to the user that a lengthened target cleaning time is to be obtained. The user, however, terminates his cleaning after 90 seconds without the timer-signal. The sub-target warning signal W 2 sounds. The evaluation device 16 determines anew a less time of 30 seconds. This deviation is added to the previously determined deviation, so that the cleaning account is set at a value of 45 seconds.
With a fourth cleaning process, first the timer is adjusted corresponding to the deviations stored in the cleaning time account. On the standard cleaning time of 120 seconds, the sum of the deviations of 45 seconds stored in the cleaning time account is added, so that the target cleaning time is adjusted to 165 seconds. With switching on, the warning signal W 3 sounds, which provides the lengthened target cleaning time. The user terminates his cleaning process this time after 135 seconds without the timer-signals. The warning signal W 2 sounds anew. This time, however, the value of the cleaning time account is reduced, since the cleaning process lasted longer than the standard cleaning time of 120 seconds. The less-cleaning time is reduced by the difference of 135 seconds to the standard cleaning time of 120 seconds. In the cleaning time account, a less time of now 30 seconds is stored.
With a fifth cleaning process, the target cleaning time corresponding to the less time of 30 seconds is set to 150 seconds, which corresponds to the sum of the standard cleaning time and the stored less cleaning time. Upon switching on, signal W 3 sounds anew. The user terminates his cleaning process, however, after 45 seconds without the timer-signal, so that the sub-target warning signal W 2 sounds anew. The evaluation device 16 determines a deviation of 75 seconds to the standard cleaning time of 120 seconds. Accordingly, the cleaning time account must be set to a less time of 105 seconds. Since, however, a capping limit of 90 seconds for the cleaning time account is provided, the threshold value of the less time of 90 seconds is stored in the cleaning time account.
According to the maximum less time of 90 seconds, which is stored in the cleaning time account MPK, the target cleaning time and, accordingly, the timer 13 is set to the sum of the standard cleaning time of 120 seconds and the maximum less cleaning time of 90 seconds, that is, to 210 seconds. Upon switching on the tooth brush, the warning signal W 3 sounds anew. The user cleans for the set timer time and after 210 seconds, the timer signal 17 is emitted from the output unit 12 . Since the target cleaning time would be completely processed, the cleaning time account is reset. The stored less time amounts now to 0 seconds.
In a seventh and last cleaning process according to the illustration, the timer is set to the standard duration of 120 seconds, since in the cleaning time account, no miss-out times are stored. This time, no warning signal sounds upon switching on of the tooth brush. The user cleans until the timer signal, which is emitted after 120 seconds and than for another 30 seconds until to a total cleaning time of 150 seconds. In the shown embodiment, the actual cleaning times over the target cleaning time are not assessed, that is, the cleaning time account is set upon reaching the target cleaning time merely to 0. This was provided in the present case, so that the value of the cleaning time account MPK remains at 0 seconds. | The invention relates to an electric tooth cleaning device and to a method for automatically indicating the cleaning duration when cleaning teeth, whereby a timer signal is emitted using a time element after the termination of a set cleaning duration in a tooth cleaning session. According to the invention, the set cleaning duration, whose termination prompts the emission of a timer signal, is modified. An actual cleaning duration in the tooth cleaning session is registered by a time registration device. The deviation of the actual cleaning duration from a predetermined standard cleaning duration is determined by means of an evaluation device. The set cleaning duration of a subsequent tooth cleaning session is then defined depending on the deviation that has been determined. | 0 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a field of carrying cases, and in particular relates to a field of carrying cases that utilize complementary, overlapping, gripper type fasteners.
2. Description of the Prior Art
Presently known carrying cases that are utilized for carrying equipment on one's person suffer from serious shortcomings among which are initial expense, heavy weight, large bulk, lack of flexibility, need for a shoulder strap, breakdown of case stitching and expense of repair thereof. These shortcomings are especially evident to police and security personnel, who carry mobile radio communication equipment in such carrying cases while walking an assigned territory. Not only is mobile communication equipment heavy (3 to 5 pounds), but the carrying case, which is generally made of 1/4-3/8 inch thick leather, is also heavy. The combination of heavily encased mobile communication equipment, in combination with a gun holster and bullet belt, makes for a burdensome combination to transport during a work-day.
The heavy communication equipment which is carried day-in and day-out by personnel, such as police officers, places a heavy stress on stitching which is utilized in holding prior art case component parts together. Eventually, such stress causes the stitching to rupture thereby requiring repair. In today's inflationary economy, it is likely that if a person skilled in leather repair can be found, cost might be prohibitive so that purchase of a new case is warranted. The expense of repair is also applicable with respect to metal buttons that are utilized in a covering flap in presently known carrying cases. Such buttons tend to eventually become loosened within the leather case so that repair is required. As with respect to stitching, button repair and replacement is expensive, a nuisance and annoying.
Other shortcomings of present day carrying cases for use with, for example, heavy communication equipment are clearly evident. Thus, large bulk and lack of flexibility of modern day carrying cases because of their thick and heavy construction make storage thereof unfeasible when not in use. In other words, inability to roll-up present day carrying case for storage purposes further detracts from its utility in the present day work world.
A prior art patent that bears on the instant invention is U.S. Pat. No. 3,900,617. This patent is particularly pertinent in view of its discussion of the shortcomings of present-day leather cases, which essentially is in agreement with shortcomings thereof discussed above. However, the prior art patentee's arrangement for overcoming the prior art radically departs for Applicant's solution. Thus, the patentee has devised a belt radio clip made of 20 gauge stainless steel and which is adapted to carry two-way communication equipment having a different lower dimension from its upper dimension. This prior art invention is not suitable for carrying heavy objects whose external dimensions are constant, nor can the patentee adapt his carrying case to all sizes and shapes which is a notable characteristic of the present invention.
Other prior art which has been discovered in a prior art search but are not deemed to be significantly pertinent are U.S. Pat. Nos. 3,057,354; 3,200,414; 3,383,738; 3,467,111; 3,841,648; 4,119,249 and 4,174,793.
SUMMARY OF THE INVENTION
The present universal carrying case invention, which is initially fabricated into a flexible T-shaped member made of complementary gripper tape fastening materials, is formed into a receiving unit for transporting an oblong, substantially heavy, object on one's person. The T-shaped member is shaped into a carrying case apparatus by uniquely locating complementary hook and pile fastening materials on certain surfaces of three free ends of the T member. Thereafter, the three free ends are brought together by looping vertical and horizontal components of the T-shaped member so that they converge at a common point. An interconnection is formed at the common point by interfacing the complementary hook and pile fastening material fastening surfaces in such a manner that the free ends become attached to one another to form a plane of engagement. Upon attachment by interfacing of the hook and pile surfaces, the interconnection formed thereby resists separation by forces parallel to the plane of engagement. However, the three free ends of the T-shaped member which form the interconnection may be separated from one another by a peeling force perpendicular to the plane of engagement. Thus, the universal carrying case as taught by this invention provides for a simple T-shaped construction wherein its free ends can be interconnected to firmly resist separation during normal usage, but nevertheless may be easily separated upon application of force in the proper direction.
The universal carrying case of the present invention also provides a simple belt loop on the underside where the vertical and horizontal members of the T-shaped member intersect. Therefore, when the horizontal and vertical members are looped and joined together to form the interconnection, the carrier merely inserts his belt into the underside loop so that the carrying case in which mobile communications equipment, or the like, is inserted may be readily transported on one's person.
The simple yet novel carrying case of this invention satisfies a real need while overcoming many of the shortcomings of existing prior known personnel carrying cases. Thus, the tape material utilized to provide the vertical-horizontal loop arrangement in combination with its complementary, overlapping, gripper type interconnecting arrangement forms a universal carrying case which is light of weight, flexible, lacking bulk, relatively economical to fabricate and long wearing. This type of carrying case satisfies a need in particular among those who are guardians of public safety and who carry heavy communication in equipment on their person.
Therefore, it is an object of this invention to provide a new and improved universal carrying case.
It is a further object of this invention to provide a universal carrying case that is simple in design and can be manufactured at low cost.
It is another object of this invention to provide a universal carrying case that is readily adaptable to different size objects which are to be carried.
It is an additional object of this invention that satisfies a need for a universal carrying case which is light, flexible with minimum bulk, and relatively long wearing.
BRIEF DESCRIPTION OF THE DRAWINGS
Referring now to the drawing there is depicted several views of the present invention for aiding in a complete understanding thereof wherein,
FIG. 1, is a view showing the universal carrying case attached to a carrier's belt and further showing how the case is assembled with respect to an object being carried;
FIG. 2 is a plan view of the universal carrying case which resembles a T configuration in an unassembled form;
FIG. 3 is a side view of the universal carrying case with respect to an object being carried;
FIG. 4 is a top view of FIG. 3;
FIG. 5 is a view of the case provided by this invention in its folded-up configuration.
FIG. 6 is another embodiment of the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to FIG. 1 in greater detail, the universal carrying case 100 of this invention is shown attached to the belt 110 of a carrier via a loop 105, which is located on the case. A two-way radio 200 (in phantom) or the like, which is often carried on the respective person of law enforcement officials, guards and fire officials is located within the carrying case 100. The case 100 is fabricated into a tape assembly having complementary, overlapping, gripper type fasteners of hook and pile material which is sold under the trademark "Velcro". As will be explained in greater detail hereinafter, the "Velcro" hook and pile surfaces are utilized because of their ability to resist separation by shearing forces parallel to the plane of engagement between hook and pile material strips that interface with one another, yet can be easily separated in response to a peeling force that is applied normal to one end of the same plane of engagement.
Referring now to the plan view of FIG. 2 wherein the universal carrying case 100 is depicted in its basic unassembled T-shaped configuration 100a, it can be readily appreciated that the configuration disclosed herein is composed of essentially two components comprising a vertical component or tape strip 101 and a horizontal component or tape strip 103. The vertical component 101 of the T-shaped member 100a has an upper surface composed essentially of a plurality of pile elements 111. However, it should be noted that the underside of the vertical component 101 is also covered with a short section 106 of the same plurality of piled elements 11 as exists on its upper surface. The section 106 of the plurality of pile elements may be formed on the underside by various ways, but in the preferred embodiment, this section is obtained by simply causing distal free end 116 of the vertical component 101 to be folded back on itself and attached thereat. It will be apparent to those skilled in the art that the section 106 might also be separately attached by various means such as attaching by sewing or other means. The formation of the plurality of pile elements 111 on the short section 106 of the underside of vertical component 101 is significant in the formation of the universal carrying case of this invention, as will be discussed in greater detail in a later paragraph.
Located at the proximal end 119 of the vertical component 101 of the T-shaped carrying case 100 is a loop 105 which can also be readily seen in FIGS. 1, 3 and 4. The loop 105 is provided in order to allow a carrier's belt 110 (FIG. 1) to be threaded therethrough for transporting the case 100 and two-way radio 200 on one's person. The loop 105 also permits the horizontal component 103 of the case 100 to be threaded therethrough as will be discussed in detail hereinafter. It should be noted hereat that again for ease of manufacture, the loop 105 can be easily formed by simply folding the distal end 119 forward upon itself so that the pile surface 111 is on both inside surfaces within the loop 105. The proximal end 119 is attached after the loop 105 has been formed by sewing or similiar means. Again it should be observed that other techniques are available to those skilled in the art to make loop 105.
The horizontal component 103 of the T-member 100a incorporates a complementary hook surface 114a, 114b at its distal free end 115 and proximal free end 117, respectively, in an upward facing direction. A hook surface 114c may also be provided on the horizontal component 103. However, for ease of manufacture the entire upward facing surface of horizontal component 103 may be made of a hook surface in order to provide a complementary surface to the pile surface within loop 105. This arrangement enables an intersection of the vertical 101 and horizontal component 103 to become attached so that they cannot slide with respect to one another. On the underside of the horizontal component 103 at its proximal end 117, a complementary pile surface 112 is formed for a short distance. The reason for the positioning of the pile surface on the right hand end of the horizontal component 103 will become significant when the T-shaped carrying case is fully assembled as will be discussed hereinafter.
Referring again to FIG. 1, there is depicted the universal carrying case 100 of this invention in partial assembly in which a radio 200 is being carried on the belt 110 of a carrier. The first step in the assembly requires that the vertical component 101 and the right hand half of the horizontal component 103 of the T-member 100a be looped back upon each other so that the distal end 116 and the proximal end 117 be brought in juxtaposition with one another. By overlapping and thereafter interfacing the pile surface 111 formed on the section 106 (underside of vertical component 101) with the hook surface 114b on the upper surface near proximal end 117, a union between these two members is formed as shown in FIG. 1. In other words, when the complementary hook surface 114b is brought into overlapping engagement with the pile surface located on section 106 they will co-act with one another to form a union so that they will resist separation by shearing forces parallel to their plane of engagement. It should be noted that the reverse pile section 106 of the vertical component 101 is made to interface and become engaged with the hook elements 114b on the horizontal component 103, the pile elements 112 formed on the underside of horizontal component 103 are now facing outwardly (see FIG. 1). The reason for this will readily become apparent upon further reading.
To complete this formation of the carrying case 100, the distal end 115 is looped to become juxtaposed to the above discussed union formed with respect to pile surface 111 and hook surface 114b. This is graphically depicted in FIG. 1 wherein the distal end 115 is looped to become juxtaposed to the above discussed union formed with respect to pile surface 111 and hook surface 114b. This is graphically depicted in FIG. 1 wherein the distal end 115 is shown just prior to engaging with pile surface 112. Again, by the interfacing of the plurality of pile elements 112 with the plurality of complementary hook elements 114a an interconnection 400 will be formed as shown in FIGS. 3, 4. Therefore, by reason of the unique placement of the complementary hook and pile surfaces along the distal and proximal locations 115, 116, 117, the vertical and horizontal components 101, 103 will be joined to one another to the interconnection 400. The interconnection 400 will resist separation by shearing forces parallel to the planes of engagement, while easily separating in response to a peeling force essentially normal to the planes of engagement.
Accordingly, it can be readily appreciated that by joining the three free ends 115, 116 and 117 of the vertical and horizontal components 101, 103, respectively, a universal carrying case 100 is provided for transporting a rectangular object such as a two-way communications radio 200 on one's person. The universal carrying case 100 is simple in design, light weight, readily fabricated and yet provides a strong support for a heavy device, such as a two-way radio 200, which may weight as much as ten pounds. It should be further noted and appreciated that the universal carrying case of the present invention is readily adaptable for various sized objects which are to be carried on one's person. This results from the fact that the horizontal and vertical components 101, 103, respectively, can be readily adapted to the size of the object being transported and carried on one's person. In other words, depending upon the size of the object to be transported and carried, the horizontal and vertical components are merely tightened or enlarged as the case may be. Thus, by way of example, the universal carrying case 100 as taught by this invention can be formed with the communication equipment 200 in place after which the free ends 115, 116 and 117 (FIG. 2) are joined to form an interconnection 400. However, in an event that a smaller or slightly larger device is to be transported on one's person the free ends 115, 116 and 117 are joined to one another and are merely adapted to the new dimensions of the device being carried.
Referring now to FIG. 5, there is depicted the universal carrying case 100 of this invention in a folded-up configuration which is suitable for storage during non-use. In the folded configuration, the vertical and horizontal components 101, 103 are individually wrapped around each other until a small, neat, pocket-size unit is provided for storage purposes.
Referring now to FIG. 6, another embodiment of the invention is shown wherein an additional horizontal component 103' is provided to support a multi-dimensional device 200'. In all respects the operation of this configuration is similiar to that of FIG. 1 except for the additional component 103'. | A light weight and convenient universal article case or carrier for transporting mobile communication equipment, or the like, on one's person is disclosed. The case is formed by initially fabricating two flexible tape strap lengths into a T-shaped member. Proximal and distal ends of vertical and horizontal components of the T-shaped member selectively carry complementary hook and pile fastening surfaces which enable the ends to interface with one another to provide an interconnection and which thereby results in the universal article case disclosed herein.
The interconnection formed by a novel placement of the hook and pile fastening surfaces of the proximal and distal ends of the T-member resists separation by shearing forces at their respective planes of engagement, but nevertheless, can be easily separated in response to a peeling force normal to the plane of engagement. | 0 |
CROSS REFERENCE TO RELATED APPLICATIONS
This application is a continuation-in-part of application Ser. No. 08/199,524 filed Jun. 20, 1994, now abandoned which application is incorporated herein by reference.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates, in general, to sporting games, and in particular, to basketball games utilizing a specially adapted playing board.
2. Related Art.
Various types of games played with the conventional 52 card playing deck, such as poker, draw poker, 5 card stud poker, solitaire, pinochle, etc., are well known. Also, the use of non-conventional playing card decks with corresponding games is well known. Such decks have a different number of cards and/or suits from the conventional 52 card deck.
The conventional games associated with the conventional playing card deck are extremely popular and date back hundreds of years. However, most games associated with playing card decks are non-contact and non-action. For instance, most games played with the conventional playing card deck are performed sitting at a table for hours. Thus, although the conventional playing card deck is extremely popular and well known, games played with the conventional deck lack athletic action because they are played in a seated position for hours.
However, the game of basketball is athletic and involves action. Basketball is an extremely popular contact athletic sport played all over the world. Basketball is played on a court with an inflated ball by two opposing teams each having at least one player. The object of basketball is to put a ball through an annular member, referred to as a goal or basket, secured to a backboard. One annular member is located at one end of the basketball court, while the other annular member is located at the other end. Each of the annular members have a net which extends downward from the outer rim of the annular member. The basketball is typically thrown from different locations on the basketball court.
The team with the ball is the offensive team. The offensive team advances the ball to the basket on the court which is designated as their basket by passing the ball to a teammate or by dribbling or bouncing the ball along the floor with one-hand taps. The offensive team scores by throwing the ball so that it descends through the designated basket. The team scoring the most such throws, wins the game.
The team without the ball is the defensive team. The defensive team attempts to take the ball from the offensive team by intercepting passes, blocking shots, or even by literally stealing the ball from a player with the ball. After a basket is made, the ball is awarded to the team that was previously on defense. Because of the continuous action, contact with opposing players, competition for the ball, and frequent scoring, basketball is one of the most popular spectator as well as participant sports in the world. Nevertheless, since basketball is a very fast paced and a high contact game, it requires high endurance capabilities because offense and defense is constantly changing. Consequently, young children, physically handicapped individuals, as well as individuals desiring a slower paced game, cannot play the conventional full court basketball as described above.
Therefore, what is needed is an athletic game that does not require a fast pace but still involves skill and athletic action. What is also needed is a game that allows players to exhibit offensive basketball skills without defensive interference. What is further needed is an action based sporting game that combines offensive basketball skills with the conventional playing card deck.
Whatever the merits of the above mentioned systems and methods, they do not achieve the benefits of the present invention.
SUMMARY OF THE INVENTION
To overcome the limitations in the prior art described above, and to overcome other limitations that will become apparent upon reading and understanding the present specification, the present invention discloses a basketball game having a basketball, a basketball court, and a plurality of basketball goals. A plurality of teams each having a plurality of players plays the basketball game on the court and shoots the basketball in the direction of the basketball goals.
A deck of cards is also included. Each card in the deck has a front face containing a separate and distinct identifier unique to each card. The basketball court includes a playing board with varying sizes facilitating the playing of basketball games in a variety of areas corresponding to the playing board. The playing board has site identifiers located on the playing board which are associated with each of the unique identifiers of each of the cards. Each player draws a card and attempts to successfully shoot the basketball through one of the basketball goals while located on a matching site identifier. Succeeding players reiterate the procedure until the game is ended based by predetermined rules. Point scoring is associated with each of shot.
A feature of the present invention is to have a basketball game utilizing a playing board. Another feature of the present invention is to have a basketball game that combines offensive basketball skills with the conventional playing card deck. Yet another feature of the present invention is a basketball game having offensive action without defensive action.
An advantage of the present invention is that it can be played by small children and physically handicapped individuals. Another advantage is that the present invention requires skill and has athletic sporting action. Another advantage is that the present invention allows players to exhibit offensive basketball skills without defensive interference.
BRIEF DESCRIPTION OF THE DRAWINGS
Referring now to the drawings in which like reference numbers represent corresponding parts throughout:
FIG. 1 illustrates the overall layout of the present invention;
FIG. 2 illustrates the preferred playing board for use with the present invention; and
FIG. 3 illustrates the preferred card deck for use with the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
In the following description of the preferred embodiment, reference is made to the accompanying drawings which form a part hereof, and in which is shown by way of illustration a specific embodiment in which the invention may be practiced. It is to be understood that other embodiments may be utilized and structural changes may be made without departing from the scope of the present invention.
FIG. 1 illustrates an exploded overall sectional view 10 of the present invention. The present invention includes a basketball 12, two basketball goals 14 (only one shown), a playing board 16 adaptable as a basketball court 17, and two or more teams with players 18. The playing board 14 contains site identifiers or positions 20 associated as unique indicia. The positions 20 are strategically organized about the playing board 14.
In the preferred embodiment, the basketball goal 14 is ten feet above the court 17 and a conventional National Basketball Association basketball 12 is used. However, in an alternative embodiment, the basketball goal 14 and basketball 12 can be adapted for indoor use as well as miniaturized for table top use.
FIG. 2 illustrates the playing board 16 utilized in the preferred embodiment of the present invention. The playing board 16 is preferably in the form of one integrated floor mat but can be separate floor mats or painted appropriate positions. The playing board 16 corresponds to the particular size of the basketball court 17 (shown in FIG. 1).
The playing board 16 has a first 22 and second 24 longside and a first 26 and second 28 wideside. The center of the playing board has a "BJ" 30 logo contained in a circle. Small netted 32 and 34 circles are located at the edge of each longside 22 and 24 respectively, and are centered about the longsides. The playing board 16 is positioned on the basketball court 17 so that each small netted circle 32 and 34 corresponds to a location directly below each of the basketball goals 14 (shown in FIG. 1). Thus, the basketball goals 14 are located on opposite longsides 22 and 24 of the playing board 16 and basketball court 17 and face each other.
The set of dimensions for the playing board 16 and basketball court 17 used in the present invention can vary. For example, in the preferred embodiment, a forty-four feet long, and twenty-two feet wide basketball court 17 and playing board 16 can be utilized. In addition, a playing board 16 suitable for home use, such as twenty feet long and ten feet wide playing board 16 can be used. Further, a playing board 16 suitable to be used on a table-top, such as five feet long and three feet wide playing board 16 can be used.
FIG. 3 illustrates a conventional playing card deck 40 utilized in the present invention. The conventional playing card deck 40 utilized in the present invention contains a front side 42 with varying suit symbols 44 and colors and identical back sides 46. Each front side 42 preferably has a rank 46 represented by the numeric values 2-10 and by the alpha characters J, Q, K, and A, imprinted therein. The alpha characters J, Q, and K contain personage visual representations of a Knave or Jack for J, a Queen for Q, and a King for K.
Also, the cards 40 contain four suits, each being the Spade 44, Heart (not shown), Diamond (not shown), and the Club (not shown). Each suit 44 is represented by a pip symbol 44 (shape and color representing the suit). The pip color of the Spades and Clubs are black and the pip color of the Hearts and Diamonds are red. Standard size playing cards are used, such as the 3.5 inches long and 2.5 inches wide poker deck, as well as the 3.5 inches long and 2.25 inches wide standard bridge deck.
Referring back to FIGS. 1 and 2 along with FIG. 3, there are fifty two positions on the playing board 16 that each correspond to one of the fifty two playing cards 40. The suits 44 and ranks 46 of each playing cards is marked on each respective corresponding position 48 on the playing board 16. The fifty two positions on the playing board are arranged around the circle with the "BJ" logo. The fifty two positions are strategically distanced from the basketball goal 14 (shown in FIG. 1). The color of the suit on each respective position indicates which basketball goal is the target goal or the goal that a particular player 18 shoots at.
Specifically, a red colored heart 50 and diamond 52 are located between the "BJ" 30 logo and the first longside 22. These red colored shapes 50 and 52 indicate that the far basketball goal above the red small netted circle 34, is the target goal for all red suited positions. Likewise, a black colored spade 54 and club 56 are located between the second longside 24 and the "BJ" logo 30. These black colored shapes 54 and 56 indicate that the far basketball goal 14, represented by the black netted circle 32, is the target goal for all black suited positions. In addition, every position on the playing board 16 between the heart 50 and the spade 54 and the first wideside 26 has a spade or heart as a suit. Similarly, every position on the playing board 16 between the diamond 52 and the club 56 and the second wide 28 side has a diamond or club as a suit.
A 2 point semi-circle 60 with only red suits located thereon is located between the heart 50 and the diamond 52 and the first longside 22 and extends from the second longside 24 near the first wideside 26 to the second 24 longside near the second wideside 28. A 3 point semi-circle 62 only with red suits located thereon is located between the 2 point and semi-circle 60 and the first longside 22 and extends from the intersection of the first wideside 26 and the second longside 24 to the intersection of the second wideside 28 and the second longside 24.
Likewise, a 2 point semi-circle 64 and a 3 point semi-circle 60 only for black suits are located similarly to the 2 and 3 point semi-circles for the red suits such one set of semi-circles mirror the other set. Each 2 point semi-circle 60 and 64 is preferably twenty feet from each small netted circle 34 and 32 respectively. Each 3 point semi-circle 62 and 66 is preferably twenty two feet from each small netted semi-circle 34 and 32 respectfully.
Some, but not all, of the positions with the suit and rank corresponding to the cards of FIG. 2 are located on the 2 and 3 point semi-circles 60, 62, 64, and 66, respectfully. A team is awarded two points for shots taken and made from the 2 point semi-circle 60 and 62 into the respective target basket and three points for shots taken and made from the 3 point semi-circles 64 and 66 into the respective target basket. For example, the Ace, King, Jack, and Ten rank cards are located on respective 3 point semi-circles 64 and 66 while some lower ranking cards are located on the 2 point semi-circles 60 and 62.
In accordance with the present invention, the game is played by first having a player 18 from one team draw a card 43 from the card deck 40. The player 18 then shoots the basketball 12 from one of the fifty two positions 48 on the board 16 that matches the card drawn 43 from the deck 40. Since each of the fifty two positions located on the playing board 16 has a point value associated with a successful basket, the team is awarded or not awarded points accordingly. Next, the procedure is reiterated with succeeding players of each team until the game is ended, which is decided by predetermined rules.
Sample Game
Numerous games with different rules can be played with the present invention. For instance, the following is a description of one sample basketball game. Referring to FIGS. 1-3, a card 43 is drawn form the deck of playing 40 cards by one player at a time. There are at least two teams each comprised of at least two players. The player 18 from one team matches the suit and rank on the card drawn 43 with the suit and rank location 48 on the playing board 16. The player 18 then shoots the basketball 12 from that matched location 48 on the playing board 16 toward the designated basketball goal. A joker card can also be used as player's 18 "choice" shot. Players from opposite teams alternate.
All players drawing black suited cards shoot at the designated black goal. Likewise, all players drawing red suited cards shoot at the designated red goal. Players drawing a card with the rank of A, K, Q, J, or 10, are awarded three points for a shot successfully made into the designated basketball goal from the matching position on the playing board. Players drawing a card with the rank of 10, 9, 8, 7, 6, 5, 4, 3, or 2 are awarded two points for a shot successfully made into the designated basketball goal from the matching position on the playing board.
The card deck is drawn through two times. Cards are not mixed after first time drawn through. Instead, the team that started first starts now goes second and the team that went second starts. Also, each team can decide which player will draw their first card and take their first shot. As a result, since the cards are not mixed in the deck after the deck has been drawn through, the rotation of teams will give each team the opportunity to play all the cards at least once.
In addition, the last player can take a three point shot from a position on the playing board if needed for a win or tie. The other team will indicate the position of the three point shot. The team with the most points at the end of the second draw wins.
However, in the case where each team has the same amount of points, a special tiebreaker round is played. Each team draws a card to determined which team will go first. For example, the team drawing the highest ranking card according to conventional card rules, goes first. The team going first designates a player to shot for the team. The player can shoot toward the designated goal from any position on the playing board. If the player makes the goal, a designated player from the second team must shoot the basketball at the same goal from the same position. If this player from the second team does not make the same shot, his team receives a "miss" point. However, if the player from the second team makes the shot, a new designated player from the first team must also make the same shot or receive a "miss" point. If all the players from each team make that shot, then the first player to shoot must choose another location to shoot. This special round is continued until a team receives three "miss" points.
The foregoing description of the preferred embodiment of the invention has been presented for the purposes of illustration and description. It is not intended to be exhaustive or to limit the invention to the precise form disclosed. Many modifications and variations are possible in light of the above teaching. It is intended that the scope of the invention be limited not by this detailed description, but rather by the claims appended hereto. | The present invention is a basketball game having a basketball, a basketball court, a plurality of basketball goals. A plurality of teams each having a plurality of players plays the basketball game on the court and shoots the basketball in the direction of the basketball goals. Also included is a deck of cards that each have a front face containing a separate and distinct identifier unique to each card. The basketball court includes a playing board with varying sizes facilitating the playing of basketball games in a variety of areas corresponding to the playing board. The playing board has site identifiers located on the playing board which are associated with each of the unique identifiers of each of the cards. Each player draws a card and attempts to successfully shoot the basketball through one of the basketball goals while located on a matching site identifier. Succeeding players reiterate the procedure until the game is ended based by predetermined rules. Point scoring is associated with each shot. | 0 |
CROSS-REFERENCES TO RELATED APPLICATIONS
This application is a division of U.S. application Ser. No. 12/845,673, filed Jul. 28, 2010, which is a continuation-in-part of U.S. application Ser. No. 11/129,224, filed May 13, 2005, now U.S. Pat. No. 7,298,498, which claims the benefit of U.S. Provisional Application No. 60/570,843, filed May 13, 2004, the disclosures of which are all hereby expressly incorporated by reference.
BACKGROUND
The present invention relates generally to hospital/clinical layouts, and more particularly, to the layout, structure and usage of intervention/operating rooms (OR), and related intubation, extubation and patient rooms.
Currently, a patient at a hospital or medical clinic is moved from location to location numerous times in order for a procedure to be completed. Also, typically, OR and intervention rooms and equipment used therein are underutilized in most hospitals and medical facilities, thereby increasing the cost of procedures. In addition, OR/intervention rooms are typically so crowded with equipment, lighting fixtures, booms, monitors, utility columns or booms, hoses, tubes and lines, that it is difficult for OR/intervention room personnel to actually move about efficiently. Also, such equipment can impair the vision of OR/intervention room personnel and impede laminar air flow from an overhead source, over the patient, and then out of the OR/intervention room. Such lighting fixture booms, equipment booms, etc., often set up air eddies or dead spaces. Also, fixtures, equipment, etc., can collect dust particles that can then be blown into the surgical field within the laminar air flow column at the surgical/intervention site thus compromised the laminar air flow system's purpose of reducing surgical/intervention wound infections.
In addition, an extensive period of time is required to clean and prepare an OR/intervention room after a procedure has been completed. The room is manually cleaned, and the soiled equipment, diagnostics, linen, etc., must be removed manually from the room and new supplies, equipment, etc., delivered to the room and set up. This takes time, which reduces throughput and the number of cases per day. The cost of the personnel for carrying out these tasks is not insignificant.
The present invention seeks to address the foregoing drawbacks of existing OR/intervention room structures and procedures. The present invention strives to reduce the number of patient moves, enhance patient safety and provide flexibility and adaptability of the OR/intervention room for future advances in patient care.
SUMMARY
This summary is provided to introduce a selection of concepts in a simplified form that are further described below in the Detailed Description. This summary is not intended to identify key features of the claimed subject matter, nor is it intended to be used as an aid in determining the scope of the claimed subject matter.
One aspect of the present invention pertains to a plurality of adjacent OR/intervention rooms for performing medical procedures where each room comprises a surgical/intervention zone of a pre-determined area, generally surrounding the location in which the patient is positioned. The surgical/intervention zone is substantially free of monitors, displays, mountings for monitors and displays, overhead utility sources and outlets, equipment booms and mountings, equipment and supply cabinet mountings, as well as equipment, instrument and supply table mountings. The OR/intervention rooms also include an adjustable lighting system incorporated into the ceiling of the room to provide substantially unobstructed light to the surgical/intervention zone. In addition, a ventilation system provides unimpeded laminar flow of air from the ceiling through the surgical/intervention zone.
In an aspect of the present disclosure, the OR/intervention room is constructed with a drop-down ceiling structure that defines a surgery/intervention zone around the patient that is free from articulating arms from monitors, from lighting fixtures, from equipment, and also free from hose drops and utility columns from the ceiling, or other electrical, data, medical gas, vacuum, or evacuation lines, tubes, or cords. The drop-down ceiling can be of a selected size and ideally from about 7 to 8 feet above the floor to establish an unobstructed, sterile zone for the surgery/intervention room.
In a further aspect of the present invention, multiple light sources are recessed in the ceiling of the OR/intervention room and are carried by movable mounting systems that may be aimed, focused, or otherwise controlled as desired by the OR/intervention room personnel. The lighting system may be controlled by microchips mountable on gloves, wristbands, or other articles worn by OR/intervention room personnel, or may be controlled by radio frequency identification tags located on, or incorporated into, instruments used by the OR/intervention room personnel, or may be activated by audio commands.
In another aspect of the present invention, a plurality of large, high resolution audio/video monitors are positioned outside of the intervention zone. Such monitors are configured to provide patient physiological information and digital images, provide communications within and outside of the OR/intervention room, and provide high resolution image guidance for intervention procedures. The content of the monitors may be controlled by a voice-actuated system.
In another aspect of the present invention, movable imaging equipment is shared among the OR/intervention rooms. In this regard, a transportation system is provided for transporting the moving of the mobile imaging equipment among the OR/intervention rooms. Such mobile imaging equipment may include, for example, CT scanners and MRI devices. In addition, the transportation system may include an overhead rail system incorporated into the ceilings of the OR/intervention rooms.
The present invention further comprises intubation rooms adjacent the OR/intervention rooms. The intubation rooms are configured and equipped to prepare patients for procedures to occur in the OR/intervention rooms. Such preparation can take place while the OR/intervention room is being prepared. The present invention also contemplates extubation rooms located adjacent the OR/intervention rooms. The extubation rooms are configured and equipped to post-intervention, awaken, and extubate patients. The OR/intervention room may be cleaned and readied for the next case while the patient would otherwise be awakening in the room.
In accordance with a further aspect of the present invention, the foregoing OR/intervention rooms, intubation rooms and extubation rooms are part of a general hospital layout which also includes a plurality of universal patient rooms located adjacent the OR/intervention rooms. Such universal patient rooms are configured and equipped to admit patients for intervention, prepare patients for intervention, allow patients to recover post-intervention, and discharge patients post-recovery. Such universal patient rooms are adaptable to provide high-level intensive care post-intervention, as well as to function at a lower level in the manner of a traditional patient room, for example, for patient recovery and discharge after relatively minor or routine surgery.
As a further aspect of the present invention, the hospital layout may also include procedural rooms located adjacent the OR/intervention rooms. Such procedural rooms are configured and equipped to share imaging equipment with the OR/intervention rooms. Regular imaging procedures can be carried out at high volume in the procedural rooms. As a consequence, the expensive imaging equipment may be more efficiently utilized than is currently the case.
A further aspect of the present invention includes a novel surgical table, including an articulating platform, pedestal supporting the platform, and a floor-engaging base. The surgical table includes a connection system for connecting the base to a connector hub integrated into the floor of the OR/intervention room, thereby connecting the surgical table to utility outlets for medical gases, electricity, data lines, and cable connectors. In addition, the surgical table includes arm structures at the foot and head of the table, each having outlets or connections for the aforementioned utilities. Such arms are movable between an ergonomically correct position for connection to the utilities of gases, electricity, data, etc., and then movable to a position below the top surface of the table platform so as to be retracted out of the way. The outlet arms at the head or foot of the table permit the sterile surgical drape over the sides of the table to be undisturbed during a procedure.
In a further aspect of the present invention, an anesthesia machine is detachably dockable to the base of the surgical table. The anesthesia machine has a connection system for connecting the anesthesia machine to the connector hub integrated into the floor of the OR/intervention room and also for connecting the anesthesia machine to the surgical table for utilities, communications, control cables, etc. A control system for controlling the anesthesia machine may be at a remote location so that several patients may be monitored at the same time.
DESCRIPTION OF THE DRAWINGS
The foregoing aspects and many of the attendant advantages of this invention will become more readily appreciated as the same become better understood by reference to the following detailed description, when taken in conjunction with the accompanying drawings, wherein:
FIG. 1 is a schematic view of patient flow when utilizing a high volume OR/intervention room of the present invention.
FIG. 2 is a schematic diagram of patient flow utilizing a high-acuity OR/intervention room of the present invention;
FIG. 3 is a schematic layout of a hospital or clinical setting in accordance with the present invention;
FIG. 4 is a perspective view of universal patient rooms in accordance with the present invention;
FIG. 5 is a perspective view of several high volume OR/intervention rooms with adjacent intubation and extubation rooms in accordance with the present invention.
FIG. 6 is a perspective view of an extubation room flanked by intubation rooms on either side in accordance with the present invention;
FIG. 7 is a partial perspective view of a portion of an intubation room;
FIG. 8 is a perspective view of two side-by-side high-volume OR/intervention rooms;
FIG. 9 is a perspective view of the area above the OR/intervention rooms of FIG. 8 ;
FIG. 10 is a perspective view of a portion of the OR/intervention room of FIG. 8 ;
FIG. 10A is a fragmentary elevational view of a ceiling light of the present invention;
FIG. 10B is a fragmentary elevational view of a connector hub to supply medical gases, vacuum source, electricity, data, and other utilities to the OR/intervention room;
FIG. 11 is a perspective view of a high-acuity OR/intervention room;
FIG. 12 is a perspective view of the area above the OR/intervention room of FIG. 11 ;
FIG. 13 is a perspective view of a portion of the OR/intervention room of FIG. 8 shown partly in cross-section;
FIG. 14 is a further perspective view of a portion of a high-acuity OR/intervention room illustrating the intervention zone created by the present invention;
FIG. 15 is an isometric view of a surgical table in accordance with the present invention with an anesthesiology machine dock thereto;
FIG. 15A is a side elevational view of a surgical table with an anesthesia machine docked therewith, the anesthesia machine is connected to a floor hub to supply medical gases, a vacuum source, electricity, data and other utilities to the anesthesia machine.
FIG. 15B is an enlarged, fragmentary view of FIG. 15A , showing the connection hub in larger scale.
FIG. 16 is the view similar to FIG. 15 but with the anesthesia machine dedocked therefrom;
FIG. 17 is a perspective view of a typical robot used in conjunction with the present invention.
FIG. 18 is a perspective view of a portion of an OR/intervention room, looking upward toward a drop-down ceiling portion that defines the surgery/intervention zone;
FIG. 19 is a view similar to FIG. 18 , but taken in a downward direction;
FIG. 20 is a cross-sectional view of the drop-down ceiling portion of FIG. 19 .
FIG. 21 is a view of the drop-down ceiling portion of FIGS. 18-20 , looking upward from below.
FIG. 22 is an enlarged, fragmentary view of FIG. 21 ;
FIG. 23 is a side elevational view of one of the controllable light assemblies utilized in the drop-down ceiling of FIGS. 18-21 ; and
FIG. 24 is a view similar to FIG. 23 , showing the light assembly tilted at an angle.
DETAILED DESCRIPTION
FIGS. 1 and 2 schematically illustrate patient flow utilizing the present invention. These figures will be discussed more fully below.
Next, referring to FIG. 3 , a hospital layout 30 , in accordance with one embodiment of the present invention, is illustrated. The layout includes a lobby area 32 , a portion of which may be occupied by a retail sub-area 34 offering flowers, gifts, toiletries, and other products, as in a typical hospital. Public/family support area 36 is adjacent to the lobby. In this area, family members can meet with hospital personnel to discuss/conduct administrative matters and consult regarding procedures being carried out or to be carried out. Also, waiting areas and restrooms may be provided. Concierge stations 38 are also located in the lobby adjacent to universal patient rooms 40 that are arranged in two rows on the opposite side of a center courtyard 42 . A nursing support area 44 is located at the opposite end of the courtyard from the public/family support area 36 . Nursing stations, a lounge, lockers, and other facilities for medical staff are in the support area 44 .
A series of high volume intervention or operating rooms 46 and a series of high-acuity intervention or operating rooms 48 are located adjacent the nursing support area 44 . A series of imaging procedural rooms 50 are located adjacent or between the OR/intervention rooms 46 and 48 to create imaging suites. As discussed more fully below, the imaging procedural rooms and OR/intervention rooms share CT, MRI, and other imaging equipment. OR/intervention room Intubation rooms 52 , as well as extubation rooms 54 , are located adjacent to the high volume OR/intervention rooms 46 . A corridor 56 extends around the OR/intervention rooms and the intubation and extubation rooms and between rows of patient rooms 540 . The structure and use of universal patient rooms 40 , high volume OR/intervention rooms 46 , and corresponding intubation and extubation rooms 52 and 54 and high-acuity OR/intervention rooms 48 are described in further detail.
FIG. 4 illustrates two universal patient rooms 40 , positioned side by side. Such patient rooms are located closely adjacent to the OR/intervention rooms 46 and 48 and are designed to eliminate several separate rooms or stations currently used for patient care between admission and discharge. Patients are initially met at the concierge station 38 and then taken directly to the universal patient rooms 40 for admission and preparation prior to the surgical/intervention procedure. From the patient room 40 , the patient is taken either to an intubation room 52 or directly to a high-acuity OR/intervention room 48 . Family members may be with the patient in rooms 40 .
As shown in FIG. 4 , the patient rooms 40 may include a bed 60 and a lounge area 61 furnished with a couch 62 or other types of seating furniture for the patient or family members. The rooms 40 are also configured with a desk surface 64 and desk chair 66 for use by the patient and/or family members. Toilet and bathing facilities 68 are provided for each of the universal patient rooms. A large screen monitor 70 is provided to display applicable physiological data of the patient being monitored, as well as to serve as a patient television for education, ordering of meals, and entertainment.
As noted above, patients are taken from universal patient rooms 40 directly to an intubation room immediately prior to a procedure to be performed in a high volume OR/intervention room 46 , or directly to a high acuity OR/intervention room 48 . After the procedure is completed, patients are returned directly to the universal room 40 from either the high-acuity OR/intervention room 48 or a high volume OR/intervention room 46 , or via an extubation room 54 . In the universal patient room 40 , the patient is reunited with family members after an initial recovery period (Stage I Recovery) The patient remains in the universal patient room 40 during the recovery period and until discharged. The patient may be discharged directly from the universal patient room 40 , rather than having to be transported to a separate inpatient bed unit or discharge station/area.
The use of the universal patient room 40 reduces the number of patient transports needed, thereby enhancing not only patient safety and reduced anxiety, but also operation efficiency, as well as reduction of potential medical errors. As a result, the satisfaction of both patients and medical staff is increased. To meet these goals, the universal patient rooms need to be “acuity adaptable.” In other words, the patient rooms must be able to accommodate a variety of activities, from an intensive care level, after an organ transplant, to a more traditional patient room, for example, for a patient recovering from surgery for a broken arm. The patient room is capable of accommodating the equipment and monitoring devices needed for intensive patient care.
Next, the high volume OR/intervention rooms 46 and associated intubation rooms 52 and extubation rooms 54 will be described with reference to FIGS. 5-10 . FIG. 5 illustrates a series of high volume OR/intervention rooms 46 positioned in side-by-side pairs and separated by a common wall 80 . As also shown in FIG. 5 , a singular extubation room 54 is positioned at the end of common wall 80 to serve both of the two OR/intervention rooms 46 . An intubation room 52 is located on opposite sides of the extubation room 54 so as to be adjacent a corresponding OR/intervention room 46 . A scrubbing station 82 may be located along each side of the intubation rooms 52 opposite the extubation room 54 . Also an equipment room 84 may be located between adjacent sets of OR/intervention rooms 46 . Of course, rooms for other purposes may also be positioned between the sets of OR/intervention rooms 46 .
Next, referring to FIG. 6 , one extubation room 54 is illustrated as positioned between two intubation rooms 52 . As described above, the extubation room 54 is shared by two adjacent OR/intervention rooms 46 . Some of the activities/tasks currently carried out in the OR/intervention room are instead performed in the intubation and extubation rooms 52 and 54 . A patient is prepped and induced in the intubation room while the previous procedure is being completed in the OR/intervention room and while the OR/intervention room is being cleaned and prepared for the patient. In this regard, the intubation room, as noted above, is located directly adjacent an OR/intervention room. Also in the intubation room, the patient is placed on a surgical table 90 , which is then simply rolled into the adjacent OR/intervention room and used during the procedure. As discussed more fully below, the surgical table includes an anesthesia unit 92 that docks to the surgical table and remains with the table until the patient has been extubated after the procedure. The patient is anesthetized in the intubation room so that the procedure may begin immediately upon the patient being moved to the OR/intervention room.
As shown in FIG. 7 , the OR/intervention room may include a large wall screen display 100 on which the patient's physiological condition, including vitals, can be displayed in large format. Also, digital X-rays, the results of prior CT scans, or MRIs can be shown on the screen display 100 . The intubation room may include other screens, for example, the ceiling 102 of the room can display various scenes, for instance the sky, even the condition of the actual sky outside of the hospital clinic. Another wall 104 of the intubation room may display a television screen or a video screen for the comfort and/or distraction of the patient. Once the patient has been prepared and the OR/intervention room has been turned over, the patient is moved directly into the OR/intervention room for the start of the procedure.
After the procedure has been completed, the patient is immediately moved to the extubation room to be awakened and extubated. This allows the OR/intervention room to be immediately cleaned and readied for the next patient. As a consequence, the OR/intervention room can be used for more procedures than in a conventional or existing hospital or clinic, especially when the OR/intervention room is being used for interventions of less than about two hours duration. Such interventions may include, for example, orthopedic, general, urological, ENT, ophthalmological or plastic procedures.
As in the OR/intervention room, the extubation room may include a large format screen display on one of the walls 106 of the room to display the physiological condition of the patient. Also, the room is equipped to provide medical cases, fluids, medication, etc., to the patient. In the room, the patient may be lying on the same surgical table previously used in the OR/intervention room and the intubation room. This reduces having to move the patient from a procedure surface to a recovery surface and then a transport surface.
From the extubation room, the patient is returned to the same room 40 where the patient was admitted. The patient will recover and remain in the same room 40 until discharged.
The OR/intervention room 46 will now be described with reference to FIGS. 8 , 9 , and 10 , 10 A and 10 B. As shown in FIGS. 8 and 9 , two OR/intervention rooms 46 are located side-by-side. This enables the two OR/intervention rooms to share an extubation room 54 . However, more than two OR/intervention rooms may be positioned side-by-side to each other.
One severe problem with current OR/intervention rooms is that there is so much equipment, tables, booms, cords, and tubes leading to and from the patient and monitors, devices, etc., that mobility around the patient may be very difficult, and in fact dangerous. The present invention establishes a surgery/intervention zone of a defined size around the patient that is free from articulating arms for monitors, lighting, equipment, etc., free from hose drops and utility columns from the ceiling, or other electrical, data, medical gases, vacuum, or evacuation lines, tubes, and cords. Such surgery/intervention zone may be of a select size, for example, a 20-foot diameter. This establishes an unobstructed sterile zone for the surgery/intervention team to freely and efficiently function within.
To establish the surgery/intervention zone, medical gases, electrical and data outlets, vacuum lines, evacuation lines, and communication lines, are brought into the OR/intervention room through an interstitial space located in the floor for connection to the base portion of the surgical table 90 . A connector hub assembly 107 for such medical gases, utilities, data, communications, vacuum, and evacuation, as shown in FIG. 10B , is located centrally in the surgery/intervention zone for automatic and secure connection to the base 244 of the surgical table 90 when the surgical table is positioned over the connector hub assembly. FIG. 10B shows various lines that enter into the OR/intervention room 46 through a sleeve 108 in the floor 142 . The lines can include, for example, a vacuum line 110 , a power line 111 , a gas line 112 , and a data line 113 . Additional or alternative lines can be provided for other fluids and purposes, such as oxygen or nitrous oxide. Preferably, the sleeve and lines 110 - 113 are hermetically sealed at the floor 142 .
Continuing to refer to FIG. 10B , the hub assembly 107 includes a connection collar 114 for securely supporting the ends of the lines 110 - 113 . The connection collar 114 can be received in close registry within an indexing socket or cavity 115 at the bottom of the table base 244 , so that the terminal ends of line 110 - 113 are disposed in registry with the lower ends of corresponding lines 110 A, 111 A, 112 A and 113 A, having associated connectors 110 B, 111 B, 112 B, and 113 B. The connectors 110 B- 113 B may be powered or otherwise configured to automatically engage with the corresponding ends of lines 110 - 113 when the collar 114 is properly indexed with socket 115 . The present invention also contemplates a digital monitoring system 116 for receiving lines 110 A- 113 A, and for monitoring and controlling the gas, liquid or other fluid or data or electricity flowing through such lines.
Although the hub assembly 107 is illustrated as utilized in conjunction with the base 244 of the surgical table 90 , alternatively or in addition, the same or similar hub arrangement may be utilized in conjunction with the anesthesia machine 92 when docked with the surgical table 90 , as discussed below. Also, when the surgical table 90 and/or anesthesia machine 92 is disengaged from hub assembly 107 , the adjacent ends of the lines 110 - 113 and 110 A- 113 A are automatically closed to prevent gas/liquid/data flow or contamination.
Alternatively, the water-tight collar 114 may be flush with the floor surface when not in use to permit unobstructed cleaning of the floor between cases. The collar may be motorized to raise automatically from the floor surface for quick connection and disconnection to the utility portals in the surgical table.
To establish a surgical/intervention zone, the OR/intervention room 46 is free from the typical lights mounted on articulated arms suspended from the ceiling. Such arms are difficult to manipulate and create barriers between medical personnel, as well as block sightlines of the personnel. Moreover, such arms, as well as the lighting fixtures themselves, interfere with the laminar airflow over the surgical/intervention site, as discussed more fully below.
In the present situation, multiple lights 118 are positioned in recesses 120 formed in the ceiling. The lights may be of various types, including, for example, halogen or xeon lights. As shown in FIG. 10A , the lights 118 may include a bulb 122 mounted in a socket assembly 124 . A high performance reflector 126 , for instance a cold mirrored glass reflector, may be used to direct the light from the bulb 122 . The lights include individual mounting systems 128 that enable the direction of the lights to be moved or manipulated, and focused as desired. For example, the light 118 can be tilted and swiveled about the mounting system to direct the light as desired. Actuation of the mounting systems may be by microchip-driven radio frequency controls or other types of controls positioned in the glove of surgical/intervention room personnel to enable the lights to be aimed and focused as desired as well as the intensity of the light to be varied. Rather than being mounted on a glove, the microchip controls can be mounted in other locations, such as on a wrist band, or head band of OR/intervention room personnel.
The light controls can also be tied to a radio frequency identification device or tag that can be embedded in or mounted on a clamp or other device located within the surgical/intervention zone that would remain static in the area during the procedure. Further, the lights can be pre-set by an automatic lighting system based on the procedure being performed. In this regard, the positioning of the lights can be programmed using a wall panel or remote control unit, or controlled from a central computer system. Additionally, or alternatively, the lights can be voice actuated. Lights of the nature of the present invention are articles of commerce, but retrofitted with special high intensity bulbs capable of achieving optimum focal length from the surface of the OR/intervention room ceiling to the surgical/intervention site. As shown in FIG. 10 , substantially the entire ceiling portion of the intervention zone is covered with openings 120 for placement of the lights for the present invention.
As mentioned previously, in current OR/intervention rooms, light fixtures, utility cord drops, and other items obstruct the laminar air flow from the ceiling of the OR/intervention room to the surgical/intervention site This situation is corrected by establishing the surgical/intervention zone in the OR/intervention room, including by eliminating typical boom-mounted light fixtures. As a consequence, air can be introduced into the OR/intervention room through openings 120 similar to those used for the lights, and the air can flow, unobstructed, in a laminar manner down to the surgical/intervention site and out through exit outlets 140 located about the OR/intervention room near the floor 142 .
As shown in FIGS. 5 and 9 , relatively deep wells 144 are formed in the interstitial space above the ceiling of the OR/intervention room where the ventilation air that is routed downwardly into the OR/intervention room through ceiling panel diffusers using openings 120 . Use of the ventilation wells 144 ensures that a uniform flow of ventilation air is supplied to the entire volume of the OR/intervention rooms, so that no significant “dead air” space exists. Moreover, with the elimination of lighting fixtures, equipment, etc., from the intervention zone, air flow eddies are eliminated within the laminar air flow to the surgical/intervention site.
Other sources of “congestion” in the OR/intervention room are the various monitors used to display physiological data of the patient, anesthesia data, as well as for image guidance, for example, during laparoscopic surgery or other procedures that utilize endoscopic cameras. Moreover, these monitors and display screens block light from the typical lighting fixtures used in OR/intervention rooms, as well as block the flow of ventilation air. Such monitors currently typically are mounted on articulating booms suspended from the ceiling within the surgical intervention zone.
In accordance with the present invention, a plurality of large flat screen monitors 160 are arrayed outside of the surgical/intervention zone. In this regard, see also FIG. 14 which illustrates a high-acuity OR/intervention room 48 . The monitors are suspended from arms 162 that suspend downwardly from a rail system extending around the perimeter of the OR/intervention room outwardly of the intervention zone. The monitors may be of various types, such as plasma screen monitors, LCD screen monitors, etc. The important point is that the monitors 160 are of a size and high resolution so that their content may be easily viewed by the personnel in the OR/intervention room. The monitors include screens 164 that are supported by a mounting structure 166 that enables the screens to be adjusted both vertically and horizontally. In addition, the mounting structure 166 can be designed to enable the screens 164 to be rotatable about a vertical axis, and also about a horizontal axis for better viewing by personnel. To this end, the mounting structure 166 may include upper and lower tracks 168 and 170 as well as vertical end tracks 172 for guiding horizontal and vertical movement of the screens 164 . Alternatively, the mounting structure 166 may be designed to move vertically relative to arms 162 . The position of the screens can be controlled by voice command. The content of the screens can also be controlled by voice command. Moreover, the instruments and other devices that are being monitored on the screens 164 may also be controlled by voice command. Such control systems are articles of commerce. Voice recognition software is commercially available for use with voice command systems. The large screen monitor may be pre-programmed and arrayed for specific procedures and individual surgeon/interventionist preferences.
To create the surgical/intervention zone, a perimeter ring or rail system 180 is formed in the ceiling of the OR/intervention room around a perimeter thereof. As shown in FIG. 10 , arms extend downwardly from the rail system to support previously floor-mounted tables, equipment, and cabinets. For example, a vertical arm 184 is illustrated as extending downwardly from rail system 180 to support the distal end of a first horizontal articulating arm 186 which in turn is pivotally coupled to a second horizontal articulating arm 186 . A telescoping vertical arm system 188 extends downwardly from the proximal end of horizontal arm 186 . The corners of two vertically spaced apart upper and lower shelves 190 and 192 are coupled to telescoping arm 188 by collar assemblies 194 . The collar assemblies allow the shelves 190 and 192 to pivot relative to telescoping arm assembly 188 and then lock in position once the position of the shelves is as desired. A telescoping arm assembly 188 enables the shelves 190 and 192 to be raised and lowered as desired. When the shelves 190 and 192 are not in use, they can be removed beyond the intervention zone by rotation of horizontal arms 184 and 186 . The movement of such arms, as well as the operation of telescoping arms 188 , can be controlled by various means, such as a remote control device. Also, the movement of such arms can also be controlled by voice command.
FIG. 10 also illustrates cabinet 200 which is mounted on a pair of horizontal articulating arms 202 and 204 , which in turn are supported by a vertical arm 206 that extends downwardly from track system 180 . The cabinet 200 may include shelves and drawers for storing various instruments, supplies, and other equipment. Cabinet 200 can be positioned by personnel at desired locations by remote control or by voice command, in the manner of the shelves 190 and 192 . As with the shelves 190 and 192 , the cabinet 200 can be moved out of the way, and outwardly of the surgical/intervention zone, when not in use.
Referring to FIG. 14 , utilities needed for cauteries, lasers, drills, and other accessories may be stationed remote from the surgical/intervention zone as a secondary utility distribution system from that provided in the floor 142 . Such utilities can be provided in a vertical arrayed mounting system 210 which illustrates various medical gas, electrical, data and communications outlets 212 - 222 . Such outlets will supplement corresponding outlets provided in the floor of the OR/intervention room beneath the table 90 . It will be appreciated that the above described lighting system, monitors, table supports, cabinet supports, and auxiliary utilities allow elimination of virtually all ceiling and floor mounted obstructions in the surgical/intervention zone. Moreover, they also keep the floor free from obstructions whereby the floor can be cleaned by automated robots, described below.
Next, describing the surgical table 90 in greater detail, referring specifically to FIGS. 10 , 15 , and 16 , in basic form, the table includes a top portion 240 , a pedestal portion 242 , and a base portion 244 . The top portion 240 is constructed in various sections, including a head section 246 , a shoulder section 248 , a torso section 250 , and a lower extremity section 252 . Each section may be pivotable or elevatable relative to the adjacent section.
The retractable arm structures 254 and 256 are positioned at the head and foot of the tabletop 240 , on which are mounted outlets for all medical gases, vacuum source, evacuation source, electrical supply, data and communications that are brought into the OR/intervention room through the floor 142 , as described above. The arm structures 254 and 256 include connections that are made at an ergonomically correct height and then are rotatable downward to a position below the surgery intervention table surface so as to move out of the way and not be accidentally bumped. Also by locating the arm structures at the head and foot of the table 90 , the outlets are maintained clear of a sterile surgical drape which may be clamped on the sides of the patient. Further, an arm structure is accessible to the anesthesiologist located at the head of the patient.
The medical gases, vacuum, utilities, data lines, tubes, and cords are routed to the arms 254 and 256 through pedestal 242 from the base 244 . As mentioned previously, the base has a connector assembly that connects with the connector hub located in the OR/intervention room floor 142 . In this manner, ceiling drops, columns, and articulating booms and cords to carry medical gases, vacuum, evacuation, electrical, and data to the location of the immediate patient area are eliminated.
As previously discussed, the same table 90 is used to support the patient from the intubation room 52 , the OR/intervention room 46 and the extubation room 54 . As such, the surgical table 90 is provided with wheels in the base 244 to enable the table to be easily moved from place to place. As also mentioned above, an anesthesia machine 94 is configured to be dockable and dedockable to the table base 244 . The anesthesia machine 94 has quick disconnect fittings to connectors located on the table base 244 or pedestal 242 , which, in turn, are connected to the utility hub in the floor 142 . Anesthesia outlets may also be incorporated into the table arm structure 254 and 256 . By this construction, the anesthesia machine 94 is independently mobile relative to the table for cleaning and servicing. Moreover, the anesthesia machine may be controlled by an anesthesiologist or technician in a remote control room. As such, physical intervention and manipulation of the anesthesia machine in the OR/intervention room is not required. Of course, a nurse anesthesiologist may be present in the OR/intervention room to administer to the patient. However, the anesthesiologist can move from OR/intervention room to OR/intervention room or be located in a remote control room to monitor a number of patients at one time, thereby increasing efficiency of the anesthesiologist and safety of the patient.
FIGS. 15A and 15B illustrate an anesthesia machine 304 , docked with surgical table 90 , but with the anesthesia machine coupled to a hub assembly 307 in a manner similar to hub 107 coupled to the surgical table 90 shown in FIG. 10B . In FIGS. 15A and 15B the components similar to those shown in FIG. 10B are given corresponding part numbers but as a “300” series.
As in FIG. 10B , in FIGS. 15A and 15B medical gases, vacuum lines, evacuation lines, electrical and data outlets and communication lines are interfaced with the OR/intervention room through an interstitial space located in floor 342 for connection to the base portion of anesthesia machine 304 . As in FIG. 10B , a connector hub assembly 307 is utilized for such medical gases, utilities, data, communications, vacuum and evacuation. The connection hub assembly 307 includes a lower connection collar 314 A that is nominally disposed within a recess 309 formed in the floor 342 . The collar 314 A may be raised upwardly into engagement with a corresponding collar 314 B, positioned at the base portion of the anesthesia machine. The upward extension or downward retraction of the lower collar 314 A is via linear actuator 318 connected to the collar 314 A via push-pull rod 319 .
As shown in FIGS. 15A and 15B , the terminal ends of vacuum line 310 , power line 311 , gas line 312 , and data line 313 , are attached to connection collar 314 A. Connectors 310 C, 311 C, 312 C, and 313 C are provided for the lines 310 - 313 , which connectors are held securely by the connection collar.
The lines 310 , 311 , 312 , and 313 are connectable to the lower ends of corresponding lines 310 A, 311 A, 312 A, and 313 A, which extend downwardly from the anesthesia machine to terminate at connectors 310 B, 311 B, 312 B, and 313 B, securely held by upper collar 314 B. As in FIG. 10B , a control and monitoring system 316 is interposed in lines 310 A- 313 A for monitoring and controlling the gas, liquid or other fluids, or evacuation or data or electricity transmitted through such lines. Also, when lower connection collar 314 A is in refracted position within recess 309 , connectors 310 C, 311 C, 312 C, and 313 C automatically close off corresponding lines 310 , 311 , 312 , and 313 .
When the anesthesia machine 304 is docked with surgical table 90 , lines 310 A, 311 A, 312 A, and 313 A automatically connect to corresponding lines 310 D, 311 D, 312 D, and 313 D of the surgical table 90 . To this end, a second set of connection collars 320 and 322 are provided between the anesthesia machine and the surgical table. The collars 320 and 322 automatically mate with each other upon the docking of the anesthesia machine with the surgical table, thereby to permit flow between lines 310 A- 313 A to corresponding lines 310 D- 313 D. As in connection collar 314 A, one or both of the connection collars 320 and 322 can be designed to extend forwardly or retract rearwardly to lock with the corresponding connection collar. When the anesthesia machine and surgical table are disengaged from each other, the adjacent ends of lines 310 A- 313 A and 310 D- 313 D are automatically closed to prevent gas, liquid, data, vacuum, electrical flow or contamination.
As an alternative to the foregoing, when the anesthesia machine 304 is docked with surgical table 90 , a hub assembly similar to hub 307 can be used to connect utilities, gases, data, to the surgical table rather than to the anesthesia machine. In this option, when the anesthesia machine is docked with the surgical table, a connection system is utilized at the lower portion of the anesthesia machine to connect to the surgical table, in a manner similar to connection collars 320 and 322 . In this situation, the anesthesia machine controls the flow of gases and other utilities to and from the surgical table in a manner similar to that contemplated in the embodiment of the present disclosure shown in FIGS. 15A and 15B . This may be a less desirable option than having the hub assembly 307 connectible to the anesthesia machine, since it requires that the surgical table also be configured to connect to the hub assembly, thereby duplicating the connection capabilities of the anesthesia machine.
In FIG. 15 , the anesthesia machine 94 is shown as supported on the floor 342 by wheels. As an alternative, when the anesthesia machine 304 is docked with surgical table 90 , the anesthesia machine could be carried by and supported by the surgical table. To this end, wheel channels or supports (not shown) could extend along the inside portions of rails 245 of base 244 of the surgical table to receive wheels 340 of the anesthesia machine 304 .
Another source of expense and inefficiency in a typical hospital or medical clinic setting is that patients must be transported from OR/intervention rooms to remote locations where imaging equipment is located. Alternatively, the costly imaging equipment may be dedicated to a single OR/intervention room. The transport of the patient to a remote imaging room can increase the incident of medical errors and compromise patient safety.
In accordance with the present invention, scanning equipment, for example, scanner 270 , shown in FIGS. 8 and 10 may be brought into an OR/intervention room, as needed, by an overhead monorail system 272 , as shown in FIGS. 8 and 9 . The monorail system allows the scanner 270 to be moved among a number of OR/intervention rooms for real time use during an intervention procedure. When not needed in an OR/intervention room, the scanner can be used for routinely scheduled diagnostic studies in imaging suites 50 , see FIG. 3 . This enables the scanner to be used more efficiently than in existing hospitals and medical facilities.
Various types of scanners can be employed in the mobile manner of the present invention, including CT scanners, MRI machines, fluoroscopy C-arm, ultrasound, and other types of scanners. As shown in FIG. 10 , the scanner 270 is connected to the lower end of a vertical arm 274 , with the upper end of the arm connected to a powered carriage 276 which moves along the monorail system 272 . All required electrical and data services are provided by retractable cables. In the case of moveable MRI scanners, a telescoping duct system extends or retracts to exhaust cryogen gases in the event of an unexpected “quench” of the cryogen system. Appropriate retractable openings 278 can be formed in the walls of the OR/intervention rooms to allow passage of the vertical arm 274 . The imaging equipment can be controlled and operated by a logistics core, for example, located at the center of a number of OR/intervention rooms. This provides for efficient usage of imaging equipment personnel.
Alternatively, the scanning device such as a CT or MRI scanner may be fixed in an imaging room positioned between two OR/intervention rooms. In this alternative, the patient is automatically transported from the surgical/intervention zone to the centrally located scanner on a commercially available surgical/intervention table.
FIGS. 8-10 illustrate OR/intervention room 46 , which is specifically designed for relatively high volume usage, meaning for procedures of about two hours or less. To make maximum usage of the OR/intervention room 46 adjacent intubation and extubation rooms 52 and 54 are utilized, as described above. FIGS. 12-14 illustrate the high-acuity OR/intervention room 48 which is used for longer and more extensive procedures than in OR/intervention room 46 . Such procedures may include, for example, orthopedic, general, craniofacial, cardiovascular interventions, neurological interventions and organ transplants. As such, intubation rooms and extubation rooms are typically not utilized with the high-acuity OR/intervention room 48 . However, in other respects, the OR/intervention room 48 is constructed and laid out similarly to the OR/intervention room 46 described above. Thus, like components and structures used in OR/intervention room 48 are given the same part numbers as the corresponding structure/components used in OR/intervention room 46 . As in OR/intervention rooms 46 , the high-acuity OR/intervention rooms 48 also utilize mobile imaging equipment 270 . Further, as in the high volume OR/intervention rooms, a surgical/intervention zone is established in the high-acuity OR/intervention rooms 48 . In addition, as in the high volume OR/intervention room 46 , the high-acuity OR/intervention room 48 includes a utilities hub in the floor of the room for connection to the base of the surgical table 90 .
An area of hospital/clinical practice usage that has not kept pace with diagnostic and treatment technologies is materials logistics, supplying the instruments, equipment and other items needed in the OR/intervention room. These are typically delivered to the OR/intervention room manually and also removed from the OR/intervention room manually after usage.
The present invention incorporates the use of robots to deliver case packs, supplies, instruments, etc., to the OR/intervention room and remove used linens, supplies, instruments from the OR/intervention room in an efficient and quick manner. Case packs and supply cabinets can be configured as part of a robot itself, for example, robot 300 , shown in FIG. 17 . Also, the instrument 302 shown in FIG. 14 may be incorporated into a robot. Such robots enter the room vertically by automatic cart lifts incorporated into the OR/intervention room, for example, along the perimeter thereof. The robots are delivered to the OR/intervention room from a logistics core, located at the center of a plurality of OR/intervention rooms. The deployment of the robots and their return to the logistics core can be completely or partially automated or controlled from the logistics core. The robots return soiled linens, instruments, equipment and waste to a decontamination area of Central Sterile Supply.
Robots of the foregoing nature are articles of commerce. Such robots are available, for example, from PYXIS Corporation. Such robots may operate without fixed tracks or guidewires. Another robot is marketed under the designation Transcar Automated Guided Vehicles from Swisslog HCS. Such robots are able to efficiently travel from location to location, avoiding stationary moving objects. Some may need elevators or lifts. Such robots announce their arrival at a destination, signaling closed doors to open and maintaining communications with a central computer system.
Instruments and re-usable supplies are frequently not available when needed in an OR/intervention room, often due to breakdowns in the logistics system. This may result in costly as well as dangerous or compromising delays during a procedure. As a consequence, greater inventories are often prescribed than actually needed, to compensate for such delays. The present invention contemplates tracking instruments and re-usable equipment with a radio frequency system, which is not affected by the sterilization process. Radio frequency tags may be mounted on, or incorporated into, such instruments and re-usable equipment. The location of such equipment can then be monitored or readily ascertained. As a consequence, instrument and re-usable equipment loss, as well as inventories, may be reduced, thereby resulting in lower operational costs, fewer or shorter delays, as well as reduced medical errors. Radio frequency tags are articles of commerce, as well as equipment from monitoring or reading such tags.
In another aspect of the present invention, OR/intervention rooms, as well as intubation and extubation rooms, are automatically cleaned between uses. Currently, OR/intervention rooms are manually cleaned requiring a significant length of time. As such, if existing clean durations can be reduced significantly, the number of surgical interventions performed in an OR/intervention room per day can be increased. To this end, the present invention incorporates the use of several cleaning robots 304 that are housed in the OR/intervention room or in the intubation/extubation rooms, see FIGS. 10 and 13 . Such cleaning robots are capable of dispensing a biocidal cleaning solution onto the floor and then scrubbing and vacuuming the floor thoroughly. Such robots have a biocidal cleaning solution storage compartment, scrub brushes, a vacuum system, and a waste bin for collecting the used cleaning solution and other debris or items removed from the OR/intervention room floor. Waste cleaning solution and debris are automatically purged from the cleaning robots in their docked position. Cleaning robots somewhat similar to robots 304 are available from iRobot Corporation.
After cleaning by the cleaning robots, a biocide aerosol is dispensed into the OR/intervention room through ports in the ceiling. The aerosol decontaminates all surfaces of the OR/intervention room. The aerosol is exhausted from the OR/intervention room through the exhaust ports 140 located near the floor. The biocide aerosol is non-hazardous to humans, though typically staff will not be in the room during the cleaning process. Applicants estimate that the time for cleaning an OR/intervention room using the foregoing equipment and process to be reduced to about two minutes. This dramatically shortens cleaning time over current manual procedures.
A further aspect of the present invention to improve the quality and efficiency of hospital/clinical procedures is to utilize an automated hand/arm scrubbing system. Currently, manual scrubbing by the intervention team takes at least eight minutes. The present invention contemplates utilizing an automatic scrubber system, not shown, utilizing power brushes to gross clean the hands and arms of the surgical/intervention team members. The system could include efficient powered brushes to reach all areas of the users hands, fingers, and arms, as well as a biocide cleaning solution and sterile water for rinsing. The system also contemplates a self-cleaning system for the brushes after usage. After gross cleaning by the brushes, final cleaning occurs by the application of a biocidal solution, for instance, by spraying such solution onto the hands and arms of the user. Using the foregoing equipment and procedure, it is estimated that the time required for scrubbing can be reduced from eight minutes to approximately two minutes with greater effectiveness.
Alternatively, the hand wash system may not utilize brushes, but instead numerous rotating nozzles that automatically spray water and anti-bacterial solution on the hands and under the fingernails. Thereafter, the hands are rinsed with non-irritating, high-pressure water spray, and then dried with a built-in air dryer. Alternatively, paper towels can be used for drying. Such hand washers are articles of commerce, for example, available from Meritec, Inc., of Centennial, Colo.
Referring to FIG. 1 , the method of the present invention is schematically illustrated. In accordance with the method, a patient is received at a medical/clinical facility at the concierge area 38 by personnel having information about the patient, the intervention to take place, and the schedule of the intervention. The patient is taken to a universal patient room 40 . Here the patient can be admitted, and pre-preparation tasks performed. Also in the patient room, family members may be present. From the patient room 40 , the patient is taken to the induction room 52 for induction tasks performed, including, for example, attachment of monitoring and fluid lines to the patient, performing anesthesiology on the patient, and carrying out final pre-intervention preparation of the patient. In the next step the patient is transported to the OR/intervention room 46 , where the intervention is performed. As noted above, such interventions typically are of relatively short duration, typically two hours or less. After the intervention, the patient is transported to an adjacent extubation room 54 for extubation of the patient, including awakening the patient and possibly removing monitoring and fluid lines from the patient. Next, the patient is returned to the patient room for recovery. The patient room, as noted above, is adaptable to the acuity level required for the patient, from high level intensive care to traditional low level recovery and rest. Subsequently the patient is discharged directly from the patient room.
FIG. 2 is a schematic flow diagram similar to FIG. 1 , but for high acuity interventions, wherein the intubation room 52 and extubation room 54 are not utilized. Rather, the patient is taken directly from the patient room 40 to the high acuity OR/intervention room 48 for performance of the intervention procedure. Thereafter the patient is taken directly from the OR/intervention room back to the patient room 40 for recovery.
Next, referring to FIGS. 18 , 19 , and 20 , a further disclosure of an OR/intervention room 400 constructed and operationally very similar to the other OR/intervention rooms of the present application. The OR/intervention room 400 includes a drop-down ceiling structure 402 which is shown as being circular in shape to define the surgery/intervention zone around the patient that is free from articulating arms, from monitors, lighting, equipment, etc., and also free from hose drops and utility columns from the ceiling or other electrical, data, medical gas, vacuum or evacuation lines, tubes, or cords. The surgical/intervention zone may be of a selected size defined by the size of the drop-down ceiling structure 402 which may be from, for example, 10-20 feet in diameter. As previously discussed, this establishes an unobstructed sterile zone for the surgery/intervention team to freely and efficiently function within.
As shown in FIGS. 18-20 , the drop-down ceiling structure 402 extends downwardly from the ceiling height of the rest of the OR/intervention room 400 , with the ceiling height of structure 402 being, in one disclosure of the present application, approximately 7.5 feet above the floor. Of course, this height may be varied somewhat, for example in the range of about 7 feet to 8 feet above the floor. The lowered height of the ceiling structure 402 has advantages in providing a better focal length for the lighting of the OR/intervention room, as discussed more fully below, and requiring a shorter distance for the ventilation air to flow from the ceiling structure to the floor and then out of the OR/intervention room 400 .
As previously mentioned, in conventional OR/surgical sites, lights are mounted on booms directly over the surgical site. These lights must be positioned manually by the surgeon or scrub nurse. Also, the suspended lights and boom obstruct the work zone. In addition, the lights and their support beams dramatically disrupt laminar flow of the ventilation air. Further, particulates and squames collect on the lights and the support beams, including during the time that the OR/surgical site is not in use, and then are drawn into the surgical site by the laminar ventilation flow. These drawbacks are substantially reduced, or even eliminated, by the OR/intervention room 400 and drop-down ceiling 402 that promote laminar air flow for the entire distance from the ceiling, to the surgical site, and then to the floor.
Also, the typical ten-plus-foot high ceilings in existing OR/surgical sites (necessitated by surgical light beams) enable cold air from the ceiling to accelerate in the downward air flow direction due to gravity. Air supplied at 30 feet per minute at the ceiling can accelerate to 90 feet per minute at the surgical site. This relatively high velocity air can overcome the “thermal plume” from the surgical wound and impinge contaminated particles into the wound site.
Also, the heat disseminated from typical surgical lights can cause the surgical staff to require lower ambient room temperatures for their comfort. For example, the supply air at the ceiling can be from about 5 to 15 degrees cooler than the ambient temperature. The requirement for lower ambient temperature due to heat from typical surgical lights, and the increase in laminar air flow velocity due to the ten-foot-plus high ceiling, can create a condition of hypothermia at the wound site. It has been documented that achieving nomothermia at a wound site can enhance healing and reduce the risk of surgical site infections. Thus, laminar air flow systems in typical OR/surgical sites can result in less than optimal conditions and may contribute to increased risk of surgical site infections.
The OR/intervention room 400 with its drop-down ceiling structure 402 also leads to “reduced age” of the air for the entire OR/intervention room generally, and also at the surgical site. Studies have shown that the age of the air in the OR/intervention room 400 is about 16% less than in a typical OR room with 10-foot-plus high ceilings. This reduced length of time air remains in the OR/intervention room 400 reduces the likelihood that the air is simply recirculating in the OR. It also reduces the possibility that the air at the surgical site comes from entrainment.
The drop-down ceiling structure 402 includes a perimeter sub-substructure 404 that defines the outer perimeter of the ceiling structure. A support grid 406 (see FIGS. 22 and 23 ) is supported by the lower portion of the perimeter substructure 404 which in turn supports a diffuser in the form of a perforated stainless steel ceiling panel 408 . The support grid may be composed of inverted “T” members or structural members of other shapes. The ceiling panel 408 serves as a laminar airflow diffuser so that the uniform, laminar flow of ventilation air is supplied to and flows downwardly through the surgical zone. This uniform laminar air flow system reduces, or even substantially eliminates, any dead air spaces or air flow eddies that commonly occur in conventional OR/surgical rooms.
The perforated ceiling panel diffuser 408 supports a HEPA or other type of filter 410 , see FIGS. 23 and 24 . Of course, the HEPA filters may be alternatively located upstream. The ceiling structure also includes a diffuser housing 425 spaced above the diffuser in the form of panel 408 ). An insulation layer 414 overlies the upper panel 412 of the diffuser housing 424 . The insulation layer can be composed of an appropriate material for heat and noise insulation. The ceiling structure is supported by a series of spaced apart support beams 415 that span across the ceiling 402 of the OR/intervention room, see FIG. 20 . The beams 415 can be composed of structural channels, I beams or numerous other structural shapes and types that are sufficient to support the ceiling structure.
Referring specifically to FIG. 20 , ventilation air for the OR/intervention room 400 is supplied from a building source to large ducts 420 . The ducts 420 are attached to the building source ducts by a “quick connect” coupling apparatus pre-installed on both components for convenient and rapid installation. A series of branch distribution ducts 422 direct the ventilation air from ducts 420 downwardly and exhaust the ventilation air through volume control dampers 423 and old exhaust nozzles 424 at a location above ceiling diffuser panel 408 . The distribution ducts 422 are arranged about the area of the diffuser 408 to provide substantially uniform flow of laminar air downwardly through the surgical site. Of course the volume, temperature, and other aspects of the air can be automatically or manually or semi-automatically controlled. As noted above, the reduced height of the ceiling structure 402 results in a shorter distance that the ventilation air flows from diffuser housing 424 and diffuser 408 to the floor, thereby enhancing the ability to provide laminar air flow through the surgical zone than if the air were required to flow downwardly from the full height of the OR/intervention room, typically at least 10 feet.
Referring additionally to FIGS. 21-23 , the series of light assemblies 430 are spaced about the area of ceiling panel 408 . Several light assemblies 430 are clustered about the central portion of the ceiling panel to provide increased light at the surgical/operational site. The lights may be of various constructions. In FIGS. 22-24 , such lights are shown as composed of an array of LED lights 432 , each having a high performance reflector 434 . The lights 432 and corresponding reflectors 434 are mounted on a carrier 436 , which in turn is mounted on a yoke 438 to pivot about pivot axis 442 . A servomotor 444 acts through a linkage assembly 446 to pivot the carrier 436 , and thus lights 432 , about axis 442 .
The yoke 438 is in turn carried by a shaft 450 , which may be rotated by a second servomotor 452 , thereby to rotate the yoke about axis 454 . The servometer 452 is mounted to and carried by a housing 456 constructed from perforated aluminum or other suitable material that can serve to mount the light assembly 430 rigidly to ceiling structure 402 and provide ventilation to remove the heat generated by the lights 432 . As noted above, such removal of the heat from the lights can significantly improve the thermal conditions in the OR/intervention room 400 . Rather than perforations, other types of ventilation openings can be used. Through the operation of the two servomotors 444 and 452 , the lights 432 may be pivoted about a dual axis to enable the lights to be aimed at a desired direction, see FIG. 24 .
A combination optical lens and dust-proof cover 460 is generally semi-circular in shape to cover the lights 432 as well as provide a desired directionality and focal length for the lights. The cover 460 mates with the housing 456 to protect and encase the internal components of the light assemblies 430 described above. As noted above, the drop-down ceiling structure 402 places the light assemblies 430 closer to the operational site than if the light assemblies were positioned at a higher elevation, as in present typical operating rooms for example, the elevation of ambient lights 470 , as shown in FIG. 18 .
The intensity and direction of lights 432 can be individually controlled or controlled in groups or collectively controlled to not only aim the light in desired direction(s), but also change the intensity and color temperature of the of the LED lights. Such control can be carried out by systems described above, including microchip-driven radio frequency controls, controls positioned in or on the glove of surgical/intervention room personnel, on a wrist band or head bank worn by surgical/intervention room personnel, or controlled by voice actuation. In addition, as described above, the controls for lights 432 can be tied to a radio frequency identification device or tag that can be imbedded in or mounted on a surgical tool or other device, located within the surgical/intervention zone, that would remain in static position during the procedure being conducted. Also, the lights can be pre-set by an automatic lighting system based on the procedure being performed. In this regard, the positioning of lights can be programmed using a wall panel or a remote control unit, or controlled from a central computer system or controlled by voice actuation.
The OR/intervention room 400 , as in the other OR/intervention rooms of the present disclosure, includes a support ring or rail system 480 formed in the ceiling 482 of the room, see FIGS. 18 and 20 . As in the rail system 180 discussed above, arm assemblies 484 extend downwardly from the rail system to support previously floor-mounted cabinets 486 , tables, equipment, etc. The arm assembly 484 may be constructed to telescope upwardly and downwardly, and also includes articulating horizontal arms to move the cabinet 486 closer or further from the center of the surgical zone. Such movement can be controlled by remote-controlled device, including by voice actuation. As shown in FIGS. 18 and 20 , additional arm structures 488 are provided for mounting monitors 490 . The arm structure 488 is illustrated as being telescopically extendable downwardly or retractable upwardly. The monitor 490 could be mounted on other types of arm assemblies, including arm assembly 484 , or arm assemblies described above and illustrated in other figures of the present disclosure. The rail system 440 also may be used to support a utility supply system, such as similar to system 210 shown in FIG. 14 .
Although the drop-down ceiling structure is shown as circular in shape, it can be of other shapes, such as oval, triangular, square, or rectangular. Also, the drop-down ceiling structure and the associated lighting, ventilation, and other components described above can be pre-manufactured in an off site factory environment and subsequently installed in the OR/intervention room 400 as substantially a unitary product. For example, the unitary ceiling structure 402 can be designed to be attached to ceiling beams 414 by any number of standard attachment methods, such as by bolting or 5 welding.
The foregoing has described a number of advances in the structure, construction and usage of hospital/clinical facilities for performing of surgery interventions. It is to be understood that some or all of the foregoing advancements can be utilized in a particular situation. Also, although specific examples of the foregoing structures, apparatus and 10 methods have been described, the present invention is not limited thereto.
While illustrative embodiments have been illustrated and described, it will be appreciated that various changes can be made therein without departing from the spirit and scope of the invention. | A hospital layout comprising a plurality of adjacent OR/intervention rooms ( 46, 48 ) uniquely configured and equipped to perform surgical and other interventional procedures, with adjacent intubation rooms ( 52 ) configured and equipped to prepare patients for procedures to occur in the OR/intervention rooms and at least one extubation room ( 54 ) adjacent the OR/intervention rooms, configured and equipped to post-intervention awaken and extubate patients. A plurality of universal patient rooms ( 40 ) are located adjacent the OR/intervention rooms and universal patient rooms, and are configured and equipped to admit patients for surgery/intervention, prepare patients for surgery/intervention, allow patients to recover post-intervention, and discharge patients post-recovery. | 0 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to a martial arts training device that can be used to help people train a particular movement. Other references which may be related to this field are known, such as U.S. Pat. No. 5,205,799 to Carbonero; U.S. Pat. No. 67,310 to Jadwin; U.S. Pat. No. 1,991,087 to Falcon; U.S. Pat. No. 3,917,231 to Fink; U.S. Pat. No. 5,735,775 to Miasserian; U.S. Pat. No. 5,888,179 to Singhal; and U.S. Pat. No. 444,420 to Chandler, wherein the disclosures of which are hereby incorporated herein by reference.
SUMMARY OF THE INVENTION
[0003] The invention relates to a martial arts training device comprising a stand comprising a base and at least one substantially vertically extending arm extending up from the base. There is also at least one guide coupled to the stand which is for guiding a user in performing exercises. In addition, to stabilize the stand, there is a stabilizer for stabilizing against movement so that when a user accidentally contacts the guide, the stand remains substantially in place.
[0004] This stabilizer can be in the form of a strap coupling the substantially vertically extending arm to an adjacent fixed object. In addition, this stabilizer further includes at least one water tank disposed in the base, wherein the water tank is designed to receive water to increase a weight of the base to stabilize the stand.
[0005] In addition, the vertically extending arm can comprise at least two arms which are coupled to each other in a telescoping manner, and at least one coupling element for allowing at least one of these two arms to move vertically in relation to the other and to be selectively locked in place at a desired height.
[0006] In addition, as another optional feature, at least one of the at least two telescoping arms further comprises a set of indicia to help a user determine the height at which the arms extend.
[0007] Another optional feature is least one hinge coupling the vertically extending arm to base. This hinge allows the vertically extending arm to rotate to at least a vertically upright position and to at least one folded down position.
[0008] An alternative form of the stabilizer can be a shaft which extends up from the base, wherein the shaft is for receiving weights having a hollow center. Thus, when these weights are placed on the shaft, the weights stabilize the base in place.
[0009] Another optional feature is a laterally extending arm coupled to the vertically extending arm. In this case, the guide extends along the laterally extending arm so that the guide is spaced apart from the substantially vertically extending arm.
[0010] This laterally extending arm is coupled to a top end of the vertically extending arm and can further comprise a hinge. This hinge is for rotatably coupling the laterally extending arm to the vertically extending arm.
[0011] In addition, an additional laterally extending arm can be coupled to the vertically extending arm wherein there is also at least one hinge with at least a first hinge for coupling at least one of the laterally extending arms to the vertically extending arm, and wherein the second hinge is for coupling at least one additional laterally extending arm to the substantially vertically extending arm.
[0012] The guide, which can be in the form of a cord, cable or rope, is disposed in the base optionally on a spool wherein this spool is spring loaded to selectively retract the guide into the base when the guide is not in use. In addition, there can also be a brace coupled to the vertically extending arm, wherein this brace is also coupled to the optional strap. This brace is used to help the strap support the substantially vertically extending arm.
[0013] This device can offer many advantages. For example, it be conveniently set in place and supported by other stationary objects, the guides can be adjusted in height or in lateral spacing from the vertical arm by rotating and then setting the lateral arms. In addition, the guides such as ropes or cords can also be recoiled back into the stand so that the guides can be stored away when not in use.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] Other objects and features of the present invention will become apparent from the following detailed description considered in connection with the accompanying drawings. It should be understood, however, that the drawings are designed for the purpose of illustration only and not as a definition of the limits of the invention.
[0015] In the drawings, wherein similar reference characters denote similar elements throughout the several views:
[0016] FIG. 1 discloses a side perspective view of an embodiment of the invention;
[0017] FIG. 2 shows a side perspective view of a second embodiment of the invention;
[0018] FIG. 3 shows a top view of the first embodiment of the invention in use;
[0019] FIG. 4A shows another embodiment of the stand;
[0020] FIG. 4B shows an another embodiment of the stand;
[0021] FIG. 5 shows a side view of a user using the device.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0022] Turning now in detail to the drawings, FIG. 1 shows a side perspective view of a first embodiment of the invention. In this view, this embodiment of the device 10 includes a stand 12 , which includes a base 14 and a vertically extending arm or shaft 14 . Shaft 14 can be essentially a telescoping shaft that comprises at least two poles 14 . 1 and 14 . 2 . In this case, shaft 14 also contains an adjuster 16 which is in the form of a twisting lock. Twisting lock 16 can be rotated to allow top pole 14 . 2 to slide up and out from bottom pole 14 . 1 . Top pole 14 . 2 extends up from lock 16 to an upper region 20 where a set of lateral extending arms 22 and 24 extend out therefrom. In this case, top pole 14 . 2 can slide down into bottom pole 14 . 1 up to a region where lateral arms 22 and 24 extend out therefrom.
[0023] Lateral extending arms 22 and 24 are coupled to top pole 14 . 2 via a hinge coupling such that lateral extending arms 22 and 24 are rotatably mounted on top pole 14 . 2 . In this case, arm 22 is coupled to top pole via hinge 25 while arm 24 is coupled to top pole 14 . 2 via hinge 27 .
[0024] A cap 28 is also disposed on top of top pole 14 . 2 wherein cap 28 is used to lock hinges 25 and 27 to top pole 14 . 2 .
[0025] Thus, lateral arms 22 and 24 can swing out or in from different radial positions to create different levels of lateral extension from pole 14 . 2 .
[0026] Disposed inside of base 12 and also extending up and out from shafts or poles 14 . 1 and 14 . 2 are a plurality of guides 30 and 32 which are in the form of at least one rope, cord, cable or line. These guides 30 and 32 are coiled up in base 12 and can be extended out from poles 14 . 1 and 14 . 2 and guided away from stand 12 via extending arms 22 and 24 respectively. In this case, guide 30 extends out from arm 22 and guide 32 extends out from arm 24 .
[0027] Essentially, only one guide is needed but two or more guides 30 and 32 can be used so that there can be either one spool or two spools 40 and 42 disposed in base 12 . Spools 40 and 42 can be spring loaded so that the guides will retract into the base for easier transport.
[0028] The spring loading of the guides is also important to provide a sufficient amount of rigidity in the line so that the unspooled line does not sag or remain limp but is instead taut and forms a generally straight line across a ring while still allowing a sufficient amount of flexibility if a user bumps into the line. This guide can also be selectively locked in place in relation to stand 12 such that the guide cannot extend any further out from stand R.
[0029] FIG. 2 shows a second embodiment of the invention wherein this device 11 shows a stand 12 with a vertical pole 14 including telescoping poles 14 . 1 and 14 . 2 which telescope in coupling 16 and extend up to endcap 28 . There is also shown a strap 35 which includes a brace 35 . 1 and a strap element 35 . 2 which is coupled to brace 35 . 1 . A single guide 30 extends up to endcap 28 and out of pole 14 from a spindle or spool 40 disposed in base 12 . One of the differences between this embodiment and the embodiment shown in FIG. 1 is that this embodiment does not disclose rotatable arms 22 and 24 or a second guide 32 . In this respect, this embodiment is a simplified version as compared to the embodiment shown in FIG. 1 . In this view there is also shown a plurality of brackets 88 and 89 which are coupled to the base. In this case brackets 88 and 89 are for receiving an optional strap 90 such as a strap that can be slid in through brackets 88 and 89 and then fastened using a hook and loop fastener or any other type fastener for securing this strap. Strap 90 can then be used to allow a user to carry this device to other locations.
[0030] In this view there are also shown markings 91 which can be used to designate a height at which top pole 14 . 2 extends out from bottom pole 14 . 1 . In this way top pole can be set at a height that allows a user to set the device in a manner that is most effective for training.
[0031] FIG. 3 shows a top view of the embodiment shown in FIG. 1 disposed inside of a ring such as a boxing ring 50 . In this case, the device 10 includes a plurality of straps 35 . 2 , which extend out and wrap around a turnbuckle. These straps are used to stabilize a top end of the device so that it can be used to keep the line or guide 30 or 32 taut or level as it extends across the ring.
[0032] In this case, the device can be used so that only one guide 30 or 32 from each one of the devices 10 is extended from one arm across the ring. This guide or rope is then attached to an opposite laterally extending arm disposed in an opposite corner of the ring. The ropes or guides can be tied off on the opposite spaced poles so that when these poles are tied off, the device has two lines disposed on either side for balancing the stand.
[0033] FIGS. 4A and 4B show two different embodiments of a stand that can be used to support these ropes. For example, FIG. 4A discloses a stand that has at least one but preferably a plurality of tanks 60 and 62 which can be used to hold a fluid such as water to stabilize stand 12 . When tanks 60 and 62 are filled, it provides additional weight to stabilize stand 12 in place so that it would be less likely to tip over. In addition, this view also shows that stand 12 can have an optional hinge coupling pole 14 . 1 to stand 12 so that pole 14 can be folded down and the device can then be placed in storage.
[0034] FIG. 4B shows a second embodiment of stand 12 wherein in this embodiment there is a shaft 66 which extends out from stand 12 . Shaft 66 is used to receive weights which have a center hole and can then fit over shaft 66 . In this case, the weights are placed on stand 12 to add additional weight to the stand to stabilize stand 12 . This view also shows that stand 12 has hinge 64 in place as well.
[0035] FIG. 5 shows the device in use wherein a boxer is shown ducking under guides 30 , 32 to practice the necessary movements for training in martial arts.
[0036] In any one of the above described or shown embodiments, pulleys or other rope or cord conveying means may be used or incorporated therein to the device. The use of pulleys are well known in the art. For example, pulleys can be disposed in a region at a base or bottom end of coupling pole 14 . 1 or at an opposite end adjacent to top end 28 . Pulleys may be used or disposed at lateral outside ends of lateral arms 22 and 24 .
[0037] Accordingly, while a few embodiments of the present invention have been shown and described, it is to be understood that many changes and modifications may be made thereunto without departing from the spirit and scope of the invention as defined in the appended claims. | A martial arts training device comprising a stand having a base and at least one substantially vertically extending arm extending up from the base. There is also at least one guide coupled to the stand which is for guiding a user in performing exercises. In addition, to stabilize the stand there is a stabilizer for stabilizing against movement so that when a user accidentally contacts the guide, the stand remains substantially in place. The guide can be in the form of a rope, cord, or cable. | 0 |
FIELD OF THE INVENTION
The present invention relates to a cleaning device for cleaning dirt, and more especially to a safe cleaning device when using corrosive chemical cleaning material to clean the dirt produced from manufacturing equipment.
BACKGROUND OF THE INVENTION
The highly corrosive cleaning material such as potassium hydroxide (KOH) or hydrochloric acid (HCI) solution is used for cleaning the dirt adhered to the surface of an ordinary or semiconductor manufacturing equipment. In the art, there is no well-designed cleaning machine or cleaning apparatus which can be safely and conveniently used to clean the dirt. In a general situation, the cleaner must put on the mask and anti-corrosive gloves to process the cleaning work by adhering the cleaning material in a dirt-free cloth or by directly slopping the cleaning material on the manufacturing equipment and then wiping off the dust with a dirt-free cloth. The highly corrosive cleaning material may splash out during the cleaning process which will be dangerous to the cleaner and consume lots of dirt-free cloths to finish the cleaning work. The cleaning process mentioned above not only wastes the cost of the dirt-free cloth but also bears high risk of causing face, skin or any contacted region of the cleaner to be hurt.
Seeing that the cleaning process is a must, an improved device for reducing the risk of using corrosive chemical cleaning material is desirable.
Therefore, it is attempted by the applicant to provide a cleaning device which can be safely used with the strong corrosive chemical cleaning material.
SUMMARY OF THE INVENTION
It is therefore an object of the present invention to provide a safe, convenient and recycling cleaning device such that the aforementioned drawbacks and dangerous situation for processing the cleaning work in the prior art can be overcome.
It is therefore another object of the present invention to provide a cleaning device for safely, conveniently and recyclingly storing strong chemical cleaning material such as potassiumn hydroxide (KOH) or hydrochloric acid (HCI) solution during the cleaning process.
It is therefore further an object of the present invention to provide a safe, convenient and recycling cleaning device which can prevent the cleaner from being splashed with a strong corrosive chemical cleaning material.
The safe, convenient and recycling cleaning device of the present invention comprises a container for receiving cleaning material therein, a permeating element disposed in said container for introducing cleaning material, and having a cleaning head mounted on one end of a container and connecting with a permeating element for cleaning the dirt.
According to the present invention, the cleaning device further comprises a connector disposed on the other end of the container opposite to one end and the connector can be further connected with a filling bottle by a method of connecting with a duct or directly putting the container into a filling bottle for supplying cleaning material to the container. The filling bottle as mentioned above is made of a soft and compressible material. Further, the connector comprises a one way valve for preventing cleaning material from leaking out of container which is made of a transparent material for allowing a user to inspect the cleaning material contained therein.
According to the present invention, the cleaning material is a strong corrosive solution which can be potassium hydroxide (KOH) or hydrochloric acid (HCI) solution.
According to the present invention, the cleaning device also comprises a cover detachably mounted on one end of the container for protecting the cleaning head, and the cover is made of a transparent material.
According to the present invention, the cleaning device has a retarder which can be a sponge disposed between the connector and the permeating element for absorbing cleaning material and preventing cleaning material from being introduced to the permeating element rapidly.
According to the present invention, the cleaning device comprises a cleaning head integrally formed and detachably connected with one end of the permeating element by a fixing element. And the fixing element is made of an anti-corrosive material such as the stainless steel material. Characteristically, the cleaning head can be formed at any geometric shape such as round shape, square shape, oblong shape or trapezoid shape for cleaning different shapes of cleaned objects. The cleaning head is made of the same material as that of permeating element, and the material can be Polyester, Polyamide or Polyurethane.
According to the present invention, the cleaning material in the cleaning device can travel from the permeating element to the cleaning head by capillarity.
According to the present invention, the cleaning device is offset pen-shaped or flexible.
It is therefore another object of the present invention to provide a cleaning device capable of bending and turning during the cleaning process, which comprises a main body for receiving a cleaning material and cleaning dirt by a cleaning head thereof, and a flexible element disposed in main body for allowing a user to bend main body.
It is therefore another object of the present invention to provide an anti-leaking cleaning device for cleaning the dirt, which comprises a main body for receiving a cleaning material and cleaning dirt by a cleaning head thereof, and a one-way valve disposed in the connector for preventing said cleaning material from leaking out of main body.
Furthermore, the object of the present invention is to provide a cleaning device which can be shrunken or enlarged in respect of the size on the demand of the environment when processing the cleaning work.
Also, the present device allows for a number of other advantages, which can be understood upon review with reference to the accompanying drawings the detailed descriptions which follow.
BRIEF DESCRIPTION OF THE DRAWINGS
The accompanying drawings, which are incorporated in and constitute a part of the specification, illustrate presently preferred embodiments of the invention and, together with the general description given above and the detailed description of the preferred embodiments given below, serve to explain the principle of the invention.
FIG. 1 is a schematic view showing substances and elements of a preferred embodiment of a cleaning device according to the present invention;
FIG. 2 is a schematic view showing a one-way valve of a cleaning device according to the present invention; and
FIG. 3 is a schematical view showing a flexible element of another preferred embodiment of a cleaning device according to the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 is a schematical view showing substances and elements of a preferred embodiment of a cleaning device according to the present invention., As shown in FIG. 1, the cleaning device of the present invention includes a container 11 , a permeating element 14 and a cleaning head 15 . The container 11 has a connector 12 disposed on one end thereof and is connected with a filling bottle 13 via the connector 12 thereof. The filling bottle 13 is connected to the connector 12 of the container 11 by direct engagement therewith. Alternatively, the filling bottle 13 is connected to the connector 12 of the container 11 via a duct. And the filling bottle 13 is made of soft and compressible material for the cleaner's easily squeezing the cleaning material into the container 11 . As can be seen in FIG. 1, the retarder 18 , which can be a sponge material, is disposed between the connector 12 and the permeating element 14 for absorbing the cleaning material and preventing the cleaning material from being introduced to the permeating element 14 rapidly.
As shown in FIG. 1, a cleaning head 15 is integrally formed with one end of the permeating element 14 . The cover 17 includes a griping annulus 19 to grip therewith the container 11 for protecting the cleaning head 15 from being scratched. Alternatively the cover 17 can be screwedgly engaged with the container 11 .
The detailed procedure for a cleaning device processing the cleaning work is described as follows. When the cleaning material flows from the filling bottle 13 into the container 11 , the cleaning material will travel from the permeating element 14 to cleaning head 15 by capillarity. Next, the permeating element 14 made of one of Polyester, Polyamide or Polyurethane material introduces the cleaning material such as potassium hydroxide (KOH) or hydrochloric acid (HCI) solution from high concentration area to low concentration area by capillarity. That is to say, after the cleaning head 15 contacting the dirt and releasing the cleaning material and then mixing with the solution produced from the cleaned object, the concentration of the cleaning material around cleaning head 15 will be reduced, and the cleaning material reserved in container 11 which remains in a high concentration state will keep on being introduced to the permeating element 14 for supplying the cleaning material to cleaning head 15 by capillarity. Hereinafter, we describe another situation which might occur. As the cleaning material is sent to the cleaning head 15 and contacts the cleaned object, the cleaning material is permeating from one end of the permeating element 14 opposite to the end near the cleaning head 15 by capillarity no matter whether the concentration of the cleaning material changes or not. Anyway, after the cleaning processing is continuously performed, the cleaning material will be run out and the exhausted cleaning material must be supplied by filling bottle 13 . As the cleaning process described above, the cleaning device possesses a reusable and recycling advantage.
Because the cleaning material is strong, corrosive material, some of substances and elements of the cleaning device in the present invention, such as the container 11 , permeating element 14 , cleaning head 15 and fixing element 16 , are made of anti-corrosive material. Mentioned particularly here, the fixing element 16 in the present invention can be a stainless steel material for preventing from being corroded.
The present invention also provides a see-through cleaning device for cleaner to inspect the chemical of the cleaning material, such as the cover 17 in FIG. 1 is made of a transparent material the same as that of the permeating element 14 for cleaners to protect the cleaning head, examine the volume of the cleaning material and inspect whether the quality of the cleaning material reserved in container 11 changes or not. As precipitating, impure or cloudy solution is produced in the cleaning material, the cleaner must renew the cleaning material.
Significantly, the cleaning head 15 in FIG. 1 can be formed in any geometric shape such as round shape, square shape, oblong shape and trapezoid shape for cleaner to clean the corner and the irregular shape of the cleaned objects and prevent the cleaned objects from being scratched.
FIG. 2 schematically shows a one-way valve in the cleaning device. The one-way valve 21 disposed in the connector 12 provides the advantages for preventing the cleaning material from reflux or leaking out of container 11 when supplying the cleaning material into the cleaning device.
FIG. 3 is another preferred embodiment of the present invention showing the flexible element in the main body of the cleaning device. The flexible element 31 in FIG. 3 is disposed in main body 30 for a cleaner's easily bending and turning the cleaning device. The preferred embodiment of the cleaning device in FIG. 3 can be extensively put in application for cleaning differently angled surfaces, the corner and the irregular shape of cleaned objects. In other word, the flexible element can be made into any shape such as a slanting, a curved, a pen-shaped or an angled cleaning device for the user to clean various kinds of cleaned objects.
Accordingly, a safe, convenient and recycling cleaning device has been provided by the present invention. The present architecture provides for every cleaner to perform the cleaning work in a safe situation to clean the dirt produced from an ordinary or semiconductor manufacturing equipment.
Additional advantages and modification will readily occur to those skilled in the art. Therefore, the invention in its broad aspects is not limited to the specific details, and representative devices shown and described herein. Obviously many modifications and variations will be apparent to practitioners skilled in this art. It is intended that the scope of the invention be defined by the following claim and their equivalents. | A cleaning device for cleaning the dirt is disclosed. The cleaning device includes a container for receiving the cleaning material therein, a permeating element disposed in the container for introducing the cleaning material, and a cleaning head mounted on one end of the container and connecting with the permeating element for cleaning the dirt. | 1 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention relates in general to elevator systems, and more specifically, to elevator systems which utilize chain compensation for the weight of the hoist roping.
2. Description of the Prior Art
Chain compensation for the weight of the hoist roping in a traction elevator system has distinct economic advantages over wire rope compensation. The major drawbacks of chain compensation are sway and noise, both of which increase in intensity with car speed. Thus, chain compensation has been limited to use on relatively slow speed elevator systems, but considerable effort has been directed toward reducing sway and noise in order to enable the use of chain compensation at higher and higher car speeds. For example, U.S. Pat. No. 3,768,596, which is assigned to the same assignee as the present application, teaches an arrangement for reducing chain noise. This arrangement extends the upper speed limit for chain compensated elevator systems to about 500 feet per minute. This patent discloses the use of resilient spacers formed of a material such as rubber, which are disposed about alternate links of the chain. The spacers are dimensioned to fully extend the links of the chain to maintain them in their extended position, which reduces noise in the natural loop of the chain formed below the elevator car and counterweight, and it also reduces the noise due to the chain striking components in the hoistway due to chain sway. U.S. Pat. No. 3,810,529, which is also assigned to the same assignee as the present application, teaches an arrangement which successfully extends chain compensation to still higher speed elevator systems, such as 700 feet per minute, which arrangement eliminates sway and reduces the noise level to a greater extent than the use of resilient spacers on the chain itself. In the arrangement of this patent, the compensating chain is firmly guided by a chain wheel or sheave which has a groove formed in its outer periphery by spaced elastomeric members. Alternate links of the chain extend edgewise into the circumferential grooves. The intervening links rest flatwise on the outer peripheries of the elastomeric members, outside the circumferential groove. This arrangement provides silencing and guiding functions without scraping, digging and twisting of the chain links.
While the arrangement of the latter patent substantially reduces chain noise and it eliminates sway, a certain amount of car vibration and/or airborne noise may occasionally be experienced with chain compensation, especially at the higher car speeds, such as 700 feet per minute. It has also been found that the magnitude of such vibration and noise varies substantially from installation to installation. Thus, it would be desirable to further reduce vibration and noise due to chain compensation, and to be able to reliably obtain such reductions under the widely varying conditions encountered in different elevator installations.
SUMMARY OF THE INVENTION
Prior art compensation systems support the chain wheel in the loop of the chain. Any springs provided in such systems are for the purpose of adding tension to the chain. Rope compensation systems also support the compensator sheave in the loop of the ropes, with any springs being associated with shock absorbing functions in lock-down arrangements. The present invention recognizes that vibration and airborne noise in chain compensation systems is increased by increased tension in the chain. Thus, instead of using springs to add tension to the chain, springs are used to reduce chain tension. The chain wheel is adjustably spring mounted, such that the springs support a portion of the weight of the chain wheel. It is only necessary to retain sufficient weight on the chain such that movement of the chain will rotate the chain wheel without slippage between the chain wheel and chain. This arrangement reduces vibration set up in the chain, and thus in the car, due to chordal action of the chain, and it reduces the airborne noise audible at the lower floor, or floors, due to the chain entering and leaving the circumferential groove in the outer periphery of the chain wheel.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention may be better understood, and further advantages and uses thereof more readily apparent, when considered in view of the following detailed description of exemplary embodiments, taken with the accompanying drawings, in which:
FIG. 1 diagrammatically illustrates a traction elevator system constructed according to the teachings of the invention; and
FIG. 2 is an enlarged, elevational view of the elevator system shown in FIG. 1, taken between and in the direction of arrows II--II.
DESCRIPTION OF THE PREFERRED EMBODIMENT
The present invention relates in general to traction elevator systems having chain compensation, and more specifically, to a new and improved mounting arrangement for the chain wheel of such systems. The teachings of the invention are applicable to any chain wheel construction, with the constructions disclosed in the hereinbefore mentioned U.S. Pat. No. 3,810,529 being particularly desirable, as they provide accurate guiding of the chain while reducing chain vibration and noise. U.S. Pat. No. 3,810,529 is hereby incorporated into the present application by reference, and it may be referred to for specific constructional details of a suitable chain wheel or compensator sheave.
Referring now to the drawings, and FIG. 1 in particular, there is shown a traction elevator system 10 constructed according to the teachings of the invention. Elevator system 10 includes an elevator car 12 mounted for movement in a hoistway 14 of a structure or building having a plurality of floors, indicated generally at 16, which floors are served by the elevator car 12. An elevator drive motor 18 may be mounted on the floor of a penthouse in the building, which floor is illustrated generally by line 20, with the drive motor having a drive shaft 22 to which a traction sheave 24 is secured. An idler or deflection sheave 26 may be secured to the lower surface of the penthouse floor 20, if required.
Hoist ropes or cables 28 interconnect the elevator car 12 with a counterweight 30. The hoist ropes 28, as illustrated, interconnect the elevator car 12 and counterweight 30 with a one-to-one roping arrangement, wherein they are directly connected to the crossheads of the elevator car 12 and counterweight 30, but a two-to-one roping may be used for either the car, or counterweight, or both, if desired.
Depending upon building height, the weight of the hoist ropes 28 may add significantly to the unbalanced load which must be lifted and accelerated by the elevator drive machine, with the amount of the unbalance continuously changing as the elevator car and counterweight move in the hoistway. Thus, it is conventional to provide some type of compensation system to reduce the unbalanced load for any position of the elevator car and counterweight in the hoistway. The compensation system makes torque requirements more uniform and assists in landing accuracy.
Compensation for the weight of the hoist ropes 28 is provided by a chain 32, a compensator sheave or chain wheel 36 disposed below the travel path of the elevator car 12, i.e., in the bottom part 38 of the hoistway 14, commonly referred to as the pit, and means 39 constructed according to the teachings of the invention for mounting the chain wheel in the pit. Buffers for the elevator car and counterweight 30 are also disposed in the pit, such as counterweight buffer 40.
The chain wheel 36 includes elastomeric means 49 disposed about the outer periphery thereof, providing a circumferential groove about the outer periphery of the chain wheel.
The chain 32 is an ordinary link chain having a series of interconnected metallic links, with alternate links 71 being of like orientation, and the intervening links 73 being of like orientation. The alternate links 71 extend edgewise into the circumferential groove provided by the resilient means on the outer periphery of the chain wheel, while the intervening links 73 lie flatwise on the outer periphery of the resilient means.
Chain wheel 36 is mounted according to the teachings of the invention to reduce the operating noise of the chain 32, and prevent sway thereof, at all elevator speeds at least up to 700-800 ft. per minute.
FIG. 2 is an enlarged, elevational view of the chain wheel mounting means 39 shown in FIG. 1, taken between and in the direction of arrows II--II. As illustrated in FIG. 2, chain wheel 36 is rotatably mounted on an axis 37 between first and second spaced plate members 42 and 44. Plate members 42 and 44 are pivotally mounted to a suitable support in the pit, such as to the counterweight buffer 40. The pivot axis, shown at 46 in FIG. 1, is horizontally oriented, permitting plate members 42 and 44, as well as chain wheel 36, to be pivoted about axis 46 in a vertical plane.
Simply pivotally mounting chain wheel 36 in the pit causes the full weight of the chain wheel to be applied to the chain 32. I have found that when the entire weight of the chain wheel 36 rests on the chain 32, the chordal action of the chain, as well as any unevenness or roughness in the chain wheel, may set up objectionable vibrations in the chain which are transmitted to the elevator car. In addition, airborne noise due to the chain entering and leaving the circumferential groove in the outer periphery of the chain wheel may be loud enough to be heard at the lower floor, or floors, such as at the lobby floor. I have found that the vibration and noise is proportional to the tension in the chain. Thus, instead of deliberately adding tension to the chain, such as in certain prior art installations, the present invention includes mounting means 39 for the chain wheel that is constructed to reduce the weight of the chain wheel resting on the chain, which reduces the tension in the chain accordingly. The amount of the load taken off the chain 32 is adjustable, permitting the load to be taken off the chain until the vibration and noise are not noticeable, either to passengers in the car, or to prospective passengers in the hallways. It is only necessary that sufficient weight be maintained on the chain to enable frictional engagement between the chain and the resilient outer periphery of the chain wheel to drive the chain wheel about its rotational axis 37.
More specifically, the mounting means 39 includes first and second threaded rod members 48 and 50, respectively, which are vertically mounted and secured to the floor of the pit. As illustrated, rod members 48 and 50 may be welded to plate members 52 and 54, respectively, and plate members 52 and 54 may have openings therein for receiving bolts for bolting the plate members to angle members 56 and 58, respectively. Angle members 56 and 58 are attached to upstanding stud members 60 and 62, which are secured to the floor of the pit via nuts 64 and 66, respectively.
Adjustable spring seats 68 and 70 are provided on each rod member 48 and 50, such as by a nut 72, a washer 74 and a collar 76 on rod member 48. In like manner, adjustable spring seat 70 includes a nut 78, a washer 80, and a collar 82. The positions of the spring seats 68 and 70 are adjustable selected merely by turning nuts 72 and 78, respectively.
Spiral springs 84 and 86 are telescoped over the upstanding ends of rod members 48 and 50, respectively, and upper spring seats are provided on their upper ends, such as by collars 88 and 90. Rod members having an O.D. of 0.625 inch, and spring members having a 0.362 inch wire diameter, a 3.25 inch O.D., and a free length of 10.312 inches, have been found to provide the desired results, but other sizes may be successfully used.
Right angle members 92 and 94 have one leg attached to plate members 42 and 44, respectively, such as by nut and bolt assemblies, and their other legs have openings therein sized to slidably receive rod members 48 and 50. The chain wheel 36 with its angle members 92 and 94 secured thereto, is lowered between rod members 48 and 50 such that the rod members extend through the openings in angle members 92 and 94. The angle members 92 and 94 thus rest against the upper spring seats or collars 88 and 90, and press downwardly on spring members 84 and 86. Adjusting nuts 72 and 78 are adjusted up, or down, to provide the desired division of the weight of the chain wheel 36 between the springs 84 and 86, and between the chain 32. In practice, the positions of nuts 72 and 78 are selected to provide the lowest chain vibration and the lowest airborne noise. Sufficient weight is always maintained on the chain to provide the necessary friction between the chain and the chain wheel in order to drive the chain wheel about its rotational axis without slippage.
While the invention has been described relative to a single chain wheel, it is to be understood that the invention is equally applicable to installations which use two spaced chain wheels to obtain the required spacing of the chain between the elevator car and counterweight. Also, the invention is applicable to installations which use two chains, either with a single chain wheel per chain, or two spaced chain wheels per chain. | An elevator system including an elevator car and counterweight, hoist roping, and chain compensation for the weight of the hoist roping. A chain wheel spaces and guides the compensating chain. Vibration in the elevator car, and airborne noise due to the chain, are substantially reduced by a mounting assembly for the chain wheel which mounts the chain wheel on springs. The springs are adjustably biased to partially support the weight of the chain wheel, to reduce the loading on the compensating chain. | 1 |
CROSS REFERENCE TO RELATED APPLICATIONS
This application claims priority under 35 U.S.C. §119(e) from U.S. Provisional Patent Application No. 61/533,042 entitled “DROP: The Durable Reconnaissance and Observation Platform” filed on Sep. 9, 2011, which is incorporated herein by reference in its entirety.
STATEMENT OF GOVERNMENT GRANT
The invention described herein was made in the performance of work under a NASA contract, and is subject to the provisions of Public Law 96-517 (35 USC 202) in which the Contractor has elected to retain title.
FIELD
The present teachings relate to terrain traversing devices such as robots that may be used for reconnaissance purposes. More specifically, the present disclosure relates to terrain traversing device having a wheel with microhooks that can travel across a horizontal surface such as a floor of a room and then carry out vertical traversal operations such as climbing up a wall, climbing up the steps of a staircase, or climbing over an obstacle such as a curb.
BACKGROUND
Unexpected obstacles are often encountered when a remotely operated device is used for traversing a hostile and unfamiliar environment, thereby requiring the remotely operated device to have capabilities and features that address and conquer at least some of these unexpected obstacles.
SUMMARY
According to a first aspect of the present disclosure, a terrain traversing device includes a first microspine wheel assembly. The first microspine wheel assembly has a circular planar rotor with a plurality of microspine hooks arranged along a circumferential edge of the circular planar rotor. Each individual microspine hook is mounted on an independently flexible suspension that accommodates a variable engagement angle between the individual microspine hook and an irregularity on a terrain surface when the circular planar rotor is rotated in one of a clockwise or a counter-clockwise direction to urge the terrain traversing device to traverse the terrain.
According to a second aspect of the present disclosure, a terrain traversing device includes a first microspine wheel assembly comprising a circular planar rotor with a plurality of microspine hook assemblies arranged on a circumferential edge of the circular planar rotor. The plurality of microspine hook assemblies includes a first microspine hook assembly having a first independently flexible suspension configuration supporting a first microspine hook. The first independently flexible suspension is configured to permit the first microspine hook to initially engage an irregularity in a terrain surface with a parallel orientation between the terrain surface and the first microspine hook assembly and subsequently engage the irregularity with a continuously varying engagement angle between the first microspine hook and the terrain surface when the circular planar rotor is rotated in one of a clockwise or a counter-clockwise direction to urge the terrain traversing device to traverse a terrain surface.
According to a third aspect of the present disclosure, a terrain traversing device includes a first annular rotor element with a plurality of co-planar microspine hooks arranged on a periphery of the annular rotor element. Each microspine hook has an independently flexible suspension configuration that permits the microspine hook to initially engage an irregularity in a terrain surface at a preset initial engagement angle and subsequently engage the irregularity with a continuously varying engagement angle when the annular rotor element is rotated for urging the terrain traversing device to traverse a terrain surface.
According to a fourth aspect of the present disclosure, a terrain traversing device includes a cylindrical housing and a pair of motors. A first motor is housed in the cylindrical housing and coupled to a proximal end of a first axle. A first annular rotor element is coupled to a distal end of the first axle, the first annular rotor element having a first set of co-planar microspine hooks arranged on the periphery of the first annular rotor element. Each microspine hook is arranged to engage upon contact with irregularities in a terrain surface when the first axle is rotated for urging the terrain traversing device to traverse the terrain surface. A second motor is also housed in the cylindrical housing and coupled to a proximal end of a second axle. A second annular rotor element is coupled to a distal end of the second axle, the second annular rotor element having a second set of co-planar microspine hooks arranged on the periphery of the second annular rotor element. Each microspine hook is arranged to engage upon contact with irregularities in the terrain surface when the second axle is rotated for urging the terrain traversing device to traverse a terrain surface.
According to a fifth aspect of the present disclosure, a rotary microspine device includes a circular planar rotor with a plurality of microspine hooks arranged on a circumferential edge of the circular planar rotor. Each individual microspine hook is mounted on an independently flexible suspension that accommodates a variable engagement angle between each individual microspine hook and an irregularity on a traversal surface when the circular planar rotor is rotated.
Further aspects of the disclosure are shown in the specification, drawings and claims of the present application.
BRIEF DESCRIPTION OF THE DRAWINGS
The accompanying drawings, which are incorporated into and constitute a part of this specification, illustrate one or more embodiments of the present disclosure and, together with the description of a few example embodiments, serve to explain the principles and implementations of the disclosure. The components in the drawings are not necessarily drawn to scale. Instead, emphasis is placed upon clearly illustrating various principles. Moreover, in the drawings, like reference numerals designate corresponding parts throughout the several views.
FIG. 1 shows a perspective view of a terrain traversing device according to an example embodiment of the present disclosure.
FIG. 2 is a line drawing that shows certain features of a microspine wheel assembly that is a part of the terrain traversing device shown in FIG. 1 .
FIG. 3 shows a microspine hook, which is a part of the microspine wheel assembly shown in FIG. 2 , engaged to an irregularity in a vertical surface.
FIG. 4 shows an exploded view of a terrain traversing device that illustrates a few component parts according to an example embodiment of the present disclosure.
FIG. 5 shows a series of figures to illustrate a terrain traversing device traversing from a horizontal surface to a vertical surface in accordance with the present disclosure.
FIG. 6 indicates dimensional values associated with a terrain traversing device shown traversing a step in accordance with the present disclosure.
FIG. 7 shows a line drawing indicating various parameters associated with a terrain traversing device when traversing a vertical surface in accordance with the present disclosure.
DETAILED DESCRIPTION
Throughout this description, embodiments and variations are described for the purpose of illustrating uses and implementations of the inventive concept. The illustrative description should be understood as presenting examples of the inventive concept, rather than as limiting the scope of the concept as disclosed herein. For example, it will be understood that terminology such as, for example, “microspine wheel assembly,” “rotor,” “annular,” and “irregularity” are used herein as a matter of convenience for description purposes and should not be interpreted literally in a narrowing sense.
For example, the term “rotor” may be broadly understood as representing a circular support element, a circular housing, a cylindrical mount, or an annular element. A person of ordinary skill in the art will understand that these terms may be used interchangeably and as such must be interpreted accordingly. It will be also be understood that the drawings use certain symbols and graphics that must be interpreted broadly as can be normally understood by persons of ordinary skill in the art. As one example, of such interpretation, the microspines are shown in various figures as pointing in a clockwise direction. However, one of ordinary skill in the art will understand that in certain alternative embodiments, microspines may be oriented to point in a counter-clockwise direction. Furthermore, while the description below is directed at two-wheeled robots of a relatively small size, various aspects of the invention may be implemented in various other sizes and ways, including for example, a one-wheeled device, a three-wheeled device, or a four-wheeled vehicle, wherein such devices may further include a chassis associated with the wheels and a compartment mounted on the chassis.
Attention is now drawn to FIG. 1 , which shows a perspective view of a terrain traversing device 100 according to one of several example embodiments of the present disclosure. Terrain traversing device 100 includes a first wheel assembly 105 that is composed of several individual microspine wheel assemblies stacked together in an array arrangement that is described below in more detail. Terrain traversing device 100 further includes a second wheel assembly 125 that is also formed by assembling several other individual microspine wheel assemblies in a cooperative arrangement so as to permit propulsion of terrain traversing device 100 as a two-wheeled device over various surfaces.
Tail assembly 115 , which includes a bulb 120 at one end, is coupled to a cylindrical housing 130 . Tail assembly 115 helps stabilize terrain traversing device 100 during terrain traversal, especially when terrain traversing device 100 transitions from a horizontal surface to a vertical surface. Bulb 120 may be designed for various purposes, such as for example, as a cushioning element to help protect terrain traversing device 100 when terrain traversing device 100 falls to the ground from a high location such as a roof of a building. In alternative embodiments, bulb 120 may be replaced by a pair of tines (not shown), or other suitable termination, directed at providing stability in various planes, providing maneuverability during travel, or for protecting against damage during various types of impacts.
In this example embodiment, terrain traversing device 100 has a camera unit 110 mounted on cylindrical housing 130 . In other embodiments, camera unit 110 may be supplemented or complemented with other sub-assemblies such as a microphone or a detector device (for example, to detect chemicals, heat, movement etc.). Furthermore, in this example embodiment, cylindrical housing 130 houses a pair of motors (not shown) that individually drive each of first and second wheel assemblies 105 and 125 via two separate axles (not shown).
Terrain traversing device 100 also includes various other elements (not shown) such as a controller unit, communications unit, battery pack, and sensor assemblies for sensing motion-related parameters such as rpm, torque, slippage, acceleration etc., of wheel assemblies 105 and 125 . These various elements may be suitably housed in one or more of cylindrical housing 130 , tail assembly 115 and/or bulb 120 and used not only to propel terrain traversing device 100 forward or backwards, but to provide communication interactions with a remote communications unit (not shown). The remote communications unit may be human-operated or may be incorporated into a computer in accordance with various embodiments.
Attention is now drawn to FIG. 2 , which shows a microspine wheel assembly 200 that is a part of terrain traversing device 100 . As indicated above, each of wheel assemblies 105 and 125 of terrain traversing device 100 are formed by stacking a plurality of such microspine wheel assemblies in an array arrangement on an axle. Using a rotary movement to grasp a surface (carried out via wheel assemblies 105 and 125 containing microspine wheel assemblies) provides several advantages over prior art techniques such as those incorporating a linear sliding motion used by robotic legs for obtaining a grip upon a surface. The linear sliding motion required by robotic legs make them unsuitable for quick transitions from a horizontal to a vertical surface and is also unsuitable for curb mounting or stair climbing.
Microspine wheel assembly 200 may be generally described as a substantially circular planar element with a plurality of microspine hooks (each substantially similar to microspine hook 220 ) mounted on a peripheral edge 206 of the circular element. Peripheral edge 206 may be alternatively referred to herein as a circumferential edge of rotor 205 . The microspine hooks provide a grabbing/grasping action by engaging with irregularities on a traversal surface so as to propel terrain traversing device 100 over the traversal surface. Though the example embodiment of FIG. 2 shows four microspine hooks, it will be understood that in other embodiments, the number of microspine hooks may range from a single one to quantities other than four.
Furthermore, it will be understood that the term “irregularities” is used herein to generally indicate any feature of a surface, such as for example, a protrusion or an indentation, that is suitable for one or more microspine hooks to obtain purchase as a part of the grabbing action. It will be also understood that the term “engage” is generally used herein in the context of the grabbing action, and one of ordinary skill in the art will recognize that alternative terms such as “purchase,” may be used instead without deviating from the spirit of the invention. It will be further understood that the phrase “substantially circular planar element” that is used above may be alternatively referred to herein by various other terms such as for example, “rotor,” “circular planar rotor,” “circular housing,” “cylindrical mount,” or an “annular rotor element.” However, for convenience of description vis-à-vis identification with reference to FIG. 2 , this element will be generally referred to below as “rotor 205 .”
Microspine wheel assembly 200 is selected to have any suitable thickness based on various factors, such as mechanical strength, rigidity, machinability etc. While there is no particular limitation on the upper end of a thickness range, the lower end of the thickness range is only constrained to a cross-sectional dimension (e.g., diameter, width, etc.) of one or more of microspines 220 . The range of thickness permits microspine wheel assembly 200 to be used in a wide variety of applications over a wide variety of surfaces and environments.
The diameter d 1 245 of microspine wheel assembly 200 is selected to have any suitable value based on a few parameters, such as, for example, the weight, height and/or a desired rate of travel of terrain traversing device 200 . However, in contrast to certain prior art devices, diameter d 1 245 of microspine wheel assembly 200 is not constrained by the height of certain objects to be traversed, such as for example, the height of a step or a curb. This aspect is described below in more detail using FIG. 6 . Specifically, given the lack of prior knowledge of the type of terrain to be traversed, it is generally desirable that diameter d 1 245 of microspine wheel assembly 200 not be constrained by the height of various obstacles. However, it will be understood that in certain applications, it may be desirable to use a small diameter so as to accommodate traversal of certain obstacles such as narrow passageways.
Attention is now drawn to microspine hook 220 that is mounted on a flexible suspension 210 , which is one of four suspensions shown as parts of mount 235 . Mount 235 may be formed in several alternative ways using several alternative materials. For example, in one embodiment, mount 235 is a unitary mount formed as a rigid structure using a material such as a metal or a hard plastic. In another embodiment, mount 235 is formed as a unitary flexible or semi-flexible structure using a rubber-based compound, for example. Furthermore, in a first implementation, mount 235 and rotor 205 are fabricated as two separate parts and subsequently mount 235 is attached to rotor 205 in an arrangement whereby mount 235 rotates along with rotor 205 when rotor 205 is rotated. The attachment may be carried out using suitable attachment mechanisms such as screws, dowels, washers, seals etc., or via a force-fit process. In a second implementation, mount 235 and rotor 205 are fabricated together as a single unitary assembly.
Flexible suspension 210 includes a hook assembly 225 that anchors a microspine hook 220 , and further includes two flexible elements that support hook assembly 225 in a manner that provides a flexing action when microspine hook 220 engages with an irregularity in a traversal surface. More particularly, flexible loop element 215 couples one end of hook assembly 225 to a first attachment location 217 along the circumferential edge of rotor 205 , while stretchable element 216 couples an opposing end of hook assembly 225 to a second attachment location 218 located on mount 235 .
Microspine hook 220 is composed of a suitable material that permits microspine hook 220 to be repeatedly engaged and disengaged from hard surfaces without significant damage or wear and tear. One example of a suitable material is a metal such as stainless steel.
Rotor 205 may be implemented in various ways using various materials. Typically, rotor 205 is composed of a hard material (a metal or a hard plastic, for example) and includes a central opening having a diameter d 2 240 that is selected in order to accommodate an axle (not shown) that is inserted through the central opening. This arrangement may be better understood from FIG. 1 , wherein each of wheel assemblies 105 and 125 include multiple microspine wheel assemblies arranged in parallel with each other with individual axles (not shown) inserted therethrough.
The multiple holes shown along the annular body of rotor 205 may be used in several ways. In one case, these holes assist in arranging multiple microspine wheel assemblies on an axle in a manner that provides for an intentional misalignment between the microspine hooks of adjacent microspine wheel assemblies. The intentional misalignment permits each of the plurality of microspine hooks of a first microspine wheel assembly to engage to irregularities in the terrain surface at different engagement instances when compared to engagement instances of the plurality of microspine hooks of a second microspine wheel assembly (which may or may not be immediately adjacent to the first microspine wheel assembly).
Attention is now drawn to FIG. 3 , which shows microspine hook 220 engaged to an irregularity in a vertical surface 305 . The probability of microspine hook 220 engaging to various irregularities in vertical surface 305 is dependent on various factors, such as the size of microspine hook 220 , shape and stiffness of flexure 215 , engagement angle “θ,” and smoothness/roughness of vertical surface 305 .
Flexible loop element 215 flexes bi-directionally as shown by the pair of bi-directional arrows 301 that is indicative of a compression/expansion action on the part of flexible loop element 215 as microspine wheel assembly 200 rotates in the process of traversing up vertical surface 305 . The compression/expansion action allows the separation distance between attachment location 217 and location 304 to vary, while simultaneously providing other benefits, such as preventing tangling between adjacent microspine wheel assemblies and providing alignment as microspine wheel assembly rotates.
Stretchable attachment 216 accommodates stretching as shown by the bi-directional arrow 303 , thereby allowing the separation distance between attachment location 218 and location 306 to vary as microspine wheel assembly rotates. In addition to providing a stretching action, stretchable attachment 216 also operates as a load bearing member by bearing at least a part of the weight of microspine wheel assembly 200 during certain phases of the rotation of microspine wheel assembly 200 when microspine hook 220 is engaged to the irregularity on vertical surface 305 .
The first flexing action provided by flexible loop element 215 cooperates with the second flexing action provided by stretchable attachment 216 and permits microspine hook 220 to remain engaged with the irregularity through a larger engagement angle “θ” than would be feasible with a rigidly mounted microspine hook. While the embodiment shown in FIG. 2 shows flexure 215 as a c-shaped joint, in other embodiments, the flexing action can be provided using various other mechanisms using elements such as springs, elastomers, and cantilevers.
However, it is desirable to limit the range of engagement angle θ so as to increase the probability of microspine hook 220 engaging to various types of irregularities in various types of climbing surfaces. More particularly, an engagement angle θ ranging from about 30 degrees to about 45 degrees is preferable in order to maximize a ratio of climbing force (F c ) to adhesion force (F a ).
The desirable angular displacement θ range (from about 30 degrees to about 45 degrees) is based on two contributory angles, which are based, at least in part, on selecting suitable values for “l h ” and “h.” Specifically, microspine hook 220 initially engages to the irregularity at a first contributory angle of about 30 degrees that occurs when hook assembly 225 is oriented substantially parallel to vertical surface 305 . This engagement action by microspine hook 220 is followed by a flexing action (indicated by the pair of arrows 301 ) of flexible suspension 210 (as a result of rotation of microspine wheel assembly 200 indicated by arrow 302 ), which results in angular displacement θ increasing by a second contributory angle. The second contributory angle is intentionally constrained to about 15 degrees, so that the sum of the two contributory angles provides an angular displacement θ in the range from about 30 degrees to about 45 degrees.
It will be also pertinent to point out that the engagement characteristic of each individual microspine hook in microspine wheel assembly 200 is independent of other microspine hooks in microspine wheel assembly 200 . Furthermore, each individual microspine hook when engaged to the irregularity in vertical surface 305 can retain grip even when terrain traversing device 100 is deprived of a power source.
In contrast to the desired engagement characteristics described above, disengagement of microspine hook 220 from the irregularity on vertical surface 305 automatically occurs as a result of a decrease in engagement angle θ towards zero when microspine wheel assembly 200 rotates in order to climb up vertical surface 305 .
FIG. 4 shows an exploded view that reveals a few component parts of a terrain traversing device 400 in accordance with the present disclosure. It will be understood that some of the components referred to below are not shown in the drawing because people of ordinary skill in the art will readily understand the nature and characteristics of these components.
Axle 430 is coupled to a central housing 435 in which is housed one or more motors for driving wheel assemblies 405 and 425 . In one embodiment, a first brush motor 436 and a second brush motor 437 are housed in central housing 435 , with each motor individually driving a respective wheel assembly 405 and 425 . Tail assembly 415 , which terminates in a weighted bulb 420 , may house one or more batteries that are used to provide power to the one or more motors in central housing 435 , and may also house additional items such as a radio-frequency (RF) transceiver and a controller unit incorporating a microprocessor or microcontroller. In one embodiment, tail assembly 415 is composed of alternating sections of rigid and elastic materials (indicated by the alternating dark and light bands) that are loosely modeled to vertebrae in a spine. Such an arrangement allows terrain traversing device 400 to bend and twist, thus providing certain advantages during motion, as well as during impact when falling from a height. Various other elements such as cushions, pads, springs, extension arms, and cladding may be incorporated into various parts (e.g., axle, tails section, etc.) of the terrain traversing device 400 in order to protect the device during impact from falls at various heights.
Axle 430 has a modular design and is fabricated using a suitable material having desirable properties such as light weight, durability, and impact absorption. In one implementation, axle 430 is formed of selective laser sintered (SLS) high-elongation polyamide-based materials.
Each of wheel assemblies 405 and 425 is composed of an array of microspine wheel assemblies. More particularly, wheel assembly 425 includes a first microspine wheel assembly 200 a that is mounted adjacent to a second microspine wheel assembly 200 b with a divider disk 426 interposed therebetween. The major surfaces of rotors 205 of each of the first and second microspine wheel assemblies 200 a and 200 b , with divider disk 426 interposed therebetween, are arranged substantially parallel to each other.
Divider disk 426 that is interposed between adjacent pairs of microspine wheel assemblies is operative to provide a separation distance between the microspine hooks of the adjacent microspine wheel assemblies thereby limiting the motion of each microspine hook to a rotary plane and preventing entanglement between the microspine hooks. Divider disk 426 also provides a more even contact surface for the wheel assembly with a horizontal surface when terrain traversing device 400 is traversing the horizontal surface. This is achieved in part by suitably dimensioning divider disk 426 with respect to the microspine wheel assemblies, so as to provide a recessed circumferential slot between two adjacent microspine wheel assemblies. The slot may also accommodate a horizontal flexing action of the microspine hooks without entanglement with other microspine hooks, when terrain traversing device 400 is traversing the horizontal surface. In one embodiment, divider disk 426 is selected to have a thickness of about 0.15 mm.
Divider disk 426 may be alternatively referred to herein as a spacer disk. In one embodiment, the spacer disk is implemented as a separate component independent of the microspine wheel assemblies. In another embodiment, the separation between adjacent microspine wheel assemblies may be provided by providing suitable protrusions on the body of one or both of the microspine wheel assemblies.
FIG. 5 shows a sequential series of figures to illustrate a terrain traversing device transitioning from traversing a horizontal surface to traversing a vertical surface in accordance with the present disclosure. Using a rotary implementation (wheel with microspines) instead of a linear implementation (as in prior art) provides for a symmetrical transition from one traversal plane to another traversal plane, more so when the two planes are angularly oriented with respect to each other. More particularly, the use of wheels equipped with microspines allows the terrain traversing device to transition smoothly and quickly from a horizontal surface to a vertical surface (and vice-versa). In contrast, a linear implementation would entail complex maneuvers that are not only disjointed, but also relatively ineffective, especially when attempting to transition from one traversal plane to an orthogonal traversal plane.
Furthermore, in contrast to prior art wheeled devices, the traversal from the horizontal surface to the vertical surface is not constrained by the diameter of the wheel assemblies In other words, diameter d 1 245 ( FIG. 2 ) may be determined independent of a height dimension of an irregularity in the traversal surface. For example, it is not necessary that the diameter of the wheel assembly be at least, say, 75% of the height of an obstacle to be surmounted. Consequently, in one embodiment, diameter d 1 245 of the circular planar rotor is less than 75% of an object dimension such as for example, a curb height or a step height. However, in another embodiment, diameter d 1 245 of the circular planar rotor is larger than an object dimension such as for example, a protrusion or a crevasse in a wall.
More particularly, in one example application, a terrain traversing device in accordance with the disclosure includes two 10 mm brushed DC motors that provide approximately 0.2 Nm of torque, which is adequate for the terrain traversing device to climb up a vertical surface while having an intrinsic weight of 300 grams and a payload of up to 100 grams. An ATmega328 microcontroller is used to control the rotation of the wheel assemblies based on remote commands, or on input from one or more sensors (not shown). A hybrid open-loop control architecture permits various throttle settings to provide for various torques such a first torque that is desirable for high speed traversal of a horizontal surface and a different torque that is desirable for better control when the terrain traversing device climbs up a vertical surface. A 7.4 V, 180 mAh LiPo battery pack provides approximately 20 minutes of mission life to the terrain traversing device. As can be understood, a higher capacity battery pack may be used instead, thereby incorporating higher weight and reduced speed, in order to obtain a longer mission life.
Furthermore, in this example application, the terrain traversing device can traverse a horizontal surface at a ground speed of about 45 cm/second and climb up a concrete surface having an incline of up to 90 degrees at a climbing speed of about 25 cm/second.
FIG. 6 indicates dimensional values associated with a terrain traversing device shown traversing a step in accordance with the present disclosure. Specifically, as shown, diameter d 1 of the microspine wheel assembly is less than the height “H” of the step. In one implementation, diameter d 1 of the microspine wheel assembly is about 240 mm.
As indicated in the description above, in contrast to prior art devices, traversal from the horizontal surface to the vertical surface is not constrained by the diameter of the wheel assembly. In other words, diameter d 1 may be determined independent of height “H” and it is not necessary that diameter d 1 be at least, say, 75% of height “H” as is the requirement in some prior art implementations. It will be understood however, that in various other implementations, diameter d 1 may turn out to be greater than the height of certain other objects in the traversal path. In contrast to prior art practice, such variances in the terrain surface do not have to be necessarily taken into consideration when selecting diameter d 1 245 .
Attention is now drawn to FIG. 7 , which shows a line drawing indicating various parameters associated with a terrain traversing device when traversing a vertical surface in accordance with the present disclosure. The two-wheeled architecture described using FIGS. 1-6 is selected in part to provide a balance between adhesive forces created by the microspine hooks and the reactive force created by the weighted bulb at the end of the tail assembly. For the quasi-static condition indicated in FIG. 7 , it is desirable that the adhesive force (F a ) be greater than the normal reaction at the tail (F r ) and pitch-back moment. This can be expressed as follows:
F
a
,
maximum
≥
(
Fmg
*
r
)
+
T
l
t
Assuming that the radius (r) of the microspine wheel assembly is constant, the body length (l t ) may be selected so as to obtain a balance between horizontal and vertical traversal performance of the terrain traversal device. The selection of the body length is dependent on a number of factors including the mass of the terrain traversing device, surface conditions, and quality of engagement of the microspine hooks. It may be pertinent to point out that for good purchase may be obtained on certain types of surfaces that are not intrinsically smooth in nature. A few examples of such surfaces include wood, stone, stucco, and concrete surfaces that have irregularities in which the microspine hooks can obtain engagement.
In conclusion, using a rotary motion (rather than a linear dragging motion) for enabling engagement of microspine hooks on a surface (as described herein using a terrain traversal device) not only permits automatic transitioning from traversal of a horizontal surface to traversal of a near-vertical surface without manual intervention, but also permits terrain traversal at speeds higher than those obtainable via legged devices for example. The use of suitably light weight and durable materials for fabricating the terrain traversal device provides durability during impact as a result of a fall from a height, thereby eliminating the need for safety mechanisms or retrieval mechanisms. Furthermore, the terrain traversal device in accordance with the disclosure provides several advantages over prior art devices that are handicapped when traversing certain types of surfaces, such as rough or dusty surfaces (e.g., concrete, stone, etc.).
All patents and publications mentioned in the specification may be indicative of the levels of skill of those skilled in the art to which the disclosure pertains. All references cited in this disclosure are incorporated by reference to the same extent as if each reference had been incorporated by reference in its entirety individually.
It is to be understood that the disclosure is not limited to particular methods or systems, which can, of course, vary. It is also to be understood that the terminology used herein is for the purpose of describing particular embodiments only, and is not intended to be limiting. As used in this specification and the appended claims, the singular forms “a,” “an,” and “the” include plural referents unless the content clearly dictates otherwise. The term “plurality” includes two or more referents unless the content clearly dictates otherwise. Unless defined otherwise, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which the disclosure pertains.
The examples set forth above are provided to give those of ordinary skill in the art a complete disclosure and description of how to make and use the embodiments of the terrain traversal device of the disclosure, and are not intended to limit the scope of what the inventors regard as their disclosure. Modifications of the above-described modes for carrying out the disclosure may be used by persons of skill in the robotic arts, and are intended to be within the scope of the following claims.
A number of embodiments of the disclosure have been described. Nevertheless, it will be understood that various modifications may be made without departing from the spirit and scope of the present disclosure. Accordingly, other embodiments are within the scope of the following claims. | A terrain traversing device includes an annular rotor element with a plurality of co-planar microspine hooks arranged on the periphery of the annular rotor element. Each microspine hook has an independently flexible suspension configuration that permits the microspine hook to initially engage an irregularity in a terrain surface at a preset initial engagement angle and subsequently engage the irregularity with a continuously varying engagement angle when the annular rotor element is rotated for urging the terrain traversing device to traverse a terrain surface. | 1 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to a method of operating a hydro-cyclone and to a hydro-cyclone.
2. Summary of the Invention
In accordance with the invention, there is provided a method of operating a hydro-cyclone comprising
a hollow, round casing having, co-axially in series, a cylindrical portion and a frusto-conical portion, the frusto-conical portion tapering toward one end of the hydro-cyclone;
an end plate closing an axially outer end of the cylindrical portion opposed to said one end;
a tangential inlet into the cylindrical portion;
a co-axial, light fraction outlet through said end plate; and
a co-axial, heavy fraction outlet at said one, taper end of the frusto-conical portion, the method including the step of drawing-off fluid flowing from the inlet inwardly adjacent the end plate.
Such drawing-off may preferably take place annularly outwardly of the light fraction outlet. Preferably, the light fraction outlet will be provided at a position axially spaced from the end plate.
The method may include circulating the drawn-off fluid by conducting it to a feed stream upstream of the inlet. Instead, the method may include conducting the drawn-off fluid to an underflow downstream of the heavy fraction outlet.
The invention extends to a hydro-cyclone comprising
a hollow, round casing having, co-axially in series, a cylindrical portion and a frusto-conical portion, the frusto-conical portion tapering toward one end of the hydro-cyclone;
an end plate closing an outer end of the cylindrical portion opposed to said one end;
a tangential inlet into the cylindrical portion;
a co-axial, light fraction outlet through said end plate;
a co-axial, heavy fraction outlet at said one, taper end of the frusto-conical portion; and
a circulation outlet in the end plate arranged to draw-off fluid flowing in use from the inlet inwardly adjacent the end plate.
Preferably, the circulation outlet is arranged annularly outwardly of the light fraction outlet. The circulation outlet may be substantially at the level of or in the plane of the end plate, the light fraction outlet being provided by a porthole in the cylindrical portion axially spaced from the end plate.
The circulation outlet may be in communication with a plenum downstream thereof. The plenum may be connected to a feed passage upstream of the tangential inlet. Instead, the plenum may be connected to an underflow passage downstream of the heavy fraction outlet.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention is now described by way of example wit reference to the accompanying diagrammatic drawings. In the drawings,
FIG. 1 shows, in axial section, a hydro-cyclone in accordance with the invention; and
FIG. 2 shows a graph comparing reduced grade efficiency or Tromp curves for a cyclone in accordance with the invention and a conventional cyclone.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
With reference to FIG. 1 of the drawings, a hydro-cyclone in accordance with the invention is generally indicated by reference numeral 10. It comprises a casing generally indicated by reference numeral 12.
The casing 12 is of hollow, round construction and includes, extending from a position near one end of the hydro-cyclone to an intermediate position, a cylindrical wall 14 having a corresponding cylindrical inner periphery 16 defining a cylindrical volume 18. The casing 12 has a frusto-conical wall 20 extending coaxially from the inner end of the cylindrical wall 14 toward the opposed end of the hydro-cyclone 10. The frusto-conical wall 20 has a corresponding frusto-conical inner periphery 22 defining a corresponding frusto-conical volume 24.
Toward the first mentioned end of the hydro-cyclone 10, there is provided a transverse end plate 26 or disc to close the outer end of the cylindrical volume 18. A co-axially arranged tube 28 extends through the end plate 26 and penetrates into the cylindrical volume 18 to form a co-axial light fraction outlet port 29 remote from the end plate 26 and from which an overflow will emit in use.
At the opposed end, the frusto-conical wall 20 terminates to form a co-axial heavy fraction outlet 30 from which an underflow will emit in use.
In the cylindrical volume 18, there is provided an inlet 32 orientated tangentially with respect to the cylindrical volume 18, via which a feed stream will enter in use.
In the end plate 26, annularly outwardly of the periphery of the tube 28, there is provided a coaxial, annular circulation outlet 34 leading into a plenum 36. The outlet 34 is shown to be frusto-conical in FIG. 1. Instead, as preferred in many applications, it may be parallel. The plenum 36 is defined by an extension 38 of the casing 12. The extension 38 is conveniently integral with the rest of the casing 12. The extension 38 comprises a cylindrical wall 40 co-extensive with the cylindrical wall 14 and an inwardly extending boss 42 having a central aperture 44 in which the tube 28 is sealingly received by means of "O"-rings 46.
A circumferential outlet 48 is provided from the plenum 36 via a nipple 50 mounted in an outlet aperture in the cylindrical wall 40. A conduit will in use be provided over the nipple 50 to conduct fluid from the plenum 36. The conduit may, for example, conduct such fluid to the feed stream upstream of the inlet 32, or, if desired and if process circumstances permit, to the underflow downstream of the heavy fraction outlet 30.
The inventors do not wish to be bound by theory. However, the inventors believe that a theoretical explanation of flow in the region downstream of the inlet 32 will enhance an understanding of the instant invention.
It is to be appreciated that flow downstream of the inlet 32 in the cylindrical volume 18 is rotating flow. In a rotating flow field a pressure gradient exists which increases with radius i.e. the static pressure in the flow field at a large radius is larger than at a small radius. Thus, purely on account of such pressure gradient, flow will tend to move radially inwardly.
On account of the rotating nature of the flow, centrifugal forces act on flow elements tending to urge such flow elements outwardly.
On flow elements or particles of a high density, the centrifugal forces (which are a function of the mass of the flow elements or particles) tend to dominate because of the high mass : volume ratio of the dense flow element or particle and tend to move such flow element or particle outwardly.
Conversely, on flow elements or particles of low density, which have a low mass : volume ratio, the pressure forces tend to dominate and tend to move such light flow elements or particles inwardly.
The hydro-cyclone operates in accordance with the above principles. Flow containing flow elements or particles of both high and low density enter the cylindrical volume 18 tangentially via the inlet 32 thus establishing a rotating flow field in the cylindrical portion 18. The general flow pattern is away from the inlet on account of continued inflow through the inlet. Dense particles and flow elements concentrate toward the outer peripheral portion and move downwardly along the taper periphery 22 toward the heavy fraction outlet 30. Particles and flow elements of lower density tend to concentrate toward the axis of the cyclone.
The "cut" of the cyclone (i.e. the proportions of flow respectively through the light fraction outlet and through the inlet) may be controlled by suitable geometric design or by controlling the respective flows by means of valves, or by a combination thereof. Generally by far the larger proportion of flow takes place through the light fraction outlet, i.e. the overflow. Thus, flow elements and particles, especially toward the centre of the cyclone and toward the tapered end of the tapered volume 24, experience a pressure gradient urging them to flow toward the light fraction outlet. They thus undergo a flow reversal in respect of their flow component in the axial direction.
It is, however, to be appreciated that when a flow element or a particle in a rotating flow field impinges on an obstruction or when it is decelerated, such as in the boundary layer adjacent the end plate 26, the rotational component of the flow is destroyed or retarded, thus obviating or lowering the centrifugal forces while the pressure gradient is upheld. Thus, because of the pressure gradient, and regardless of density, flow elements and particles tend to move inwardly toward the axis of the cyclone.
Assume for a moment that the annular circulation outlet 34 is blocked or does not exist. Then, the inward flow in or adjacent the boundary layer of the end plate 26 will move to an annular position near the tube 28 and thence downwardly toward the light fraction outlet 29. In this fashion, undesirably, also flow elements or particles of high density exit via the light fraction outlet 29. This tendency detrimentally affects the operation of the cyclone 10. The detrimental affect described above is worse when the tube 28 extends only a small distance, or not at all, into the cylindrical volume 18. The detrimental affect is somewhat ameliorated, but only to a limited extent, if the tube 28 extends well into the cylindrical volume 18.
However, in accordance with the invention, and bearing in mind the existence of the annular circulation outlet 34, the undesirable flow described above exits via the annular circulation outlet 34 into the plenum 36 from where it is circulated either to a position upstream of the inlet 32 where it is introduced into the feedstream, or is introduced into the underflow downstream of the heavy fraction outlet 30 if circumstances are suitable, or is conducted to any other desirable reservoir or the like.
The Inventors have found in tests that the undesirable flow in or adjacent to the boundary layer of the end plate 26 is proportional to the cyclone diameter (D c ), the viscosity (μ) of the flow medium (slurry or particle containing gas stream) and the spin Reynolds number (Re.sub.θ which is defined in terms of the cyclone radius D c /2 and average inlet velocity) raised to a power of about 0.8, i.e. ##EQU1##
The value of the "constant" c varies between narrow limits with pressure ratio and is dependant from the general geometry of the cyclone. The value of c for a cyclone of specified geometric can be established experimentally.
Thus, a desired mass flow through the annular circulation outlet 34 can be pre-calculated. In practice, the mass flow through the circulation outlet can be controlled, e.g. by means of a valve downstream of the plenum 36.
The annular circulation outlet 34 should be of sufficient flow area to permit the specific boundary layer volume flow for the particular application to be extracted without preferential extraction of particles of a particular size. Desirably, the flow speed through the outlet 34 should be of the same order as flow speeds through the heavy fraction outlet 30 and the light fraction outlet 29.
With reference to FIG. 2 of the drawings, Reduced Grade Efficiency or Tromp curves are shown which were obtained respectively for a hydrocyclone in accordance with the invention and for the same hydrocyclone, but operated conventionally, i.e. without circulation via the outlet 34.
Plot 60 shows the performance of the cyclone operated conventionally. Plot 62 shows the performance of the cyclone operated in accordance with the invention. The Plots 60 and 62 are to be compared to a theoretically ideal curve described below.
Assume that the cyclone is to have a cut at a particle size of 8 micrometer. This theoretical cut is shown in dotted at 66. The 100% efficiency line is shown at 68. Ideally, all particles to the right of the cut line 66, i.e. particles larger than 8 micrometer, are separated from all particles to the left of the cut line 66, i.e. particles smaller than 8 micrometer.
For the sake of comparison, assume that the cut line 66 intersects both the plots 60 and 62 at the 50% reduced efficiency point at 64.
The area above the cut point 64 and between the plot 60 and the ideal curve 66, 68 is indicative of the degree of contamination of the light flowstream by particles larger than 8 micrometer, for the cyclone operated conventionally.
Similarly the corresponding area above the plot 62 is indicative of the degree of contamination in respect of the cyclone when operated in accordance with the invention.
It is clear that the contamination in the case of the plot 62 is a marked improvement on that of the plot 60.
By way of example the Inventors have found that in a standard 2" Mosley hydrocyclone of 44 mm diameter operating at a pressure drop of about 200 kPa with a 10% (by volume) slurry of fluorspar of 45 micrometer median particle size, a circulation flow of 25% of the inlet flow results in a decrease in the contamination of the overflow stream by particles greater than the cutsize to between about 25% and about 50% of the contamination of a comparable conventional non-circulating cyclone. Differently stated the area above the reduced grade efficiency or Tromp curve can likewise be reduced to an area between about 25% and about 50% of that of a comparable conventional cyclone by the circulation of 25% of the feedflow.
In the example mentioned, the Inlet 32 was 9,5 mm×6,5 mm, the outlet diameter 30 was 9,5 mm and the outlet diameter 29 was 10 mm.
The applicant is of opinion that it is an advantage of the invention that misplacement of denser particles or flow elements is ameliorated and that the grade efficiency curve of the cyclone is sharpened or improved. Generally, the cyclone is able to classify the flow more accurately. | A hydro-cyclone includes a hollow round casing having, co-axially in series, a cylindrical portion and a frusto-conical portion tapering toward one end of the cyclone. An end plate closes off the cylindrical portion opposed to the taper end. A tangential inlet conducts a fluid flow stream to be classified tangentially into the cylindrical portion. A co-axial, heavy fraction outlet is provided at the taper end. A co-axial, light fraction outlet is provided through the end plate, preferably via a porthole in the cylindrical portion axially spaced from the end plate. The invention provides for drawing-off of fluid flowing from the inlet inwardly in a boundary layer adjacent the end plate via a circulation outlet in the end plate, preferably annularly around the light fraction outlet. | 1 |
FIELD OF THE INVENTION
The present invention relates to a high-profile prosthetic foot that provides up to 180° of medial-lateral rotation with respect to the prosthesis frame and also provides energy storage capabilities. The present invention further relates to a prosthetic ankle joint having an adjustable range of medial-lateral rotation about the prosthesis frame.
BACKGROUND OF THE INVENTION
A prosthetic foot must provide stable support to the user under a variety of conditions. Such conditions include a variable stride and a range of different activities. In particular, a prosthetic foot has long been sought that can provide stable support for a user who is walking on an ever changing terrain, such as that encountered in normal daily activity. To achieve this objective, a prosthetic foot would ideally provide a range of motion in a medial-lateral direction. It is also desirable that the prosthetic foot has energy storage capabilities to provide a more normal gait.
Dynamic response prosthetic feet are preferred for active amputees. The energy storage capabilities of the feet give them a spring-like functionality, which improves the feel and overall function of the prostheses. Two widely used types of prosthetic feet are high profile dynamic feet and low profile multiaxial feet.
High profile dynamic feet consist of a long L-shaped piece of material attached to a base plate. The L-shaped piece of material may be alternatively referred to as a frame. Typically, the frame is elastic and therefore provides some energy storage capability. Generally, the frame is a composite, such as a carbon fiber laminate or a polymeric material. At present, all high profile dynamic feet have a rectangular cross section relative to the frame and therefore movement of the footplate is typically limited. Such high profile dynamic feet have advantages because of their high-energy storage capability. High-energy storage occurs in the frame of the prosthesis. High profile dynamic feet have the longest frame, and thus act as the biggest springs and, accordingly, store the most energy. However, high profile dynamic feet also present some drawbacks. Principally, the high profile dynamic feet have no ankle motion and therefore are not capable to conforming to a changing terrain. The foot portion of a high profile dynamic foot stays in the same position relative to the frame regardless of whether the amputee is walking on an incline, walking on uneven terrain or moving in a side-to-side direction.
The multiaxial dynamic feet of the prior art attempt to simulate motion of the ankle and are generally considered more stable than high profile dynamic feet. A disadvantage of the multiaxial dynamic foot is that generally it is a low profile prosthesis. By comparison to the high profile dynamic feet, low profile multiaxial dynamic feet can only store energy in their keel, which is a much smaller frame and, thus, a much smaller spring. Accordingly, there is correspondingly less energy storage. Therefore, with the prior art devices, there presently is a tradeoff between increased stability and improved energy storage capability.
Typically, the multiaxial feet of the prior art possess an axis of rotation through the ankle joint that lies transverse to the normal anterior-posterior alignment of the foot. Subsequently, such multiaxial prosthetic feet, although typically providing a range of rotation in an anterior-posterior direction, have limited freedom to move in a medial-lateral direction. Subsequently, the prior art multiaxial feet typically only allow a small amount of medial-lateral tilt and do not allow true rotation in the medial-lateral direction. Tilt is distinguishable from true rotation in that tilt may occur along any of a multitude of axes, whereas rotation occurs about one axis. Tilt may also be described as wobble. Typically, in the prior art devices, the amount of medial-lateral tilt is a consequence of some looseness in the ankle joint. This looseness is generally accomplished through the use of an elastomeric member in the ankle joint, which member can then compress to a limited degree, thus accommodating medial-lateral tilt. However, it can be difficult to control the tilting motion. Generally, the prior art devices do not possess an axis of rotation through an ankle joint where the axis of rotation lies in the anterior-posterior direction. Furthermore, elastomeric member tends to wear out.
Some of the prior art prosthetic feet provide a range of motion in an anterior-posterior direction. Providing this range of motion is accomplished, for example, by providing a flexible foot that includes an ankle member that flexes in the anterior-posterior direction. Another prior art device provides anterior-posterior motion by using a very high modulus material that permits limited deformation under a high load. This high modulus elastic material is typically positioned between the foot and the frame. As the load on the frame changes during the normal transfer of weight that occurs during walking, the high modulus elastic material flexes to a limited extent. Still another prior device uses an o-ring positioned at the end of the frame where the frame connects to the foot. This o-ring is typically made of a high modulus material and will deform to a limited extent as weight is transferred during a normal stride.
Typical among the devices that rely on a high modulus elastic material for flexibility, the range of motion is necessarily limited. If the material forming at least part of the connection between the frame and the foot has too low a modulus, then control over the foot during normal walking will be compromised. Some of the prior art suggests that a limited degree of medial-lateral movement will occur as a result of the compression of the high modulus elastomeric material positioned between the frame and the foot. Such movement has been described in the art as a slight rocking or a slight tilting motion. The prior art further teaches that although some medial-lateral rocking motion can be accomplished, generally, medial-lateral movement is resisted.
Still another prior art device provides an elastomeric bushing about a heel ankle connector pin. As with the other prior art devices already described, this bushing material is a high modulus elastomer. Accordingly, some compression of the elastomer may take place during the normal weight transfer accompanying walking and result in a small amount of medial-lateral tilt or wobble. As provided above, prostheses that rely on a high modulus elastic material for flexibility tend to have a problem with durability because they wear out with repeated loading and unloading.
Lack of a true hinge allowing rotation in the medial-lateral direction is a disadvantage. True control of movement in a medial-lateral direction about a unitary axis is difficult to achieve in the prior art devices. Any medial-lateral movement in these devices is limited to a tilting movement. This tilting movement can occur along any of an infinite number of axes. Because it is not possible to control every possible axis along which the prior art foot may move, medial-lateral directional control can be difficult to achieve and, therefore, medial-lateral movement is typically constrained. Not surprisingly, the prior art devices limit a full range of medial-lateral movement. For example, in many prior art multiaxial feet, movement of the foot occurs through compression of an elastomeric pad positioned in the ankle region of the foot. Thus in order to provide movement of the foot in a medial-lateral direction the entire elastomeric pad must be of a modulus that affects movement in all directions. In such a multiaxial foot, there is no independent control over movement in a singular direction or line of action.
It would therefore be an advantage to have a prosthetic foot that offered the stability advantages of a multiaxial dynamic foot with the energy storage capabilities of a high profile dynamic foot. It would be an even further advantage to have a prosthetic foot that allows true medial-lateral rotation. It would be at an even further advantage to have an adjustable prosthetic foot that would allow the manufacturer or wearer to select a range of medial-lateral rotation best suited to a wearer's needs.
It would be an even further advantage to have a high profile multiaxial prosthetic foot that could allow free rotation about an axis that lies in the anterior-posterior direction.
SUMMARY OF THE INVENTION
In accordance with the principals of the present invention, there is provided a high profile multiaxial prosthetic foot providing rotation of a footplate in a medial-lateral direction. According to one embodiment, the high profile multiaxial prosthetic foot includes a tubular frame connected to a footplate using a spring connector. In embodiments of the present invention, the spring connector may include a high modulus elastic material, a torsional spring or combinations of these. Thus, the present invention provides a high profile multiaxial prosthetic foot that includes a high profile component and a multiaxial component.
The present invention also provides a high profile multiaxial dynamic prosthetic foot having an adjustable range of medial-lateral rotation. The medial-lateral rotation of the prosthetic foot of the present invention may be adjusted to accommodate the individual needs of the wearer.
The present invention provides a prosthetic foot including: a frame having a first axis and a second axis; a connector connected to the frame, the connector being adapted to rotate about the first axis; and a footplate attached to the connector.
Thus, it will be seen that according to principals of the present invention there is provided a prosthetic foot that provides both the energy storage capabilities of a high profile prosthesis with the stability of a multiaxial prosthesis. The high profile multiaxial prosthetic foot of the present invention provides medial-lateral rotation as compared to the slight medial-lateral tilting or rocking of the prior art devices. In a preferred embodiment, the medial-lateral rotation is controlled about a unitary axis. Furthermore, the high profile multiaxial prosthetic foot of the present invention provides a true hinge in the ankle joint region.
Embodiments of the present invention further provide a high profile multiaxial prosthetic foot having an ankle joint wherein the axis of rotation lies along the longitudinal axis of the foot. The prosthetic foot of the present invention further provides the capability of free rotation about the ankle joint about its axis of rotation.
DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side view of an embodiment of the high profile multiaxial prosthetic foot made in accordance with the principles of the present invention.
FIG. 2 is a schematic showing an end view of the high profile multiaxial prosthetic foot of FIG. 1 .
FIG. 3 is a side view of the frame of FIG. 1 .
FIG. 4 is an end view of one embodiment of a frame/connector/footplate assembly made in accordance with the principles of the present invention.
FIG. 5 is an end view of an alternative embodiment of a frame/connector/footplate assembly made in accordance with the principles of the present invention.
FIG. 6 is another embodiment of a frame/connector/footplate assembly made in accordance with the principles of the present invention.
FIG. 7 is an end cross-sectional view of another embodiment of a high profile multiaxial prosthetic foot made in accordance with the principles of the present invention.
FIG. 8 is an end cross-sectional view of the high profile multiaxial prosthetic foot made in accordance with the principles of the present invention illustrating means for rotation control.
FIG. 9 is an embodiment of a high profile multiaxial prosthetic foot made in accordance with the principles of the present invention showing alternate connector means and means for rotation control.
FIG. 10 is a side view of still another embodiment of a high profile multiaxial prosthetic foot made in accordance with the principles of the present invention.
FIG. 11 is a side view of still another embodiment of a high profile multiaxial prosthetic foot made in accordance with the principles of the present invention.
FIG. 12 is an end view of a high profile multiaxial prosthetic foot made in accordance with the principles of the present invention showing rotation of the prosthetic foot about an axis aligned with the longitudinal axis of the foot.
FIG. 13 is an end view of a high profile multiaxial prosthetic foot made in accordance with the principles of the present invention showing rotation of the prosthetic foot about an axis aligned with the longitudinal axis of the foot.
FIG. 14 a is a side view of a high profile multiaxial prosthetic foot made in accordance with the principles of the present invention showing an adjustable displacement of a frame with respect to the foot.
FIG. 14 b is a side view of a high profile multiaxial prosthetic foot made in accordance with the principles of the present invention showing an adjustable displacement of a frame with respect to the foot.
FIG. 15 is an end view of a high profile multiaxial prosthetic foot made in accordance with the principles of the present invention showing the displacement of a frame with respect to the vertical alignment of a residual limb.
DETAILED DESCRIPTION OF THE INVENTION
In FIG. 1 , a high profile multiaxial prosthetic foot (“prosthetic foot”) made in accordance with the principles of the present invention is labeled 10 . The prosthetic foot 10 includes a frame 12 , a connector 15 and a footplate 19 . An upper portion of the frame 12 may be connected to socket (not shown) that is connected to a leg of the human wearer of the prosthetic foot 10 and a lower portion of the frame 12 is adapted to connect to the footplate 19 . In a preferred embodiment, the frame 12 has a generally circular cross-section. Of course, other suitable cross-sections may be used. The connector 15 is adapted to allow rotation of the frame 12 about an axis that is aligned with the longitudinal axis of the footplate 19 . As shown in FIG. 2 , an ankle joint 23 defines the connection between the frame 12 and the connector 15 . The footplate 19 is attached to the connector 15 , and, preferably, the footplate 19 is rigidly attached to the connector 15 . Thus, it can be seen that the footplate 19 is free to rotate about an axis defined by the ankle joint 23 , the axis of rotation lying along the longitudinal axis of the footplate 19 and the lower portion of the frame 12 . The prosthetic foot 10 may also be adapted for anterior-posterior movement, by, for example, providing means for the elastic deformation of the connector 15 , the frame 12 , and/or the footplate 19 . Thus, the prosthetic foot 10 may provide multiaxial movement.
The frame may be constructed of a high strength polymer or a composite material such as a carbon fiber laminate, for example. In a preferred embodiment, the frame is an L-shaped member. Being a generally L-shaped member, the frame defines a first axis and a second axis. The footplate may also be constructed of a high strength polymer or a composite material such as a carbon fiber laminate.
In FIG. 3 , the frame 12 is depicted removed from the connector 15 . The frame 12 may be described as having a generally long axis L 1 along the upper portion of the frame 12 and a generally short axis S 1 along the lower portion of the frame 12 , however, long axis L 1 and short axis S 1 may be of any length as required by a wearer of the prosthetic foot 10 . The short axis S 1 is connected to the connector 15 through the ankle joint 23 . In one embodiment, when the prosthetic foot 10 is assembled, the short axis S 1 is aligned with the longitudinal axis of the footplate 19 .
FIGS. 4 , 5 and 6 show alternative embodiments of the present invention and more particularly, show alternative means for connecting a frame to a footplate. In FIG. 4 , a frame 42 is connected to a connector 45 through an ankle joint 43 . The connector 45 may be any general shape so long as it does not preclude the utility of the prosthetic foot 10 . The connector 45 is generally configured so that it may provide an ankle joint 43 having an axis of rotation that lies along an anterior-posterior direction. The connector 45 is attached to the footplate 49 . In this embodiment, the connector 45 is adapted to frictionally receive the frame 42 . Thus, medial-lateral rotation of the frame 42 about its short axis is limited by the coefficient of friction existing between the connector 45 and the frame 42 at the ankle joint 43 . The connector 45 may be made of any suitable material that preserves the functionally of the prosthetic foot 10 . For example, a high strength polymer, a carbon fiber laminate or a high modulus elastomeric material may be used for the connector 45 . A high modulus elastomeric material, for example, may allow movement of the footplate 49 in an anterior-posterior direction via compression of the connector 45 .
In FIG. 5 , an alternative embodiment of the connector of the present invention is illustrated. Frame 52 is connected to a spring 55 through an ankle joint 53 . Spring 55 is then attached to a footplate 59 . In the embodiment depicted in FIG. 5 , connector 55 is in the form of a torsional spring. However, other spring designs, such as a leaf spring, may be used. The spring 55 is generally configured so that it may provide an ankle joint 43 having an axis of rotation that lies along an anterior-posterior direction. The spring 55 may be constructed of a carbon fiber laminate or metal, for example. Thus, the amount of rotation of the footplate 59 about the ankle joint 53 may be limited by the spring constant for the spring 55 . In this embodiment, it is preferred that the frame 52 be fixedly attached to the spring 55 at the ankle joint 53 . However, it may possible to allow rotation of the short axis of the frame 52 within the ankle joint 53 with respect to the spring 55 , by providing that the spring 55 is adapted to frictionally receive the frame 52 . Thus, the amount of rotation of the footplate 59 about the ankle joint 53 is limited both by the coefficient of friction existing between the short axis of the frame 52 and the spring 55 at the ankle joint 53 and also the spring constant of the spring 55 .
In FIG. 6 , yet another embodiment of a frame/connector/footplate assembly made in accordance with the principles of the present invention illustrated. In FIG. 6 , a frame 62 is connected to a spring 65 at an ankle joint 63 . In the embodiment depicted in FIG. 6 , spring 65 is in the form of a torsional spring. However, other spring designs, such as a leaf spring, may be used. The spring 65 is generally configured so that it may provide an ankle joint 63 having an axis of rotation that lies along the short axis of the frame 62 . The spring 65 may be constructed of a carbon fiber laminate or metal, for example. Thus, the amount of rotation of the footplate 69 about the ankle joint 63 may be limited by the spring constant for the spring 65 . In this embodiment, a connector 64 is also used. The spring 65 and the connector 64 are both attached to the footplate 69 . Rotation of the frame 62 within the ankle joint 63 may be constrained by providing that the spring 65 is adapted to frictionally receive the frame 62 . Rotation of the frame 62 within the connector 64 may be constrained by providing that the connector 64 is adapted to frictionally receive the frame 62 . The rotation of the footplate 69 may be limited by the coefficient of friction between the frame 62 and the spring 65 , the coefficient of friction between the frame 62 and the connector 64 , or the spring constant of the spring 65 , or combinations thereof.
In FIG. 7 , a cross-sectional end view of a high profile multiaxial prosthetic foot 70 is shown. In this embodiment, the frame 72 is connected to a spring 74 by a setscrew 73 . The setscrew 73 may fixedly attach the spring 74 to the frame 72 and limit or even prevent the rotation of the frame 72 within the spring 74 . A connector 75 is adapted to rotationally receive the frame 72 . The connector 75 is attached to the footplate 79 . The spring 74 may abut the footplate 79 .
In FIG. 8 , a cross-sectional end view of another embodiment of a prosthetic foot of the present invention is shown. In this embodiment, a control element 81 is adapted to receive a frame 82 . Rotation stop 87 , 88 extend from control element 81 . Also shown are a connector 85 and a footplate 89 . The rotation of the footplate 89 about its axis is limited by the rotation stop 87 , 88 . The footplate 89 may rotate either clockwise or counter-clockwise until reaching the rotation stop 87 , 88 . It will be recognized that there are other adaptations of the rotation adjustment means provided by the rotation stop 87 , 88 and the control element 81 . The structure of the rotation stop 87 , 88 and the control element 81 , and the related function of rotation control, are further described below with respect to FIG. 9 .
In FIG. 9 , a side-view of a prosthetic foot incorporating a connector 75 , a spring 74 and a control element 81 . The frame 72 is connected to a spring 74 by a setscrew 73 . The connector 75 is adapted to rotationally receive the frame 72 . The connector 75 is also attached to the footplate 79 in a known manner. The spring 74 may abut the footplate 79 . The control element 81 is adapted to receive the frame 72 . In the preferred embodiment, the control element 81 is rigidly attached to the frame 72 . The control element includes a rotation stop 87 . The rotation of the footplate 89 about its axis is limited by the rotation stop 87 . A second rotation stop may be included as described above. The footplate 89 may rotate either clockwise or counter-clockwise until reaching a rotation stop.
In FIG. 10 , yet another embodiment of a prosthetic foot of the present invention is illustrated. In this embodiment, a frame 112 is connected to a connector 115 , which in turn is attached to a footplate 119 . In this embodiment, the footplate 119 is formed to allow the use of a frame 112 wherein the angle between the short axis and the long axis of the frame 112 is greater than 90°.
In FIG. 11 , yet another embodiment of a prosthetic foot of the present invention is illustrated. In this embodiment, a frame 112 is rotatably connected to a connector 115 , which in turn is fixedly attached to a footplate 119 . The frame 112 is connected to a spring 114 . The spring 114 may abut the footplate 119 . In this embodiment, the footplate 119 is formed to allow the use of a frame 112 wherein the angle between the short axis and the long axis of the frame 112 is greater than 90°.
FIG. 12 illustrates the ability of a prosthetic foot made in accordance with the principles of the present invention to provide medial-lateral rotation. In FIG. 12 , an end view of the prosthetic foot 10 is shown. As described in the previous embodiments, a frame 12 is connected to a connector 15 at an ankle joint 13 with the connector 15 being attached to a footplate 19 . In FIG. 12 , the prosthetic foot is positioned on an inclined plane 11 . This is analogous to a wearer of a prosthetic foot standing sideways on a hill. Thus, the longitudinal axis of the footplate 19 is transverse to the direction of incline of the incline plane 11 . It can be seen that the high profile multiaxial prosthetic foot of the present invention allows rotation in a medial-lateral direction, thus, stabilizing the footplate 19 in such a position.
FIG. 13 likewise illustrates an embodiment of a prosthetic foot of the present invention positioned on an inclined plane 11 . In FIG. 13 , there is further defined an angle θ. The angle θ is the angle formed between the plane of the incline and the long axis of the frame 12 . Because of the orientation of the ankle joint 13 , θ may effectively vary between 0 and 180°.
The prosthetic foot of the present invention may be adapted to provide adjustment of a frame with respect to a connector and a footplate. In FIG. 14 a and FIG. 14 b , for example, a frame 112 is shown connected to a connector 115 . The connector 115 is attached to a footplate 119 . One end of the footplate 119 defines an imaginary vertical line v. A distance x 1 is defined by the separation distance between v and the long axis of the frame 112 . By positioning the long axis of the frame 112 closer to the connector 115 a second distance x 2 may be defined between v and the long axis of the frame 112 . The distance x 1 is less than the distance x 2 . Thus, the position of the long axis of the frame 112 may be adjusted with respect to the connector 115 and the footplate 119 . Along its longitudinal axis, the footplate 119 defines a first end and a second end. Thus the position of the long axis of the frame 112 may be adjustably located with respect to the first end or the second end of the footplate 119 . The adjustable positioning of the frame 112 with respect to the footplate 119 may accomplished, for example, by adjustably connecting the frame 112 to the connector 115 . Thus, the short axis of the frame 112 may be moved to a desired position along the longitudinal axis of the footplate 119 and then fixed in position by the connector 115 with respect to further movement along the longitudinal axis of the footplate. Referring to FIG. 7 , in one embodiment for example, the frame 72 may be adjustably positioned with respect to the footplate 79 as described above and this position fixed by tightening setscrew 73 .
In FIG. 15 , for example, a frame 112 is shown connected to a connector 115 . The connector 115 is attached to a footplate 119 . Further illustrated is a residual limb 120 . As known in the art, the residual limb is attached to a socket that is attached to the frame 112 . The residual limb 120 defines a generally vertical axis v 1 . An angle θ 1 is defined by the long axis of the frame 112 and v 1 . Thus it can be seen that θ 1 may be varied to allow the residual limb 120 to be offset with respect to the footplate 119 . The footplate 119 can be seen to also define a top plane and a bottom plane. As illustrated in FIG. 15 , the connector 115 is attached to the footplate 119 at the top plane of the footplate 119 . Thus, the long axis of the frame 112 may be adjustably positioned with respect to the top plane so that the long axis defines an angle with respect to the top plane that is different than 90°. Referring to FIG. 7 , in one embodiment for example, the frame 72 may be adjustably positioned with respect to the footplate 79 as described above and this position fixed by tightening setscrew 73 .
As is known in the art, the footplate of the prosthetic foot of the present invention may be covered with an anthropomorphic flexible polymer in the shape of a foot.
The high profile multiaxial prosthetic foot made in accordance with the principles of the present invention allows free rotation of a prosthetic footplate about an axis that lies along the longitudinal axis of the footplate. Thus, such a prosthetic foot provides free rotation from 0 to 180° in a medial-lateral direction. A high profile multiaxial prosthetic foot made in accordance with the principles of the present invention further provides means to control the amount of rotation of the footplate. Thus, the present invention provides a high profile multiaxial prosthetic foot that allows true medial-lateral rotation as opposed to mere medial-lateral tilt.
There has been provided in accordance with the present invention, a high profile multiaxial prosthetic foot providing stability for the user in conditions requiring medial-lateral rotation. While the invention has been described with specific embodiments, many alternatives, modifications and variations will be apparent to those skilled in the art in light of the forgoing description. Accordingly, it is intended to include all such alternatives, modifications and variations set forth within the spirit and scope of the appended claims. | The present invention provides a prosthetic foot that provides both energy storage capabilities and stability. The prosthetic foot of the present invention provides medial-lateral rotation as compared to the slight tilting or rocking in the medial-lateral plane of the prior art devices. Furthermore, the prosthetic foot of the present invention provides a true hinge in the ankle joint region that may be adapted so that the degree of rotation is controlled. | 0 |
FIELD OF THE INVENTION
This invention relates generally to a display rack for supporting and displaying articles, and more particularly to a multi-shelf display rack made of corrugated paper, wherein a plurality of shelves are mounted on a support frame having only two walls extending at an angle to one another with the shelves mounted between them so that two sides of the shelves are exposed for enhanced visibility of and access to articles on the shelves.
BACKGROUND OF THE INVENTION
A large variety of display stands and racks with multiple shelves are known in the prior art for supporting and displaying articles, and especially for displaying articles at a point of sale. Many of these display racks are made of corrugated material, but they typically have a back wall and two side walls, so that only one edge of the shelves is exposed. Other display stands or racks are made of wood or metal and some of these have only two angularly disposed support walls so that a substantial edge portion of the shelves is exposed. Other display racks commonly used are made of metal and have only one support wall, with hooks or other support structure mounted to the wall for supporting articles for display.
The following patents are exemplary of prior art systems. U.S. Pat. No. 1,852,471 discloses a display rack system made of paperboard in which the ends of shelves are engaged in openings in the support frame, but only one edge of the shelves is exposed and they are not cantilevered. U.S. Pat. No. 3,656,611 discloses a cabinet-like display rack wherein portions of the corners of the frame are turned inwardly to provide an abutment on which four corners of the shelves are supported. U.S. Pat. No. 3,860,305 discloses a cabinet-like display rack wherein portions of the corners of the frame are turned inwardly to define guides for vertical rods that support four corners of shelves having only one edge exposed. U.S. Pat. No. 4,763,579 discloses a shelf system for mounting in a corner, wherein the shelves are cantilevered from a combination of horizontal and vertical supports at three of the corners, and two edges of the shelves are exposed. U.S. Pat. No. 5,669,683 discloses a corrugated display shelf assembly in which tabs on the back edge and ends of the shelves are engaged in slots in the support frame. Only one edge of the shelves is exposed. U.S. Pat. No. 6,135,033 discloses corrugated paper shelves folded to have triangular reinforcing structure along opposite edges. U.S. Pat. No. 7,252,200 discloses a display system with portions made of corrugated paper and wherein tabs on the display shelf trays engage in slots in the support frame. The shelf trays are made of injected plastic and are supported at three edges, with only one edge exposed. U.S. Pat. No. 3,766,864 discloses a display system in which two edges of the shelves are exposed but they are supported along all four edges and the support is accordion-folded to define a plurality of adjacent spaces in which shelves are supported.
None of the display racks or stands known to applicant is made of corrugated paper material wherein the support has only two walls joined at an angle and has openings therein for receiving three corners of reinforced shelves so that the shelves are cantilevered from the support with two edges exposed.
Accordingly, it would be desirable to provide a display rack made fully of recyclable corrugated paper material wherein the support has only two walls joined at an angle and has openings therein for receiving three corners of reinforced shelves so that the shelves are cantilevered from the support with two edges exposed.
SUMMARY OF THE INVENTION
The present invention comprises a display rack comprising a support frame with a plurality of shelves supported thereon, wherein the rack is made of fully recyclable corrugated paper material. The support frame has only two walls, said walls extending at an angle to one another from a narrow strip at the rear corner of the frame and having forward free edges with tubular reinforcing structure extending along their length. A plurality of shelves is supported on the support frame between the two walls so that a forward portion of the shelves projects beyond the walls to provide greater visibility of and access to articles supported on the shelves. The display rack is free standing and may be used alone or in combination with other like racks. For example, multiple racks may be placed back-to-back in combinations of two, three or four racks.
More specifically, the walls extend perpendicular to one another and the shelves are rectangular in shape with front, back and opposite side corners. A reinforcing brace is integrated in each shelf and extends diagonally from the shelf rear corner to the shelf front corner. Back and opposite side corners, respectively, of the shelves are engaged in openings in the strip and in the reinforcing structures, respectively, to support the shelves on the support frame. Adhesive or double face tape or other suitable fastening means preferably is engaged between the shelves and adjacent parts of the support to help secure the parts together.
Optional graphics panels may be applied to the shelves and/or to the support frame, and in the embodiment shown in FIGS. 2-4 the graphics panels applied to the shelves assist in supporting the shelves from the support frame.
Accordingly, one aspect of the present invention is directed to a display rack for supporting and displaying articles. The display rack comprises a support frame having two walls extending at an angle to one another from a narrow strip at a rear corner of the frame and each having a forward free edge with a tubular reinforcing structure along its length. A plurality of shelves is supported on the support frame between the walls. The shelves each having first support means is engaging the strip and second support means is engaging a respective reinforcing structure so that a forward portion of the shelves projects forwardly of the support frame for greater visibility of and access to articles supported on the shelves.
Another aspect of the present invention is directed to a display rack for supporting and displaying articles that comprises a support frame having two side walls extending at an angle to one another from a narrow strip at a rear corner of the support frame. Each side wall has a forward free edge along its length and the narrow strip and the forward free edges each have a plurality of openings spaced along their length. A plurality of shelves is supported on the support frame side walls, wherein each of the shelves is rectangular in shape and has a rear corner, a front corner, opposite side corners, spaced apart parallel top and bottom walls, first and second side edges extending perpendicular to one another from the shelf rear corner and defining shelf rearward side edges. Third and fourth side edges joined to respective first and second side edges and extending perpendicular to one another from the shelf front corner and defining shelf forward side edges. A reinforcing brace between the top and bottom walls extend diagonally from the rear corner of the shelf to the front corner thereof. The rear corners of the shelves is engaged in the respective openings in the strip and the side corners of the shelves is engaged in the respective openings in the forward free edges of the support frame so that the shelves are cantilevered from the support frame with the forward side edges thereof projecting forwardly of the forward free edges of the support frame side walls.
A further aspect of the invention is directed a display rack to a display rack for supporting and displaying articles that comprises a support frame made of paper material and having only two walls. The walls extend at an angle to one another from a narrow strip at a rear corner of the frame and each having a forward free edge. A plurality of openings is spaced along the narrow strip and the forward free edges. A plurality of shelves made of paper material is supported on the support frame between the walls. The shelves are rectangular in shape with rearward side edges, forward side edges, a rear corner, a front corner, and opposite side corners. The rearward side edges lying against the walls of the support frame wherein the rear corner of each of the shelf extends into a respective opening in the narrow strip and the side corners of each of the shelf extend into a the respective opening in the forward free edges of the support frame, so that the forward side edges of the shelves project forwardly of the forward free edges of the support frame for greater visibility of and access to articles supported on the shelves.
BRIEF DESCRIPTION OF THE DRAWINGS
The foregoing, as well as other objects and advantages of the invention, will become apparent from the following detailed description when taken in conjunction with the accompanying drawings, wherein like reference characters designate like parts throughout the several views, and wherein:
FIG. 1 is a front isometric view of a first embodiment of display rack according to the invention, shown without graphic panels.
FIG. 2 is a front isometric view of the first embodiment of display rack with graphic panels applied to the shelves.
FIG. 3 is a side view of the embodiment of display rack shown in FIG. 2 .
FIG. 4 is an enlarged fragmentary view of the rack of FIG. 2 , looking at a slight angle from the back toward the outside of one corner of the rack.
FIG. 5 is an enlarged fragmentary view of the rack FIGS. 1 and 2 looking at a slight angle toward the outside of the back corner of the rack, showing how the rear corner of the shelves extend through the opening in the narrow strip at the back corner of the support frame.
FIG. 6 is a plan view of a blank for making the reinforcing brace used in the shelves of the invention.
FIGS. 7-10 depict various steps in erecting the reinforcing brace.
FIG. 11 is a plan view of a blank for making the wrap that is folded around the brace of FIGS. 6-10 to make the reinforced shelves of the invention.
FIGS. 12-16 depict the various steps in erecting a shelf according to the invention.
FIG. 17 is an isometric view looking toward the bottom of a completed shelf.
FIG. 18 is a slightly enlarged fragmentary view of the bottom of one corner of the shelf of the invention, showing tabs projecting from two adjacent edges.
FIG. 19 is a top plan view of the shelf of FIG. 18 , showing the tabs projecting coplanar with the top surface of the shelf.
FIG. 20A is a plan view of a blank for making the support frame of the invention.
FIG. 20B is an isometric view looking from the top end of an assembled support frame of the invention, prior to attachment of shelves.
FIG. 21 is an enlarged fragmentary view of one corner of the blank of FIG. 18 .
FIGS. 22-25 depict steps in assembling the display rack of the invention.
FIG. 26 is a view from the front of an optional embodiment of the invention wherein a graphics display header is attached to the top of the rack.
FIG. 27 is an isometric exploded view of a further embodiment wherein a fifth shelf extension is provided for insertion between the top of the display rack of FIG. 2 and the graphics header of FIG. 26 .
FIG. 28 is a bottom isometric view of one form of graphics shelf skirt that may be applied to the shelves.
FIG. 29 is a slightly enlarged fragmentary end view looking toward the top of the display rack, showing the slots for receiving tabs on the graphics header or fifth shelf extension to attach the extension to the rack.
FIG. 30 shows the extension being assembled to the stand.
FIG. 31 shows the graphics header of FIG. 27 being applied to the extension.
FIGS. 32-34 depict the steps in assembling the graphics skirt to a shelf.
DETAILED DESCRIPTION OF THE INVENTION
A first form of the invention, devoid of separate graphics panels, is indicated generally at 10 in FIGS. 1 and 5-25 . This form of the invention comprises a support frame 11 having two walls or panels 12 and 13 joined along one edge to a narrow corner strip 14 at the back corner of the frame and diverging outwardly from the strip perpendicular to one another. The outer edge of each panel is folded to define a tubular reinforced edge 15 and 16 , respectively, having a triangular shape in transverse cross section. As seen best in FIGS. 18-21 , a plurality of openings 17 are formed through the corner strip spaced along its length, and a corresponding number of openings 18 are formed in the inwardly facing surfaces of the reinforced edges 15 and 16 . Rectangularly shaped shelves 20 have a rear corner engaged in respective openings 17 in the corner strip, and opposite side corners engaged in respective openings 18 in the reinforced edges. As shown in the drawings, double face tape 21 (see FIGS. 18-23 ) is strategically placed between the shelves and support frame to secure the parts together. Alternatively, a suitable adhesive or other fastening means, not shown, could be used.
Adhesive, for example, could be applied in generally the same places as the double face tape shown in the drawings. A base member B preferably is attached to the underside of the bottom shelf, as seen best in FIGS. 24 and 25 .
The shelves 20 are a reinforced two-part construction comprising a diagonally extending center brace 30 and an outer wrap 40 , each made of a single piece of corrugated paper folded as described hereinafter.
The construction of the brace is shown in FIGS. 6-10 and comprises a top panel 31 shaped with converging angled end edges 32 a and 32 b defining opposite pointed ends 32 c and 32 d , first narrow side panels 33 a and 33 b foldably joined along opposite sides of the top panel 31 , bottom panels 34 a and 34 b foldably joined to respective side panels 33 a and 33 b and having outwardly divergent end edges 35 a and 35 b angled oppositely to the end edges 32 a and 32 b on the top panel 31 , and insert flanges 36 a and 36 b foldably joined to respective bottom panels 34 a and 34 b . Transverse first slots 37 a and 37 b are formed across the bottom panels 34 a and 34 b and part way into the side panels and insert flanges, and second slots 38 are formed adjacent and parallel to opposite end edges of each of the bottom panels, both for a purpose described hereinafter. Cuts are made across the juncture between the bottom panels and insert flanges approximately midway between the slots 37 a , 37 b and the opposite end edges of the insert flanges, defining openings 39 a and locking tabs 39 b , also for a purpose described hereinafter.
The wrap 40 comprises a rectangular top wall 41 having narrow side walls 42 a , 42 b , 42 c and 42 d foldably joined to its respective edges, first and second triangularly shaped bottom wall panels 43 a and 43 b foldably joined to respective opposite side walls 42 a and 42 c , narrow insert flanges 44 a and 44 b foldably joined to the hypotenuse (angled edges) of the respective first and second triangularly shaped bottom wall panels, elongate narrow tabs 45 a , 45 b , 45 c and 45 d foldably joined to opposite ends of respective side walls 42 a - 42 d , and first and second bottom flaps 46 a and 46 b foldably joined to side walls 42 b and 42 d , respectively. Third slots 47 are formed in the triangular bottom wall panels 43 a and 43 b near their folded connection with the side walls 42 a and 42 c , and fourth slots 48 are formed in the bottom flaps 46 a and 46 b near their folded connection with side walls 42 b and 42 d , respectively. Fifth slots 49 are formed in each triangular bottom wall panel 43 a , 43 b near their edge that extends perpendicular to the top wall 41 , and sixth slots 50 are formed in each bottom flap 46 a and 46 b near their opposite side edges. The third, fourth and sixth slots define first graphics attaching slots, as described hereinafter. Seventh slots or cuts 51 defining narrow tabs 52 are formed in two adjacent side walls 42 c and 42 d adjacent their folded connection with the top wall 41 , and three spaced notches 53 are formed in the free edge of each insert flange 44 a and 44 b . Locating marks 41 A and 41 B preferably are provided on the top wall panel 41 to aid in proper positioning of the brace 30 .
It is preferred that the brace 30 is folded and glued by the manufacturer, but it could be folded into operative condition by a retailer or other user. The steps of erecting the brace into its usable condition are shown in FIGS. 7-10 . Initial steps in folding the blank for making the brace are seen in FIG. 7 , wherein one of the bottom panels 34 b is shown partly folded upwardly and inwardly toward the top panel 31 . FIG. 8 shows both bottom panels 34 a and 34 b folded upwardly and inwardly toward one another over the top panel 31 , and FIG. 9 shows the bottom panels folded fully inwardly with the insert flanges 36 a and 36 b folded downwardly into parallel contiguous relationship with one another. As shown in FIG. 10 , the locking tabs 39 b on one insert flange are pressed through the openings 39 a in the opposite insert flange to hold the brace in the assembled condition shown, with the bottom panels 34 a and 34 b forming a bottom spaced from and parallel to the top panel 31 , wherein said top panel, bottom, and side panels form a tubular structure. If the brace is assembled by the manufacturer, adhesive (not shown) could be used in lieu of the openings 39 a and locking tabs 39 b.
It is preferred that the shelves be folded and glued by the manufacturer and shipped to a point of sale or other destination in condition ready to use with the support frame 11 which is shipped flat as shown in FIG. 20 , but the steps of assembling a shelf according to the invention are shown in FIGS. 11-17 . If desired, all of the components could be shipped flat to a user who would then erect the components and assemble the display rack.
As shown in FIG. 12 , the brace 30 is placed on the top wall 41 of the wrap, with its sides parallel to the angled edges of the bottom wall panels 43 a and 43 b and its opposite pointed ends lying in opposite corners of the top wall. The bottom wall panels are then folded inwardly as shown in FIGS. 13 and 14 , with the notched insert flanges 44 a and 44 b on the angled edges of the bottom wall panels inserted into the slots 37 a and 37 b in the bottom of the brace. The notches 52 in the free edge of each insert flange on the wrap receive the upper edges of the brace side panels and insert flanges located below the slots 37 a , 37 b in the erected brace as shown in FIG. 10 . The narrow tabs 45 a , 45 b , 45 c and 45 d are then folded inwardly to extend across the open ends of the brace, followed by inward folding of the first and second bottom flaps 46 a and 46 b as shown in FIGS. 15 and 16 , to form the finished shelf 20 as shown in FIG. 17 .
As seen in FIGS. 18 and 19 , the narrow tabs 52 defined by cuts 51 in two adjacent side walls 42 c and 42 d project outwardly from adjacent side edges of the shelf for cooperation with slots in the support frame 11 as described hereinafter.
As previously briefly described above, the support frame 11 , which is shipped to the user in the flattened condition shown in FIG. 20B , has two side walls or panels 12 and 13 joined along one edge to a narrow strip 14 , with the outer edges of the side walls folded to define tubular reinforced edges 15 and 16 , respectively, having a triangular shape in transverse cross section. As seen best in FIG. 20A , the side walls 12 and 13 have a double thickness formed by back panels 12 B and 13 B, respectively, folded and glued behind associated front panels 12 A and 13 A, respectively. A flap 94 on the top edge of panel 12 B is folded over and glued to the front of panel 12 A, and a flap 93 on the top edge of panel 13 B is folded over and glued to the front of panel 13 A. Slots 83 and 84 at the folded juncture of the flaps 94 and 93 with their associated panels 13 B and 12 B, and notches 84 ′ and 83 ′ are formed in respective top edges of walls 12 and 13 to receive tabs on a header panel as described hereinafter. A plurality of openings 17 are formed through the strip 14 spaced along its length, and a corresponding number of openings 18 are formed in the inwardly facing surfaces of the reinforced edges 15 and 16 in transverse alignment with the openings 17 . Shelf attaching slots 60 are made through each side panel 12 , 13 adjacent each side edge thereof in transverse alignment with the top edges of the openings 17 and 18 , and double face tape 21 is placed on each side panel adjacent and in alignment with the openings 18 in the reinforced edges 15 , 16 .
To assemble the shelves 20 to the support frame 11 , as shown in FIGS. 22-25 , typically accomplished by the end user, the frame 11 is placed on its back on a support surface and the shelves are positioned edgewise on the frame with one corner of each shelf in registry with a respective opening 17 in the corner strip 14 and an opposite corner engaged in an opening 18 in the adjacent reinforced edge 15 (or 16 , depending on which side of the frame the shelves are first placed). The narrow tabs 52 projecting outwardly from one side edge of each shelf extend into respective shelf attaching slots 60 in the side panel 12 or 13 on which the shelf has been placed. The opposite side panel 12 (or 13 ) is then folded upwardly around the shelves so that the corner of each shelf adjacent the narrow corner strip 14 extends into a respective opening 17 in the corner strip and the corner adjacent the upwardly folded side panel 12 (or 13 ) extends into a respective opening 18 in the reinforced edge 15 (or 16 ). The tabs 52 on the other side edge of each shelf extend into the slots 60 in the upwardly folded side panel 12 (or 13 ). The protective paper is peeled off the double face tape 21 prior to placement of the shelves on the frame so that the tape in combination with the tabs and slots holds the shelf and frame assembly together.
As seen best in FIGS. 24 and 25 , the base member B is attached to the underside of the bottom shelf. The base member rests on the surface on which the display rack is supported.
An optional alternate embodiment is indicated generally at 70 in FIG. 26 . In this embodiment, a graphics header 71 is attached to the top of the support frame 11 , and graphics skirts 72 are attached to the exposed edges of the shelves. Details of the skirts 72 are seen best in FIG. 28 , wherein the skirt is shown inverted. The skirts 72 each comprise side panels 73 that are oriented vertically when in use and may have a shaped top edge 74 . Narrow bottom flanges 75 and 76 are on the bottom edges of the side panels and shaped locking tabs 77 are on the free edges of the flanges. Double face tape 21 is placed on extended ends 78 of the side panels. To install the skirts, the panels 73 are placed against the exposed edges of a shelf 20 , the flanges 75 and 76 bent rearwardly beneath the shelf, and the tabs 77 inserted upwardly through the slots 50 and into slots 47 or 48 in the bottom of the shelf. The extended ends 78 of the skirts are attached to the sides of the frame by use of the double face tape 21 .
Alternatively, as shown in FIGS. 3 and 4 , the extended ends 78 wrap around the corners of the support frame 11 and tuck into slots on the back of the frame.
FIG. 27 shows a further optional embodiment 80 in which an extension piece 81 and fifth shelf 20 are assembled to the top of the support frame 11 , and a graphics wrap 82 is attached to the back of the support frame. When the extension piece is used, the graphics header 71 is attached to the extension piece in the same way it would be attached to the support frame 11 . In this regard, reference is made to FIGS. 29-31 .
FIG. 29 is an end view of the support frame 11 and shows second graphics attaching slots 83 and 84 in the upper end of the support frame for receiving tabs 85 and 86 on the bottom edge of the graphics header 71 or, as depicted in FIG. 30 , the tabs 87 and 88 on the bottom of the extension piece 81 . The extension piece has corresponding third graphics attaching slots 89 a and 89 b for receiving the tabs on the graphics header, as depicted in FIG. 31 . In the example shown and described herein, and with particular reference to FIGS. 29-31 , flaps 93 and 94 on the upper end of the support frame are folded over and glued to the walls 12 and 13 , defining a space between the flaps and walls. The slots 83 and 84 open into this space, which provides room for insertion of the tabs 85 and 86 on the lower end of the graphics header 71 or the tabs 87 and 88 on the lower end of the extension piece. Similarly, flaps 95 and 96 are folded and glued on the upper end of the extension piece 81 to provide space for insertion of the tabs 85 and 86 on the lower end of the graphics header 71 .
One method of assembly of the graphics skirts 72 to the shelves 20 is shown in FIGS. 32-34 . In the method shown in these figures the skirt is attached to the shelf by the use of double face tape 21 and insertion of tabs 73 on the free edge of skirt bottom flanges 74 and 75 through the slots 48 and 50 in adjacent edges of the bottom flaps 46 a and 46 b and into the aligned slots 47 (not seen in these figures) in the underlying triangular bottom wall panels 43 a and 43 b.
When the shelves are made by the manufacturer, the skirts are glued to the shelves and an extended rearward end 90 on each skirt is wrapped around the corner of the support frame and a tab 91 on end 90 is inserted into a respective slot 92 in the adjacent side panels 12 and 13 , respectively, of the support frame 11 . FIGS. 2-4 depict this arrangement.
The display rack of the invention is economical to make and use and is fully recyclable. The structure allows for additional product visibility and additional shopper interest, both core criteria in measuring a display's in-store effectiveness. The cantilevered mounting of the shelves provides an exceptionally strong structure, wherein each shelf is easily capable of supporting over 45 lbs of product without appreciable sagging or distress. This strength comes from the insertion of three corners of each shelf into an extended wedge in the vertical wall and the provision of a brace extending in the shelf from the rear corner to the front corner. In this regard, it is noted that the rearward ends of the braces extend into the openings 17 , whereby the brace acts as a cantilevered beam.
While particular embodiments of the invention have been illustrated and described in detail herein, it should be understood that various changes and modifications may be made in the invention without departing from the spirit and intent of the invention as defined by the appended claims. | A display rack for displaying articles has a support frame with two walls extending at an angle from a narrow strip at the rear corner of the frame. A tubular reinforcing structure extends along the forward free edge of each wall, and aligned openings are in the strip and the reinforcing structures. A plurality of shelves having front and rear corners and opposite side corners are supported on the frame between the walls, with the rear corners engaged in respective openings in the strip and the side corners engaged in respective openings in the reinforcing structures. A forward portion of the shelves projects forwardly of the frame for greater visibility of and access to articles supported on the shelves. A reinforcing brace extends diagonally in each shelf from the rear corner to the front corner, whereby the shelves are essentially cantilevered from the frame. | 0 |
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority as a non-provisional perfection of prior filed provisional application 60/689,365, filed Jun. 10, 2005.
FIELD OF THE INVENTION
[0002] The present invention relates to the field of treatment of periodontal disease and more particularly relates to treating periodontal disease with a laser and chemical combination.
BACKGROUND OF INVENTION
[0003] Periodontal disease is a pathogenic infection of the gums and it is common among all humans and animals. Periodontal disease is a major cause in the loss of teeth and oral bone throughout every society. The oral environment is a warm moist cavity that is full of nutrients; it is an excellent location to incubate numerous microbes. Therefore it is not surprising that pathogens readily ingress into the periodontal pockets and begin causing infection. Uncontrolled or rampant periodontal infection leads to bone loss that ultimately results in the teeth becoming loose from their sockets.
[0004] Until now, treatments have involved extensive and painful processes to clean the infected area and the use of drugs to control the infection. Recently, lasers have been used to treat periodontal disease by using a fiber-optic guide to direct laser energy into periodontal pockets to kill bacteria. This less invasive and painful form of treatment does have its limitations, however, in that the laser is limited by the relative size of the guide and the ability to adequately control its direction. As such, areas needing treatment may not be adequately treated or missed entirely. What is needed is a method to improve upon the use of the laser treatment of periodontal disease for maximum coverage and disinfection of the treated area.
BRIEF SUMMARY OF THE INVENTION
[0005] In view of the foregoing disadvantages inherent in the known types of treatment of periodontal disease, this invention provides a new and improved method of treatment merging the benefits of laser and chemical treatment. As such, the present invention's general purpose is to provide a new and improved method that is safe, efficient, with minimal discomfort to the patient and providing a broader treatment area than the use of the laser guide alone.
[0006] The present invention provides an improved method for treating periodontal disease. The method comprises the use of a laser or radiant energy source that is capable of being absorbed by pathogens. Said laser light is applied to infected periodontal pockets with the intention of destroying any susceptible pathogens. The periodontal pocket is then flushed with an anti-microbial substance with the intention to destroy any residual susceptible pathogens. The advantage of the flushing is that any residual organisms have been already weakened by the applied laser light and the use of a liquid anti-microbial substance will reach areas missed by the direction of the guide.
[0007] The more important features of the invention have thus been outlined in order that the more detailed description that follows may be better understood and in order that the present contribution to the art may better be appreciated. Additional features of the invention will be described hereinafter and will form the subject matter of the claims that follow.
[0008] Many objects of this invention will appear from the following description and appended claims, reference being made to the accompanying drawings forming a part of this specification wherein like reference characters designate corresponding parts in the several views.
[0009] Before explaining at least one embodiment of the invention in detail, it is to be understood that the invention is not limited in its application to the details of construction and the arrangements of the components set forth in the following description or illustrated in the drawings. The invention is capable of other embodiments and of being practiced and carried out in various ways. Also it is to be understood that the phraseology and terminology employed herein are for the purpose of description and should not be regarded as limiting.
[0010] As such, those skilled in the art will appreciate that the conception, upon which this disclosure is based, may readily be utilized as a basis for the designing of other structures, methods and systems for carrying out the several purposes of the present invention. It is important, therefore, that the claims be regarded as including such equivalent constructions insofar as they do not depart from the spirit and scope of the present invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] FIG. 1 is a partial sectional view of a normal tooth and surrounding tissue.
[0012] FIG. 2 is the tooth and surrounding tissue of FIG. 1 having developed an early stage of gingivitis.
[0013] FIG. 3 is the tooth and surrounding tissue of FIG. 2 having developed advanced periodontal disease.
[0014] FIG. 4 is the tooth and surrounding tissue of FIG. 3 , being treated by a fiber optic guide through which laser light is being transmitted.
[0015] FIG. 5 is tooth and surrounding tissue of FIG. 4 being flushed with an anti-microbial substance by the means of a slender tip attached to a syringe.
DETAILED DESCRIPTION OF THE INVENTION
[0016] With reference now to the drawings, the preferred embodiment of the method of periodontal treatment is herein described. It should be noted that the articles “a”, “an” and “the”, as used in this specification, include plural referents unless the content clearly dictates otherwise. With reference to FIG. 1 , a healthy tooth 2 rests in a bony socket 4 in the jaw 6 . The entire area is covered by the gingiva 10 , or “gums”, to protect the juncture. Over time, if left without proper oral care, tartar 12 will build up against tooth 2 (shown in FIG. 2 ), causing the gums 10 to recede and exposing the root 3 of the tooth in a condition called “gingivitis”. FIG. 3 displays a condition further deteriorated from gingivitis, peridontitis. The gums 10 have receded to the point of forming an open pocket 20 around the tooth 2 and its root system 3 . The pocket is filled with inflamed tissue 22 and infectious matter 24 . If left untreated the tooth 2 and socket 4 may deteriorate, causing loss of the tooth 2 .
[0017] Treatment of the condition is shown in FIGS. 4 and 5 . The method harnesses the benefits of a radiant energy source that is lethal to pathogens, coupled with anti-microbial agents that are chemically lethal to a wide variety of pathogens. The combined effect of radiant energy bombardment and the additional challenge of anti-microbial agents is intended to destroy a broad spectrum of pathogens; such that remaining pathogens can eventually be controlled by the normal functions of the immune system.
[0018] The method warrants a radiant energy source with sufficient energy to become lethal to pathogens. The radiant energy can be produced from sources such as a diode laser, examples of which are the gallium nitride, aluminum gallium arsenide diode laser and the like. The radiant energy can be produced from sources such as high intensity light from incandescent, halogen or plasma arc devices. The radiant energy can be produced from sources such as solid state lasers, examples of which are neodymium YAG, titanium sapphire, thulium YAG, ytterbium YAG, Ruby, holmium YAG lasers and the like. The radiant energy can be produced from sources such as EB or electron beam devices. The radiant energy can be produced from sources such as gas lasers, examples of which are the Carbon dioxide laser, argon gas, xenon gas, nitrogen gas, helium-neon gas, carbon monoxide gas, hydrogen fluoride gas lasers and the like. There are also many dye lasers that utilize a radiant energy source that pass through various dyes or stains to achieve various wavelengths. Dye lasers are also within the scope of this method.
[0019] The method also warrants an anti-microbial substance that is capable of destroying pathogens. There are numerous substances with anti-microbial or anti-pathogenic activity. Any substance that is capable of destroying or stemming the growth of a pathogen is within the scope of this method. A few possible examples of antimicrobial substances include: ethanol, isopropanol, methyl paraben, ethyl paraben, butyl paraben, propyl paraben, hydrogen peroxide, carbamide peroxide, eugenol, sodium chlorite, chlorhexidine, chlorhexidine gluconate, sodium chlorite, thymol, cetyl pyridinium chloride, chloroxylenol, iodine, hexachlorophene, triclosan, quaternary ammonium compounds, sodium hypochlorite, calcium hypochlorite, or any like substance that is capable of destroying or limiting the reproduction of pathogens.
[0020] Many of these antimicrobial agents are a dry powder in their raw form and would benefit by being dissolved into a solvent. Liquid antimicrobial agents are able to migrate easier into difficult areas, thus having an advantage over powders. A few examples of possible solvents include: water, propylene glycol, glycerin, polysorbates, liquid polyethylene glycols, ethanol or any solvent capable of dissolving or liquefying an antimicrobial substance.
[0021] Optionally, the antimicrobial agent can contain additional components that would improve patient comfort such as a flavor, sweetener or anesthetic. A few possible substances that would aid in patient comfort include: sodium saccharin, phenylalanine, benzocaine, lidocaine, dyclonine hydrochloride, peppermint oil, spearmint oil, methyl salicylate and any like substance.
[0022] Numerous formulas are capable of being produced during the practice of this method. Compositions may be made in any combination according to the following Table A, dependant upon the desired agents used and overall effect.
TABLE A Rinse Percentage by component total weight Function Antimicrobial 0.01%%-100% % Kill bacteria agent Solvent 0%-99.99% Allows the rinse to be a fluid that will easily flow into a periodontal pocket. Flavoring 0%-5% Make the rinse palatable. Anesthetic 0%-30 Reduce patient discomfort.
A few specific examples could include:
Formula #1
6.0%—chlorhexidine gluconate 20% aqueous 94.0%—Water
Formula #2
1%—chlorhexidine 99.0%—Water
Formula #3
5.0%—sodium hypochlorite 95.0%—Water
Formula #4
1.0%—calcium chlorite 99.0%—Water
Formula #5
0.5%—sodium chlorite 99.5.0%—Water
Formula #6
10.0%—chlorhexidine gluconate 20% aqueous 73.4%—Water 0.3%—peppermint oil 15.0%—ethanol 0.3%—Phenylalanine 1.0%—dyclonine hydrochloride
Formula #7
3.0%—hydrogen peroxide 55.4%—glycerin 0.3%—peppermint oil 40.0%—water 0.3%—Phenylalanine 1.0%—benzocaine
Formula #6
1.0%—methyl paraben 25.0%—Water 0.3%—methyl salicylate 25.0%—ethanol 0.3%—sodium saccharin 1.0%—lidocaine 47.4%—propylene glycol
The above example formulas would be sufficiently adequate over one or multiple applications to destroy or limit the growth of pathogens in the oral environment.
[0052] A typical procedure of events during a routine periodontal treatment regime would be to first identify areas of greatest infection. These areas would be selected for additional exposure to radiant energy. The radiant energy source would then be focused into these infected pockets by means of a thin fiber optic guide 40 , FIG. 4 . The fiber optic guide being small enough to be directed between the teeth and gums. The periodontal pocket 20 is then radiated with radiant energy while the optical fiber 40 is moved in increments around the gums 10 . When the treatment of the gums by radiant energy is complete, the periodontal pocket 20 is then flushed with an antimicrobial fluid 46 by means of a small tip 42 attached to a syringe 44 , shown in FIG. 5 . The treatment regime may include multiple treatments, these factors depend on the degree of infection present. The treatment regime usually continues until the swelling and redness of infected gums is no longer apparent and only pink healthy gums persist.
[0053] The treatment regime can also begin by flushing the periodontal pockets with antimicrobial agents, followed by radiating with radiant energy. This would allow any additional anisthetic contained in the antimicrobial agent to anesthetize the working area prior to receiving radiant energy.
[0054] Although the present invention has been described with reference to preferred embodiments, numerous modifications and variations can be made and still the result will come within the scope of the invention. No limitation with respect to the specific embodiments disclosed herein is intended or should be inferred. | Present invention provides a method for treating periodontal disease. Periodontal disease is a pathogenic infection of the gums. The method comprises the use of a laser or radiant energy source that is capable of being absorbed by pathogens. Said Radiant energy is applied to infected periodontal pockets with the intention of destroying any susceptible pathogens. The periodontal pocket is then flushed with an anti-microbial substance with the intention to destroy any residual susceptible pathogens. | 0 |
TECHNICAL FIELD
The present invention relates to injection-moldable compositions including inorganic fillers and organic binders. More specifically, wherein the fillers have been surface-treated with certain organosilane agents prior to mixing to improve dispersibility and reduce mixing torques.
BACKGROUND OF INVENTION
It is well known in the art that compatibility of metallic or inorganic fillers with organic polymers may be improved by surface treatment of the former with organosilanes or surfactants. For example, U.S. Pat. No. 4,336,284 teaches pretreating coal ash fly with organotitanates, organosilanes and the like.
U. S. Pat. No. 4,724,167 similarly teaches the art of procreating silicon with organopolysiloxanes, U.S. Pat. No. 4,369,265 concerns readily dispersible pigments coated with organo-silicone polymer.
U. S. Pat. No. 4,162,245 teaches the method of pretreating inorganic fillers with certain silanes which process advantageously reduces the viscosity of the composition on mixing with an organic polymer resin that can then be heat-cured. Four silanes were found to be useful in that process: (CH 3 O) 3 SiCH 2 CH 2 Cl; (CH 3 O) 3 SiCH 2 CH 2 CF 3 ; (HCl) (CH 3 CH 2 ) 2 NCH 2 CH 2 ) 3 SiC 18 H 37 and (CH 3 O) 3 SiCH 2 CH 2 OCOC(CH 3 )═CH 2 . Other silanes were tried but found not useful. The silanes were used to pretreat filler materials in an acidic environment. The isolated filler material was then combined with the organic resin. The content of treated filler material in the final formulation was from 50 to 75 wt %, equivalent to a range of about 34 to about 62 volume percent.
Inspection of such earlier methods and compositions reveals significant drawbacks especially when high density metallic or ceramic parts are desired. Requirements for getting such a high density metallic or ceramic part include: (1) the presence of large amounts (greater than 63 volume percent) of metallic or inorganic filler in the molding composition, and (2) the filler being present often in finely divided state with an optimal particle size distribution. If one attempts to prepare such molding compositions with high loading of filler (greater than 63 volume percent) by using prior art methods, poor particle dispersion occurs, and it becomes difficult to achieve uniform mixing and fine powder dispersion, leading to high mixing torques, high mixing energies, long mixing times and difficult mixing operation, and may yield dry, friable, agglomerated compositions. This also precludes processability in conventional mixing and molding equipment.
Accordingly, it is a general objective of the present invention to provide novel molding compositions containing finely divided metallic or inorganic fillers in excess of 63 volume percent dispersed in organic binder matrix resins.
It is another object of the present invention to provide a method of surface treatment for such filler particles that increases their dispersibility and reduces mixing torques upon mixing with organic binder components at high concentrations.
It is yet another object of this invention to provide improved injection moldable compositions, that are capable of being processed by conventional mixing and molding equipment while employing low mixing torques and energies.
These and other objects, as well as the scope, nature and utilization of the invention will be apparent from the following description and claims.
SUMMARY OF INVENTION
in accordance with the present invention there is provided a composition suitable for injection molding. The composition includes an organic matrix resin and a pretreated filler material. Examples of organic matrix resins include polyolefins, polyamides, polyesters, polycarbonates, polyacetals and the like. Polyacetal resins are thermoplastic materials and can be homopolymers or copolymers. For example, the Delrin® resin (available from E. I. DuPont de Nemours & Co., Wilmington, Del.) is a homopolymer of formaldehyde, while the Celcon® resin (available from Hoechst Celanese Corporation, Somerville, N.J.) is a copolymer of trioxane with ethylene oxide consisting essentially of repeating units of carbon-oxygen bonds. The binder resin is present in the injection molding composition in concentrations generally ranging from about 8 to about 37 volume percent and preferably from about 22 to about 30 volume percent. The other major component in the molding composition contains particles of metal or inorganic filler such as silicon powder that has been pretreated by coating on its surface an organosilane represented by the formula:
SiX.sub.1 X.sub.2 X.sub.3 X.sub.4
wherein at least one of X 1 , X 2 , X 3 or X 4 is an unfunctionalized alkyl or alkenyl group having generally from about 10 to about 35 carbon atoms, typically from about 12 to about 30 carbon atoms and preferably from about 15 to about 20 carbon atoms, more preferably 18 carbon atoms, and at least one of X 1 , X 2 , X 3 or X 4 is an alkoxy group or halide such as F, Cl, Br or I. If more than one alkyl/alkenyl group is present, at least one of them is described as above; the other(s) could be the same or very similarly long alkyl(s). If alkoxy groups are present, they may contain from about 1 to 5 carbons, preferably 2. It is essential that the alkyl/alkenyl group is unfunctionalized. Particularly functionalities such as ester and amine are not desirable. Several such silanes are commercially available like for example, n-octadecyltriethoxysilane, n-octadecylsilane, n-octadecy-ldimethylmethoxysilane, n-octadecyltrichlorosilane and the like.
In addition to the two major components, additives such as other binder components, surfactants, wetting agents, dispersing agents, mold release agents, plasticizers, nucleating agents and the like could be used in the composition. Some typical examples of such additives include waxes as antiadhesion agents (e.g., N,N'-ethylene bis-stearamide, sold under the name Wax C by Hoechst AG, Frankfurt, Germany) polyethylene glycol as plasticizer (e.g., PEG 8000 from Union Carbide), polydioxolane as plasticizer, or surfactants such as, Hypermer KD-3, a polymeric dispersant from ICI Specialty Chemicals, Wilmington, Del.) and stearic acid. Also mold release agents (e.g., Okerin 1865Q, a casting wax supplied by Astor Wax Corp., Harrison, N.Y.) and nucleation agents (e.g., Celcon U10, a high strength acetal terpolymer from Hoechst Celanese Corp., Engineering Plastics Division, Chatham, N.J.) may be included in the formulation. Some Celcon® resins give off formaldehyde during processing steps encountered in the present invention. When such resins are used as binders, formaldehyde traps such as cyanoguanidine may be included in the composition. When additives are used, they are used in quantities such that the filler powder content in the composition is at least 63 volume percent.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The molding compositions of the present invention contain surface-treated filler materials which are uniformly and finely dispersed in an organic matrix resin such that even when high loading levels of the filler are employed in the formulation, low initial mixing torques are achieved during mixing and low total mixing energies result. Loading levels of the filler materials in the composition are generally from about 63 volume percent to about 92 volume percent, typically about 64 to 84 volume percent and preferably about 67 volume percent. Surface treatment of the filler material is preferably done prior to mixing with the binder and is preferably accomplished by treating it with a silane of the general formula:
SiX.sub.1 X.sub.2 X.sub.3 X.sub.4
wherein at least one of X 1 , X 2 , X 3 or X 4 is an unfunctionlized alkyl or alkenyl group having from about 10 to about 35 carbon atoms, typically from about 12 to 30 carbons, preferably from about 15 to about 20 carbons, and more preferably 18 carbon atoms, and at least one of X 1 , X 2 , X 3 or X 4 is an alkoxy group or halide such as F, Cl, Br or I. If more than one alkyl/alkenyl group is present, at least one of them is described as above; the other(s) could be the same or very similarly long alkyl(s). If alkoxy groups are present, they may contain from about 1 to 5 carbons, preferably 2. It is essential that the alkyl/alkenyl group is unfunctionalized. Particularly functionalities such as ester and amine are not desirable. Several such silanes are commercially as noted above.
The silane is used in amounts from about 0.1 to 15 wt % based on the filler; the exact amount required depends on the surface area of the filler. In general, the filler particles should have at least one monolayer of silane coverage. For example, for a typical silicon powder with 1 m 2 /gm surface area and a mean particle size of 1 to 10, 0.1 to 1 wt % silane is required.
The filler material used in the composition is chosen according to the intended function of the designed part as is known to those skilled in the art. Typical materials include (i) inorganics such as silicon, silicon nitride, silicon carbide, alumina, aluminum nitride, titania, zirconia and mixtures thereof, and (ii) metal powders such as iron, stainless steel, chromium alloys, nickel alloys, bronze, and the like.
The filler materials used in the present invention have mean particle diameters and particle size distributions as mentioned earlier. Preferred mean particle diameters range from about 0.01 to 1000 (chemical formula), and more preferably 0.1 micron to 100 microns. The use of powders with such preferred characteristics enables the fabrication of molding formulations with high filler contents, while retaining good moldability.
The binder matrix resins used in the present invention could be any organic resin mentioned above. Preferred resins are the polyacetal materials, some of which are described above.
The present invention also relates to the process of obtaining an injection moldable composition. The process starts with surface-treating the filler material. In an embodiment of the invention, silicon filler powder is uniformly well dispersed in isopropyl alcohol, or isopropyl alcohol containing added water from about 5 to 50 vol. %, with a high-speed mixer, while octadecyltriethoxysilane was slowly added to this slurry. An acid such as acetic acid could also be present, but not always necessary. Temperature rose during this operation and was maintained at around 60° C. It was stirred and maintained at around 60° C. for about 15-60 minutes, after which time it was transferred to a centrifuge and centrifuged to isolate the surface-modified silicon as a cake. This was further washed with isopropyl alcohol and dried at about 120° C. for about 5 to 10 hours.
A polyacetal resin (Celcon® M450, PEG 8000,) and Wax C powders were well mixed, to which the above surface-modified silicon was added and mixed again. This mix was melt compounded by adding the powder to the mixing bowl of a Computerized Brabender Prep Center drive unit (Model PLD-651, supplied by C. W. Brabender Instruments, Inc., S. Hackensack, N.J. fitted with a 60 cc Prep Mixer mixing bowl), and mixing at about 190° C. and rotating speed of 50 rpm. This dispersibility was checked by measuring the mixing torque from initial mixing time until it no longer changed.
Plotting the torque versus mixing time gives an indication of the ease of dispersion; dispersion time is critical to processibility in conventional equipment. The total mixing energy is calculated from the area under the curve. The lower the mixing torque, both initial and final, and the mixing energies are, the easier and faster is the dispersibility and, as it would be obvious to those skilled in the art, the easier would be processing of such a formulation, thus enabling processing by conventional mixing and molding equipment. Conventional mixing and molding equipments are equipments that have been developed in the industry to process commodity thermoplastic polymers and thus readily available. Such polymers can be processed at temperatures up to about 300° C. and they exhibit relatively low melt viscosities from about 100 to about 10,000 Pas at shear rates in the range 1 to 1,000 s -1 .
In the embodiment described above using surface treated silicon powder and a polyacetal binder, the initial torque and final, after 60 minutes, torque were both found to be under 100 meter grams and the total mixing energy over 60 minutes of mixing was less than 2000 meter grams. Because of such low torques, addition of one ingredient to the other could be continuously maintained. However when the silicon powder was not surface-modified by silanes according to the present invention, as well as when it was modified only by conventional surfactants such as stearic acid or Hypermer KD-3 without any silane modifier, high initial torques, typically over 1,000 meter grams, final torques after 60 minutes, typically over 200 meter grams, and total mixing energies over 60 minutes, typically in 8000-15,000 meter gram range, were observed. In addition, because of the high initial torques which did not subside fast enough, addition of ingredients to the mixing bowl had to be periodically suspended, in order to bring down the torque before resuming addition. The timing of additions of material is thus very tedious and requires special skills on the part of the operator.
The mixing torques and mixing energies observed while employing formulations of the present invention are low enough to enable continuous processing of such formulations using conventional equipment such as those described above. In the present embodiment a Brabender Prep Center drive unit (Model PLD-651) fitted with a Twin Screw Extruder was used to fabricate continuous cohesive strands of the compounded mix which were then pelletized to a form suitable as a feed to an injection molding machine. On the other hand, when the silicon powder was not treated according to the present invention and then compounded with the polyacetal binder, a poorly and inhomageneous compounded mix resulted. This mix was dry, abrasive, voluminous, and was not extrudable in a continuous strand.
The pelletized mix obtained from this invention could be shaped and converted into metal or ceramic parts by employing standard techniques known to those skilled in the art. In one embodiment of the present invention, the pelletized mix was dried in air and shaped by injection molding with an Arburg "All Rounder" machine (Model 221-55-250, supplied by Polymer Machinery, Kensington, Conn.). In a typical molding experiment, the molding conditions were: melt temperature was between 175 and 200° C., while the mold temperature was between 130 and 140° C. Injection pressure was between 500-1,000 psig and the injection speed varied between medium and maximum. The screw speed was 200-300 rpm and back pressure was zero. The mold had three cavities to form three different shapes including a disk, a stepped bar, and a flex,bar. The molded parts faithfully retained the shape of the mold cavity and had smooth surfaces.
The organic components in the resulting molded part were removed by controlled oxidation in an air oven whose temperature was raised according to a carefully designed time-temperature schedule. A visually porous, blister-free and crack-free silicon body retaining the shape of the mold resulted. The parts were also shown to be defect free upon examination by X-Ray Radiography. This body was then converted into a dense silicon nitride body, still retaining the shape of the mold, by reacting in a nitrogen atmosphere at temperatures from about 1,000° C. to 1,450° C. at a heating rate of 6° /hour.
The following examples are provided in order to further illustrate the present invention. The examples are in no way meant to be limitative, but merely illustrative.
EXAMPLE I
Molding composition from surface-treated silicon powder and a polyacetal binder:
Octadecyltriethoxysilane (5 g) was mixed into a solution of water (836 g), acetic acid (46 g) and isopropyl alcohol (47 g) in a kettle of a high energy, high rpm dispersion mixer (Kady mixer). Silicon powder (Sicomill, grade 4c-p, supplied by Kema Nord Industriekemie, Ljungaverk, Sweden; with mean particle diameter of 7.9 rpm)(250 g) was added slowly with vigorous stirring to disperse it. Temperature was allowed to rise to 60° C. when more octadecyltriethoxysilane (5 g) and silicon powder (250 g) were added in a similar fashion. It was stirred for another 30 minutes and then centrifuged at 3,500 rpm for 30 minutes to separate a wet cake. This cake was washed with isopropyl alcohol and then spread out in shallow trays to air dry. It was further dried in a nitrogen purged oven at 120° C. for 10 hours.
A molding formulation including a polyacetal binder was made as follows. A powder mix was made by mixing the above silane-treated silicon powder (83.30 g), Celcon® M450 polyacetal (an acetal copolymer resin with a melt index of 45, melting point 162° C., and flow temperature 174° C., supplied by Hoechst Celanese Corporation, Engineering Plastics Division, Chatham N.J.) (20.00 g), PEG-8000 and Wax C. This powder mix was melt compounded by adding to a 55 cc Brabender mixing head fitted with roller blades and operated at 190° C. and 50 rpm. The mixing torque rose to 100 meter grams without exhibiting an initial torque maximum. Because of this low torque, the entire addition could be finished in 2.5 minutes. The formulation was well mixed within minutes but mixing was continued for one hour. Final torque was 70 metergrams. Total mixing energy after ten minutes was 251 metergrams and after 60 minutes was 1681 meter grams.
In the above formulation, the quantity of silicon powder amounted to 68 volume percent. At the end of the operation, a continuous strand of melt compounded material was extruded; the strands had sufficient strength to withstand cooling while being conveyed on a moving belt to a pelletizer where it was pelletized.
EXAMPLE 2
Attempt To Mix and Extrude Formulation With Untreated Silicon Powder (comparative Example I):
Untreated silicon powder (Sicomill, grade 4c-p, supplied by Kema Nord Industriekemie) (83.30 g), Celcon® M450 resin (20.13 g), polyethyleneglycol PEG 8000 (4.07 g) and Wax C (1.24 g) were mixed as powders. This powder mix was added to a 55 cc Brabender mixing bowl fitted with roller blades and operated at 190° C. and 50 rpm. The torque rose steeply to values in the 1800 mg range, forcing the addition to be suspended until the initial torque subsided. Addition was then resumed. By this process it took 12 minutes for the entire addition to be complete.
Torque decreased slowly over 1 hour to 300 mg. Total energy of mixing at 1 hour was 14432 mg. Since torque was still decreasing after 1 hour, it was obvious that uniform mixing had not been achieved even in 1 hour mixing time. At the end of the operation, no continuous strand of melt compounded material could be extruded. The short segments that did emerge had a dry appearance. After a short period, the mixer was packed with poorly compounded powder that would not pass.
EXAMPLE 3
Molding formulation from surface-treated silicon powder and polypropylene binder:
Silicon powder (Sicomill, grade 4c-p, 1,000 g) was surface treated as in Example 1 using octadecyl triethoxysilane in isopropyl alcohol. The product was isolated as before and 85.86 grams were mixed with atactic polypropylene (8.573 g), isostatic-polypropylene (2,98 g), Okerin Wax 1865Q (2.614 g) and stearic acid (1.81 g) and melt blended in a Brabender mixer described in Example 1 at 190° C. and 50 rpm speed. The above composition, containing 67.5 volume percent silicon, had a total mixing energy of 12 mg after 60 minutes.
When silicon powder was not surface-treated in the above formulation, the total mixing energy over 60 minutes was 3959 mg.
EXAMPLE 4
Molding formulation from silicon surface modified by stearic acid surfactant only (Comparative Example II)
Silicon powder (Sicomill, grade 4c-p) (1000 g) was treated with stearic acid (20 g) in isopropyl alcohol in a manner similar to Example 1 and the product was isolated and dried in trays. However, on drying, stearic acid became separated and appeared as a white deposit on the surface of the black layer of silicon particles, indicating an inhomogeneous binding. The powder (84.94 g) was mixed with Celcon® M450 (18.186 g), polyethylene glycol PEG 8000 (3,667 g) and Wax C (1.121 g) and melt blended in a Brabender mixer as above at 190° C. and 50 rpm. A high initial torque of 1800 mg was observed which declined to about 300 mg after 60 minutes. Total mixing energy in 60 minutes was 8935 mg.
EXAMPLE 5
Molding formulation from silicon powder surface treated by Hypermer KD-3 only (Comparative Example III):
Untreated silicon powder (Sicomill, grade 4c-p) (83.3 g), Celcon® M450 (17.84 g), PEG 8000 (3.60 g), Wax C (1.10 g) and the processing aid Hypermer KD-3 (2.20 g) were mixed and the mixed formulation and added to a Brabender mixer as above and blended at 190° C. and 50 rpm. Initial torque went above 3000 mg forcing the addition to be suspended temporarily until the mixing torque decreased. Due to the delay this resulted in an addition time of 8 minutes. After 60 minutes, the torque was 275 mg and the total mixing energy 10654 mg.
The effect of changing the composition of the silane reagent used to modify the filler material is shown in Table I.
TABLE I______________________________________Effect of varying the silane reagent onformulations containing Silicon powder, Celcon M450binder, PEG 8000, and Wax C Vol % of Silicon Initial Final Total mixingSilane filler in the Torque Torque Energyreagent composition (mg) (mg) (mg)______________________________________Octadecyl 65.0 104 70 1681triethoxy-silaneOctadecyl 67.0 160 143 2645triethoxy-silaneOctyl 67.0 563 294 6321triethoxy-silaneMethacryl- 65.0 1765 99 5959oxypropyltrimeth-oxysilaneTrimeth- 67.0 1896 178 10587oxysilyl-propyldie-thylene-triamine______________________________________
EXAMPLE 6
Injection molding of the formulation and conversion to a finished part:
A 3 kg batch of moldable formulation was prepared and pelletized as in Example 1, and dried overnight in air at 50° C. It was then injection molded on an Arburg "All Rounder" (Model 221- 55-250 machine (250 KN tons Maximum clamp force, 25 mm screw diameter, screw L/D =18, 2.58 cu. in. maximum shot size) fitted with a "pre-combustion chamber" mold and set for the following conditions:
Injection and Hold Pressures : 750 and 650 psi
Mold Temperature : 130° C.
Barrel Temperature : 190° C.
Hold Time : 20 sec.
Sixty molded parts, each weighing 33 grams were produced.
The organic binder components were removed from the molded shapes by a programmed-temperature oxidation according to the Schedule in Table 2.
TABLE 2______________________________________Schedule for rapid removal of binder componentsfrom a pre-combustion chamber shapeTemperature Heating Rate Elapsed Time°C. °C./hour (hour)______________________________________Ambient to 125 18.0 5.6125-150 9.0 2.8150-240 4.5 20.0240-280 9.0 4.4280-400 20.0 6.0______________________________________
This schedule produced porous, blister-free, crack-free bodies that still retained the original molded pre-combustion chamber shape.
The burnt out bodies were then nitrided in a nitrogen atmosphere at 735 torr. at temperatures that were programmed from 1000° C. to 1450° C. at a heating rate of 6° C. per hour. The parts that resulted had densities higher that 2.5 gram/cc and strengths of more than 200 MPa. | Provided is an injection moldable composition suitable for forming ceramic or metallic greenbodies. The composition comprises in combination an inorganic or metallic filler in an amount of from about 63 volume percent to about 92 volume percent, a binding organic matrix resin, and an organosilane processing reagent represented by the general formula:
SiX.sub.1 X.sub.2 X.sub.3 X.sub.4
wherein at least one of X 1 , X 2 , X 3 or X 4 is an unfunctionalized alkyl or alkenyl group having 10 to 35 carbon atoms and at least one of X 1 , X 2 , X 3 or X 4 is an alkoxy group or halide, such that the moldable composition exhibits a low initial mixing torque upon mechanical agitation. These compositions offer excellent advantage in processibility using conventional mixing and molding equipment.
Also provided is a process for preparing the moldable compositions. | 1 |
CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a U.S. National Stage application under 35 U.S.C. §371 of International Application No. PCT/FR2008/001505 (published as WO 2009/092878 A3), filed Oct. 24, 2008, which claims priority to French Application No. 0707537, filed Oct. 26, 2007. Each of these prior applications is incorporated by reference in its entirety.
The present application claims the priority of the French application No. 0707537 filed on Oct. 26, 2007, the content of which is incorporated by reference into the present application.
TECHNICAL FIELD
The invention relates to a bottle for a cosmetic product containing at least one volatile solvent and more particularly a bottle for mascara. The invention also relates to a distributor/applicator of mascara.
STATE OF THE ART
Such a bottle commonly comprises an aperture and a rigid lateral wall molded in a plastic material or polymer comprising an inside lateral surface in contact with the cosmetic product and an outside lateral surface on which a label is affixed.
Plastic material is preferred to metal or to glass for making mascara bottles because it is lightweight, does not break, has relatively low cost and is easy to use for industrial manufacturing. Also, the mascara bottles are today molded by injection-blowing or by extrusion-blowing so as to obtain bottles including both a lateral wall, an integrated neck and bottom. With blowing it is possible to obtain a solid bottom and a neck including an aperture with a diameter of less than the diameter of the lateral wall in order to receive a wiper for a mascara applicator. The advantage of such moldings by blowing as compared for example with injection-molding is that it is not necessary to attach a separate end, i.e. a bottom and/or a neck, onto the lateral wall, in order to form the bottle.
With increasing sophistication of mascara formulas, and in particular the increasing use of so-called “waterproof” mascara based on volatile solvents for example of the type of alcohols or hydrocarbon compounds such as isododecane, there is an increasing need for bottles for mascara having good barrier properties against volatile solvents. In order to limit losses of volatile solvent by migration or evaporation through the walls of the bottle and thereby avoid drying of the mascara, it is presently necessary to wisely select the constitutive plastic material of the bottle depending on its barrier properties with respect to the volatile solvent and on its compatibility with the formulation of the mascara.
The use of certain grades of polyamides or polyester is thereby known for making mascara bottles because of their barrier properties with respect to non-polar volatile solvents. Such plastic materials are however costly.
Another known solution consists of co-extruding different layers of plastic material, for example three layers, with an intermediate layer including good barrier properties with respect to the volatile solvent, for example in EVOH, for making the mascara bottle. In addition to inducing a high cost, this multilayer co-extrusion makes the molding method complicated and not very reliable, resulting in general lower bottle quality, notably in terms of tolerance on the dimensioning of the neck or of aesthetics at the joint lines.
An object of the present invention is therefore to solve the drawbacks mentioned above and to propose another type of bottle having improved barrier properties with respect to the volatile solvent contained in the cosmetic product, while limiting the cost of the bottle thereof.
Another object of the present invention is to propose a bottle in which the step for checking the compatibility of the bottle with the cosmetic product and for checking the barrier properties may be reduced.
Another object of the present invention is to propose a bottle having both good barrier properties with respect to the volatile solvents and to water.
OBJECT OF THE INVENTION
For this purpose, the object of the invention is a bottle for cosmetic product containing at least one volatile solvent, notably for mascara, comprising an aperture and a rigid lateral wall molded in plastic material comprising an inside lateral surface in contact with said cosmetic product and an outside lateral surface on which a label is affixed, in which the label has barrier properties with respect to the volatile solvent.
The label is then used, in addition to its function of information medium or decoration, for ensuring to the lateral wall of the bottle, a good barrier property with respect to the volatile solvent. According to a preferred embodiment of the invention, this label covers the whole of said outside lateral surface so as to maximize the surface area of the lateral wall having a barrier property with respect to the volatile solvent. As mascara bottles generally have a diameter close to 17 mm for a length close to 80 mm, the lateral wall accounts for about 90% of the exchange surface area of the bottle, so that improving the barrier properties of the lateral wall amounts to strongly improving the barrier properties of the bottle on its whole.
Advantageously, it is no longer necessary to use a plastic material or a multilayer plastic structure having barrier properties with respect to the volatile solvent contained in the cosmetic product in order to form this lateral wall, the barrier with respect to the volatile solvent being ensured by the label, so that it is possible to limit the cost of material for forming the bottle. Therefore it is possible to use any, preferably low cost, plastic material, in order to form the lateral wall of a bottle intended to receive a cosmetic product containing a volatile solvent, regardless of the barrier properties with respect to the volatile solvent of this plastic material, from the moment that this plastic material is compatible with the cosmetic product.
Therefore it is possible to use high density polyethylene (HDPE) in order to form the lateral wall of a bottle intended to receive a cosmetic product containing a volatile solvent in spite of the generally poor barrier properties of HDPE with respect to volatile solvents. In addition to its reasonable price, HDPE has the advantage of being inert and therefore compatible with the compounds used in the cosmetic product formulations. Many tests of compatibilities of the cosmetic product with the bottle may therefore be avoided or reduced. Thus, HDPE further has good barrier properties with respect to water so that a bottle including an HDPE wall covered with a barrier label with respect to volatile solvents has universal barrier properties, i.e. both with respect to water and with respect to volatile solvents, and may receive any type of cosmetic product without it being necessary to be concerned about the evaporation of the cosmetic product. By good barrier properties with respect to water, is meant in the field of mascara, that water confined for 3 months at 40° C. in the tested plastic material is subject to a weight loss of less than 2%.
According to a preferred embodiment of the invention, the label includes an external decoration and/or protection layer, an intermediate barrier layer with respect to the volatile solvent and an internal adhesive layer.
The intermediate barrier layer may comprise a physical barrier such as an aluminium layer, which forms a total barrier with respect to the volatile solvents, but also with respect to water. Such a bottle therefore has universal barrier properties and enables non-evaporation of any mascara formulation stored within it.
This physical barrier may further be formed by a metallized film, for example a film covered with a coating which is deposited by physically depositing a vapor phase, more known under the name of PVD (Physical Vapor Deposition). A film covered with a fine layer of SiO x (10-100 nanometers) is perfectly suitable for this application.
The intermediate barrier layer may otherwise comprise a barrier polymer such as EVOH which forms a known barrier with respect to volatile solvents. This barrier polymer may further be selected from an acetal resin, PET, PVC, a HDPE/EVOH mixture or polyethylene having been subject to fluorination.
The adhesive layer preferably consists of the same material as the lateral wall or of a material compatible with the material of the lateral wall.
The external layer may preferably be a layer of polyethylene terephthalate (PET), polyethylene (PE) or polypropylene (PP), bearing an imprint on its face facing the intermediate layer.
When the adhesive layer consists of a polyolefin, a polyolefin (PE or PP) is advantageously used for forming the external layer so that the adhesive layer properly adheres onto the external layer when there is overlapping of the edges of the label.
According to a preferred embodiment, the bottle comprises a lateral wall and at least one end, the lateral wall and said end consisting of different plastic materials, the plastic material of said end having greater barrier properties with respect to the volatile solvent than those of the plastic material of the lateral wall. A bottle in addition to its natural wall includes two ends formed by a neck forming an aperture and a bottom opposite to this aperture. As the ends are not covered by the label, it is particularly advantageous to mold one of the two ends—or both ends—separately from the lateral wall by using a plastic material having better barrier properties with respect to the volatile solvent than those of the plastic material of the lateral wall and by bringing together the lateral wall and the end—or the ends—in order to form the bottle. The barrier properties of the bottle are then improved. The material overcost for using plastic materials having suitable barrier properties and/or the molding difficulties with such plastic materials are thus advantageously limited to said end and not to the bottle in its whole. Advantageously, the lateral wall may be injection-molded with one of the ends, while the other end including the better barrier properties is added. The added end is preferably the bottom of the bottle since the bottom of the bottle commonly includes a larger exchange surface area than the neck.
According to a preferred embodiment, the plastic material of the end has high barrier properties, so that the volatile solvent confined in this plastic material for 3 months at 40° C. undergoes a weight loss of less than 3%. Such a seal level is suitable for mascara applications.
Also, the basis of the plastic material of said end may be selected from acetal resin, PET, HDPE/EVOH mixture, polyethylene having been subject to fluorination or PVC. The HDPE/EVOH mixture is particularly appreciated for its joint barrier properties with respect to water and with respect to volatile solvents.
According to different preferred embodiments:
the plastic material of the lateral wall may further advantageously have high barrier properties with respect to water, so that the water confined in this plastic material for 3 months at 40° C. undergoes a weight loss of less than 2%; there actually exists a need for a bottle having good barrier properties both with respect to water and with respect to solvents. In order to be used as a bottle of universal use or for containing mascaras containing both volatile solvents and water; the basis of the plastic material of the lateral wall is selected from HDPE or from polylactic acid (PLA); the plastic material of the lateral wall is a plastic material inert with the cosmetic product, selected from PP, PE, biodegradable materials, or a mixture of PP/biodegradable material or PE/biodegradable material; the lateral wall consists of HDPE and the bottom consists of HDPE/EVOH; the lateral wall is injection-molded and the label is affixed on said outside lateral surface during the injection-molding of the lateral wall by a label molding technique in the mold; the fact that the label covers the surface of the lateral wall and is laid by injection-molding allows a reduction in the thickness of the lateral walls while having the same rigidity and strength characteristics as earlier; the thickness of the lateral wall, commonly comprised between 0.8 and 1 mm may then be reduced to a thickness of less than 0.8 mm, which allows reduction in the raw material cost; with label molding in the mold, it is moreover possible to obtain higher adhesion and aesthetical quality than what may be obtained with simple sizing.
Still according to another embodiment of the invention, the bottle further includes a bottom covered with a second label having barrier properties with respect to the volatile solvent. The evaporation of the volatile solvents contained in the bottle is then advantageously prevented at the lateral wall by the label covering the outside lateral surface and by the bottom by this second label.
The invention also extends to a mascara distributor, comprising:
a bottle as defined above intended for receiving mascara; a wiper positioned in the aperture of the bottle; and a means for closing said aperture comprising a gripping means, a rod and a means for applying mascara.
Finally, the invention also extends to a method for making a bottle for a cosmetic product including volatile solvents, notably for mascara, having at least one lateral wall portion in molded plastic material covered by a label and comprising the steps of:
providing a label having barrier properties with respect to the volatile solvents and including an outside decoration or protection layer, an intermediate barrier layer with respect to the volatile solvents and an adhesive internal layer; inserting said label in a mold; injecting said plastic material in the mold so as to achieve label molding in the mold.
Such manufacturing by label molding in the mold allows limitation of the number of successive operations to be carried out in order to obtain the bottle and notably the adhesive bonding of the label on the lateral wall as this is commonly carried out.
In order that such a method be economically viable, the manufacturing by label molding in the mold has however to be carried out at a high rate.
The invention will be better understood by means of the following description and of the appended figures given as a non-limiting example.
SHORT DESCRIPTION OF THE DRAWINGS
FIG. 1 illustrates in a perspective top view a bottle and a label intended to be put on the lateral surface of the bottle.
FIG. 2 is a sectional view of a mascara distributor according to the invention.
FIG. 3 schematically illustrates a label according to the invention.
FIG. 4 illustrates in a top perspective view, a bottle including a bottom added onto the lateral wall.
FIG. 5 is a sectional view of a portion of the bottle of FIG. 4 and schematically illustrates a means for assembling the bottom on the lateral wall.
FIG. 6 illustrates in a top perspective view, a bottle including a neck added onto the lateral wall.
FIG. 7 is a sectional view of a portion of the bottle of FIG. 6 and schematically illustrates a means for assembling the neck on the lateral wall.
FIG. 8 schematically illustrates a machine by means of which the bottle according to the invention may be manufactured.
FIG. 9 illustrates in a front view the devices placed at a station for affixing labels of a particular machine.
FIG. 10 illustrates in a perspective view, the device of FIG. 8 , the transfer means this time being in a position for introducing the labels into imprints of matrices.
FIG. 11 schematically illustrates the vicinity of a mandrel used for transferring the label from a storage area towards the molding cavity, very shortly before the label is conformed around the mandrel.
FIG. 12 a schematically illustrates a molding assembly intended for making a substantially flat bottom and a lateral wall after depositing a label in the imprint of the matrix.
FIG. 12 b details the diagram of FIG. 12 a in the peripheral portion of the imprint which is found in the vicinity of the connection between said bottom and said lateral wall.
DETAILED DESCRIPTION OF THE INVENTION
A label 100 rolled around a bottle 101 intended to receive a cosmetic product and visible by transparence through the label 100 is illustrated in FIG. 1 . The bottle includes a bottom 102 , a lateral wall 103 , the outside lateral surface of which 104 is visible, and a neck 105 including an aperture 106 . The cosmetic products, and notably the mascara, increasingly include non-polar volatile solvents, notably of the alcohol or hydrocarbon type, such as isododecane. The label is further selected for its barrier properties with respect to volatile solvent(s) contained in the cosmetic products and is intended to be adhesively bonded on the outside lateral surface of bottle 101 in order to form the bottle according to the invention.
As mascara bottles generally have a diameter close to 17 mm for a length close to 80 mm, the lateral wall accounts for about 90% of the exchange surface area of the bottle, so that preventing the evaporation of the volatile solvents through this lateral wall by means of the label amounts to limiting 90% of the evaporation of the volatile solvent relatively to a standard bottle.
With the bottles according to the invention, it is possible to observe at lesser costs the requirements as regards preserving the mascara in its package, regularly set to a maximum weight loss of 3% of the volatile solvent after storage for 3 months at 40° C.
A mascara distributor according to the invention including the bottle 101 with its lateral wall 103 covered with the label 100 and a mascara applicator 107 which will be screwed onto the neck 105 for closing the aperture 106 and consisting of a gripping means 108 , of a rod 109 and a means for applying the mascara 110 are illustrated in FIG. 2 . A wiper 111 is further inserted into the aperture 106 of the neck 105 . The label 100 advantageously covers the whole outside lateral surface 104 of the bottle 101 . As shown in FIG. 1 , label 100 bears imprint 120 .
As visible in FIG. 3 , the label includes an external decoration and/or protection layer 112 , an intermediate barrier layer 113 with respect to the volatile solvent and an internal adhesive layer 114 . The intermediate barrier layer 113 is preferably a layer of aluminium which forms a total barrier with respect to volatile solvents, but also with respect to water, this aluminium layer for example having a thickness from 6.5 to 65 μm and preferably from 8 to 12 μm. As shown in FIG. 3 , the external layer 112 may bear an imprint 120 on its face facing the intermediate barrier layer 113 .
The intermediate barrier layer may further be formed by a metallized film, for example a film covered with a SiO x coating with a thickness from 10 to 100 nanometers, deposited by physical vapor phase deposition.
The intermediate barrier layer may however also be formed by a known polymeric material for its barrier properties with respect to volatile solvents such as an EVOH layer.
The internal adhesive layer 114 is made up in the same way as the lateral wall and with a material compatible with the material of the lateral wall. A PE adhesive layer 114 is for example used when the lateral wall 103 is in HDPE. The adhesion between the label and the lateral wall is therefore very strong and there is no risk of delamination or detachment of the label, even after a long period.
The external layer is preferably a layer of polyethylene terephthalate (PET), polyethylene (PE) or polypropylene (PP), bearing an imprint on its face facing the intermediate layer. Such external layers are commonly used for decorating and protecting flexible packages. Quality decorations may be obtained on such external layers by flexography or photogravure which provides vast opportunities in terms of coloration or fineness.
The bottle 101 is advantageously molded in HDPE because HDPE has a reasonable price and is inert and therefore compatible with the compounds used in cosmetic product formulations. HDPE further has good barrier properties with respect to water so that a bottle including a HDPE wall covered with a barrier label with respect to volatile solvents has universal barrier properties, i.e. both with respect to water and with respect to volatile solvents, and may receive any type of cosmetic products without it being necessary to be concerned about the evaporation of the cosmetic product. By good barrier properties with respect to water, is meant in the field of mascara, that water confined for 3 months at 40° C. in the tested plastic material undergoes a maximum weight loss of 2%.
The bottle 101 may also be molded in polylactic acid (PLA) appreciable for its biodegradability properties and for its compatibility with volatile solvents.
Other plastic materials may also be used in cosmetics for molding the bottle 101 after determining their compatibility with the cosmetic product such as for example PP, PE, biodegradable materials such as for example polyhydroxyalkanoate (PHA), polyhydroxybutyrate (PHB), polyhydroxyvalerate (PHV), starch derivatives, succinic acid derivatives, PP/biodegradable material mixtures and PE/biodegradable material mixtures.
Tests were conducted in order to demonstrate the seal of the bottle 101 according to the invention. Cylindrical HDPE bottles (product reference MG9601 of Borealis) with a height of 77 mm for a diameter of 15 mm were filled with 5 ml of water or 5 mL of isododecane, sealed hermetically, and then subject to a temperature of 40° C. for 3 months. The water and isododecane weight losses were 0.8% and 9.9%, respectively. The same bottles with the outside lateral surface covered by a label including an aluminium layer were subject to the same experiment and the water and isododecane weight losses were 0.1% and 1.9%, respectively. Water and isododecane evaporation was strongly reduced with this bottle according to the invention. Such a bottle according to the invention may therefore be used without any modification in order to receive as required, a mascara based on water or a mascara based on isododecane.
In order to further improve the barrier properties of the bottle with respect to a volatile solvent without modifying the advantageously economical and practical constitution of the lateral wall 103 , it is contemplated to additionally act on the barrier properties of the sole portions of the bottle 101 not covered by the label 100 , i.e. the neck 105 and/or on the bottom 102 , further defined by the term of ends.
Thus, two other advantageous embodiments according to the invention are shown in FIGS. 4 , 5 and in FIGS. 6 , 7 , respectively.
As visible in FIGS. 4 and 5 which show the bottle 101 without the label 100 for the sake of clarity, the bottle 101 includes a bottom 102 ′ added on an aperture at the base of the lateral wall 103 ; i.e. the bottom of the bottle is formed by a distinct element 102 ′ which has not been molded with the lateral wall 103 . The bottom 102 ′ is attached to the base of the lateral wall 103 for example by snapping a ridge 115 formed on the lateral wall 103 onto a groove 116 formed on a tab of the bottom 102 ′. The attachment should provide a perfect seal. Other attachment means may of course be used, such as adhesive bonding, welding, screwing . . . .
The bottom 102 ′ was molded in a plastic material having good barrier properties with respect to the volatile solvent of the cosmetic product and more particularly in a plastic material different from the plastic material of the lateral wall and having higher barrier properties with respect to the volatile solvent than those of the plastic material of the lateral wall.
The plastic material of the bottom 102 ′ has high barrier properties, so that the volatile solvent confined in this plastic material for 3 months at 40° C. undergoes a weight loss of less than 3%.
The plastic material of the bottom 102 ′ is more particularly selected from acetal resin, PET, a HDPE/EVOH mixture or polyethylene having undergone fluorination and PVC.
By preventing the evaporation of the volatile solvent through the lateral wall 103 by means of the label 100 and through the bottom 102 ′ by selecting a suitable material, a bottle is obtained which is perfectly adapted to the requirements in the field of cosmetic products and more particularly in the field of mascara.
According to a preferred embodiment of the invention, the bottom 102 ′ consists of a HDPE/EVOH mixture, the lateral wall 103 consists of HDPE and the label 100 includes an aluminium layer.
As visible in FIGS. 6 and 7 which show the bottle 101 without a label 100 for the sake of clarity, the bottle 101 includes a neck 105 ′ added onto an aperture at the top of the lateral wall 103 ; i.e. the neck of the bottle is formed by a distinct element 105 ′ which has not been molded with the lateral wall 103 . The neck 105 ′ is attached to the lateral wall 103 , for example by snapping a ridge 117 formed on the lateral wall 103 onto a groove 118 formed on the neck 105 ′. The attachment should provide a perfect seal. Other attachment means may of course be used, such as adhesive bonding, welding, screwing . . . .
The neck 105 ′ was molded in a plastic material having good barrier properties with respect to the volatile solvent of the cosmetic product and more particularly in a plastic material different from the plastic material of the lateral wall 103 and having higher barrier properties with respect to the volatile solvent than those of the plastic material of the lateral wall 103 .
The plastic material of the neck 105 ′ has high barrier properties, so that the volatile solvent confined in this plastic material for 3 months at 40° C., undergoes a weight loss of less than 3%.
The plastic material of the neck 105 ′ is more particularly selected from acetal resin, PET, HDPE/EVOH mixture or polyethylene having undergone fluorination and PVC.
By preventing the evaporation of the volatile solvent through the lateral wall 103 by means of the label 100 and through the neck 105 ′ by selecting a suitable material, a bottle is obtained which is perfectly adapted to the requirements in the field of cosmetic products and more particularly in the field of mascara.
According to a preferred embodiment of the invention, the neck 105 ′ consists of a HDPE/EVOH mixture, the lateral wall 103 consists of HDPE and the label 100 includes an aluminium layer.
Of course, for greater efficiency, it is also possible to add both a neck 105 ′ and a bottom 102 ′ on a lateral wall 103 covered with a label 100 .
We shall discuss hereafter as an example a particularly advantageous method for making the product according to the invention, and more particularly the bottle 101 illustrated by FIGS. 6 and 7 .
In fields other than that of mascara bottles, bodies in plastic material are known for which the outer surface is provided with a label. These labels may be applied on the outer surface by means of so-called “in-mold labeling” (IML) method but which we shall prefer to subsequently designate by label molding in the mold. It is particularly interesting for making bottles in plastic material, having a lateral wall covered by a label, said lateral wall extending along an axisymmetrical surface with a perpendicular axis, such as cylinder or a frustum, to the plane of the bottom. It is intended even more particularly for containers or bottles, the dimensions of which are relatively small, i.e. with a diameter comprised between 13 and 60 mm and a height comprised between 40 and 200 mm and the lateral wall of which is entirely covered or almost entirely covered by said label.
The molding is carried out by injecting plastic material into a mold including at least two portions movable relatively to each other, which, by bringing them closer to each other, allows a molding cavity to be made and which by moving them away from each other allows the molded part to be ejected. For more specifically targeted axisymmetrical bottles, the mold comprises a female portion or die, including at least one hollow imprint corresponding to the external shape of the bottle, and a male portion or punch, including at least one raised imprint corresponding to the internal face of said bottle.
In order to make the present invention economically viable by using a label molding technique in the mold, it is possible to use a manufacturing method with which a manufacturing cycle time for such bottles, as short as possible, may be ensured. Moreover it is interesting that this method may repeatedly ensure accurate positioning of the label, in particular when the latter has to entirely cover the lateral wall of the bottle.
For this, it is possible to use, as a non-limiting example, the manufacturing method described below and illustrated by FIGS. 7-12 b.
In order to mold mascara bottles having a substantially flat bottom and an asymmetrical or quasi-cylindrical lateral wall entirely covered with a label, a machine is used which comprises:
an indexed rotary plate 60 operating stepwise and subdivided into six sectors for serving six work stations. On this plate are mounted in each of the six sectors, six molding assemblies 50 , each comprising six dies 31 , grouped in a die-holder assembly 30 and six punches 41 grouped in a punch-holder assembly 40 ; the punches and the dies appear here as a rake, aligned so that their axes are parallel to each other and equidistant; an injection press (not shown), placed on one of the work stations of the rotary plate, a device for affixing labels located upstream from the injection press, schematized in FIG. 1 and detailed in FIGS. 2 and 3 , comprising six interdependent mandrels 21 and placed as a rake with a distance between their axes identical to that of the dies and of the punches, each acting as a means 20 for transferring the labels, driven by a first actuator 90 , which in fact is an assembly of actuator cylinders and rotary motors allowing the mandrels 21 to be presented substantially horizontally so that they receive the labels 5 and the latter to be presented substantially vertically so that they may be introduced, provided with their labels, inside the imprints 32 of the dies 31 , the molding assembly 50 being opened at said station for affixing the labels, so that said labels may be deposited in said imprints.
Supply of labels is ensured by a rotary table 71 comprising two diametrically opposite magazines 72 and 73 , one ( 72 ) ready to be filled, the other one ( 73 ) comprising six stacks of labels is placed under six cylinders with suction cups 11 , each acting as a means 10 for picking up labels. The whole of the suction cup cylinders 11 may be displaced above an area where the mandrels 21 actuated by the actuator 90 , are placed horizontally so as to each receive a label 5 ′.
The labels 5 ′ have been cut out in a multilayer flexible sheet in plastic material, comprising an external layer printed in four colors by flexography and an aluminium layer forming a barrier with respect to diffusion of gases. They have larger width, of the order of 1 mm at the circumference of the lateral wall of the bottle to be made. They have greater length of the order of 1 mm, at the height of the lateral wall of the bottle to be made.
The labels 5 ′ are presented in such a way that they arrive slightly unbalanced on their mandrels 21 : their middle axis 7 forms with the upper generatrix 24 of the associated mandrel an angle close to 10° (measured in a plane perpendicular to the axis of the mandrel).
The mandrels 21 are cylindrical with sections of 0.5 mm smaller diameters than those of the dies. Each mandrel 21 is provided with channels 22 opening onto its surface and in which air may be sucked up or blown.
While sucking up air through the channels 22 of the mandrels 21 , the labels 5 ′ are released from the suction cups 11 and the latter will rest on the upper generatrix 24 of the mandrels 21 placed horizontally. In order to conform the labels 5 ′ on the mandrels 21 , 6 upper half-shells 83 also arranged as a rake, which apply the labels against the upper portion of the mandrels, are moved down. The shaping of the label is continued by moving up the 6 lower half-shells 83 . During this upward movement, for each label, the edges follow the wall of the hollow surface 84 of the lower half-shells 83 until they overlap by over about 1 mm. The final geometrical configuration of the thereby conformed label is such that the edges or any other portion of the label do not touch the wall of the imprint of the die, during the introduction of the mandrel into the imprint of the die.
The half-shells are removed while maintaining suction of air through the mandrels 21 . By means of the first actuator 90 , the mandrels 21 are displaced towards the rotary plate and the 6 molding assemblies 50 maintained in the open position. The six mandrels 31 are introduced into the six imprints 32 of the dies 31 while maintaining sufficient suction power so that the labels are maintained conformed in this way.
Each mandrel 21 is provided with three rows of opening channels 22 , one row aligned on the upper generatrix 24 of the mandrel and two rows aligned along the symmetrical generatrices relatively to the vertical diametrical plane of said mandrel, the closest edge of the orifices being located at a distance close to 3 mm from the lower generatrix 25 . The orifices are regularly positioned on said generatrices, at a distance close to 3 mm from each other. By sucking up air with a negative pressure of the order of 4-5 bars, one manages to maintain said flattened labels on their mandrels and to introduce the latter inside the imprints of the dies without there being any collision.
When the mandrels 21 have penetrated into the imprints 32 to a predetermined depth, the airflow direction is reversed in the channels 22 of the mandrels 21 so that the labels unroll and their edges come into contact with the lateral walls of imprints 32 .
The predetermined penetration depth of the mandrels into the imprints is defined so that, when the latter is reached, the ends of the labels extend beyond the imprints of the dies by a distance close to 1 mm.
The punches 41 have a lateral surface which is provided at the base of a shoulder 42 forming a joint plane with the associated die 31 . The shoulder is placed at a distance such that when the punch 41 and the matrix 31 are brought closer together, the jutting-out end 6 of the label 5 ′ comes into abutment against said shoulder 42 and is driven by the latter towards the bottom 33 of the die 31 until it occupies it final position.
When the punch 41 and the die 31 are side-by-side in order to form the molding cavity, the second end 8 of the label juts out from the punch 41 into the molding cavity. The peripheral portion 34 of the imprint has the following shape:
at the periphery, the lateral wall 35 of the imprint facing the punch 41 remains substantially axial; when the die 31 and the punch 41 are in contact with each other, the bottom 33 of the imprint 32 of the die 31 being at right angles to the lateral wall is at a greater depth than the jutting-out height of the second end 8 of the label, so that said end does not come into abutment on the bottom of said die imprint and that, during the injection, the plastic material injected in a point located close to the axis, has to flow radially in an annular peripheral area 36 located above the apical slice of said end portion; the bottom of the die has an annular boss 37 which is an obstacle to the flow of the plastic material towards said annular peripheral area 36 , the outside edge 38 of said annular boss 37 and the inside edge of the second end being distant from each other by a value smaller than the average thickness of said bottom.
The molding assemblies are then closed and locked and the rotary plate rotates so that the molding assemblies arrive at the molding station. Downstream, two stations are dedicated to cooling the thereby molded elements and a station is dedicated to ejecting the molded elements after the molding devices have been opened. A maneuvering device ensuring the opening, closing and locking of the mobile portions of the molding assemblies is placed in each sector of the rotary plate, associated with six punches and with six dies. Thus, this operation may be performed concurrently independently of the immobilization time at each station.
With such a machine, mascara containers for which the lateral wall comprised between 0.6 and 1.5 mm is entirely covered with a label are easily made at a clearly higher rate relative to standard injection.
Still according to another advantageous embodiment of the bottle, the bottom 102 of the bottle 101 of FIG. 1 may further be covered with a second label having barrier properties with respect to the volatile solvent. The bottom generally forming an outside planar surface, the attachment of the second label onto the bottom may be carried out in a simple way. The evaporation of the volatile solvents contained in the bottle 101 is then advantageously prevented at the lateral wall 103 by the label 100 covering the outside lateral surface 104 and through the bottom 102 by this second label. This second label for example has physical characteristics and properties identical with those of the label 100 . The bottom 102 as for it, may have physical characteristics identical with those of the lateral wall.
The bottom 102 and the lateral wall 103 may for example have been molded together with the label 100 as the second label. The label 100 and the second label may form a single label or two distinct labels.
The label 102 and the lateral wall 103 may further have been molded together only with the label 100 . The second label may then be adhesively bonded subsequently, for example during the filling of the bottle in order to reference the bottle.
The lateral wall 103 may further be molded with the label 100 separately from the bottom which is molded with the second label, and then the bottom 102 added onto the lateral wall 103 . | Bottle ( 101 ) for a cosmetic product containing a volatile solvent, especially for mascara, comprising an opening ( 106 ) and a rigid side wall ( 103 ) produced as a plastic molding having an inside lateral surface in contact with said cosmetic product and an outside lateral surface ( 104 ) to which a label ( 100 ) is affixed, said label having barrier properties with regard to the volatile solvent. This label advantageously covers the entire outside lateral surface. | 1 |
This application is a continuation of application Ser. No. 10/089,991, filed Dec. 23, 2002, now U.S. Pat. No. 6,649,651, which is a national stage filing under 35 U.S.C. §371 of International Application No. PCT/EP00/09917, filed Oct. 6, 2000, which claims the benefit of U.S. Provisional Application Ser. No. 60/157,850 filed Oct. 6, 1999, the disclosures of which are herein incorporated by reference.
STATEMENT OF FEDERALLY SPONSORED RESEARCH
The U.S. Government may have certain rights in the invention described herein.
This application claims priority benefit to U.S. Provisional Application No. 60/157,850, filed on Oct. 6, 1999, the contents of which are expressly incorporated by reference herein.
The present invention relates to novel bis-tetrahydrofuran benzodioxolyl sulfonamide compounds, compositions comprising them and processes for their preparation. It also relates to the use of the present compounds as pharmaceutical active compounds for the therapy and prophylaxis of retroviral infections, particularly HIV infections, and most particularly for multidrug resistant HIV infections in a mammal.
Resistance of HIV against inhibitors is a major cause of therapy failure. Half of the patients receiving anti-HIV combination therapy do not respond fully to the treatment, mainly because of resistance of the virus to one or more drugs used. Moreover, it has been shown that resistant virus is carried over to newly infected individuals, resulting in severely limited therapy options for these drug-naive patients. Therefore, there is a need in the art for new compounds for retrovirus therapy, more particularly for AIDS therapy. The need in the art is particularly acute for compounds that are active not only on wild type virus, but also on the increasingly more common resistant viruses. Moreover, protease inhibitors are commonly administered to AIDS patients in combination with other anti-HIV compounds such as, for instance NRTIs and/or NNRTIs. This causes a high pill burden upon the patient. One way of reducing this pill burden is finding anti-HIV compounds like protease inhibitors with good bioavailability, i.e. a favorable pharmacokinetic and metabolic profile, such that the daily dose can be minimized. Another important characteristic of a good protease inhibitor, and for anti-HIV compounds in general is that protein plasma binding of the protease inhibitor has minimal or even no effect on its potency.
Several published patent applications disclose HIV protease inhibitors. For instance, WO 95/06030 discloses HIV protease inhibitors with a hydroxyethylamino sulfonamide core structure. Also Ghosh et al. (Bioorganic & Medicinal Chemistry Letters, 8, 1998, 687–690) discloses hydroxyethylamino sulfonamide HIV protease inhibitors.
The compounds of the present invention are surprisingly effective HIV protease inhibitors in terms of their activity over a broad range of HIV mutants and in terms of their bioavailability. Additional objects and advantages will be set forth in part in the description which follows, and in part will be obvious from the description, or may be learned by practice of the invention. The objects and advantages of the invention will be realized and attained by means of the elements and combinations particularly pointed out in the claims.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 illustrates the serum concentration of the compound 13 after a single oral dose administration as a function of time.
FIG. 2 compares the activity of the inventive compounds 13 and 14 and several commercially available anti-viral compounds against a small panel of viral stains.
DETAILED DESCRIPTION OF THE INVENTION
In order that the invention herein described may be more fully understood, the following detailed description is set forth.
The present invention relates to the compounds having the formula
and N-oxides, salts, esters, stereoisomeric forms, racemic mixtures, prodrugs and metabolites thereof. The molecular structure depicted above is named hexahydrofuro[2,3-b]furan-3-yl-N-{3-[(1,3-benzodioxol-5-ylsufonyl)(isobutyl)amino]-1-benzyl-2-hydroxypropyl}carbamate.
This invention also envisions the quaternization of the nitrogen atoms of the present compounds. A basic nitrogen can be quaternized with any agent known to those of ordinary skill in the art including, for instance, lower alkyl halides, dialkyl sulfates, long chain halides and aralkyl halides. Water or oil-soluble or dispensible products may be obtained by such quaternization.
The term prodrug as used throughout this text means the pharmacologically acceptable derivatives such as esters, amides and phosphates, such that the resulting biotransformation product of the derivative is the active drug as defined in the compounds of formula (I). The reference by Goodman and Gilman (The Pharmacological Basis of Therapeutics, 8 th ed, McGraw-Hill, Int. Ed. 1992. “Biotransformation of Drugs”, p 13–15) describing prodrugs generally is hereby incorporated. Typical examples of prodrugs are described for instance in WO 99/33795, WO 99/33815, WO 99/33793 and WO 99/33792 all incorporated herein by reference.
Prodrugs are characterized by excellent aqueous solubility, increased bioavailability and are readily metabolized into the active inhibitors in vivo.
For therapeutic use, the salts of the compounds of formula (I) are those wherein the counterion is pharmaceutically or physiologically acceptable. However, salts having a not-pharmaceutically acceptable counterion may also find use, for example, in the preparation or purification of a pharmaceutically acceptable compound of formula (I). All salts, whether pharmaceutically acceptable or not are included within the ambit of the present invention.
The pharmaceutically acceptable or physiologically tolerable addition salt forms which the compounds of the present invention are able to form can conveniently be prepared using the appropriate acids, such as, for example, inorganic acids such as hydrohalic acids, e.g. hydrochloric or hydrobromic acid, sulfuric; nitric; phosphoric and the like acids; or organic acids such as, for example, acetic, propanoic, hydroxyacetic, lactic, pyruvic, oxalic, malonic, succinic, maleic, fumaric, malic, tartaric, citric, methanesulfonic, ethanesulfonic, benzenesulfonic, p-toluenesulfonic, cyclamic, salicylic, p-aminosalicylic, pamoic and the like acids.
Conversely said salt forms can be converted by treatment with an appropriate base into the free base form.
The term salts also comprises the hydrates and the solvent addition forms which the compounds of the present invention are able to form. Examples of such forms are e.g. hydrates, alcoholates and the like.
The N-oxide forms of the present compounds are meant to comprise the compounds of formula (I) wherein one or several nitrogen atoms are oxidized to the so-called N-oxide.
The present compounds may also exist in their tautomeric forms. Such forms, although not explicitely indicated in the above formula are intended to be included within the scope of the present invention.
The term stereochemically isomeric forms of compounds of the present invention, as used hereinbefore, defines all possible compounds made up of the same atoms bonded by the same sequence of bonds but having different three-dimensional structures which are not interchangeable, which the compounds of the present invention may possess. Unless otherwise mentioned or indicated, the chemical designation of a compound encompasses the mixture of all possible stereochemically isomeric forms which said compound may possess. Said mixture may contain all diasteromers and/or enantiomers of the basic molecular structure of said compound. All stereochemically isomeric forms of the compounds of the present invention both in pure form or in admixture with each other are intended to be embraced within the scope of the present invention.
Pure stereoisomeric forms of the compounds and intermediates as mentioned herein are defined as isomers substantially free of other enantiomeric or diastereomeric forms of the same basic molecular sure of said compounds or intermediates. In particular, the term ‘stereoisomerically pure’ concerns compounds or intermediates having a stereoisomeric excess of at least 80% (i.e. minimum 90% of one isomer and maximum 10% of the other possible isomers) up to a stereoisomeric excess of 100% (i.e. 100% of one isomer and none of the other), more in particular, compounds or intermediates having a stereoisomeric excess of 90% up to 100%, even more in particular having a stereoisomeric excess of 94% up to 100% and most in particular having a stereoisomeric excess of 97% up to 100%. The terms ‘enantiomerically pure’ and ‘diastereomerically pure’ should be understood in a similar way, but then having regard to the enantiomeric excess, respectively the diastereomeric excess of the mixture in question.
Pure stereoisomeric forms of the compounds and intermediates of this invention may be obtained by the application of art-known procedures. For instance, enantiomers may be separated from each other by the selective crystallization of their diastereomeric salts with optically active acids. Alternatively, enantiomers may be separated by chromatographic techniques using chiral stationary phases. Said pure stereochemically isomeric forms may also be derived from the corresponding pure stereochemically isomeric forms of the appropriate sting materials, provided that the reaction occurs stereospecifically. Preferably, if a specific stereoisomer is desired, said compound will be synthesized by stereospecific methods of preparation. These methods will advantageously employ enantiomerically pure starting materials.
It is clear to a person skilled in the art that the compounds of formula (I) contain 5 centers of chirality and thus exist as stereoisomeric forms. These 5 centers of chirality are indicated with a numbered asterisk (*1, *2, *3, *4 and * 5) in the figure below.
The absolute configuration of each asymmetric center may be indicated by the stereochemical descriptors R and S, this R and S notation corresponding to the rules described in Pure Appl. Chem. 1976, 45, 11–30. The preferred configuration of the bis-tetrahydrofuran ring is the one where carbon atom *1 has an R configuration, carbon atom *2 an S configuration and carbon atom *3 an R configuration, where carbon atom *1 has an S configuration, carbon atom *2 an R configuration and carbon atom *3 an S configuration. Carbon atom *4 is preferably in the S configuration and carbon atom *5 in the R configuration.
The following 32 enantiomeric forms in table 1 exist of the compound with basic structure (I). The chiral carbon atoms are named as shown in the figure above.
TABLE A
Comp
*1
*2
*3
*4
*5
a
R
R
R
R
R
b
R
R
R
R
S
c
R
R
R
S
R
d
R
R
S
R
R
e
R
S
R
R
R
f
S
R
R
R
R
g
R
R
R
S
S
h
R
R
S
R
S
i
R
S
R
R
S
j
S
R
R
R
S
k
R
R
S
S
R
l
R
S
R
S
R
m
S
R
R
S
R
n
R
S
S
R
R
o
S
R
S
R
R
p
S
S
R
R
R
q
R
R
S
S
S
r
R
S
R
S
S
s
S
R
R
S
S
t
R
S
S
R
S
u
S
R
S
R
S
v
R
S
S
S
R
w
S
R
S
S
R
x
S
S
S
R
R
y
S
S
R
S
R
z
S
S
R
R
S
aa
S
S
S
S
R
bb
S
S
S
R
S
cc
S
S
R
S
S
dd
S
R
S
S
S
ee
R
S
S
S
S
ff
S
S
S
S
S
Compounds l and w are the preferred enantiomeric pure forms, in particular
Whenever used hereinafter, the term “compounds of formula (I)”, or “the present compounds” or similar term is meant to include the compound as depicted above, their N-oxides, salts, esters, stereoisomeric forms, racemic mixtures, prodrugs and metabolites, as well as their quaternized nitrogen derivatives.
The present compounds can thus be used in animals, preferably in mammals, and in particular in humans as pharmaceuticals per se, in mixtures with one another or in the form of pharmaceutical preparations.
Furthermore, the present invention relates to pharmaceutical preparations which as active constituents contain an effective dose of at least one of the compounds of formula (I) and/or of a physiologically tolerable salt thereof in addition to customary pharmaceutically innocuous excipients and auxiliaries. The pharmaceutical preparations normally contain 0.1 to 90% by weight of a compound of formula (I) and/or its physiologically tolerable salts. The pharmaceutical preparations can be prepared in a manner known per se to one of skill in the art. For this purpose, at least one of a compound of formula (I) and/or its physiologically tolerable salts, together with one or more solid or liquid pharmaceutical excipients and/or auxiliaries and, if desired, in combination with other pharmaceutical active compounds, are brought into a suitable administration form or dosage form which can then be used as a pharmaceutical in human medicine or veterinary medicine.
Pharmaceuticals which contain a compound according to the invention and/or its physiologically tolerable salts can be administered orally, parenterally, e.g., intravenously, rectally, by inhalation, or topically, the preferred administration being dependent on the individual case, e.g., the particular course of the disorder to be treated. Oral administration is preferred.
The person skilled in the art is familiar on the basis of his expert knowledge with the auxiliaries which are suitable for the desired pharmaceutical formulation. Beside solvents, gel-forming agents, suppository bases, tablet auxiliaries and other active compound carriers, antioxidants, dispersants, emulsifiers, antifoams, flavor corrigents, preservatives, solubilizers, agents for achieving a depot effect, buffer substances or colorants are also useful.
Due to their antiretroviral properties, particularly their anti-HIV properties, especially their anti-HIV-1-activity, the compounds of the present invention are useful in the treatment of individuals infected by HIV and for the prophylaxis of these individuals. In general, the compounds of the present invention may be useful in the treatment of warm-blooded animals infected with viruses whose existence is mediated by, or depends upon, the protease enzyme. Conditions which may be prevented or treated with the compounds of the present invention, especially conditions associated with HIV and other pathogenic retroviruses, include AIDS, AIDS-related complex (ARC), progressive generalized lymphadenopathy (PGL), as well as chronic CNS diseases caused by retroviruses, such as, for example HIV mediated dementia and multiple sclerosis.
The compounds of the present invention or any subgroup thereof may therefore be used as medicines against above-mentioned conditions. Said use as a medicine or method of treatment comprises the systemic administration to HIV-infected subjects of an amount effective to combat the conditions associated with HIV and other pathogenic retroviruses, especially HIV-1. Consequently, the compounds of the present invention can be used in the manufacture of a medicament useful for treating conditions associated with HIV and other pathogenic retroviruses, in particular with medicaments with retroviral protease inhibitory action.
Also, the combination of an antiretroviral compound and a compound of the present invention can be used as a medicine. Thus, the present invention also relates to a product containing (a) a compound of the present invention, and (b) another antiretroviral compound, as a combined preparation for simultaneous, separate or sequential use in treatment of retroviral infections, in particular with multidrug resistant retroviruses. Thus, to combat or treat HIV infections, or the infection and disease associated with HIV infections, such as Acquired Immunodeficiency Syndrome (AIDS) or AIDS Related Complex (ARC), the compounds of this invention may be co-administered in combination with for instance, binding inhibitors, such as, for example, dextran sulfate, suramine, polyanions, soluble CD4; fusion inhibitors, such as, for example, T20, T1249, SHC-C; co-receptor binding inhibitors, such as, for example, AMD 3100 (Bicyclams), TAK 779; RT inhibitors, such as, for example, foscarnet and prodrugs; nucleoside RTIs, such as, for example, AZT, 3TC, DDC, DDI, D4T, Abacavir, FTC, DAPD, dOTC; nucleotide RTIs, such as, for example, PMEA, PMPA; NNRTIs, such as, for example, nevirapine, delavirdine, efavirenz, 8 and 9-Cl TIBO (tivirapine), loviride, TMC-125, TMC-120, MKC-442, UC 781, Capravirine, DPC 961, DPC963, DPC082, DPC083, calanolide A, SJ-3366, TSAO, 4″-deaminated TSAO; RNAse H inhibitors, such as, for example, SP1093V, PD126338; TAT inhibitors, such as, for example, RO-5-3335, K12, K37; integrase inhibitors, such as, for example, L 708906, L 731988; protease inhibitors, such as, for example, amprenavir, ritonavir, nelfinavir, saquinavir, indinavir, lopinavir, BMS 232632, DPC 681, DPC 684, tipranavir, AG1776, DMP 450, L 756425, PD178390; glycosylation inhibitors, such as, for example, castanospermine, deoxynojirimycine.
The combination may provide a synergistic effect, whereby viral infectivity and its associated symptoms may be prevented, substantially reduced, or eliminated completely. The compounds of the present invention may also be administered in combination with immunomodulators (e.g., bropirimine, anti-human alpha interferon antibody, IL-2, methionine enkephalin interferon alpha, and naltrexone) or with antibiotics (e.g., pentamidine isothiorate) to ameliorate, combat, or eliminate HE infection and its symptoms.
For an oral administration form, the compounds of the present invention or a salt thereof is mixed with suitable additives, such as excipients, stabilizers or inert diluents, and brought by means of the customary methods into the suitable administration forms, such as tablets, coated tablets, hard capsules, aqueous, alcoholic, or oily solutions. Examples of suitable inert carriers are gum arabic, magnesia, magnesium carbonate, potassium phosphate, lactose, glucose, or starch, in particular, corn starch. In this case the preparation can be carried out both as dry and as moist granules. Suitable oily excipients or solvents are vegetable or animal oils, such as sunflower oil or cod liver oil. Suitable solvents for aqueous or alcoholic solutions are water, ethanol, sugar solutions, or mixtures thereof. Polyethylene glycols and polypropylene glycols are also useful as further auxiliaries for other administration forms.
For subcutaneous or intravenous administration, the active compounds, if desired with the substances customary therefor such as solubilizers, emulsifiers or further auxiliaries, are brought into solution, suspension, or emulsion. The compounds of formula (I) and their physiologically tolerable salts can also be lyophilized and the lyophilizates obtained used, for example, for the production of injection or infusion preparations. Suitable solvents are, for example, water, physiological saline solution or alcohols, e.g. ethanol, propanol, glycerol, in addition also sugar solutions such as glucose or mannitol solutions, or alternatively mixtures of the various solvents mentioned.
Suitable pharmaceutical formulations for administration in the form of aerosols or sprays are, for example, solutions, suspensions or emulsions of the compounds of formula (I) or their physiologically tolerable salts in a pharmaceutically acceptable solvent, such as ethanol or water, or a mixture of such solvents. If required, the formulation can also additionally contain other pharmaceutical auxiliaries such as surfactants, emulsifiers and stabilizers as well as a propellant. Such a preparation customarily contains the active compound in a concentration from approximately 0.1 to 50%, in particular from approximately 0.3 to 3% by weight.
In order to enhance the solubility and/or the stability of the compounds of formula (I) in pharmaceutical compositions, it can be advantageous to employ α-, β- or γ-cyclodextrins or their derivatives. Also co-solvents such as alcohols may improve the solubility and/or the stability of the compounds of formula (I) in pharmaceutical compositions. In the preparation of aqueous compositions, addition salts of the subject compounds are obviously more suitable due to their increased water solubility.
Appropriate cyclodextrins are α-, β- or γ-cyclodextrins (CDs) or ethers and mixed ethers thereof wherein one or more of the hydroxy groups of the anhydroglucose units of the cyclodextrin are substituted with C 1-6 alkyl, particularly methyl, ethyl or isopropyl, e.g. randomly methylated β-CD; hydroxyC 1-6 alkyl, particularly hydroxy-ethyl, hydroxypropyl or hydroxybutyl; carboxyC 1-6 alkyl, particularly carboxymethyl or carboxyethyl; C 1-6 alkylcarbonyl particularly acetyl; C 1-6 alkyloxycarbonylC 1-6 alkyl or carboxyC 1-6 alkyloxyC 1-6 alkyl, particularly carboxymethoxypropyl or carboxy-ethoxypropyl; C 1-6 alkylcarbonyloxyC 1-6 alkyl, particularly 2-acetyloxypropyl. Especially noteworthy as complexants and/or solubilizers are β-CD, randomly methylated β-CD, 2,6-dimethyl-β-CD, 2-hydroxyethyl-β-CD, 2-hydroxyethyl-γ-CD, 2-hydroxypropyl-γ-CD and (2-carboxymethoxy)propyl-β-CD, and in particular 2-hydroxypropyl-β-CD (2-HP-β-CD).
The term mixed ether denotes cyclodextrin derivatives wherein at least two cyclodextrin hydroxy groups are etherified with different groups such as, for example, hydroxy-propyl and hydroxyethyl.
An interesting way of formulating the present compounds in combination with a cyclodextrin or a derivative thereof has been described in EP-A-721,331. Although the formulations described therein are with antifungal active ingredients, they are equally interesting for formulating the present antiretroviral compounds. The formulations described therein are particularly suitable for oral administration and comprise an antifungal as active ingredient, a sufficient amount of a cyclodextrin or a derivative thereof as a solubilizer, an aqueous acidic medium as bulk liquid carrier and an alcoholic co-solvent that greatly simplifies the preparation of the composition. Said formulations may also be rendered more palatable by adding pharmaceutically acceptable sweeteners and/or flavours.
Other convenient ways to enhance the solubility of the compounds of the present invention in pharmaceutical compositions are described in W0-94/05263, PCT application No. PCT/EP98/01773, EP-A-499,299 and WO 97/44014, all incorporated herein by reference.
More in particular, the present compounds may be formulated in a pharmaceutical composition comprising a therapeutically effective amount of particles consisting of a solid dispersion comprising (a) a compound of formula (I), and (b) one or more pharmaceutically acceptable water-soluble polymers.
The term “a solid dispersion” defines a system in a solid state (as opposed to a liquid or gaseous state) comprising at least two components, wherein one component is dispersed more or less evenly throughout the other component or components. When said dispersion of the components is such that the system is chemically and physically uniform or homogenous throughout or consists of one phase as defined in thermo-dynamics, such a solid dispersion is referred to as “a solid solution”. Solid solutions are preferred physical systems because the components therein are usually readily bioavailable to the organisms to which they are administered.
The term “a solid dispersion” also comprises dispersions which are less homogenous throughout than solid solutions. Such dispersions are not chemically and physically uniform throughout or comprise more than one phase.
The water-soluble polymer in the particles is conveniently a polymer that has an apparent viscosity of 1 to 100 mPa.s when dissolved in a 2% aqueous solution at 20° C. solution.
Preferred water-soluble polymers are hydroxypropyl methylcelluloses or HPMC. HPMC having a methoxy degree of substitution from about 0.8 to about 2.5 and a hydroxypropyl molar substitution from about 0.05 to about 3.0 are generally water soluble. Methoxy degree of substitution refers to the average number of methyl ether groups present per anhydroglucose unit of the cellulose molecule. Hydroxy-propyl molar substitution refers to the average number of moles of propylene oxide which have reacted with each anhydroglucose unit of the cellulose molecule.
The particles as defined hereinabove can be prepared by first preparing a solid dispersion of the components, and then optionally grinding or milling that dispersion. Various techniques exist for preparing solid dispersions including melt extrusion, spray-drying and solution-evaporation, melt-extrusion being preferred.
It may further be convenient to formulate the present antiretrovirals in the form of nanoparticles which have a surface modifier adsorbed on the surface thereof in an amount sufficient to maintain an effective average particle size of less than 1000 nm. Useful surface modifiers are believed to include those which physically adhere to the surface of the antiretroviral agent but do not chemically bond to the antiretroviral agent.
Suitable surface modifiers can preferably be selected from known organic and inorganic pharmaceutical excipients. Such excipients include various polymers, low molecular weight oligomers, natural products and surfactants. Preferred surface modifiers include nonionic and anionic surfactants.
Yet another interesting way of formulating the present compounds involves a pharmaceutical composition whereby the present antiretrovirals are incorporated in hydrophilic polymers and applying this mixture as a coat film over many small beads, thus yielding a composition with good bioavailability which can conveniently be manufactured and which is suitable for preparing pharmaceutical dosage forms for oral administration.
Said beads comprise (a) a central, rounded or spherical core, (b) a coating film of a hydrophilic polymer and an antiretroviral agent and (c) a seal-coating polymer layer.
Materials suitable for use as cores in the beads are manifold, provided that said materials are pharmaceutically acceptable and have appropriate dimensions and firmness. Examples of such materials are polymers, inorganic substances, organic substances, and saccharides and derivatives thereof.
The dose of the present compounds or of the physiologically tolerable salt(s) thereof to be administered depends on the individual case and, as customary, is to be adapted to the conditions of the individual case for an optimum effect. Thus it depends, of course, on the frequency of administration and on the potency and duration of action of the compounds employed in each case for therapy or prophylaxis, but also on the nature and severity of the infection and symptoms, and on the sex, age, weight and individual responsiveness of the human or animal to be treated and on whether the therapy is acute or prophylactic. Customarily, the daily dose of a compound of formula (I) in the case of administration to a patient approximately 75 kg in weight is 1 mg to 1 g, preferably 3 mg to 0.5 g. The dose can be administered in the form of an individual dose, or divided into several, e.g. two, three, or four, individual doses.
Organic Synthesis of hexahydrofuro[2,3-b]furan-3-yl-N-{3-[(1,3-benzodioxol-5-ylsufonyl)(isobutyl)amino]-1-benzyl-2-hydroxypropyl}carbamate
The synthesis of hexahydrofuro[2,3-b]furan-3-yl-N-{3-[(1,3-benzodioxol-5-ylsufonyl)(isobutyl)amino]-1-benzyl-2-hydroxypropyl}carbamate was accomplished via a coupling step between the bis-tetrahydrofuran ring and the corresponding benzodioxolyl amine as outlined below.
1) Synthesis of hexahydrofuro[2,3-b]furan-3-ol 5
The racemic synthesis of bis-tetrahydrofuran (bis-THF) 5 was accomplished as illustrated in Scheme 1, according to the procedure of Ghosh et al., J. Med. Chem. 39:3278–3290 (1996). Reaction of commercial 2,3 dihydrofuran with N-iodosuccinimide and propargyl alcohol in methylene chloride at 0–25° C. or 2 hours gave the iodo ether 2 (yield 88%). Radical cyclization of the iodo ether 2 with tributyltin hydride in toluene at 80° C. in the presence of a catalytic amount of 2,2′-azobisisobutyronitrile (AIBN) afforded the bicyclic acetal 3. Ozonolytic cleavage produced ketone 4. Reduction of the resulting ketone with sodium borohydride in ethanol at −15° C. finished the racemic endo alcohol 5 (see Scheme 1).
2) Synthesis of the amino alcohol 8 N-{3-[(1,3-benzodioxol-5-ylsufonyl)(isobutyl)amino]-1-benzyl-2-hydroxypropyl}amine
Reduction of acyl chloride 9 with NaBH 4 in 1:1 methanol:tetrahydrofuran (step a, Scheme 2 below) produced the racemates 10 a and 10 b , which were separated and the appropriate enantiomer reacted with KOH in ethanol (step b,c) to produce the epoxide 11 according to published procedures (Getman et al., J. Med. Chem. 36:288–291 (1993), Luly et al., J. Org. Chem. 52(8):1487–1492 (1987)). The epoxide was treated with an excess of isoamylamine in refluxing 2-propanol (step d) to generate the amino alcohol 12. The amino alcohol 12 was then reacted with 1,3-benzodioxol-5-ylsulfonyl-chloride (step e) which generated amino alcohol 8 with a carbobenzoxy (Cbz) protected amine. Hydrogenation of the Cbz group with 10% Pd/C and H 2 in methanol (step f) provided the free amino alcohol 8. These steps were accomplished according to generally published procedures (Vazquez et al., J. Med. Chem. 38:581–584 (1995), Scheme 2).
3) Synthesis of hexahydrofuro[2,3-b]furan-3-yl-N-{3-[(1,3-benzodioxol-5-ylsufonyl)(isobutyl)amino]-1-benzyl-2-hydroxypropyl}carbamate
Reaction of the bis-tetrahydrofuran ligand 5 with disuccinimidyl carbonate 6 and triethylamine in methylene chloride afforded the carbonate 7 which was mixed in situ with amine 8. This coupling produced the final compound 13 (Scheme 3). Compound 13 is a mixture of 2 diastereoisomers having the stereoisomeric forms as defined for compounds l and w in the table A. This mixture can be separated using art-known separation techniques.
Alternatively, the pure enantiomeric form corresponding to compound l and w, hereinafter referred to as compounds 14 and 15 can be prepared by resolving the racemic bis-THF 5 via an enzymatic resolution step as described in Tetrahedron Letters, 36, 4, (1995), 505–508, incorporated herein by reference. The enantiomeric pure bis-THF intermedites can then be reacted analogously to the procedure described above, thus obtaining enantiomerically pure compound 14 and 15.
Experimental Section
To a stirred solution of (500 mg, 3.84 mmol) of (3R,3aS,6aR)-3-hydroxyhexahydrofuro[2,3-b]-furan 5 (Scheme 1) in CH 2 Cl 2 (50 ml) at 25° C., disuccinimidyl carbonate 6 (1.08 g, 4.23 mmol) and triethylamine (0.77 g, 7.68 mmol) were added The resulting mixture was stirred for 6 h at 25° C. and the amine 8 (Scheme 2, 2.42 g, 5.76 mmol) was added. The resulting solution was washy with water and dried over anhydrous Na 2 SO 4 . Evaporation of solvent under reduced pressure afforded a residue which was purified by chromatography (CH 2 Cl 2 /MeOH: 98/2) which furnished 1.36 g (62%) of the inhibitor 13 (Scheme 3) of the instant invention as a white solid.
The 1 H-NMR spectrum in CDCl 3 of compound 13 was as follows: 7.4–7.1 (br m, 7H), 6.9 (d, J=8.1 Hz, 1H), 6.1 (s, 2H), 5.7 (d, J=5.1 Hz, 1H), 5 (d, J=6.7 Hz, 1H), 5.1–4.8 (br m, 1H), 4–3.4 (br m, 7H), 3.25–2.6 (br m, 6H), 2.35–1.2 (br m, 4 H), 1.17–0.7 (br m, 6H). Likewise, the 13 C-NMR spectrum in CDCl 3 was as follows: 151 (CO), 148–138 (C—O), 132–129.4–129.34–128.55–126.67–126.59–123.1 (Ar—C), 109.16–108.36–107.52–102.36 (CH—O), 73–0.43–72.58–70.73–69.47–58.87–53.78–45.04–36–35–27, 27–25.76–20.1–19.85. Mass spectrometry gave the expected ion (m/z) 577, corresponding to M + +H.
The resulting compound 13 and compound 14 were then tested for biological and antiviral activity in several assays as described below. Surprisingly, these compounds were found to be more effective and more active as a protease inhibitor than previously known compounds.
Antiviral Analyses:
Compound 13 and compound 14 were then examined for anti-viral activity in a cellular assay. The assay demonstrated that these compounds exhibited potent anti-HIV activity against a wild type laboratory HIV strain. The cellular assay was performed according to the following procedure.
Cellular Assay Experimental Method:
HIV- or mock-infected MT4 cells were incubated for five days in the presence of various concentrations of the inhibitor. At the end of the incubation period, all HIV-infected cells have been killed by the replicating virus in the control cultures in the absence of any inhibitor. Cell viability is measured by measuring the concentration of MTT, a yellow, water soluble tetrazolium dye that is converted to a purple, water insoluble formazan in the mitochondria of living cells only. Upon solubilization of the resulting formazan crystals with isopropanol, the absorbance of the solution is monitored at 540 nm. The values correlate directly to the number of living cells remaining in the culture at the completion of the five day incubation. The inhibitory activity of the compound was monitored on the virus-infected cells and was expressed as IC 50 and IC 90 . These values represent the amount of the compound required to protect 50% and 90%, respectively, of the cells from the cytopathogenic effect of the virus. The toxicity of the compound was measured on the mock-infected cells and was expressed as CC 50 , which represents the concentration of compound required to inhibit the growth of the cells by 50%. The select index (SI) (ratio CC 50 /IC 50 ) is an indication of the selectivity of the anti-HIV activity of the inhibitor.
Cellular Assay Results:
Compound 13 exhibits an IC 50 of 1.1 nM and an IC 90 of 2.4 nM (representing the median value of 12 determinations) against HIV-1 strain LAI. The CC 50 of compound 13 is 15.3 μM and its SI is 13,900. Compound 14 exhibits an IC 50 of 0.8 nM against HIV-1 strain LAI. The CC 50 of compound 13 is greater than 100 μM.
Protein Binding Analyses:
Human serum proteins like albumin (HSA) or alpha-1 acid glycoprotein (AAG) are known to bind many drugs, resulting in a possible decrease in the effectiveness of those compounds. In order to determine whether compound 13 would be adversely effected by this binding, the anti-HIV activity of the compound was measured in the presence of physiological concentrations of HSA or AAG, thus evaluating the effect of the binding of the inhibitor to those proteins.
Results:
In a typical experiment, HSA at a concentration of 45 mg/ml had no effect on the potency of compound 13. AAG at a concentration of 2 mg/ml decreased the potency of compound 13 by two to four fold
Antiviral Spectrum:
Because of the increasing emergence of drug resistant HIV strains, compound 13 and compound 14 were tested for its potency against HIV strains harbouring several mutations. These mutations are associated with resistance to protease inhibitors and result in viruses that show various degrees of phenotypic cross-resistance to five of the currently commercially available drugs (Saquinavir, Ritonavir, Nelfinavir, Indinavir and Amprenavir).
Results:
Table 1 shows the results of this testing as IC 50 values in 1μM. Compounds 13 and 14 are effective in inhibiting even these resistant viruses at low concentrations that are well below attainable plasma levels. FIG. 2 shows a comparison of the fold resistance of various viral stains to commercially available protease inhibitors and compound 13. The swains surprisingly show an enhanced sensitivity to the compound 13 as compared to Saquinavir (SAQ), Ritonavir (RIT), Indinavir (IND), Nelfinavir (NEL), and Amprenavir (AMP).
TABLE 1 Activity of compounds 13 and 14, and 5 commercial protease inhibitors against Protease Inhibitor Resistant HIV Strains Resistance associated Strain mutations SAQ RIT IND NEL AMP Comp 14 Comp 13 LAI 0.0079 0.0304 0.0276 0.0331 0.0359 0.0008 0.0014 r13020 L10I, K20R, M36I, 3.51 9.28 1.38 3.75 0.107 0.0008 0.0014 154V, A71V, V82T, 184V r13021 L10I, K20R, L24I, 1.45 >10 1.75 4.10 0.212 0.0015 0.0055 M36I, I54V, L63P, A71V, V82T, I84V r13022 K20R, M36I, M46I/M, 0.665 >10 1.70 4.03 0.181 0.0011 0.0017 154V, L63P, A71V/I, V82T, L90M r13023 L10I, M36I/M, I54V/I, 0.783 3.82 0.680 1.02 0.217 0.0028 0.0068 L63P, A71V, G73S, I84V, L90M r13024 L10I, M36I, L63P, 2.09 2.85 1.07 3.26 0.180 0.0055 0.0081 A71V, G73S, I84V, L90M r13025 L10I, M46I, L63P, 0.157 2.24 1.25 9.13 0.661 0.0328 0.0454 A71V, I84V r13026 L10I, M46I, I54V, 1.99 >10 2.72 1.22 0.136 0.0008 0.0014 L63P, A71V, V82T, I84V r13027 L10M/I, K20R, M36I, 2.92 3.14 0.714 3.20 0.645 0.0073 0.0074 L63P, A71V, G73S, V77I, I84V, L90M r13029 L10I/L, M36I, M46L, 2.61 3.60 0.922 3.79 0.214 0.0052 0.0070 L63P, A71V, I84V, N88D, L90M r13030 L10V/I, M36I, I54V, 0.173 2.99 0.574 0.995 0.0491 0.0002 0.0004 L63P, A71V, V82T. L90M r13031 G48V, I54V, V77I, 0.673 0.856 0.1542 0.497 0.0341 0.0003 0.0005 V82A, L90M/L r13033 L10I, M46L,I54V, 0.0521 3.47 0.848 1.19 0.194 0.0011 0.0017 L63P, A71V, V82A, L90M r13034 L10I, M36I, I54V, 1.01 >10 0.638 1.99 0.677 0.0055 0.0080 L63P, A71V, I84V r13035 D30N, L63P, V77I, 0.0053 0.0311 0.0074 0.361 0.0105 0.0002 0.0003 N88D r13036 L10I, L63P,A71V, 0.514 2.83 0.638 3.25 0.445 0.0029 0.0054 G73S, L90M r13037 L10I, M46I, I54V, 0.0274 2.72 0.196 0.656 0.165 0.0005 0.0003 L63P, A71T, V77I, V82A, L90M
Biovailability:
The oral absorption of compound 13 was then measured in rats to determine bioavailability. The compound was administered by gavage to rats, as a single dose of 20 mg/kg in PEG400. Animals were sacrificed at different time points after administration, whole blood was collected and serum prepared by standard methods. Concentration of the compound in serum was determined by titrating the anti-HIV activity present in the sample according to the procedure described above.
Bioavailability Results:
The results are shown in Table 2 and illustrated graphically in FIG. 1 . Compound 13 serum concentration rises to 1 μM 1 hour after oral administration and is still superior to the IC 50 of the compound against protease inhibitors multi-resistant strains up to 3 hours after administration. Compound 13 therefore has a significant advantage in terms of therapeutic margin. This unexpectedly high plasma bioavailability is especially important against resistant viruses.
TABLE 2
Compound Concentration in Serum after Oral Administration
Time after administration
Compound concentration in serum (μM)
(minutes)
compound 13
0
0.0000
60
0.9858
180
0.6869
300
0.2159
The present invention may be embodied in other specific forms without departing from its spirit or essential characteristics. The described embodiments are to be considered in all respects as illustrative only and not restrictive. The scope of the present 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. | Compositions comprising bis-tetrahydrofuran benzodioxyolyl sulfonamide compounds that are surprisingly effective protease inhibitors and a second antiretroviral compound are disclosed. Methods of inhibiting retrovirus proteases, in particular multi-drug resistant retrovirus proteases, methods of treating or preventing infection or disease associated with retrovirus infection in a mammal, and methods of inhibiting viral replication are also disclosed. | 2 |
This application is a continuation-in-part of U.S. application Ser. No. 08/077,023, filed Jun. 15, 1993, now U.S. Pat. No. 5,306,749 and a continuation-in-part of U.S. application Ser. No. 08/150,435 filed Nov. 10, 1993, now U.S. Pat. No. 5,322,880 and a continuation-in-part of U.S. application Ser. No. 07/976,553, filed Nov. 16, 1992, now U.S. Pat. No. 5,284,897.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to a thixotropic, water based general purpose, polyvinyl alcohol adhesive gel for porous and semiporous substrates such as paper, card board, cloth and wood.
2. Background Art
Many different general purpose adhesives are available for adhering porous and semiporous substrates such as paper. However, such adhesives have shortcomings for use in projects which are performed on wall boards and other vertical surfaces such as in a class room by young children.
The gels of this invention contain water, polyvinyl alcohol, and xanthan gum within certain proportions so as to provide viscosities and a thixotropic index within certain ranges. Optionally, the gel includes a diphenyl methane dye to provide color to the gel. Preferably, the gel consists essentially of: water; a partially hydrolyzed polyvinyl alcohol; xanthan gum; a water-soluble defoamer; and a water-soluble plasticizer for the polyvinyl alcohol which does not destroy the clarity of the gel. Optionally, other ingredients can be added which do not destroy the advantageous properties of the gel. Compatible preservatives and dyes are generally added to the gel.
Our copending applications Ser. No. 07/976,553 filed Nov. 16, 1992 and its divisional 08/150,435 filed on Nov. 10, 1993, both of which are incorporated herein in their entirety by reference, relate to clear, thixotropic aqueous adhesive gels containing water, partially hydrolyzed polyvinyl alcohol, various polymeric thickening agents such as about 0.5% to 1.5% of xanthan gum, colorants, a water soluble plasticizer for the polyvinyl alcohol, and a defoamer. Our copending application Ser. No. 08/077,023 filed on Jun. 15, 1993, which is also incorporated herein in its entirety by reference, relates to an aqueous thixotropic adhesive gel containing water, polyvinyl acetate, polyvinyl alcohol, wood flour, glyoxal, and xanthan gum as the thickening agent.
Applicants have found that smaller quantities of the xanthan gum from that recited in their copending applications filed on Nov. 16, 1992 and Nov. 10, 1993 are operable and the color of water soluble triphenyl methane dyes in the gels of these copending cases has better stability in sunlight when xanthan gum is used in comparison to the use of the sodium salt of carboxymethylcellulose (CMC) which is the preferred gum in these copending cases.
SUMMARY OF THE INVENTION
In one aspect of the invention, a clear, water based polyvinyl alcohol adhesive gel is provided which contains xanthan gum which provides thixotropic properties to the gel. A water-soluble plasticizer for the polyvinyl alcohol and a water-soluble defoamer in the composition assist in meeting the desirable properties of the gel. Due to its thixotropic properties, the viscosity of the adhesive will break down when a flexible tube or squeeze bottle is finger-pressed and have a sufficiently low viscosity to allow for easy extrusion from a small orifice such as one having a diameter of about 0.06 to 0.15 inches. When pressure is released after the desired amount of adhesive flows out of the orifice, the adhesive quickly reverts to very close to its original gel state so that a horizontal line of the gel will not run when applied to a vertical surface of a porous substrate such as paper.
In another aspect, the adhesive gel is crystal clear or transparent.
In still another aspect, the adhesive gel has a strong wet tack with a low rate of set. This holds a second substrate in position with a first substrate in a vertical plane after contact of the substrates with the gel while permitting sliding and repositioning of the second substrate for a prolonged period of time prior to formation of permanent adhesion and fiber tearing bonds due to setting of the adhesive.
In a further aspect of the invention, a portion of the polyvinyl alcohol adhesive polymer is replaced with polyvinylpyrrolidone.
In still a further aspect, the gels of this invention contain a dye or colorant.
Additional aspects of the invention will be evident from a reading of the entire specification and claims.
Advantages of the invention include: (1) The adhesive gel will not run when applied to porous and semiporous vertical surfaces and will not spill when used as a general purpose school glue. (2) The adhesive gel extrudes easily and in a steady stream from a small orifice when a flexible tube or squeeze bottle is finger pressed and reverts to gel when finger-pressure is released. (3) The combination of adhesive gel and small dispenser opening, e.g. from about 0.06 inches to 0.15 inches in diameter, minimizes or eliminates wrinkling of paper upon drying of the adhesive. (4) The adhesive in a clear resilient plastic dispenser can be viewed within the dispenser as clear which may include a tint of color. (5) The adhesive gel is preferably crystal clear or has a clear colored tint and provides a clear dry film. (6) The dry adhesive film is flexible and will not crack on bending. (7) The adhesive gel has a strong wet-tack to hold paper surfaces together while drying. (8) It has a long rate of set so as to permit sliding and positioning of substrates before fiber tearing permanent adhesive bonds are developed. (9) The adhesive gel as well as dried films thereof will launder-out in hot or cold water. (10) The adhesive gel can be tinted easily with non-toxic water-soluble dyes. (11) The adhesive gel is non-toxic and is not an irritant to the skin and eyes as defined in the Federal Hazardous Substances Act. (12) Color of triphenyl methane dyes in the gel is more stable than with the use of thickening agents such as the sodium salt of carboxymethylcellulose (CMC).
DETAILED DESCRIPTION OF THE INVENTION
The preferred adhesive gels of this invention are clear. The term "clear" is used herein in contrast to opaque. The term "clear" includes transparent, i.e., see through, as well as translucent.
The term "water-soluble" as used herein refers to solutions of either solids or liquids which are soluble or miscible in water to provide a solution which is clear at the concentration employed.
The "thixotropic index" is the difference in viscosity for the gel from an undisturbed state to that wherein the gel is being displaced by force. The term "thixotropic" as used herein is also meant to cover pseudoplastic. The thixotropic index used in this invention permits extrusion of the gel from the dispenser opening by use of finger-pressure on a flexible dispenser such as a tube or squeeze bottle. The adhesive rapidly reverts to a higher viscosity after extrusion from the orifice. The adhesive gel does not run, i.e. extensive spreading without the application of external force, when applied to paper in a vertical plane when extruded through the small orifices of the dispensers used in this invention.
The thixotropic index for the adhesive gel of this invention varies from about 1.5 to 4.5 preferably about 1.5 to 4 and particularly 1.8 to 2.5. The thixotropic index used herein is obtained by dividing the viscosity reading of the gel at 2 RPM (revolutions per minute) by the viscosity reading at 20 RPM by use of an RVF Brookfield viscometer using a number 6 spindle at 25° C. The viscosity readings are taken after the gel has been at rest e.g. undisturbed, for a period of time such as 12 hours after any agitation or other disturbance of the gel structure. It should be noted that different methods for measuring thixotropic index will give different results.
The adhesive gels of this invention have a viscosity of about 6,000 cps (centipoise) to 80,000 cps at 25° C., preferably about 8,000 cps to 70,000 cps at 25° C., and particularly about 10,000 to 40,000 cps at 25° C. as measured with an RVF Brookfield viscometer by use of a number 6 spindle at 2 RPM (revolutions per minute). When measured at 20 RPM with an RVF Brookfield viscometer at 25° C. by use of a No. 6 spindle, the viscosity is about 3,500 cps to 50,000 cps, preferably about 7,000 cps to 25,000 cps, provided that the thixotropic index is within the ranges set forth herein.
The major ingredient in the adhesive gel of this invention is water. The quantity of water can vary over a broad range such as that from about 70% to 93% by weight of the adhesive gel, preferably 75% to 93% and particularly from about 80% to 90% by weight thereof.
It has been found that triphenyl methane colors such as FD&C Blue No. 1 of the clear gels of the parent cases filed on Nov. 16, 1992 and Nov. 10, 1993 fade on exposure to sunlight when the sodium salt of carboxymethylcellulose (CMC) is the gelling agent whereas such fading is minimized when xanthan gum is used as the gelling agent. The time it takes for a sample such as that of EXAMPLE 1 in these parent cases to loose its blue tint can be as short as one day or less in direct sunlight. On the other hand, when xanthan gum was used instead of CMC, there was no color fading under substantially the same test conditions. Additionally, CMC loses some of its viscosity during such exposure to sunlight whereas this does not happen with xanthan gum.
Polyvinyl Alcohol Adhesive Polymer
The adhesive agent used in this invention is partially hydrolyzed polyvinyl alcohol or such polyvinyl alcohol with polyvinylpyrrolidone (PVP) wherein the PVP replaces up to about half of the polyvinyl alcohol. The polyvinyl alcohol will normally have a molecular weight of about 25,000 to 100,000 and preferably about 40,000 to 80,000. The viscosity of the polyvinyl alcohol can vary over a wide range such as that of about 5 or 6 cps, which is referred to in the art as low viscosity, to 40 to 50 cps, which is referred to in the art as high viscosity as measured with an LVF Brookfield viscometer using a number 1 spindle at 60 RPM at 20° C. for a 4% aqueous solution. The preferred degree of hydrolysis for the partially hydrolyzed polyvinyl alcohol is 87% to 89%.
The PVP can have a molecular weight, expressed as a K value, which varies over a wide range such as that of a K value of about 26 to 100.
The quantity of polyvinyl alcohol or polyvinyl alcohol together with PVP in the gel can vary over a wide range such as that of from about 5% to 25% by weight of the adhesive gel, preferably from about 5% to 20% and particularly 10% to 15% by weight of the adhesive gel.
Xanthan Gum
The thickening agent polymer used in this invention is xanthan gum. Xanthan gum is a natural high-molecular weight branched polysaccharide. It functions as a hydrophilic colloid to thicken, suspend, and stabilize water-based systems. The quantity of xanthan gum used in this invention is that which is sufficient to provide the adhesive gel with the desired thixotropic index and viscosity. Such quantity can vary over a broad range such as that of about 0.1% to 1.5% by weight of the adhesive, preferably the quantity of xanthan gum will vary from about 0.2% to 0.8% by weight of the adhesive and particularly from 0.3 to 0.7%.
The Water-Soluble Plasticizer
Any water-soluble plasticizer for the polyvinyl alcohol, which does not destroy the clarity of the gel is suitable for use in this invention. Such plasticizers soften the polyvinyl alcohol, make the adhesive stickier, and assist in making the dried film easier to wash out of clothing. Illustrative of such plasticizers there can be mentioned: alkanes having from 2 to 5 carbon atoms and 2 to 3 hydroxyl groups such as: propylene glycol; glyceroi; ethylene glycol; and diethylene glycol; although ethylene glycol and diethylene glycol can have some toxic properties. The quantity of the water-soluble plasticizer is that which is sufficient to plasticize the polyvinyl alcohol and will generally vary from about 0.5 to 3% by weight of the adhesive gel.
The Coloring Agents or Dyes
The coloring agents used in this invention are water soluble and preferably are conventional certified food colors such as the triphenyl methane class of colors, e.g., FD&C Green No. 3 or FD&C Blue No. 1. Chemically, FD&C Green No. 3 is the disodium salt of 4{[4(-N-ethyl-p-sulfobenzyl amino )-phenyl]-(4-hydroxy-2-sulfonium phenyl)-methylene}-[1-N-ethyl-N-p-sulfobenzyl)-Δ 2 ,5 -cyclohexadienimine]. Chemically, FD&C Blue No. 1 is the disodium salt of ethyl[4-[p[ethyl (m-sufobenzyl)amino]-a-(o-sulfophenyl)benzylidene]-2,5-cyclohexadien-1-ylidene] (m-sulfobenzyl)ammonium hydroxide inner salt. One supplier of such certified food colors is the Warner-Jenkinson Company of South Plainfield, N.J. FD&C Green No. 3 has a Warner-Jenkinson (W.J.) Code No. 6503 and a common name of Fast Green FCF. FD&C Blue No. 1 has a W.J. Code No. of 5601 and a common name of Brilliant Blue FCF. These products of W.J. are sold as 2% solutions of the coloring agent. The salts of the triphenyl methane class of colors need not be limited to those of sodium but instead can be that of other alkali metals such as potassium as well as other water soluble salts of the triphenyl methane colors.
The quantity of the coloring agent used in the compositions of this invention can vary over a wide range. Generally, a minimum quantity of dye will be used such as to provide a tint of color to the gel. Thus, as a 2% solution of the dye, the quantity of such solution can preferably vary from about 0.05% to 0.00025%. About 0.005% to 0.01% of such 2% solution is particularly preferred. Applicants have found good results with about 0.00875% of the 2% solution.
The Water-Soluble Defoamer
Conventional water-soluble defoamers can be used in this invention such as the polyalkoxylated polyethers e.g., butoxy polyoxyethylene-propoxyl propylene glycol. Silane defoamers can also be used but they can adversely affect transparency of the gel. The quantity of the defoamer is that which is sufficient to eliminate air bubbles in the gel in a concentration which destroys the clarity of the gel. Generally, the quantity of the defoamer varies from about 0.05% to 0.35% by weight of the gel composition. The defoamer also maintains density of the gel, prevents excessive foam in the manufacturing process, and facilitates filling of the dispensers with the gel.
When applied to a substrate in the vertical plane, the gels of this invention do not run due to the thixotropic properties of the gel. Due to the ability of the thixotropic gel to be applied through a small dispenser opening, a thin glue line can be provided on a first substrate such as construction paper which minimizes the amount of adhesive as well as wrinkling of paper upon drying. When a second substrates such as a second piece of construction paper is pressed over the first piece in order to be adhered thereto, the high tack of the gel holds the second substrate in place on the vertical surface. The slow rate of set permits a prolonged period of time for positioning the second substrate such as by sliding of the second surface over the first before fiber tearing adhesive bonds develop between the two substrates which permanently hold the pieces in place.
In order that those skilled in the art may more fully understand the invention presented herein, the following examples are set forth. All parts and percentages in the examples, as well as elsewhere in this application, are by weight, unless otherwise specifically stated. Also, set forth below are procedures for determining "wet tack" and "rate of set".
PROCEDURE FOR DETERMINING WET TACK
This procedure uses blocks of Grade 1 or Grade 2 white pine with each block being 2 inches long, 0.75 inches high and 1.75 inches wide. The grain of the wood is parallel to the length of the block and the sides which are 0.75 inches high and 2 inches long are planed and smooth. Such sides are referred to herein as test sides. Each test side therefor provides a surface of 1.5 square inches.
A series of tests are performed with the above described blocks of wood with two blocks being required for each test. In each test an eye screw is placed in the center of one of the test sides of each block. Gel adhesive is then placed on the opposite side of the eye screw of one of the test blocks so that it covers the entire 1.5 square inches of surface. The test side of the second block opposite the second block eye screw and the side of the first block having the glue thereon are pressed against each other in sliding relationship while being placed in register so that the edges of one block do not extend beyond the edges of the other. A scale is attached to the eye screw of the first block whereas a weight is attached to the eye screw of the second block. The scale is then lifted upwardly by the operator and the two blocks are lifted vertically so as to lift the weight. Thus, The operator lifts the scale by hand which in turn lifts the first block through the eye screw. This in turn lifts the second block due to the wet tack of the adhesive which in turn lifts the weight which is attached to the second block eye screw. This test is repeated with clean blocks of wood and the weight is increased each time until the adhesive between the two blocks fails to lift the second block and its attached weight. The last weight which was lifted in this test is referred to as the quantity of wet tack or simply wet tack of the adhesive. This test measures the wet tack in a direction which is perpendicular to the adhered surfaces. In spite of the lengthy description of this test, it can be performed, and for reliability is performed, rapidly by the operator. The glue, when the wet tack is measured between the blocks of wood is very close to the physical and chemical condition of the glue when it left the dispenser orifice. The wet tack is a measure of what is often referred to as the grabbing power of the adhesive. A minimum amount of wet tack is needed when gluing on substrate to another in a vertical plane, otherwise, the substrate which is not held in place but rather depends on the wet glue for positioning would slip off of the vertical surface of the first substrate. The wet tack of the gel of this invention preferably varies from about 225 g per square inch to over 600 grams per square inch and preferably from about 250 to 500 grams per square inch.
PROCEDURE FOR DETERMINING RATE OF SET
Determinations for the rate of set are performed on a white paper pad. A glue line is placed on smooth white paper of a 5.5×8.5 inches paper pad. The single glue line is placed in about the middle of the pad parallel to the length of the paper. This glue is then spread evenly by the use of a No. 22, WIRE-CATOR which is supplied by the Leneta Company. The WIRE-CATOR is also referred to as a wire wrap rod. The WIRE-CATOR draws down a uniform thickness of film from the single glue line. Use of the No. 22 WIRE-CATOR draws down a glue line to a thickness of 1.5 mil.
A second sheet of the same paper has one of its narrow ends raised so that it can be grasped by the fingers. The second sheet is pressed over the first sheet. The two pieces are then slowly pulled apart by lifting the raised end of the second sheet and holding the first sheet down in place. The time that it takes to encounter fiber tearing bond is the rate of set. The preferred rate of set for the gels of this invention is from about 16 seconds to 35 seconds and preferably from about 18 to 32 seconds.
The values for both the wet tack and rate of set recited herein are obtained at 25° C. and a relative humidity of 35%.
EXAMPLE 1
This example shows the composition, preparation and properties of an adhesive gel of this invention.
______________________________________Ingredient Parts By Weight______________________________________Deionized water 83.51Polyvinyl alcohol.sup.1 13.93Xanthan gum.sup.2 0.40DEFOAMER.sup.3 0.25Ethyl parahydroxybenzoate 0.05Benzoic Acid 0.10Propylene Glycol 1.75Blue dye.sup.4 0.01______________________________________ .sup.1 VINOL 523 which is a partially hydrolyzed polyvinyl alcohol supplied by Air Products and Chemicals, Inc. .sup.2 KELZAN, an industrial grade xanthan gum supplied by the Kelco Division of Merck & Co. .sup.3 DEFOAMER 622 which is a monofunctional polyalkoxylated polyether defoamer supplied by the Thomas W. Dunn Corp of Ridgefield, N.J. .sup.4 No. 5601, FD&C Blue No. 1 which is supplied by Warner Jenkinson Cosmetic Colors of South Plainfield, New Jersey.
The adhesive of EXAMPLE 1 was prepared by conventional techniques of mixing the various ingredients. A preferred method is as follows. Slowly add the polyvinyl alcohol and xanthan gum to water under fast agitation in a jacketed tank equipped with agitators. The gum is preferably blended with a portion of the polyvinyl alcohol before addition to the water. The defoamer is then added. A small portion of the total amount of water in the gel can be obtained from steam condensation when the mixture is heated in contact with steam. The ethyl parahydroxybenzoate and benzoic acid are then mixed in the composition and the temperature of the mixture is raised to 85° C. to 90° C. with slow agitation for about 15 to 20 minutes until the composition is smooth and homogeneous. The composition is then cooled to 50° C. with continued slow agitation. The blue dye is then added. Mixing is continued until the batch color is uniform.
The adhesive can then be filled into conventional 3 fluid ounce clear, low density polyethylene tubes, or such 4 fluid ounce bottles, having a cap and nozzle with an opening of about 0.073 inches in diameter. The portion of the tube or bottle in direct contact with the gel is transparent with a slight blue tint. The portion of tube or bottle which is not in direct contact with the gel is translucent.
The adhesive gel of Example 1 was transparent with a blue tint, easily dispensed with finger-pressure from a conventional resilient plastic tube or bottle having an orifice of 0.073 inches diameter. It was free of air bubbles, and when dispensed from such tube and orifice on to a sheet of paper held vertically, it formed a uniform, thin, horizontal bead of adhesive which did not run and formed fiber tearing adhesive bonds on drying to a clear film. The gel can be dispensed in a steady stream through the dispenser orifice. The strong wet tack held a second sheet of paper in place on the vertical surface while the lengthy time of set permitted sliding and repositioning of the second sheet on the first before permanent adhesive bonds were formed. The gel washed out of clothing both before and after drying. It had a pH of about 4.6, a 15.4% solids content, a W.P.G. (weight per gallon) of 8.5 pounds and a thixotropic index of about 2.3 initially and 1.95 on standing for about 12 hours. The viscosity of the adhesive gel when measured at 25° C. with an RVF Brookfield viscometer with a No. 6 spindle was as follows:
Initially, after manufacture, and at a speed of 2 RPM, a viscosity of about 25,000 cps;
Initially, after manufacture, and at a speed of 20 RPM, a viscosity of about 11,000 cps;
After standing for about 12 hours and at a speed of 2 RPM, a viscosity of about 20,000 cps;
After standing for about 12 hours and at a speed of 20 RPM, a viscosity of about 10,250 cps.
By substituting the same quantity of FD&C Green No. 3 dye in place of the Blue dye, a gel is prepared having substantially the same properties of EXAMPLE 1 above with a light green color in place of the blue color.
EXAMPLE 2
This example provides another formulation of the clear gels of this invention. The blue dye, xanthan gum, polyvinyl alcohol and defoamer were the same as in EXAMPLE 1 above.
______________________________________Ingredient Parts By Weight______________________________________Deionized water 83.51Blue dye 0.01Polyvinyl alcohol 14.03Xanthan gum 0.30Defoamer 0.25Ethyl parahydroxybenzoate 0.05Benzoic acid 0.10Propylene glycol 1.75______________________________________
After standing for about 12 hours, this gel had a viscosity of 17,500 cps at 2 RPM and 7,750 cps at 20 RPM when measured at 25° C. with a Brookfield RVF viscometer having a No. 6 spindle. The thixotropic index was 2.25.
EXAMPLE 3
This example illustrates another formulation of this invention.
______________________________________Ingredient Parts By Weight______________________________________Deionized water 84.01Blue dye 0.01Defoamer 0.25Polyvinyl alcohol 13.33Xanthan gum 0.50Propylene Glycol 1.75Benzoic acid 0.10Ethyl parahydroxybenzoate 0.05______________________________________
The blue dye, polyvinyl alcohol, defoamer and xanthan gum used in EXAMPLE 3 were the same as that of EXAMPLE 1. The formulation of this EXAMPLE 3 had a viscosity as measured immediately after manufacture of 27,500 cps at a speed of 2 RPM and 9,500 cps at a speed of 20 RPM for a thixotropic index of 2.9, a pH of 4.6, a 14.8% solids content and a W.P.G. of 8.6 pounds. After standing overnight, this gel had a viscosity of 30,000 cps at a speed of 2 RPM and a viscosity of 10,750 cps when measured at 20 RPM for a thixotropic index of 2.8. The above viscosities are measured at 25° C. with an RVF Brookfield viscometer with a No. 6 spindle.
EXAMPLE 4
This example illustrates a composition of this invention which contains a substantial quantity of polyvinylpyrrolidone. The blue dye and defoamer were the same as in EXAMPLE 1.
______________________________________Ingredient Parts By Weight______________________________________Deionized Water 83.51Defoamer 0.25Polyvinyl alcohol 7.27Xanthan gum 0.40Polyvinylpyrrolidone* 6.66Propylene Glycol 1.75Blue dye 0.01Ethyl parahydroxybenzoate 0.05Benzoic acid 0.10______________________________________ *LUVISCOL K90 which is supplied by B.A.S.F. Aktiengesellschaft.
EXAMPLE 5
This example illustrates another composition of this invention.
______________________________________Ingredient Parts by Weight______________________________________Deionized water 83.51FD&C Blue No. 1 0.01Polyvinyl alcohol 13.33Xanthan gum.sup.1 1.00Defoamer 0.25Ethyl parahydroxybenzoate 0.05Benzoic acid 0.10Propylene glycol 1.75______________________________________ .sup.1 KELZAN, an industrial grade xanthan gum supplied by the Kelco Division of Merck & Co.
The gel of EXAMPLE 5 was clear and had a viscosity of 62,000 cps and 13,500 cps for a thixotropic index of about 4.6. The viscosity was measured at 25° C. by use of a Brookfield RVF viscometer with a No. 6 spindle after the gel was undisturbed for about 12 hours. This product had a wet tack of 400 grams per square inch.
EXAMPLE 6
This example shows incompatibility of hydroxypropyl methylcellulose as the thickening agent polymer. This formulation was unsatisfactory since a thick layer of the hydroxypropyl methylcellulose separated and formed on top of the sample.
______________________________________Ingredient Parts by Weight______________________________________Deionized water 83.51FD&C Blue No. 1 (2% aqueous solution) 0.01Polyvinyl alcohol 13.33Hydroxypropyl methylcellulose* 1.00Defoamer 0.25Ethyl parahydroxybenzoate 0.05Benzoic acid 0.10Propylene glycol 1.75______________________________________ *METHOCEL K 15 MS which is supplied by the Dow Chemical Co. Apart from th hydroxypropyl methylcellulose, the remaining ingredients were the same as that of EXAMPLE 1.
EXAMPLE 7
The substitution of hydroxyethyl cellulose for the hydroxymethyl cellulose of the formulation in EXAMPLE 6 also gave unsatisfactory results since a thick layer of the hydoxyethyl cellulose separated out of the formula.
EXAMPLE 8
The gel of EXAMPLE 1 above, was compared with a gel having 1% of CMC as the thickening agent. The composition of the two gels was otherwise the same except that 0.6% less of the polyvinyl alcohol was used in the CMC formulation. The two compositions were placed in clear resilient 4 ounce capacity polyethylene bottles with closed nozzles and left outdoors for four days during intermittent sunshine. The gels containing the CMC had faded in color after the 4 day test period whereas those containing the xanthan gum were unaffected.
EXAMPLE 9
This example shows that loss of color due to ultra violet rays for a gel with CMC was much greater than for a gel containing xanthan gum or sodium alginate. The gels consisted of 1% of either CMC, xanthan gum, or sodium alginate, as indicated in Table 9 below, together with 83.51% of water; 13.33% of polyvinyl alcohol; 0.25% of a defoamer; 0.05% of ethyl parahydroxy benzoate; 0.10% of benzoic acid; 1.75% of propylene glycol; and 0.01% of FD&C Blue No. 1. The gels were in clear 4 ounce polyethylene squeeze bottles. Ultra violet light was provided by a laboratory UV lamp apparatus fitted with a shortwave UV 254 nm bulb (General Electric Co. lamp G8T5). During exposure, all specimens were kept 12 inches away from the UV light bulb. After exposure, all of the specimens were visually compared with specimens unexposed to UV light to determine any color fading. The test result are shown in Table 9 below. It can be seen from the results in Table 9 that loss of color with the gel using CMC as the thickener was greater than the gels with xanthan gum or sodium alginate.
TABLE 9______________________________________Specimen 24 hrs. Exposure 40 hrs. Exposure______________________________________Gel with CMC Moderate fading Excessive fadingGel with xanthan No fading Slight fadingGel withsodium alginate No fading Slight fading______________________________________ | A water based thixotropic adhesive gel is disclosed which contains: water; polyvinyl alcohol, or wherein a portion of the polyvinyl alcohol is replaced with polyvinylpyrrolidone; xanthan gum to impart thixotropic properties to the gel; and a plasticizer for the polyvinyl alcohol. The gel has a thixotropic index which permits the viscosity of the adhesive to break down when a flexible tube or squeeze bottle dispenser is finger-pressed while having a sufficiently low viscosity to allow for easy extrusion from an orifice having a diameter of about 0.06 to 0.15 inches. When pressure is released, after the desired amount of adhesive has flown out of the dispenser, the adhesive quickly reverts to very close to its original gel state so that it does not run on a vertical surface of porous or semiporous material such as paper. Preferred gels contain a water soluble dye and are clear. | 2 |
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority to U.S. patent application Ser. No. 14/211,049, entitled Cost Effective Broadband Transducer Assembly and Method of Use, filed Mar. 14, 2014, which claims priority to U.S. provisional patent application Ser. No. 61/788,469 which is entitled Cost Effective Broadband Sonar Transducer, filed Mar. 15, 2013, the entirety of which are incorporated herein by reference.
TECHNICAL FIELD OF THE INVENTION
[0002] The present invention relates generally to electroacoustic transducers and more particularly to ultrasonic broadband transducer assemblies used in marine applications. A method of using a broadband transducer assembly in marine environments also is provided.
SUMMARY OF THE INVENTION
[0003] The present invention is directed to a broadband acoustic structure operable for the purpose of imaging in marine applications, the acoustic structure having a bandwidth. The acoustic structure comprises a sufficiently thin transducer element for transmitting and receiving acoustic signals, the sufficiently thin transducer element having a transverse resonant frequency, and a base to which the sufficiently thin transducer element is securable. The sufficiently thin transducer element produces transverse vibrations which result in loading of the transducer element and the loading of the transducer element results in broadening of the bandwidth of the acoustic structure, wherein the bandwidth of the acoustic structure includes the transverse resonant frequency of the sufficiently thin transducer element.
[0004] The present invention further is directed to a broadband transducer assembly operable for the purpose of imaging in marine applications. The transducer assembly comprises an acoustic structure having a bandwidth, a base and a sufficiently thin transducer element having a transverse resonant frequency. The sufficiently thin transducer element is securable to the base of the acoustic structure, and the sufficiently thin transducer element produces transverse vibrations which result in loading of the transducer element and wherein the loading of the transducer element results in broadening of the bandwidth of the acoustic structure. The bandwidth of the acoustic structure includes the transverse resonant frequency of the sufficiently thin transducer element.
[0005] Finally, the present invention is directed to a method of imaging marine environments. The method comprises the steps of transmitting an acoustic signal into a sufficiently thin transducer element having a bandwidth and producing transverse vibrations of the sufficiently thin transducer element and thereby loading the sufficiently thin transducer element to result in broadening of the bandwidth of the sufficiently thin transducer element.
[0006] The foregoing and other objects, features, and advantages of the invention will appear more fully hereinafter from a consideration of the detailed description that follows.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] FIG. 1 illustrates an exploded view of an exemplary configuration by which an embodiment of a transducer assembly of the present invention is mounted to the transom of a watercraft.
[0008] FIG. 2 shows an isometric view of an exemplary broadband transducer assembly of the present invention.
[0009] FIG. 3 is a side elevation view of an exemplary broadband transducer assembly of the present invention.
[0010] FIG. 4 is a rear elevation view of an exemplary broadband transducer assembly of the present invention.
[0011] FIG. 5 is a perspective view of an alternative housing embodiment of the broadband transducer assembly of the present invention, having a window over at least a portion of the acoustic element.
[0012] FIG. 6 is a cross-sectional view of an exemplary broadband transducer assembly of present invention, taken along line 6 - 6 of FIG. 4 .
[0013] FIG. 7A illustrates a cross-sectional view of an exemplary acoustic structure of the broadband transducer assembly of the present invention, the acoustic structure comprising a base and a transducer element.
[0014] FIG. 7B illustrates a cross-sectional view of an alternative exemplary acoustic structure wherein an aperture and cap at least partially enclose the transducer element.
[0015] FIG. 7C shows a perspective view of the bottom surface of an exemplary housing of the broadband transducer assembly of the present invention, wherein the base of the acoustic structure forms an aperture for receiving the transducer element.
[0016] FIG. 8 is a graph illustrating favorable ranges of diameter-to-thickness ratios of transducer elements of the broadband transducer assembly of the present invention, both with and without an aperture and/or cap.
[0017] FIG. 9 illustrates a perspective view of an exemplary acoustic structure of the broadband transducer assembly of the present invention, propagating ultrasonic waves longitudinally through water.
[0018] FIG. 10 illustrates a conventional narrowband transducer element, without voltage applied.
[0019] FIG. 11 illustrates a conventional narrowband transducer element in operation with voltage applied.
[0020] FIG. 12 illustrates an exemplary transducer element of the broadband transducer assembly of the present invention, without voltage applied.
[0021] FIG. 13 illustrates an exemplary transducer element of the broadband transducer assembly of the present invention, in operation with voltage applied.
[0022] FIG. 14A is a graph illustrating bandpass characteristics of an exemplary broadband transducer assembly of the present invention.
[0023] FIG. 14B is a graph illustrating bandpass characteristics of an alternative embodiment of an exemplary broadband transducer assembly of the present invention.
[0024] FIG. 15 is a perspective view of an exemplary broadband array transducer assembly of the present invention containing an array of four acoustic structures in the bottom section of a transducer housing.
[0025] FIG. 16 is a side elevation view of the exemplary broadband array transducer assembly of FIG. 15 .
[0026] FIG. 17 is a rear elevation view of an exemplary broadband array transducer assembly of FIG. 15 .
[0027] FIG. 18 is cross-sectional view of an exemplary broadband array transducer assembly of the present invention, taken along line 18 - 18 of FIG. 17 .
DETAILED DESCRIPTION OF THE INVENTION
[0028] Broadband transducers are electroacoustic devices used to increase sonar resolution and definition of products and have application, for example, in scanning sonar, three-dimensional sonar, echo sounders and sonar-GPS combinations. These devices can determine the depth of the marine floor, locate fish, identify other submerged targets, locate structure, show contours, avoid collisions and produce underwater images and the like.
[0029] Conventional broadband transducers used in military and commercial applications are too expensive to incorporate into most fish finding systems. While broadband transducers offer new capabilities for these devices, a conventional broadband fishfinder must meet the requirements for broadband in each aspect of the device, including the transducer, transmitter, receiver, and signal-processing-software. Most broadband transducers are comprised of porous ceramic elements or composite ceramic elements, which are expensive and contribute to the high cost of broadband devices. These requisite materials and components make broadband fishfinders cost prohibitive for many commercial and recreational marine activities.
[0030] Conventional narrowband fishfinders incorporate transducers that operate within a limited range of active frequencies. Lead zirconate titanate (Pb[Zr x Ti 1-x ]O 3 or “PZT”) is a piezoelectric ceramic material widely used in transducers. However, the range of active resonant frequencies of this PZT ceramic material are extremely narrow. Due to the discontinuity between the acoustic impedance of the piezoelectric ceramic material comprising the transducer and the surrounding environment, the bandwidth of conventional narrowband fishfinders typically have a Quality Factor (“Q Factor”) of about 15 and above. These conventional narrowband devices generally are useful in freshwater and some saltwater environments but are limited in capability as compared to broadband devices, which offer many advantages.
[0031] Various tactics have been employed in attempts to create broadband transducers for use in marine applications, including the use of composite or porous piezoelectric ceramic materials. Composite PZT ceramic material (“composite PZT”) comprised of epoxy, plastic and rubber, are placed into a homogeneous mixture with small pieces of PZT ceramic to form a monolithic transducer. The composite PZT transducer will have an acoustic impedance between PZT and epoxy, moving the acoustic impedance closer to that of water and creating a broadband effect. Porous piezoelectric materials (“porous PZT”) are used in commercial and military sonar applications and medical electronics. To create a porous ceramic material, the PZT is mixed with select powders and is heated, leaving microscopic voids in the PZT. The voids reduce specific gravity of the PZT ceramic material, thereby moving the acoustic impedance of the device closer to that of water and achieving broadband results. Both porous PZT and composite PZT are extremely expensive due to material and manufacturing costs. Other methods of achieving broadband include the use of head and tail masses, also impedance matching layers are placed between the piezoelectric element and water.
[0032] The present invention overcomes these problems of expense and complexity. The present invention comprises a cost-effective broadband transducer assembly that not only reduces the cost of existing broadband fishfinder systems but, due to the low cost of the transducer, will allow all fishfinding systems to operate with broadband. The present invention achieves broadband operation by using an internally-housed, low cost transducer element which is sufficiently thin, as described herein, thereby generating a relatively large amount of transverse vibration in the transducer element and increasing the load between the transducer element and an acoustic structure. Broadband operation may be enhanced by at least partially enclosing the transducer element with a cap or within an aperture sized to receive the transducer element, which has the effect of increasing the load between the transducer element and the acoustic structure. As used herein, the term “broadband” and the phrases “broadband operation” or “operates within broadband” and the like are used interchangeably to mean having a Q Factor of about 5 or less.
[0033] Unless defined otherwise, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which the invention belongs. Although any methods and materials similar or equivalent to those described herein can be used in the practice or testing of the present invention, the preferred methods and materials are described herein. All references cited herein, including published or corresponding U.S. or foreign patent applications, issued U.S. or foreign patents, and any other references, are each incorporated by reference in their entireties, including all data, tables, figures, and text presented in the cited references.
[0034] Turning now to the drawings in general and to FIG. 1 in particular, there is shown therein an embodiment of the broadband transducer assembly 10 of the present invention mounted to the transom 12 of a watercraft 14 or other vessel for use in marine applications. As used herein, “marine” and “marine applications” are used interchangeably to refer to activities and/or applications involving or relating to bodies or accumulations water, whether fresh water or salt water, including, without limitation, oceans, seas, lakes, ponds, rivers, streams, springs, creeks, gulfs, sounds, harbors, coves, channels, lagoons and the like. The transducer assembly 10 may be affixed to the watercraft 14 via known methods, such as mounting bracket 13 , although it will be appreciated that other embodiments and other watercraft mounting methods are possible. For example, the transducer assembly 10 may be affixed via through-hull-mounting, in-hull-mounting, trolling-motor-mounting, pole-mounting, adhesives and the like. Additionally, the transducer assembly 10 may be used without affixation to any watercraft or other device and simply may be floated or suspended on or near the surface of the water 18 where it is to be employed, for example, in marine activities such as ice fishing or from a boathouse and other activities where physical connection with a vessel or watercraft is neither useful nor desirable.
[0035] The broadband transducer assembly 10 optimally is used such that sonar beam 20 emitted from the transducer assembly is generally perpendicular to the water surface 18 . However, it will be appreciated that the present invention also may be used with the transducer assembly 10 in any orientation with respect to the water surface 18 so long as the sonar beam 20 is emitted from transducer assembly 10 in a direction that is within the water. For example, the broadband transducer assembly 10 may be positioned so that the sonar beam 20 is emitted at a 45 degree angle with respect to the surface of water 18 or even parallel with respect to surface 18 , so long as the sonar beam is emitted within the water.
[0036] Turning now to FIGS. 2 through 4 , the transducer assembly 10 comprises a housing 24 . In one embodiment of the invention, the housing 24 comprises a top surface 26 , a bottom surface 28 and a connector 30 . There are many types of brackets, clamps, struts, fixtures and other connectors 30 appropriate for use in mounting the transducer assembly 10 to the watercraft 14 or other vessel or device, depending upon the desired application. As aforementioned, the transducer assembly 10 need not be connected to another device or vessel to achieve optimal operation, so the connector 30 is optional.
[0037] The housing 24 may be of any shape that adequately stores the interior components, yet to be described. In one embodiment of the invention, the housing 24 is comprised of interlocking top and bottom surfaces 26 and 28 , respectively, which are securely connected to protect the interior components of the broadband transducer assembly 10 from water, dust, contaminants and other foreign materials, particles or objects. It will be appreciated that the housing 24 may be constructed of multiple components or comprise a single, integrally-formed structure having a top surface 26 and bottom surface 28 .
[0038] The housing 24 may be comprised of a variety of materials that preferably impart properties of impact resistance, toughness and water-resistance. Some such materials include plastics and metals. Examples of plastic materials suitable for construction of the housing 24 include polypropylene, delrin, polycarbonate, urethane, polyethylene, polystyrene, nylon, acrylic, polyvinylchloride and ultem. In one embodiment of the invention, the housing 24 of the broadband transducer assembly 10 is comprised of acrylonitrile butadiene styrene (“ABS”) plastic. The housing 24 also may be constructed of metals, such as bronze, brass, aluminum or steel. Alternatively, the housing 24 may be constructed from a combination of materials. The material comprising the housing 24 should be selected so as to yield the most desirable characteristics of acoustic performance, strength, durability and cost-effectiveness for the particular application.
[0039] In an alternative embodiment, the housing 124 is generally tubular, as shown in FIG. 5 , forming a top surface 126 and a bottom surface 128 , and may be constructed from metal. An acoustic structure 36 (not shown in FIG. 5 ) is acoustically isolated within the housing 124 . Longitudinal waves or the sonar beam 20 from an acoustic structure, yet to be described, are coupled into water through an acoustic window 170 , made of urethane or similar material.
[0040] Turning now to FIGS. 6 and 7A through 7 C, the broadband transducer assembly of the present invention further comprises an acoustic structure 36 . FIG. 6 illustrates therein a cross-section of an embodiment of the broadband transducer assembly 10 taken long line 6 - 6 of FIG. 4 , wherein an exemplary acoustic structure 36 of the present invention readily is seen. The acoustic structure 36 comprises a base 38 and a transducer element 40 . It will be appreciated that the base 38 of the acoustic structure 36 may take any form suitable for supporting the transducer element 40 . In one embodiment of the invention, shown in FIG. 7A , the base 38 of acoustic structure 36 comprises a generally level support for the transducer element 40 .
[0041] Alternatively, the base 38 of the acoustic structure 36 may form an aperture 42 for receiving the transducer element 40 , as illustrated in FIGS. 6 , 7 B and 7 C. The depth of the aperture 42 preferably approximates the thickness of the transducer element 40 . The aperture 42 need not be formed by a continuous sidewall 46 or sidewalls, depending upon the configuration, and may be formed, for example, with intermittent breaks in the sidewall. Consequently, the sidewall 46 of aperture 42 either may directly contact the transducer element 40 or any filler materials therebetween, such as an adhesive or potting compound. Typically, though not necessarily, a gap between the sidewall 46 of the aperture 42 and the transducer element 40 would be filled with an adhesive that is also used to secure the transducer element to the base 38 .
[0042] The aperture 42 may be formed integrally with or from the base 38 . The aperture 42 may be formed from the same material as the base 38 or from another material. In one embodiment of the invention, the base 38 and the sidewall 46 forming the aperture 42 are formed as an integral unit from ABS. It will be appreciated that the aperture 42 may be formed from a separate component that is then connected to the base 38 .
[0043] The base 38 and aperture 42 may comprise the same material or different materials, among which include ABS, nylon, polyethylene, polystyrene, polyvinylchloride, polypropylene, epoxy resin, vinyl ester resin, polyester resin, acrylic, delrin, polycarbonate, ultem and combinations thereof.
[0044] The acoustic structure further may comprise a cap 44 , which may be employed in conjunction with the aperture 42 or without the aperture. The optional cap 44 serves a variety of purposes, one of which is to provide additional loading of the transducer element 40 . The cap 44 also reduces side lobes in the beam pattern. It will be appreciated that the broadband transducer assembly 10 of the present invention achieves broadband without the cap 44 . The cap 44 may be used in conjunction with the aperture 42 to completely enclose the transducer element 40 . The cap 44 may also be positioned atop of transducer element 40 without positioning the transducer element within the aperture 42 . The cap 44 may be formed as an integral part of the aperture 42 or as a separate component which is attached to or supported above or on the aperture 42 . It is not necessary that the cap 44 completely cover the transducer element 40 to constrict the transverse vibrations of the transducer element, and to that end the cap may only partially cover or enclose the transducer element.
[0045] As shown in FIG. 6 , the base 38 of the acoustic structure 36 may be integrally formed with bottom surface 28 of housing 24 . It will be appreciated, however, that the base 38 of acoustic structure 36 may comprise a discrete article separate from the bottom surface 28 of housing 24 . In one embodiment of the invention, the base 38 and optional cap 44 are made from ABS plastic, but other suitable materials such as nylon, polyethylene, polystyrene, polyvinylchloride, polypropylene, epoxy resin, vinyl ester resin, polyester resin, acrylic, delrin, polycarbonate, or ultem may be used to construct the base. In some embodiments, the base 38 or acoustic structure 36 may be constructed from the same material or materials as the housing 24 , ABS for example, or the housing and base may be constructed of different materials. Furthermore, the acoustic structure 36 may be constructed from multiple materials so as to yield the most desirable characteristics of acoustic performance, strength, durability, and cost effectiveness. When the base 38 and housing 24 are not integrally formed, the based is secured to the bottom surface 28 of the housing with adhesives or solvents, such as epoxy, vinyl ester, methyl ethyl ketone or acetone, which do not or only minimally acoustically impede vibrations from the acoustic structure 36 into the housing.
[0046] While the acoustic structure 36 often is elliptical, the shape and design of the acoustic structure is not limited to an elliptical profile. Circular, rectangular, polygonal or free-form profiles could be used to tune the desired resonant modes of the transducer assembly 10 . The acoustic structure 36 could be constructed in any shape and dimension to achieve the desired tuning and minimize the effect of resonant characteristics of the components of the broadband transducer assembly 10 .
[0047] With continuing reference to FIGS. 6 and 7A through 7 C, the acoustic structure 36 is at least partially surrounded by an isolation material 48 which serves to minimize radiation of acoustic signals from the acoustic structure into the housing 24 , excepting the bottom surface 28 of the housing. To this end, and with the exception of the bottom surface 28 of the housing 24 , the acoustic structure 36 is isolated from the other components of the transducer assembly 10 by an isolation material 48 . The isolation material 48 may be any material that creates discontinuity in acoustic impedance so that acoustic energy remains within the acoustic structure 36 or passes into and through the bottom surface 28 of housing 24 . Some materials suitable for this purpose include foam, cork, vacuum, air and the like. The isolation material 48 reduces coupling of acoustic signals from the acoustic structure 36 into other parts of the housing 24 except at the base 38 of the acoustic structure.
[0048] Further, in order to impart rigidity and durability to the both the transducer assembly 10 and the housing 24 , the housing may be filled with a potting material 50 , such as epoxy or rigid foam, which at least partially surrounds the acoustic structure 36 . In some embodiments, the isolation material 48 and potting material 50 may be combined into a single item, such as a rigid cast-in-place foam which would furnish both the isolation and potting functions.
[0049] To achieve optimal performance of the transducer assembly 10 , certain components of the transducer assembly must be designed properly for the application. One of these important characteristics includes the tuning of the acoustic structure 36 . The acoustic structure 36 is tuned through appropriate selection of the materials, shape, diameter, thickness and dimensions of the components of the acoustic structure. Nevertheless, while these characteristics are important to performance, they alone will not result in broadband operation. A sufficiently thin transducer element 40 is required to achieve broadband operation.
[0050] With continuing reference to FIGS. 6 and 7A through 7 C, the transducer element 40 of the broadband transducer assembly 10 of the present invention now will be described. The transducer element 40 comprises a piezoelectric material or a magnetostrictive material. In one embodiment of the invention, the transducer element is a piezoelectric material selected from the group consisting of PZT (lead zirconium titanate, (Pb[Zr x Ti 1-x ]O 3 )) or barium titanate (BaTiO 3 ). In one embodiment of the invention, the piezoelectric material preferably comprises PZT.
[0051] The transducer element 40 is of any shape to be accommodated within the acoustic structure 36 and the housing 24 . The transducer assembly 10 of the present invention achieves broadband by employing a sufficiently thin transducer element 40 , in operation with the base 38 of acoustic structure 36 . The extent to which the transducer element 40 is sufficiently thin can be expressed as the diameter-to-thickness (DTT) ratio of the transducer element. For a circular transducer element 40 , the diameter thereof is clearly identifiable. For a non-circular transducer element 40 , whether regular or irregular in shape, such as a rectangular, elliptical or polygonal, the characteristic length of the element is substituted for the diameter. As used herein, the term “DTT ratio” will be used to represent all scenarios.
[0052] A range of DTT ratios achieve broadband operation in the present invention. For example, a transducer element 40 which has a DTT ratio of 9 (diameter is 9 times the thickness) or greater will result in broadband operation when included as part of a proper acoustic structure 36 . As the DTT ratio gets smaller, i.e. as the transducer element 40 gets thicker and/or smaller in diameter, the amount of transverse vibration in the transducer element decreases, causing less loading between the transducer element and the base 38 of acoustic structure 36 , thus narrowing the bandwidth.
[0053] Typically, a transducer element 40 having a large DTT ratio of 75 or greater should exhibit broadband operation, although there is a practical upper limit to the DTT ratio for sonar and fishfinder applications. First, as the DTT ratio increases (as the element gets thinner with respect to the diameter) the amount of transmit power which can be input into the transducer element 40 without damaging it is reduced. If the transducer element 40 is too thin, it will not be able to handle the required transmit power to produce the desired results in a sonar or fishfinder application. This sets a practical lower limit to the thickness of the element. Second, as the DTT ratio increases, if a reasonable thickness is maintained, the diameter will also increase. Since the present invention operates the transducer element 40 in the transverse (or radial) mode, larger diameters will result in lower operational frequencies. Center operational frequencies below 20 kHz are not typically useful for sonar and fish-finder applications. This sets a practical upper limit to the diameter of the element. Having a practical lower limit to the element thickness and a practical upper limit to the element diameter (or characteristic length) effectively bounds the practical upper limit of DTT ratios. Preferably, the center frequency of the broadband operation of the broadband assembly of the present invention ranges from about 20 kHz to about 250 kHz.
[0054] FIG. 8 illustrates some preferred DTT ratios of the transducer element 40 based on operational frequency of the broadband transducer assembly 10 . The graph in FIG. 8 plots the DTT ratio of the transducer element 40 on the y axis versus the center frequency of broadband operation of the broadband transducer assembly 10 in operation, on the x axis. The expected useful DTT ratio of the transducer element 40 of the broadband transducer assembly 10 ranges from about 9 to about 55. A preferred range of DTT ratios exists based on the most favorable combination of transducer element 40 operational frequency, transducer element 40 bandwidth, transmit power capability, size and cost. Due to these factors, the most preferable DTT ratio range will be different based on the operational frequency of the transducer element. It will be appreciated that the transducer element 40 of the acoustic structure 36 is not limited to the DTT ratios shown in FIG. 8 , although it is anticipated that a majority of viable DTT ratios of the transducer element will fall within this range.
[0055] The acoustic structure 36 need not comprise an aperture 42 or a cap 44 for the broadband transducer assembly 10 to achieve broadband operation. It will be appreciated, however, that if an aperture 42 and/or a cap 44 are employed as part of or in connection with the acoustic structure 36 , the additional load imparted between the transducer element 40 and the base 38 due to inclusion of either of these components will allow smaller DTT ratios to achieve broadband operation. When an aperture 42 and/or a cap 44 are employed as part of or in connection with the acoustic structure 36 , useful DTT ratios range from about 4.5 to about 55, as shown in FIG. 8 .
[0056] Turning now to FIG. 9 , and with continuing reference to FIGS. 6 and 7A through 7 C, the operation of the broadband transducer assembly 10 will be described. FIG. 9 shows the transducer element 40 positioned within the acoustic structure 36 , which is transmitting a sonar beam 20 into the water 18 . The housing 24 is not shown for purposes of illustration. The transverse restraining forces on the transducer element 40 increase the load on the transducer element, thus broadening the bandwidth.
[0057] The accentuated transverse vibrations from the sufficiently thin transducer element 40 enable broadband operation of the transducer assembly 10 . Additionally, the constriction of the transducer element 40 by the aperture 42 and cap 44 will constrict the transverse vibration of the transducer element, which causes loading between the transducer element and the acoustic structure, thus broadening the bandwidth of the acoustic structure. The amount of load created in these circumstances is dependent on a number of factors, including aperture 42 and cap 44 dimensions, construction materials and configuration. It will be appreciated that while the aperture 42 and/or cap 44 will load the transducer element 40 , the use of a sufficiently thin transducer element 40 in conjunction with both the aperture 42 and/or cap 44 will provide more load than use of only one of the components alone. Thus, in a number of exemplary embodiments of the present invention, both an aperture 42 and cap 44 will be utilized with a sufficiently thin transducer element 40 to achieve enhanced broadband performance.
[0058] The transducer element 40 is connected with a sonar transmitter and a receiver (not shown) via a transducer cable 54 . When a sonar pulse is applied to the transducer cable 54 , the pulse, therefore, also is applied to the transducer element 40 . The transducer element 40 then vibrates longitudinally or axially, and because it is sufficiently thin, it vibrates aggressively in the transverse or radial direction. These aggressive transverse vibrations are coupled into the acoustic structure 36 and resonate within the structure. Transverse and longitudinal resonances within the acoustic structure 36 then produce longitudinal vibrations that are coupled into the water and longitudinally as the transmitted sonar beam 20 through water 18 . The longitudinal direction may also be referred to as the axial direction, while the transverse direction may also be referred to herein as the radial direction.
[0059] With continuing reference to FIG. 9 , transverse vibrations from the transducer element 40 will couple into the base 38 and cause associated longitudinal vibrations within the acoustic structure 36 . Different transverse and longitudinal resonance modes within the acoustic structure 36 are determined by the acoustic structure components, composition, shape, and dimensions. The composite result of these transverse and longitudinal resonances is realized longitudinally at the interface of the acoustic structure 36 with the bottom surface 28 of the housing 24 and, hence, to the water 18 . The transmit sonar beam 20 is then emitted from the acoustic structure 36 and propagates through water in a longitudinal fashion.
[0060] Comparison of the transducer element of a conventional narrowband fishfinder transducer to the transducer element 40 of an embodiment of the present invention 10 demonstrates the following: 1) Longitudinal vibrations are the same in both; 2) transverse vibrations in the sufficiently thin transducer element 40 of the present invention are greatly accentuated over transverse vibrations of conventional narrowband fishfinder transducer elements.
[0061] FIGS. 10 and 11 represent a transducer element of a conventional narrowband fishfinder transducer device. FIGS. 12 and 13 illustrate a sufficiently thin transducer element 40 of an embodiment of the present invention. Both transducer elements are made of the same normal, low-cost, hard PZT. Both elements have the same piezoelectric characteristics and the same initial diameter D 0 in the unexcited state, illustrated in FIG. 10 for the conventional transducer element and in FIG. 12 for the transducer element 40 of the present invention 10 . However, with the application of an electric field, the transducer element 40 of the present invention in an excited state has a greater length change in the transverse direction than the conventional transducer element, as illustrated in FIGS. 11 and FIG. 13 .
[0062] In general, the change in length of a transducer element due to an applied electric field is shown in EQ 1:
[0000] Δ L=d ij ×E×L 0 EQ 1:
[0063] Where: L 0 =Initial length (m)
d ij =piezoelectric charge constant (pm/V) E=applied electric field strength (V/m)
[0066] Since PZT has different piezoelectric charge constants based on orientation to the polarization vector, we arrive at EQ 2 and EQ 3 to find the change in diameter and thickness of a PZT element due to an applied electric field.
[0000] Δ D=d 31 ×E×d 0 EQ 2:
[0000] Δ T=d 33 ×E×t 0 EQ 3:
[0067] Where: T 0 =Initial diameter (m)
T 0 =initial thickness (m) d 31 =piezoelectric charge constant orthogonal to the polarization vector (pm/V) E=applied electric field strength (V/m) d 33 =piezoelectric charge constant parallel to the polarization vector (pm/V)
[0072] Since the electric field is applied over the initial thickness of the element, E is derived as follows:
[0000] E=V/T 0 EQ. 4:
[0073] Based on established properties for hard PZT, using EQ. 2 and EQ 3. and applying a 600V electric field, the difference in the transverse length for the conventional transducer element and the sufficiently thin transducer element 40 of the present invention is calculated.
[0000]
TABLE 1
Conventional Narrowband
Present Invention Transducer
Transducer Element
Element
Figures 10-11
Figures 12-13
Unexcited
25.4 mm
25.4 mm
Diameter (D 0 )
Unexcited
11.2 mm
2.0 mm
Thickness (T 0 )
d 33
5x10 −10 m/V
d 31
−2.3x10 −10 m/V
Applied
600 V
Voltage (V)
E
V/t 0 = 600 V / .0112 m = 53571 V/m
V/t 0 = 600 V / .002 m = 300000 V/m
ΔD
-
2.3
x
10
-
10
m
V
*
53571
V
m
*
.0254
m
=
-
3.13
x
10
-
7
m
_
-
2.3
x
10
-
10
m
V
*
300000
V
m
*
.0254
m
=
-
1.75
x
10
-
6
m
_
ΔT
5
x
10
-
10
m
V
*
53571
V
m
*
.0112
m
=
3.0
x
10
-
7
m
_
5
x
10
-
10
m
V
*
300000
V
m
*
.002
m
=
3.0
x
10
-
7
m
_
[0074] As shown by the calculations in Table 1, both transducer elements in FIGS. 11 and 13 have the same longitudinal length change due to an applied voltage, but the transducer element 40 of the present invention broadband transducer assembly 10 has 5.6 times greater length change in the transverse direction than the conventional narrowband transducer element. It will be appreciated that the calculations in Table 1 are a comparison of two specific transducer elements. As the DTT ratio of the sufficiently thin transducer element 40 is changed, so will the difference in transverse length change with respect to a conventional narrowband transducer element with a much smaller DTT ratio.
[0075] A typical measurement of transducer performance is Q Factor, which is defined as follows:
[0000]
Q=f
c
/Δf
[0076] Where:
[0077] f c =Center frequency of the bandpass
[0078] Δf=Bandwidth
[0079] In general, transducer assemblies with a lower Q Factor are broader band. Table 2 contains a comparison of the Q Factor for a conventional narrowband transducer, typical low frequency broadband transducer, typical high frequency broadband transducer, with two embodiments of the broadband transducer assembly 10 of the present invention. While specific embodiments of the present invention will produce different performance, the measured bandpass of two embodiments substantially similar to that shown in FIGS. 2 through 4 and FIGS. 6 through 7C is represented in FIGS. 14A and 14B . Embodiment #1 has a usable bandwidth of 35 kHz with a center frequency of 82.5, while embodiment #2 has a usable bandwidth of 44 kHz with a center frequency of 85 kHz. These embodiments compare favorably with conventional narrowband, conventional high frequency broadband and conventional low frequency broadband transducers, as shown in Table 2.
[0000] TABLE 2 Conventional Conventional Present Present Conventional High Frequency Low Frequency Invention Invention Narrowband Broadband Broadband Broadband Broadband Transducer Transducer Transducer Transducer Transducer Assembly Assembly Assembly Assembly #1 Assembly #2 f c (kHz) 200 200 53.5 82.5 85 Δf (kHz) 12.5 100 23.0 35 44 Q 16.0 2.0 2.3 2.4 1.9
As demonstrated in Table 2 and FIGS. 14A and 14B , the present invention, though being significantly lower cost, is capable of broadband performance that is as good, if not better, than a typical higher cost broadband transducer assembly.
[0080] It will be appreciated that the present invention can be embodied in numerous ways. For example, the broadband transducer assembly may include a plurality of acoustic structures 36 with disk or plate-shaped transducer elements 40 , a single acoustic structure 36 with a plate transducer element 40 or any other arrangement of one or more acoustic structures 36 using transducer elements 40 which are a disk, plate, rectangular, ellipse, or other profile.
[0081] Turning now to FIGS. 15 through 18 , another embodiment of the present invention is illustrated therein. A broadband transducer assembly 210 comprises a housing 224 having a top surface 226 and bottom surface 228 and connector 230 . As shown in FIG. 18 , the broadband transducer assembly 210 comprises a plurality of acoustic structures 236 A through 236 D contained in an array arrangement within housing 224 . Each of the plurality of acoustic structures 236 A- 236 D comprises the elements of the acoustic structure 36 heretofore described. Each of the plurality of acoustic structures 236 A through 236 D could be operated individually or in a group of two or more to provide multiple transducer cone angles for use in either shallow or deep water. Other embodiments of a broadband array transducer could include acoustic structures 36 and transducer elements 40 of various sizes to achieve multiple frequencies and combinations of cone angles within the same transducer housing.
[0082] The present invention further comprises a method of using a broadband transducer assembly in a marine environment. The transducer element 40 is connected with a sonar transmitter and a receiver via a transducer cable 54 as heretofore described. When a sonar pulse is applied to the transducer cable 54 , the pulse is transmitted to the transducer element 40 , which then vibrates longitudinally, or axially. Because the transducer element 40 is sufficiently thin, it vibrates aggressively in the transverse, or radial, direction. These aggressive transverse vibrations are coupled into the acoustic structure 36 and resonate within the acoustic structure, producing longitudinal vibrations. The vibrations emitted from the acoustic structure 36 propagate longitudinally through the housing 24 and into the water 18 .
[0083] When the aperture 42 and or cap 44 are incorporated, vibrations from the transducer element 40 cause loading between the transducer element and the other components of the acoustic structure 36 , broadening the band width of the transducer assembly 10 .
[0084] The invention of this application has been described above both generically and with regard to specific embodiments. Although the invention has been set forth in what is believed to be preferred embodiments, a wide variety of alternatives known to those of skill in the art can be selected within the generic disclosure. Changes may be made in the combination and arrangement of the various parts, elements, steps and procedures described herein without departing from the spirit and scope of the invention as defined in the following claims. | A transducer assembly for transmitting broadband sonar beams and receiving broadband sonar returned echoes with a low-cost transducer element mounted into a low-cost acoustic structure. By using a transducer element which is sufficiently thin, broadband can be achieved at a significant cost savings over existing methods and devices. Since the transducer element is sufficiently thin, a large portion of the signal energy is coupled transversely into the acoustic structure, resulting in a heavy acoustic load on the transducer element which in turn results in broadband operation. Broadband operation may be enhanced by at least partially enclosing the sufficiently thin transducer element within an aperture and/or a cap. | 1 |
CROSS REFERENCE TO RELATED APPLICATION
This is continuation-in-part of Ser. No. 08/613,251, filed Mar. 8, 1996, U. S. Pat. No. 5,665,080.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to an improved suctioning device for rapid evacuation of fluid foreign material. The invention is particularly useful as an oropharyngeal suctioning device capable of rapidly removing chunky vomitus and bodily secretions and as a surgical suctioning device during exploratory laparotomy for rapidly clearing the surgical field to enable identification of ruptured blood vessels.
2. Description of Related Art
In emergency and surgical care hospital and medical provider settings, aspiration of regurgitated gastric contents in patients with an altered gag reflex (e.g., unconscious or anesthetized) is a life-threatening event. Mortality rates as high as seventy percent have been associated with massive aspiration of gastric contents. It is known that as little as twenty milliliters of gastric contents (approximately 1/5 mouthful) can cause significant lung damage when aspirated.
Treatment is simple: evacuation of the airway of the patient prevents the foreign matter from passing from the oropharyngeal cavity into upper airway passages and beyond. However, two factors affect the success of treatment. First, the time needed to evacuate the oropharyngeal cavity and airway of a patient is obviously of the essence; if vomitus can be expeditiously removed, patient morbidity and mortality should be positively influenced. Second, complete removal of vomitus and secretions is also important to prevent aspiration of secretions and minute particles after the bulk of the vomitus has been removed. Moreover, the medical care provider must maintain a sensitivity to possible soft-tissue damage within the oropharyngeal cavity caused by the suction tip during overzealous suctioning. Thus, a balance must be maintained between the need for speedily clearing a large volume of variably sized vomitus and the need for precise removal of residual secretions.
Under ideal medical care provider circumstances, removal of the regurgitated materials begins immediately after emesis. A commonly employed suction system comprises a thick-walled vacuum tubing (usually 1/4 inch inside diameter, 8 to 10 feet in length) with a suction tip for collection of vomitus from the oropharynx of a patient. The tubing is connected to a collection canister attached to a wall-mounted vacuum inlet or regulator, which is in turn connected to a central vacuum line. Standard hospital regulations require that central vacuum line systems must be capable of generating at least 304 mm Hg at any inlet, the norm ranging between 381 mm Hg and 482 mm Hg.
However, surprisingly, such standard and commonly used hospital suction equipment is inadequate for removing both chunky vomitus and the remaining secretions. Medical literature reveals that a standard hospital setup having a vacuum pressure of 550 mm Hg required 7.5 seconds to evacuate 140 milliliters of simulated vomitus, a period of time concluded to be too long to prevent clinically significant aspiration.
Moreover, commonly used suctioning tips, such as Yankauer tips also having a 1/4 inch inside diameter or less, are designed primarily for applications wherein a capability to evacuate every drop of essentially solid-free liquids or secretions (at most contaminated by small solid chips such as might be encountered during surgery) from a surface is desired. However, such tips become easily and entirely blocked by chunky vomitus. Clearing the blockage in an emergency situation requires additional precious time. Thus, reliable and effective suction equipment capable of clearing the oropharynx of secretions and chunky vomitus in a timely manner is a critical component of an emergency resuscitation procedure.
The present invention reduces the evacuation time by improving suction efficiency of such hospital suction setups. Increasing the diameter of suction tips, tubing, and connectors leading to the suction port of a suction canister increases the rate of flow through the suction device. No studies of the medical literature were found addressing suction device internal diameters to improve suction efficiency.
The prior art likewise discloses no suction apparatus or combination of components thereof having an inlet capable of being expeditiously increased to a critical range of diameters suitable for the rapid evacuation of fluid foreign material including chunky vomitus and bodily secretions. U.S. Pat. No. 4,490,138, issued Dec. 25, 1984, to Lipsky et al., discloses a pharyngeal suction device including a hollow wand and a safety tip attached thereto. U.S. Pat. No. 4,273,126 issued Jun. 16, 1981 to Grane et al. describes a hand-held attachment device for use with a tracheal aspirator directed at collection of large, solid particles from the trachea and mouth of a patient. U.S. Pat. No. 4,221,220, issued Sep. 9, 1980, to Hansen, discloses a surgical suction nozzle for removing vomitus from unconscious patients that is resistant to clogging.
Other patents reveal a wide range of applications for suction collection devices, none of which describe a combination of similar structural components directed at improving the rate of fluid flow of secretions containing solid particles to a collection container. For example, U.S. Pat. No. 4,455,140 issued Jun. 19, 1984 to Joslin describes a collapsible fluid collection device having telescopically disposed members directed at reducing its storage space. U.S. Pat. No. 4,319,570 issued Mar. 16, 1982 to Grane describes a tracheal suction pump driven by compressed gas and designed primarily for aspiration of vomitus and secretions. U.S. Pat. No. 4,925,447 issued May 15, 1990 to Rosenblatt describes an aspirator containing a bellows to isolate gases and liquids collected from the patient from the source of the suction. U.S. Pat. No. 5,002,534, issued Mar. 26, 1991, to Rosenblatt shows a potable, manually operated aspirator including a container. U.S. Pat. No. 5,251,619, issued Oct. 12, 1993, to Lee, discloses a tracheal tube including a sealant cuff. U.S. Pat. No. 5,419,769 issued May 30, 1995 to Devlin et al. describes a suction system employing a suction control device which allows manual control of application of reduced pressure in the system. U.S. Pat. No. 4,662,367 issued May 5, 1987 to Gore, Jr. describes a trachea suction tube for removing an obstruction by placing one end over laryngeal surfaces of a patient and by orally drawing air through the tube from the other end. U.S. Pat. No. 5,114,415 issued May 19, 1992 to Shedlock describes a soft, flexible adapter shallowly inserted into the nostril for suctioning secretions from upper airways.
None of the above inventions and patents, taken either singly or in combination, is seen to describe the instant invention as claimed.
SUMMARY OF THE INVENTION
The present invention relates to an improved suctioning device for rapid evacuation of fluid foreign matter, defined herein as including vomitus and bodily secretions. The improved suctioning device for evacuation of fluid foreign matter from patients uses a 3/4 inch inside diameter tubing and similarly increased diameter suction tip. This increase in diameter provides an evacuation rate of at least 10 times faster than the rate of evacuation using the prior art devices. The improved suctioning device includes a suction tip having an increased diameter ranging between 3/8 of inch and 2 inches, a patient vacuum tubing of an inside diameter between 3/8 of an inch and 2 inches and 4 to 10 feet in length, a first adapter for attaching the tubing to a pour spout of a suction canister with inside diameter measuring at least 1/2 of an inch and a second adapter for connecting the suction tip to the tubing. A central vacuum line inlet is provided to apply negative pressure to the canister.
Accordingly, it is a principal object of the invention to provide an suctioning device for the rapid evacuation of fluid foreign matter including vomitus and bodily secretions from the oropharyngeal cavity to positively affect the morbidity and mortality of patients subject to a risk of aspiration of fluid foreign matter.
It is a further object of the invention to provide a suctioning device for the rapid clearing of the surgical field during procedures such as exploratory laparotomies during which rapid identification of ruptured blood vessels is required to prevent morbidity and mortality of patients.
It is another object of the invention to provide a suctioning device with an adjustable inlet diameter to immediately provide an increased internal diameter suction system permitting the rapid emergency evacuation of substantial quantities of fluid foreign matter including solids.
It is a further object of the invention to provide a suctioning device having components adapted for use with components of suctioning devices found in the prior art.
Still another object of the invention is to provide an oropharyngeal suctioning device having components which permit an evacuation procedure to be conducted in a standard medical care facility setting.
It is an object of the invention to provide improved elements and arrangements thereof in an apparatus for the purposes described which is inexpensive, dependable and fully effective in accomplishing its intended purposes.
These and other objects of the present invention will become readily apparent upon further review of the following specification and drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an environmental, perspective, exploded view of the suction device of the present invention showing its components and connections.
FIG. 2 is a perspective, exploded view of a suction tip of the suction device as shown in FIG. 1.
FIG. 3 is a perspective view of an alternative embodiment of the suction tip.
FIG. 4 is an environmental, perspective, exploded view of a suction device known in the prior art showing its components and connections.
Similar reference characters denote corresponding features consistently throughout the attached drawings.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
The present invention relates to an improved suctioning device for rapid evacuation of fluid foreign material including chunky vomitus and bodily secretions wherein a range of internal diameters of the components of a suction system connected to a central vacuum line improves suction efficiency for the intended purpose.
As matter of background, the rate of flow through a uniform tube as defined by Poiseuille's Law is controlled by the following variables: the pressure difference applied, the length of the tube, the viscosity coefficient of the fluid, and the radius of the tube. Poiseuille's Law is stated as follows:
R=(p.sub.1 -p.sub.2) (πr.sup.4)/8ηL
where R is rate of flow; p 1 -p 2 is the pressure difference applied; r is the radius of the tube; η is the viscosity coefficient; and, L is the length of the tube.
In the present application of Poiseuille's Law, all variables but the radius of the tube are limited by external factors. Referring first to FIG. 4, the limiting factors can be explained relative to a commonly used suctioning system 50 as found in the prior art.
First, the pressure difference variable is dependent upon the negative pressure source normally supplied at the wall inlet of a central vacuum line of a hospital or medical care provider facility (as represented by the regulator dial 52), which negative pressure as previously noted ranges between 381 mm Hg and 482 mm Hg. Moreover, an optimal suction pressure has been described in medical literature at which potential injury to the oropharynx of a patient is limited. Thus, at any one hospital facility, the applied pressure difference at a central vacuum line inlet 52 is constant for purposes of maximizing suction efficiency from a central vacuum line inlet 52.
Next, the length of a patient suction tube 54 must be capable of reaching from the wall inlet 52 to a patient P, limited therefore to no less than 4 feet in length, and has traditionally been found to provide acceptable range at 8 feet in length. Although clearly the length of tubing can be shortened to increase rate of flow, standard practice and experience in hospital settings dictate that 8 feet is a necessary length of tubing associated with emergency facility settings and equipment available for evacuation of vomitus.
The viscosity coefficient for vomitus is also effectively a constant and, for experimentation purposes, has been simulated by vegetable soup. The vomitus must travel from the mouth of the patient P over the length of the tubing 54 plus the length of a suction tip 56 (employed to safely suction the oropharynx of the patient) to a suction canister 58. Although the suction tip adds to the overall length of the tubing, the suction tip 56 is commercially produced standard in length and comparable in length to alternate or substitute suction tips used in the medical profession for similar applications. Traditionally, a standard Yankauer suction tip has been the instrument of choice for evacuation of vomitus. The standard Yankauer suction tip has a tip inside diameter of no more than 1/4 inch and a length of approximately 12 inches. Standard practice and experience in hospital settings dictate that the additional constant length associated with the suction tip for evacuation of vomitus is necessary for safe and efficient procedure.
A suction canister 58 is necessary to collect evacuated vomitus and secretions and is designed to prevent aspiration of foreign material into the central vacuum line inlet 52. A vacuum inlet tube 60 is connected to a vacuum inlet port 62 of a canister lid 70 to create a negative pressure in the canister 58. A standard commercially produced canister 58 provides a 1/4 inch patient tubing port 64 for connection of the patient suction tubing 54, and a smaller diameter 3/16 inch patient tubing port 66 (shown capped by a removable cap 72). All caps are removable such that ports may be interchangeably used. Suitable connectors 74 may be used as necessary to provide a sealed, continuous path to the suction canister 58. A pour spout 68 of at least a 3/4 inch diameter (shown capped) is provided for removal of the evacuated materials from the canister 58.
Therefore, given the above limiting factors, the radius of the suction system is effectively the only variable by which the rate of flow can be increased to increase suction efficiency in a hospital setting providing a central vacuum line and standard suction equipment.
The present invention 10, as shown in FIG. 1, provides a combination of components, in part using components of the equipment as shown in FIG. 4, which are adapted such that patient suction tubing 12 having an inside diameter between 3/8 inch and 2 inches is used. The inventor has determined in experiments simulating evacuation of vomitus (maintaining the above noted constants, using a 3/4 inside diameter patient suction tubing 12) that vegetable soup is evacuated at a rate at least 10 times faster than the rate of evacuation using the prior art as shown in FIG. 4.
The present invention 10 includes a suction tip 14 having tip orifice of adjustable size, a patient suction tube 12 of an inside diameter between 3/8 inch and 2 inches and 4 to 10 feet in length. Patient suction tubing may be reinforced to prevent the larger diameter tubing from kinking and thus obstructing the suction flow. Two connectors are provided. A first adapter 18 for connecting the patient suction tube 12 to the pour spout 68 of a suction canister 58. The pour spout 68 has a diameter of at least 1/2 of an inch. A second adapter 16 connects the suction tip 14 with the patient vacuum tubing 12. A central vacuum line inlet 52 is provided to apply negative pressure to the canister 58 by means of the vacuum inlet tube 60 attached to the vacuum inlet port 62 of the canister 58. Each of the patient ports 64, 66 are capped to provide an air-tight seal to maintain the negative pressure within the canister 58.
The suction tip 14 having a adjustable tip orifice is shown in FIG. 2. The suction tip 14 includes a barrel 20 that defines a lumen 22 passing longitudinally therethrough. The barrel 20 has an tip end 24 and an opposite connection end 26. The tip end 24 includes an inlet opening 28. The inlet 28 is configured as a standard Yankauer bulb tip being smoothly contoured and having relief eyes 30 to prevent damage to soft tissue during normal suction operation. Barrel 20 is bent or curved for ease of use. The suction tip 14 has all of the advantages of the prior art suction tips 56. Suction tip 14 is capable of effectively removing all the fluid in a cavity without damaging the soft tissue in the cavity. The connection end 26 of barrel 20 defines a discharge outlet 32 for connection to the patient suction tube 12. The lumen 22 connects the inlet 28 with the discharge outlet 32.
The barrel 20 is divided into two parts: a nozzle 100 at tip end 24 and a handle 102 at connection end 26. The handle 102 has a first end 108 and an opposite second end 110. The first end 108 is configured for attachment to the patient suction tube 12. The nozzle 100 has an inlet end 104, which includes inlet 28, and an opposite attachment end 106. The nozzle 100 and the lumen 22 are tapered from attachment end 106, which has a large cross sectional area, to inlet end 104, which has a relatively smaller cross sectional area. Nozzle 100 is curved or bent for ease of use. The inlet 28 has a diameter of approximately 1/4 of an inch to provide the advantages of conventional suction tips. To provide the high flow rate possible from the large diameter suction system, the diameter of the lumen 22 increases to a large diameter of from 3/8 of an inch to 2 inches. The preferred diameter is 3/4 of an inch as suction is frequently broken by air passage if the diameter is increased beyond 3/4 of an inch.
Attachment means 112 are provided for attaching the attachment end 106 of the nozzle 100 to the second end 110 of the handle 102. Attachment means 112 provide means for positively securing the nozzle 100 to the handle 102 while permitting the nozzle 100 to be quickly removed during events requiring increased suction flow rate. Attachment means 112 that provide the necessary quick release include the twist lock pin and channel combination shown, friction joined fittings, matting screw threads, and latches.
During most surgical operations, the suction system 10 is used with nozzle 100 secured to handle 102 and functions as a conventional suction system with all the advantages of a conventional suction tip. During surgical situations where immediate removal of fluid foreign matter is critical, the nozzle 100 is quickly detached from the handle 102 to expose the large diameter of lumen 22 at the junction of the handle 102 and the nozzle 100. Upon detachment of nozzle 100 from handle 102, lumen 22 at the first end 110 forms the tip orifice. The large diameter tip orifice and large diameter patient suction tube 12 connected to the large diameter pour spout 68 of suction canister 58 provide a suction system having an increased flow rate that is not obstructed by solids in the fluid matter removed. This immediate conversion from a conventional suction system that is able to gently remove fluids to the increased diameter system able to remove chunky fluid material at a high flow rate is particularly useful when suction speed is critical such as after emesis to prevent aspiration of vomitus and during heavy internal bleeding to clear the surgical field.
A second embodiment of the suction tip of the present invention is shown in FIG. 3. Suction tip 200 includes a barrel 212 having a dilator 202 at a tip end 204. Opposite the tip end 204 is a connection end 206 for connection to the patient suction tube 12. Dilator 202 defines a tip orifice having a diameter that is mechanically adjustable. Dilator 202 includes a series of plates 208 that are retracted to increase the diameter of the tip orifice upon rotation of a control ring 210. The plates 208 are connected to control ring 210 so that rotation of the control ring in one direction causes the plates 208 to rotate toward the center of tip end 204 thus reducing the diameter of the tip orifice. Rotation of the control ring 210 in the opposite direction causes the plates 208 to rotate away from the center of tip end 204 in manner similar to the plates in a conventional camera aperture. The plates 208 are arranged to provide a tip orifice that adjusts from less than 1/4 of an inch to greater than 3/4 of an inch.
During critical surgical situations requiring high suction flow rates, dilator 202 is opened to approximately a diameter of 3/4 of an inch to increase the flow rate by utilizing the large diameter of the suction tip 200, patient tube 12, and pour spout 68. During delicate surgical situation in which the suction tip is required to keep the surgical field clear of small volumes of fluid, the dilator 202 is closed to a diameter of approximately 1/4 of an inch. When dilator 202 is closed, the suction velocity through the tip orifice is increased permitting small drops of fluid to be removed. The dilator 202 permits the increased flow rate of the large diameter system to be constantly available while preserving the advantages of the flow characteristics of known small tip orifices.
The combined features of the invention 10, increasing the internal diameters of the patient vacuum tube 12 and the suction tip orifice over the range of 3/8 inch to 2 inches and the adaptive use of the pour spout 68 to maximize flow rate, positively effect patient mortality and morbidity. The advantages of conventional suction systems are preserved through the adjustable diameter tip orifice. However, it is to be understood that the present invention is not limited to the sole embodiment described above, but encompasses any and all embodiments within the scope of the following claims. | A large diameter medical suctioning system for rapid evacuation of fluid foreign matter from patients using an increased diameter suction tube and a variable diameter suction tip. The variable diameter suction tip is expandable to a diameter of between 3/8 of an inch and 2 inches. The suction tube and connections thereto have a correspondingly increased diameter that provides an evacuation rate at least 10 times faster than the rate of evacuation using conventional suction systems. Additionally, the variable diameter suction tip is capable of performing the functions of a conventional suction tip by reducing the diameter of the variable diameter suction tip. The large diameter suctioning system is configured for connection to the pour spout of a suction canister to assure compatibility with existing medical vacuum systems. | 0 |
BACKGROUND OF THE INVENTION
The invention is based on a method for positional securing, or for component position securing, between at least two components relative to one another as defined hereinafter. A method and component position securing are known in which the positional securing of components is effected by introducing at least one pin of cylindrical or conical shape, and in particular a hollow pin, into a bore formed in each of the components for that purpose (Hutte [Smelter] II A, 28th Edition, page 41), in which the outer diameter of the pin and the inner diameters of the correlating bores are fixed in such a way that surface pressure is created between the pin and at least one bore. A disadvantageous feature of this method is that at least one of the two bores cannot be made until after the final relative position of the components has been set; particularly at the high quantities involved in mass production, this involves major production expense.
OBJECT AND SUMMARY OF THE INVENTION
The method for positionally securing components and the component position securing as defined hereinafter have an advantage over the prior art that the expensive step of drilling that follows the setting of the relative position of the components is dispensed with, so that the relative position of the components to one another can be secured in a simple manner.
It is especially advantageous to provide a taper in the region of the end of the hollow body that penetrates the component; this lessens vibrational energy and axial force required for driving the hollow body into the component.
In a further advantageous feature, both of the components to be joined are made from thermoplastic, which makes it possible for a hollow body that by the method connects the components to be driven both directly into the wall of a first component to be joined and into the wall of at least a second component to be joined.
The invention will be better understood and further objects and advantages thereof will become more apparent from the ensuing detailed description of a preferred embodiment taken in conjunction with the drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side view showing the basic outline of a method according to the invention for positionally securing components; and
FIG. 2 is a longitudinal section through a rotary adjuster for governing the idling speed, having two housing parts whose position relative to one another is secured according to the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
In FIG. 1, a hollow body of metal is identified by reference numeral 1; it protrudes partway into a continuous bore 3 disposed in a first component 2, into which bore it is introduced in a first method step. The bore 3 advantageously has an inside diameter that is somewhat smaller than the outside diameter of the hollow body 1, as a result of which after being inserted into the bore 3, the hollow body is fixed by a radial pressure.
The hollow body 1 may have an arbitrary outer shape. Advantageously, the hollow body 1 is formed cylindrically or as a conical surface and has a through bore that is correspondingly in the form of a conical surface. A continuous slit extending in the axial direction may be disposed on the circumference of the hollow body 1; as a result, the hollow body 1, if its outside diameter is adapted to the inside diameter of the bore 3, is advantageously braced in the bore 3 after being introduced into it.
The first component 2 comprises an arbitrary solid material, such as metal or plastic, and is disposed resting parallel to a second component 4 of thermoplastic, which is supported on the other side against a brace 5. The components 2, 4 may also be portions of different bodies, the portions being straps, flanges, or the like.
A sonotrode 9 of a known ultrasound source 10, for instance a commercially available ultrasonic welding unit, in an axially aligned way engages the free end 8 of the hollow body 1 protruding from the bore 3. The ultrasound source 10 is connected to a voltage source 13 via connecting lines 11 and in a known manner generates mechanical vibration in the range from 20 to 50 kHz in the axial direction. A high proportion of the vibrational energy of the ultrasound source 10 is transmitted to the hollow body 1 via the sonotrode 9 and is carried by the hollow body into its end 15 to be driven in, which is opposite the free end 8. Once the components 2, 4 have been put into a desired relative position, then by means of an axial force acting in the direction of the arrow 12, the hollow body 1 is introduced until it contacts the second component 4 and is then driven into the second component 4; the component 4, which is made of thermoplastic, is heated up to the melting point, and the molten plastic in the interior of the hollow body 1 can deflect away from the direction of introduction.
The molten plastic partly fills the interior of the hollow body 1, thereby bracing the hollow body 1 in the radial direction against the first component 2 and the second component 4. If there is an axial slit in the hollow body 1, then a residual cohesion between the component 4 and the plastic located in the interior of the hollow body 1 remains in effect, which additionally reinforces the strength of the component positional securing according to the invention.
Both the vibrational energy necessary for driving the hollow body 1 and the requisite axial force can be reduced by reducing the size of the contact area between the hollow body 1 and the second component 4. To that end, the hollow body 1 has at least one taper 16, on its end 15 that is driven in and penetrates the second component 4, and this taper is formed by way of example by one or two chamfers or bevels on the periphery of the hollow body 1.
If only a slight axial force is required for driving in the hollow body 1, then the brace 5 may be omitted. The same is correspondingly true if the second component 4 is rigidly embodied.
In a further advantageous method, both the first component 2 and the second component 4 are of thermoplastic, so that by means of an ultrasound source 10 and an axial force acting in the direction of the arrow 12 the hollow body 1 can be driven directly into both components 2, 4, without requiring the prior drilling of a bore in the second component 2. Moreover, it is conceivable for the hollow body 1 to be driven into not only the second component 4 but also other components of thermoplastic, and for the position of more than two components relative to one another to be secured thereby.
FIG. 2 shows a known rotary adjuster for controlling a flow cross section in internal combustion engines, which is composed of a driving part 20 and an adjuster part 21. The driving part 20 has a drive housing 22 of thermoplastic, which encloses a stator 23, made up for instance of sheet-metal laminations, and a winding 25 disposed around an induction core 24. A hollow body 29 is seated in an indentation 28 of the drive housing 22 and has a bore 30, into which one end of a shaft 31 is press-fitted. A carrier body 32 is rotatably supported, for instance via a roller bearing 34 and a sliding seat 35, on the shaft 31, which is fixed on its other end in an adjuster housing 40 of the adjuster part 21, for instance by extrusion coating. The carrier body 32 is partly surrounded on its circumference by a permanent magnet 36 and a control member 37, and a control arm 38 is formed on the control member 37. The control arm 38 protrudes into an adjuster chamber 41 formed by the adjuster housing 40 and has an outer face 42 that is shaped such that it is as accurately as possible equivalent to the inside diameter of an adjusting window 48 of a flow opening, not shown in further detail, that discharges into the adjuster chamber 41, and uncovers the flow opening to a variable extent depending on the rotary angle of the position of the control arm 38. The drive housing 22 of the driving part 20 and the adjuster housing 40 of the adjuster part 21 are formed-fittingly joined in the axial direction via a bayonet mount 39 and are braced without play, with the aid of a wave washer 43. A washer 44 disposed on the shaft 11 between the adjuster housing 40 and the carrier body 32 assures low-friction rotatability of the carrier body 32.
In the rotary adjuster shown in FIG. 2, for controlling a flow cross section in internal combustion engines, the rotary angle position of the control arm 38 is determined by the position of a magnetic field formed diametrically in the permanent magnet 36, and by the properties of the magnetic field induced in the stator 23 by means of an exciter current; a specific rotary angle position of the control arm 38 corresponds to each excitation state. After the installation of the rotary adjuster, in order to assure that this rotary angle position will correspond to a desired closing state of the flow cross section, a specific basic position is established by rotating the adjusting window 48, formed in the adjuster chamber 41, relative to the control arm 38. To that end, the adjuster housing 40, joined to the drive housing 22 via the bayonet mount 39, is rotated in the circumferential direction relative to the drive housing 22 until the outer face 42 of the control arm 38 uncovers a desired flow cross section of the adjusting window 48.
Since the bayonet mount 39 offers no security against torsion, the position between the drive housing 22 and the adjuster housing 40 is secured by the introduction, according to the invention, of the hollow body 1 as described in conjunction with FIG. 1. The adjuster housing 40 then corresponds to the first component 2 and the drive housing 22 correspond to the second component 4 of FIG. 1, and the positional securing of components takes place between a strap 45 of the adjuster housing 40 and a strap 46 of the drive housing 22. To that end, in the manner described above, the hollow body 1 is mounted on the strap 45 of the adjuster housing 40 and is driven into the straps 45 and 46 by means of the sonotrode 9 shown in FIG. 1. Because of the penetration of the hollow body 1 into the second component strap 46, the second component 4 or strap 46 exhibits a plastic deformation in the region positively displaced by the hollow body 1.
The plastic melted upon penetration of the hollow body 1 into the second component 4 strap 46 is partly positively displaced counter to the direction of penetration of the hollow body 1 and fills the interior of the hollow body 1 in such a way that a surface pressure is created between the second component strap 46 and this surface pressure fixes the hollow body 1 in the strap 46. This surface pressure is sufficient to make small axial forces transferrable between the components 45 and 46. For greater axial forces, additional fixation is necessary, for example by means of the bayonet mount 39. The components 45, 46 are fixed via the hollow body 1 in the tangential direction.
The foregoing relates to a preferred exemplary embodiment of the invention, it being understood that other variants and embodiments thereof are possible within the spirit and scope of the invention, the latter being defined by the appended claims. | A method for positionally securing two components together, in which a hollow body is introduced into the two components. Once the final position of the components relative to one another has been established, the hollow body is driven directly into the second component with the application of axial pressure and sonic energy. The method is suitable for employment with thermoplastic components whose relative position to one another is known beforehand, an example being in the assembly of housing parts of a rotary adjuster for controlling a flow cross section in internal combustion engines. | 1 |
CROSS-REFERENCE TO RELATED APPLICATIONS
Not applicable.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
Not applicable.
BACKGROUND OF THE INVENTION
This invention relates broadly to liquid treatment of hollow articles and, more particularly, pertains to improvements in the removal of liquid applied to inverted cans transported upon a conveyor belt moving through a can washing apparatus.
Newly formed metal food and beverage cans are typically cleaned of forming oils and other contaminants in a high volume can washer in which masses of upstanding or inverted cans are moved on a mesh conveyor between banks of water supply pipes or risers to each of which a plurality of particularly oriented spray nozzles are attached. By carefully controlling nozzle orientation, flow and pressure, the cans may be moved through the washer supported solely from below by the wire mesh conveyor belt on which the cans are carried.
In a typical can washer, as many as six separate liquid treatment stations are provided in serially connected orientation with the cans conveyed by the conveyor belt through, for example, pre-wash, acid cleaning, rinse, surface fixing, and two final rinse stations. Each station has its own underlying liquid collection tank and, to enhance recycling and prevent cross-contamination caused by the conveyor belt moving through multiple stations, it is desirable to remove as much liquid as possible from the cans and the belt as the cans move from one station to the next. Below the belt, a number of different devices may be used, including brushes which contact the underside of the belt or a vacuum stripper system which runs the full lateral width of the belt to extract excess liquid from the belt and the cans. In addition, compressed air blow-off units forming a blow-off system are positioned above the cans on the belt as they exit each treating station. The blow-off system blows free liquid out of the dished bottoms of the inverted cans and provides a flow of drying air.
The vacuum stripper system in the can washing system described above includes a vacuum tube sometimes provided with a pair of splitters which serve to distribute the vacuum applied to opposite ends of the tube so that the center of the tube receives a divided flow. In many instances, this flow modification proves to be insufficient such that the removal of excess liquid from the cans and belt by vacuum is less than desired. Because the conveyor belt is subjected to various substances, the excess liquid removed from the belt and the cans is often contaminated. Contaminated excess liquid evacuated from the vacuum stripper tube is generally collected at the ends of the tube and drained into a tank beneath the belt. However, because of the drainpipe structure extending between the vacuum stripper tube and the tank, contaminated air and liquid are frequently withdrawn back into the system in a manner which will impair the suction force applied to the vacuum stripper tube. In addition, the blow-off unit employed upstream of each treating station and the blower providing the suction force for the vacuum stripper tube are each driven by separate motors such that the intake of the blow-off unit is subject to handling contaminated air and the blower will blow an undesirable, contaminated mixture of excess liquid and air into a blower discharge pipe for return to the cans and the belt.
Accordingly, it is desirable to provide a system in which the vacuum induced flow which is split and travels through opposite ends of the vacuum stripper tube is better balanced so as to improve the amount of the excess liquid extracted from the cans and the belt. It is likewise desirable to provide a system having an excess liquid collection system which will prevent contaminated air and excess liquid from being withdrawn into the system in a manner which will not adversely affect the vacuum applied to the vacuum stripper tube. It is further desirable to provide a system in which the blower discharge pipe is connected to a separation device to remove any remaining contaminated excess liquid from the flow and direct a dry decontaminated air discharge into a return duct used to supply the blow-off system. It is further desirable to provide a system employing a single electric motor driven blower to supply the vacuum stripping flow and the compressed air for blow-off.
BRIEF SUMMARY OF THE INVENTION
The present invention advantageously provides a multi-station, liquid treatment system employing enhanced vacuum flow and compressed air blow-off for removing excess liquid from both hollow containers and a container-carrying conveyor belt in a manner which minimizes cross-contamination from any upstream liquid treatment station.
It is one object of the present invention to improve the distribution of vacuum flow used to remove excess liquid from the hollow containers and container-carrying belt.
It is another object of the present invention to collect excess liquid withdrawn from the hollow containers and the conveyor belt in a manner which will maintain such excess liquid in a collection tank.
It is a further object of the present invention to extract wet, contaminated air from the hollow articles on the conveyor belt, separate the wet air for reentry into the system and utilize the dry air for downstream blow-off of the hollow articles.
In one aspect of the invention, a liquid treatment system for hollow articles having an open end facing downwardly upon a moving conveyor belt includes a vacuum stripper tube for carrying a suction force for withdrawing excess liquid from the belt and from the hollow articles on the belt. The vacuum stripper tube has a top surface, a bottom surface and a pair of splitters for distributing the suction force applied to opposite ends of the vacuum stripper tube. The improvement comprises a baffle disposed within the vacuum stripper tube for further improving the distribution of suction force applied in the vacuum stripper tube. The baffle is oriented generally transverse to the longitudinal axis of the vacuum stripper tube. The baffle has an upper edge and a lower edge, at least the upper edge being spaced from the top surface of the vacuum stripper tube to ensure flow equalization. The baffle is a planar element located equidistant from each of the splitters in the center of the vacuum stripper tube.
In another aspect of the invention, a liquid treatment system for hollow articles transported upon a moving conveyor belt comprises a vacuum stripper tube for withdrawing excess liquid from the hollow articles and the belt. A vacuum pipe system is connected to the vacuum stripper tube for carrying a suction force to the vacuum stripper tube. The vacuum pipe system includes a sump connected to the vacuum stripper tube for collecting of excess fluid withdrawn from the vacuum stripper tube. An excess liquid collection arrangement is constructed and arranged to establish a one-way flow of and collect the excess liquid from the sump. The excess liquid collection arrangement comprises a tank positioned beneath and upstream of the vacuum stripper tube for collecting excess liquid from the hollow articles the conveyor belt and the sump, the tank having an air space creating a head above the excess liquid collected therein. A drainpipe system is connected between the sump and the tank for allowing the excess liquid to drain into the tank. The drainpipe system creates a trap preventing the excess liquid from being withdrawn into the vacuum pipe system and prohibiting air in the air space from being evacuated from the tank. The drainpipe system includes a generally horizontally disposed drainpipe extending from the pump to the air space above the excess liquid in the tank. The drainpipe system further includes a generally vertically disposed drainpipe extending between the generally horizontally disposed drainpipe and the excess liquid in the tank. The generally vertically disposed drainpipe has a length which is greater than the head created in the tank and has a bottom end continuously submerged in the excess liquid in the tank.
In yet another aspect of the invention, a system for applying and removing liquid relative to hollow articles transported along a moving conveyor belt comprises a vacuum stripper tube for withdrawing excess liquid from the hollow articles and the conveyor belt. A vacuum pipe system is joined to the vacuum stripper tube and has a blower and a blower discharge pipe. The blower generates a suction force for the vacuum stripper tube such that a combination of excess liquid and air from the vacuum stripper tube is fed to the blower discharge pipe for returning the excess liquid and air to the hollow articles on the conveyor belt. A blow-off unit is operably connected to the blower for supplying dry air to the hollow articles on the conveyor belt. A separation device is mounted on the blower discharge pipe for separating the combination of excess liquid and air into separated excess liquid and dry air. The separation device includes an inlet pipe for receiving the combination of the excess liquid and air from the blower discharge pipe, an outlet pipe for returning the separated excess liquid into the system upstream of the blow-off unit, and a blower duct for delivering the separated dry air to the blow-off unit. The blow-off unit is located adjacent the conveyor belt upstream of the blower and is dependent upon the blower.
Various other objects, features and advantages of the invention will be made apparent from the following description taken together with the drawings.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING
The drawings illustrate the best mode presently contemplated of carrying out the invention. In the drawings:
FIG. 1 is a fragmentary side elevational view of a representative station of a can washing system embodying the present invention;
FIG. 2 is a partial sectional view with parts broken away taken on line 2--2 of FIG. 1;
FIG. 2A is a partial sectional view with parts broken away taken on line 2A--2A of FIG. 1;
FIG. 3 is a top view of a vacuum stripper tube employed in the present invention;
FIG. 4 is a sectional view with parts broken away taken on line 4--4 of FIG. 3; and
FIG. 5 is an enlarged sectional view of the vacuum stripper tube taken on line 5--5 of FIG. 4.
DETAILED DESCRIPTION OF THE INVENTION
Referring to FIG. 1, reference numeral 10 designates a typical preliminary rinse station in a liquid treatment system, preferably a can washing system, comprising a tunnel 12 in which multiple surface treatment processes take place continuously throughout a series of pre-wash, acid cleaning, drag-out, preliminary rinse, surface fixing and two final rinse stations. An endless conveyor belt 14 comprising an open mesh steel framework supports hollow articles 16, preferably in the form of can bodies, in spaced apart, inverted positions with their dished bottoms up, and travels through the individual treatment stations. It should be understood that the spacing of the can bodies 16 is exaggerated in FIGS. 1 and 2, and that, in actuality, the conveyor is fully loaded with very closely spaced, densely packed can bodies 16 covering substantially the entire upper surface of conveyor belt 14 so as to maintain the stability of the can bodies 16. As the inverted can bodies 16 advance in the direction, as shown by the arrow, they proceed from an upstream station 22 through preliminary rinse station 10 to a downstream station 24. As is well known, a plurality of particularly oriented nozzles (not shown) are provided above and beneath conveyor belt 14 for directing various sprays of water and liquid chemical treatment against can bodies 16. In addition, the bottom 26 of the tunnel 12 is conventionally formed to channel the sprayed excess liquid into different collection tanks such as the tank 27 located beneath the treatment stations. It should be understood by the reader that the preferred embodiment describes a typical rinse station in a can washing system, but that the principles of the invention encompass any liquid treatment station in a liquid treatment system.
Looking more closely at FIG. 1, inverted can bodies 16 exit from the upstream station 22 where they receive a rinse which is collected in a tank 28 located under the tunnel 12. Tank 28 is commonly equipped with a suitable valve 30, and pipes 32 to control ingress and egress of liquid relative to tank 28. As they continue to advance, the can bodies 16 carry excess liquid in their dished bottoms as well as on their inner and outer surfaces 16a, 16b, respectively (FIG. 5). Excess liquid in the dished bottoms is blown out by compressed air from a blow-off unit 34 positioned above and downstream of tank 28. The blow-off unit 34 typically includes a blower 36 and a blow-off header 40 which overlies can bodies 16 on conveyor belt 14 so as to properly direct a blast of compressed air which will effectively remove the excess liquid in the dished bottoms of the can bodies 16.
Immediately upon passing through the blow-out header 40, the can bodies 16 traverse over a vacuum stripper tube 42 which is best illustrated in FIGS. 2-5. Vacuum stripper tube 42 typically includes an elongated, tubular base 44 of rectangular cross-section which is interposed between a pair of cylindrical pipe stubs 46. The top of the base 44 is provided with a support plate 48 on top of which a stripper pad 50 is secured by fasteners 52. Both the support plate 48 and the stripper pad 50 are provided with aligned apertures 54, 55 (FIG. 5) which together form a series of spaced apart slots 56 placing the inside surfaces 16a of the can bodies 16 riding on the open conveyor belt 14 in communication with the inside of the vacuum stripper base 44. Secured within the vacuum stripper base 44 is a pair of flow splitters 58, each of which is a curved plate having an inner end 60 which is joined to a central portion of vacuum stripper base 44, and an outer end 62 which is joined to an end cap 64 inwardly of pipe stub 46. The splitters 58 also have an intermediate portion 66 which extends axially of the base 44.
Turning particularly to FIGS. 1 and 2, vacuum stripper tube 42 is connected to a vacuum pipe system 68 which provides a vacuum source and establishes a flow path between the vacuum source and vacuum stripper tube 42. Vacuum pipe system 68 includes a pair of connection lines 70 extending laterally from each side of the tunnel 12 for connecting the pipe stubs 46 to a pair of lower vacuum pipes 72 which in turn are joined at flanges 74 to a pair of upper vacuum pipes 76. A suitable valve 78 is interposed in the right side connection line 70 to selectively open and close the line to fluid flow therethrough. Each of the upper vacuum pipes 76 is maintained in position by support braces 80 extending upwardly from the top of tunnel 12, and terminates at its upper end in a flange 82 which is secured to a horizontally and forwardly extending blower pipe 84. Mounted at the end of blower pipe 84 is a blower 86 driven by an electric motor 88 supported on a pedestal or stand 90 (FIG. 1). A blower discharge pipe 92 rising upwardly has an lower end 94 connected to blower 86. With this arrangement, the blower 86 defines a suction force which draws excess liquid from the inside and outside surfaces 16a, 16b of the can bodies 16 as well as from the conveyor belt 14 into the vacuum stripper tube 42, the distribution of the vacuum flow being assisted by the flow splitters 58.
In accordance with one feature of the invention, a baffle 98 is centrally positioned in the vacuum stripper tube 42 to further improve the distribution of vacuum flow therein in a manner heretofore unattainable with the splitters 58. Baffle 98 is a generally rectangular planar element secured transversely to the longitudinal axis of the vacuum stripper tube 42 across the base 44 at a location substantially equidistant from the inner ends 60 of the splitters 48. The baffle 98 has an upper flat edge 100 (FIG. 5) which is spaced slightly from the bottom of the support plate 48, and a bottom flat edge 102 which is elevated slightly from the bottom 104 of base 44. The spacing of upper flat edge 100 functions to provide an improved pressure equalization of the vacuum flow emanating from the center of the base 44, while the spacing of the lower flat edge 102 prevents the excess liquid from puddling on the flat bottom 104 of the base 44. As will be further appreciated hereafter, the baffle 98 cooperates with the flow splitters 58 to enhance the vacuum flow within the vacuum stripper tube 42 to optimize the excess liquid extracted from both the conveyor belt 14 and the can bodies 16.
Excess liquid and air suctioned outwardly from the vacuum stripper tube 42 are delivered through opened connection lines 70 to the bottom portion of each lower vacuum pipe 72. It is important to understand that the excess liquid dropping from the can bodies 16 and belt 14 carries contaminates transferred from the mesh conveyor which is in direct contact with the open end of the can bodies 16. That is, the conveyor belt 14 being exposed to various substances in its travel through the various treatment stations cross-contaminates the excess liquid collected from the can bodies 16 in the vacuum stripper tube 42. Such contamination is undesirable because it may have an effect on the coating of the can bodies 16 in a later process. Each pipe 72 forms a sump 106 into which the majority of the contaminated excess liquid extracted from vacuum stripper tube 42 falls, with the remaining combination of the contaminated air and liquid being transported as moist air through the vacuum pipe system 68. The left-side sump 106 is provided with a drainline 105 and a suitable valve 107 if it is desirable to drain fluid therefrom. In prior art devices, excess fluid removed from the conveyor belt 14 and can bodies 16 is simply drained to a collection tank beneath the tunnel in a manner such that air and excess liquid can be withdrawn from the collection tank. Not only does this withdrawal deleteriously affect the suction force supplied by the blower 86, but it also reintroduces contaminated fluid back into the system which, as noted above, can negatively impact on the quality of further processes such as painting of the can bodies 16.
In accordance with another feature of the invention best depicted in FIGS. 1 and 2A, the contaminated excess liquid collected in the right side sump 106 is led to the upstream collection tank 28 beneath the tunnel 12 or to a drain (not shown) through a drainpipe system 110 which provides one-way flow of fluid from the sump 106. Collectively, the tank 28, its connection to drain, and drainpipe system 110 form an excess liquid collection arrangement. The tank 28 has a changeable air space 112 defining a head between the bottom 26 of the tunnel 12 and the upper surface 114 of the collected excess liquid. Contaminated fluid collected in the left side sump 106 is selectively drained through the horizontally extending drain line 105 extending into the tank 28. Drainpipe system 110 includes a first generally horizontally disposed, straight drainpipe 118 (FIG. 1) extending from sump 106 to a second generally horizontally extending, straight drainpipe (not shown) extending substantially perpendicularly thereto. Drainpipe 118 is provided with a suitable valve 107 if it is desired to drain liquid from right side sump 106. Drainpipe 118 has an end extending into the air space 112 above the collected excess fluid and is connected to a generally vertically and downwardly disposed straight drainpipe 122 extending between drainpipe 118 and tank 28. According to the invention, vertically disposed drainpipe 122 has a length which is always greater than the head 112 created in the tank 28, and includes a bottom end 124 continuously submerged at least one inch below the excess liquid in tank 28. As shown in FIG. 1, tank 28 is provided with overflow pipes 32 for delivering excess fluid to drain once the excess liquid rises to an excessive level.
The drainpipe system 110 set forth above effectively creates a trap which prevents contaminated excess liquid from being withdrawn into the vacuum pipe system 68 and also prohibits air in the air space 112 from being evacuated from the tank 28. As a result, a strong vacuum force can be maintained so as to suction and remove as much excess liquid as possible before the can bodies 16 and conveyor belt 14 move to the next station. In addition, the return of contaminated liquid is limited to the small amount withdrawn into the vacuum pipe system 68 which is further decontaminated as described below.
With further reference to FIG. 1 and in accordance with yet another feature of the invention, blower discharge pipe 92 includes an input line 134 and an output line 136. Both the input and output lines 134, 136 are connected to a filtered, separation device 138, such as a cyclone separator, for separating the combination of liquid and air from the moist contaminated air withdrawn into the vacuum pipe system 68 and blown in to the blower discharge pipe 92 by blower 86. Extending from the top of the cyclone separator 138 is a blow-off duct 140 which connects with the blow-off unit 34 located adjacent the conveyor belt 14 upstream of the blower 86. Incorporating the separation device 138 into the blower discharge pipe 92 enables compressed filtered and decontaminated air to be supplied via blow-off duct 40 to blow-off unit 34 so as to remove excess liquid from the advanced conveyor belt 14 and can bodies 16. Also, separation device 138 serves to separate excess liquid from the moist air and return that separated excess liquid back into the output line 136 for return to the top of the tunnel 12 upstream of blow-off unit 34. Unlike prior art upstream blow-off units, there is no need to drive blow-off unit 34 with a separate electric motor directly attached thereto. Instead, the electric motor 88 and blower 86 provide the driving force for delivering compressed air to the blow-off header 36 of blow-off unit 34 in addition to providing the vacuum source for vacuum tube stripper 42. Making the blow-off unit 34 dependent on the blower 86 is an important advantage which demonstrates both energy efficiency and contamination consciousness.
While the invention has been described with reference to a preferred embodiment, those skilled in the art will appreciate that certain substitutions, alterations and omissions may be made without departing from the spirit thereof. Accordingly, the foregoing description is meant to be exemplary only, and should not be deemed limitative on the scope of the invention set forth with following claims. | A liquid treatment system for hollow articles having an open end facing downwardly upon a moving conveyor belt includes a vacuum stripper tube connected to a blower for generating a suction force withdrawing excess liquid from the hollow articles and the belts, and a pair of flow splitters for distributing the suction force applied to opposite ends of the vacuum stripper tube. The system is provided with a baffle disposed in the vacuum stripper tube for improving the distribution of suction force in the vacuum stripper tube. The system also includes an excess liquid collection arrangement constructed and arranged to establish a one-way flow of and collect excess liquid evacuated from the vacuum stripper tube. The system further contemplates a blow-off unit operably connected to the blower for supplying dry air to the hollow articles and conveyor belt. | 1 |
CROSS REFERENCE TO RELATED APPLICATIONS
This application is a continuation of U.S. Utility application Ser. No. 10/926,366 field on Aug. 25, 2004 which claims priority to U.S. Provisional Patent Application, Ser. No. 60/498,612, filed on Aug. 28, 2003, the entire subject matters of which are incorporated herein by reference in their entireties.
BACKGROUND
The present invention relates to tools, including clamping, holding and gripping type tools. More specifically, the present invention relates to clamping, holding and gripping type tools, including such tools adapted to apply a treatment to a workpiece. In some embodiments, the treatment may be selected as suitable for the workpiece to be held, clamped or gripped and for the effect sought.
Various circumstances require a clamping tool. Repair, joining or sealing conduits, pipes and the like or other workpieces may be facilitated by clamping. Often, it is advantageous to pinch or otherwise block piping through which fluid is moving. For example, a utility crew may expose a portion of a natural gas line to perform maintenance or some other type of work. The utility crew cannot access the pipe without controlling the flow of the fluid, yet it may be difficult and disruptive to cease flow to that entire line. Thus, a clamp is often used to pinch the pipe or otherwise block the piping to stop fluid flow from that point forward.
Alternatively, a clamping tool may be used to clamp a pipe or conduit and apply a treatment thereto, without disturbing the flow of the fluid through the pipe or conduit.
A number of tools have been created to address these tasks. Some of the difficulties common to these tools include positioning of the tool around the pipe within a confined area, clamping the pipe without expelling it from the tool, providing a configuration offering sufficient force to compress the pipe, and providing a treatment to the pipe. These difficulties act individually and collectively to make it more difficult to use a clamping tool to secure a pipe or conduit and stop fluid flow through the pipe or conduit.
Generally, when securing a pipe to stop fluid flow through the pipe, only a small area is provided to work in. For example, a trench may be dug through the ground to reveal a small segment of the pipe. This can make it difficult to access the pipe, to reach the pipe (it may be several feet below ground level), and to engage the pipe with a tool. Because of the generally cylindrical shape of pipes, the strength of pipes, and the typical “scissoring” (i.e., angled closing) effect of clamping tools, pipes often become expelled from the clamping tool as the tool is actuated. That is, the pipe may not be easy to compress and, as the tool closes, the angled closing may cause the tool to disengage rather than clamping the pipe.
The small workspace, the resistance of the pipe to clamping, and the depth of the pipe in the ground make it difficult to provide a tool that an operator can use to develop sufficient force to apply a treatment to a pipe or to stop fluid flow through the pipe. Traditionally, when manually operated tools are needed to exert a greater force, a longer lever arm is provided. However, such a solution, in this context, is impractical for the reasons previously noted.
In some applications, it would be helpful if a radially directed force could be applied substantially completely and uniformly around a workpiece using a clamping or gripping type tool. This is difficult with a traditional scissor type jaw movement, or with clamp type tools having the typical generally flat jaw surfaces.
Thus, there exists a need to provide an improved clamping tool.
SUMMARY
A tool for gripping, clamping or holding an object, wherein the tool has a handle portion, a linkage portion and a working portion, and wherein the working portion includes two workpiece contacting surfaces, at least one of the surfaces being shaped to generally conform to at least a portion of the outer surface of a workpiece to be clamped, gripped or held. In some embodiments, at least one of the workpiece contacting surfaces is adapted to provide a treatment to a workpiece being clamped, gripped or held. For example, in some embodiments, a chemical may be applied to at least a portion of the workpiece while it is being held in the tool. In some embodiments, a collar, patch or other structure may be all or part of the treatment.
In one embodiment, the present invention provides a tool for gripping, clamping or holding an object, wherein the tool comprises a handle portion, a linkage portion and a working portion, and wherein the working portion comprises two workpiece contacting surfaces wherein the surfaces are shaped to generally conform to the outer surface of a workpiece to be clamped, gripped or held therein. In some embodiments, the workpiece contacting surfaces are adapted to provide a treatment to a workpiece being clamped, gripped or held. In some embodiments, at least a portion of the jaws remains generally parallel throughout the operation of the tool, and/or shaped portions of the jaws are generally reflective as the tool is operated.
In one embodiment, the present invention comprises a tool such as disclosed in a pending international application entitled “Clamping Tool”, Int'l. Appln. No.: PCT/US02/16490, filed 23 May 2002, the disclosure of which application is incorporated herein by reference.
In one embodiment, the present invention provides a tool for gripping and/or clamping and/or holding an object, wherein the tool comprises a handle portion, a linkage portion and a working portion, and wherein the working portion comprises a double jaw design with two pivot pins per jaw. In use, the jaws generally remain parallel throughout the operation of the tool and move generally axially from a tube portion. When open, the jaws are spaced generally axially away from the remainder of the tool. The first jaw and second jaw are moveable towards one another. The first jaw and the second jaw each have a workpiece contacting surface that remains generally parallel to the other.
In one embodiment, the present invention is a tool comprising a clamp assembly having an opening; a first jaw coupled to the clamp assembly with a first four bar linkage, the first jaw being moveable within the opening; a second jaw being coupled to the clamp with a second four bar linkage, the second jaw being moveable within the opening; a first link being coupled between an actuating member and the first jaw; a second link being coupled between the actuating member and the second jaw, wherein selective actuation of the actuating member causes the first and the second link to move the first and the second jaw respectively, between an open and a closed position, wherein the first and the second jaws remain generally parallel to one another. Either or both of the first jaw and the second jaw may be provided with a workpiece contacting surface. If provided on both the first and the second jaw, the workpiece contacting surface remain generally parallel to the other.
In one embodiment, the present invention is a pipe clamping tool comprising a clamp assembly; a tube extending from the clamp assembly; a handle rotatably coupled with the tube; a first jaw coupled with the clamp assembly; a second jaw coupled with the clamp assembly, wherein rotational movement of the handle causes the first jaw to move towards the second jaw, while the first jaw and the second jaw remain generally parallel to one another. Either or both of the first jaw and the second jaw may be provided with a workpiece contacting surface. If provided on both the first and the second jaw, the workpiece contacting surface remain generally parallel to the other.
In one embodiment, the present invention is a pipe clamping tool comprising an extension tube; a threaded rod located within the extension tube and linearly moveable therein; a jaw base coupled to a first end of the threaded rod; a first jaw; a second jaw; and a linkage assembly coupled to the first jaw, the second jaw, the jaw base and the extension tube so that actuation of the threaded rod causes the first jaw to move towards the second jaw while the first jaw and the second jaw remain parallel to one another. Either or both of the first jaw and the second jaw may be provided with a workpiece contacting surface. If provided on both the first and the second jaw, the workpiece contacting surface remain generally parallel to the other.
In some embodiments, the working portion of the tool is adapted to contact a workpiece, for example, a tube or pipe, substantially completely around its outer diameter, and to apply a selected treatment to the workpiece. In some embodiments, a selected treatment applied by the tool to the workpiece may be chemical, thermochemical, electrical, or other suitable treatment or process. The treatment applied may be designed to have any desired effect on a workpiece, e.g., heating, melting, joining, patching, sealing, severing, compressing, deposition of a like or different material, etc.
In one embodiment, the present invention is a tool comprising a first jaw; a second jaw, wherein at least a portion of the first jaw and the second jaw are moveable towards one another while at least a portion of the jaws remains generally parallel, and wherein at least a portion of the jaws is configured to generally complement the shape of an intended workpiece. In some embodiments, at least one of the jaws of the tool of the present invention is adapted to apply a selected treatment to at least a portion of a workpiece.
While multiple embodiments are disclosed, still other embodiments of the present invention will become apparent to those skilled in the art from the following detailed description. As will be apparent, the invention is capable of modifications in various obvious aspects, all without departing from the spirit and scope of the present invention. Accordingly, the accompanying drawings and this description are to be regarded as illustrative, not restrictive.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a clamping assembly of a clamping tool in accordance with one embodiment of the present invention in an open position.
FIG. 2 is a perspective view of a clamping assembly of a clamping tool in accordance with one embodiment of the present invention in an open position being used in a narrow access.
FIG. 3 is a perspective view of a clamping assembly of a clamping tool in accordance with one embodiment of the present invention in a closed position.
FIG. 4 is a perspective view of a clamping assembly of a clamping tool in accordance with one embodiment of the present invention in a closed position being used in a narrow access.
FIG. 5 is a perspective view of a clamping assembly of a clamping tool in accordance with one embodiment of the present invention in a closed position.
FIG. 6 a is a perspective view of a workpiece with an irregular outer diameter.
FIG. 6 b is a perspective view of a workpiece comprising two sections, the workpiece having a ridge between the sections.
FIG. 7 a is a perspective view of a workpiece having a gash in the surface thereof.
FIG. 7 b is a perspective view of a workpiece having a gash in the surface thereof.
FIG. 8 a is a perspective view of a workpiece with a patched section placed on the surface thereof in accordance with one embodiment of the present invention.
FIG. 8 b is a perspective view of a workpiece with a patched section placed on the surface thereof in accordance with one embodiment of the present invention.
FIG. 8 c is a cross-sectional view of a workpiece with a patched section placed on the surface thereof, sealing a gash in the surface of the workpiece, in accordance with one embodiment of the present invention.
FIG. 9 illustrates a movable jaw provided with a treatment structure in accordance with one embodiment of the present invention.
FIG. 10 illustrates a sectional view of a clamping assembly of a clamping tool in accordance with one embodiment of the present invention in an open position.
FIG. 11 illustrates a schematic view of a handle assembly with a threaded rod in accordance with one embodiment of the present invention.
FIG. 12 is a schematic view of a clamping assembly of a clamping tool in accordance with one embodiment of the present invention.
DETAILED DESCRIPTION
With regard to fastening, mounting, attaching or connecting components of the present invention to form a tool as a whole, unless specifically described otherwise, such are intended to encompass conventional fasteners such as threaded connectors, snap rings, detent arrangements, rivets, toggles, pins, and the like. Components may also be connected by adhesives, glues, welding, ultrasonic welding, and friction fitting or deformation, if appropriate. In embodiments wherein electricity is involved, for example for electrical heating of a workpiece, suitable connections may be provided, along with a suitable power source or connectors for connecting to a power source. Unless specifically otherwise disclosed or taught, materials for making components of the present invention may be selected from appropriate materials such as metal, metallic alloys, vinyls, plastics and the like, and appropriate manufacturing or production methods including casting, pressing, extruding, molding and machining may be used.
Any references to front and back, right and left, top and bottom and upper and lower are intended for convenience of description, not to limit the present invention or its components to any one positional or spatial orientation.
The accompanying Figures illustrate a clamping tool including a clamping assembly coupled with a handle. The handle may be permanently coupled to the assembly or may be removable, and it may have a selected length.
FIG. 1 illustrates a clamping tool 10 . The clamping tool 10 includes a clamping assembly 12 coupled with an extension tube 14 . A handle 16 is rotatably coupled to the extension tube 14 . In use, the handle 16 is rotated in one direction to cause the clamping assembly 12 to open and is rotated in the opposite direction to cause the clamping assembly 12 to close. Alternate handle configurations may be used in accordance with the present invention. That is, it is not necessary that the handle be rotatable. For example, the handle may be a push handle or a lever handle. As shown, the clamping assembly 12 is in an open position. The handle 16 may be permanently coupled with the extension tube 14 or may be removable. In one embodiment, extension tube 14 includes a standard sized bolt head so that a socket driver and socket can be use as the handle 16 . Thus, different lengths of the handle 16 or extension tube 14 can be utilized depending upon the amount of force that will be required or the distances involved (e.g., the depth of a trench). As shown, the clamping tool 10 is positioned to apply a treatment 17 to a workpiece 19 , the workpiece 19 having a gash 21 in the surface thereof.
FIG. 2 illustrates the clamping tool 10 of FIG. 1 , also in a closed position, in use in a narrow space.
As shown in FIGS. 1-5 , and 12 , the clamp assembly 12 includes a clamp base 18 . The clamp base 18 is a rigid structural element having a clamp base opening 15 defined therein. A pair of moveable jaws are defined by first movable jaw 20 and a second movable jaw 22 . In an alternate embodiment, a single movable jaw may be provided parallel to a relatively stationary structure or a movable structure formed as, for example, a block. As shown in FIG. 12 , the opposing moveable jaws 20 and 22 , via operation of linkages 7 and 9 , remain parallel to one another when opening and closing. This prevents the clamped working piece from sliding out of or away from the jaws. In addition, it becomes easier to clamp the pipe because the jaws 20 , 22 are positioned on opposite sides of the pipe and the force is applied to the pipe in a direction that is generally normal to the abutting surfaces of the jaws 20 , 22 . Portions of the first and second movable jaws 20 and 22 may be designed to be reflective during use.
One or both of the first and second jaws 20 and 22 may be provided with a moveable jaw portion for accommodating workpieces of various sizes.
Each of the first and second jaws 20 and 22 include a working surface 21 and 23 for contacting the workpiece 19 . As shown, the first and second movable jaws 20 and 22 may be configured to conform to the workpiece 19 . Thus, as shown, the working surfaces 21 and 23 together form a generally cylindrical shape for grasping a workpiece 19 such as a pipe.
In some embodiments, a plurality of interchangeable workpiece contacting surface members may be provided with the clamping tool 10 , wherein a member or members fitting or conforming to a workpiece may be selected from the set and removeably connected to the tool 10 . Thus, while generally cylindrical workpiece contacting surface members are shown, alternative shapes may be provided.
To cause the jaws to remain parallel, a “four bar linkage” may be utilized. Of course, any other suitable linkage may be utilized. The first movable jaw 20 forms one bar of the four bar linkage, and is pivotably coupled to the clamp base 18 by a top link 30 and a bottom link 32 , forming two more bars of the four bar linkage. Though not clearly shown, another top link 31 and another bottom link 33 couple the first movable jaw 20 to the clamp base 18 and are located behind the assembly, as illustrated. Thus, the two top links 30 , 31 form one “bar” of the “four bar linkage” and the two bottom links 32 , 33 form another “bar” of the “four bar linkage.” The fourth bar is formed by a portion of the clamp base 18 , and is denoted as the base link 34 .
Like the first movable jaw 20 , the second movable jaw 22 is coupled to the clamp base 18 through a four bar linkage. Top links 24 , 25 and bottom links 26 , 27 are provided along with base link 28 to form the four bar linkage with second movable jaw 22 .
While as shown in FIGS. 1 and 2 , the movable jaws 20 and 22 are generally parallel to one another, portions of the jaws may not be parallel to each other and the workpiece contacting surfaces thereof may be parallel or move toward and away from each other in a generally straight line. In addition, the workpiece contacting surfaces may be parallel at all times or may only be parallel over a portion of their path of travel, which would include contact with the outer surface of a workpiece, e.g., a pipe, and compression of the workpiece.
As shown, a top surface 29 of each of the first and second jaws 20 and 22 contact one another. In both the open position and the closed position (seen in FIGS. 3 through 5 ), the top surface 29 of each of the first and second jaws 20 and 22 contact one another to form an extension between the first and second jaws 20 and 22 . Thus, the tool 10 can be set down on top of or around a pipe in a relatively confined space. The congruent top surfaces 29 keep the pipe positioned between the jaws 20 , 22 , and in some embodiments centered between the jaws 20 , 22 . The congruent top surfaces 29 and the shaped working surfaces 21 , 23 together and independently keep the pipe positioned. The pipe generally extends in an axial direction between the jaws 20 , 22 . The clamping tool 10 is brought into position in a direction normal to the pipes axial length. The congruent top surfaces 29 aid in keeping the pipe properly positioned and the arrangement of the jaws 20 , 22 generally prevent the tool from moving off of the pipe and prevent the pipe from moving out of the jaws 20 , 22 in cases where such movement might be possible.
To close the jaws, adjusting links 44 , 46 are retracted into clamp base 18 . As this occurs, the first movable jaw 20 and the second movable jaw 22 are raised. Because of the pivoting top links 30 , 31 , 24 , 25 and the pivoting bottom links 32 , 33 , 26 , 27 , the first movable jaw 20 and the second movable jaw 22 move towards one another, while remaining generally parallel to one another (see, e.g., FIG. 12 ). To open the jaws, the process is reversed. That is, the adjusting links 44 , 46 are extended out of the clamp base 18 . This causes the jaws 20 , 22 to move in a direction away from extension tube 14 and to separate from one another, while still remaining generally parallel. As shown by comparison of FIGS. 4 and 5 , throughout the opening and closing movement of the jaws 20 , 22 , a width of the clamp base 18 , defined as a dimension of the clamp base 18 in a direction substantially parallel to the jaw movement, is fixed. Again, it is not necessary that the tool be configured such that the jaws 20 , 22 remain constantly parallel to one another.
FIG. 3 illustrates a clamp assembly 12 with the clamping tool 10 being put into a closed position around a workpiece 19 . FIG. 4 illustrates the clamp assembly with the clamping tool 10 being put in a closed position around a workpiece 19 being used in a narrow space.
FIG. 5 illustrates a clamp assembly 12 with the clamping tool 10 in a closed position around a workpiece 19 . First and second wires extend to the top surfaces 29 of the first and second movable jaws 20 and 22 . Wires 74 , to be described in more detail below, are coupled to the movable jaws 20 , 22 .
As shown in FIGS. 1 through 5 , the clamping tool 10 may be configured such that the working portion of the tool is adapted to contact a workpiece, for example, a tube or pipe, substantially completely around its outer diameter, and to apply a selected treatment to the workpiece.
FIGS. 6 a and 6 b illustrated a workpiece 19 formed of two sections. The sections are joined at ridge 77 . Additionally, FIG. 6 a illustrates a workpiece 19 having an irregularly shaped outer diameter 79 . A clamping tool 10 such as described with reference FIG. 1 may be used to clamp workpieces 19 having ridges 77 and/or irregularly shaped outer diameters 79 . The working surfaces 21 , 23 may be configured to generally conform to a cylindrical shape of a workpiece and the ridge 77 does not overly deflect the tool 10 from clamping the workpiece 10 . Further, as will be described in more detail below, the tool 10 may apply a treatment to the workpiece 19 . Such treatment may, for example, smooth out or minimize the ridge 77 .
The tool 10 may be used to grasp a workpiece 19 having an irregularly shaped outer diameter 79 as the working surfaces 21 , 23 conform generally to the shape of the outer diameter 79 . It is not necessary that the working surfaces 21 , 23 conform exactly to the shape of the outer diameter 79 . As can be appreciated from the figures, generally cylindrically shaped working surfaces 21 , 23 can snugly grasp a workpiece 19 having an irregularly shaped diameter 79 as shown in FIG. 6 a . Similarly, otherwise irregularly shaped workpieces may be grasped with a tool having otherwise shaped workpiece contacting surface members as described above.
FIGS. 7 a and 7 b illustrate perspective views of a workpiece 19 having a gash 21 in the surface thereof. Further, FIG. 7 a illustrates a workpiece 19 having an irregularly shaped outer diameter 79 . As shown in FIGS. 1 through 4 , the clamping tool 10 may be used to apply a treatment 17 over the gash 21 of the workpiece 19 . FIGS. 8 a through 8 c illustrate a treatment 17 placed over the gash 21 of the workpiece 19 . The treatment 17 shown in FIGS. 8 a through 8 c is a collar. The collar may, for example, include a patch element. The patch element is designed such that it bonds securely to the workpiece 19 and seals the gash 21 . Alternatively, other treatments such as heating, melting, joining, sealing, severing, compressing, deposition of a like or different material, etc. may be applied to the workpiece 19 by the clamping tool 10 .
FIGS. 1 through 5 illustrate the application of the treatment 17 to the workpiece 19 , from being carried into place by the tool and compressed around the workpiece 19 .
In some embodiments, the workpiece contacting surfaces 21 , 23 of the tool 10 may be adapted to deliver a chemical treatment or patch to a workpiece. FIG. 1 illustrates various structures for delivering a treatment to a workpiece. A gel or patch 80 may be provided on the working surface 21 of either or both movable jaws 20 , 22 . A quick release coating, easy release type adhesive, or other to deliver or apply a chemical or other treatment to a workpiece may be provided.
Alternatively, or additionally, the tool 10 may include structures, such as wires 74 , shown in FIGS. 1 and 5 for delivering electricity, heat or other forms of energy to the too, portions thereof, the workpiece and/or a patch by carrying suitable internal or external heating or energy producing and/or transmitting elements. Thus, wires 74 may be used to deliver heat to the working surfaces of the tool. The working surfaces may become warm and subsequently warm the workpiece. Referring to FIGS. 6 a and 6 b , the malleability of the workpiece 19 may be increased due to the warmth delivered via the wires 74 . The working surfaces 21 , 22 may be used to compress the workpiece 19 in the area of the ridge 77 to minimize the ridge 77 . The malleability of the workpiece 19 due to the warmth enhances the tool's ability to minimize the ridge 77 . Alternately, the tool 10 may be used to minimize the ridge 77 without application of heat or other energy to the workpiece 19 .
Further, the tool 10 may be provided with sensors, e.g., shown at 82 of FIG. 1 , to measure and/or display the amount of pressure, heat or other treatment being applied to a workpiece. Alternatively, sensors 82 may be provided for measuring other characteristics.
FIG. 9 illustrates one embodiment a treatment delivery structure in accordance with a further embodiment of the present invention. The working surface 21 of a jaw, here the first jaw 20 , is provided with a recess or relieved region 86 . The relieved region 86 may be adapted to receive a chemical, in liquid, solid, or semi-solid form, to be applied to a workpiece. The relieved region 86 may extend over substantially the entire working surface of the jaw or may extend over only a portion of the working surface of the jaw.
The relieved region 86 may be surrounded by heating elements 87 , which may also take the form of treatment elements, e.g., sonic horns. The selected types of elements 87 may alternately underlie or be adjacent to the relieved region 86 . Also, in some embodiments, the elements 87 may be used in a jaw without a relieved region 86 in conjunction with a material to be applied to a workpiece 19 . The elements 87 may be arranged in any suitable pattern depending on the treatment effect desired. Further, a single element 87 may be arranged under substantially all of the working surface of the jaw.
Various mechanisms may be employed to translate a rotational movement of the handle 16 into a force that extends and retracts the adjusting links 44 , 46 . Further, a rotational movement of the handle 16 is not necessary in accordance with the present invention. FIG. 10 illustrates one example of a mechanism to translate a rotational movement of the handle into a force that extends and retracts the adjusting links. Thus, a clamping tool 10 is shown wherein a threaded rod 64 is provided within a bearing assembly 60 that is coupled with extension tube 14 . The threaded rod 64 need only have threads over a portion of the rod and is coupled at one end with the handle 16 . The threaded rod 64 passes through a threaded nut 66 , so that rotational movement is translated into linear movement. The threaded rod 64 is coupled with a slider 62 . The slider 62 is pivotably connected to both the adjusting links 44 , 46 at couplings 70 , 72 respectively. Thus, when threaded rod 64 is rotated within threaded nut 66 , linear motion results, causing the slider 62 to move axially relative to the clamp base 18 ; that is, parallel to the longitudinal axis of the extension tube 14 (up or down as illustrated). As it moves down it moves the actuating links 44 , 46 out of the clamp assembly 12 . This motion causes the jaws 20 , 22 to open, as previously described. As the slider 62 is moved up, the adjusting links 44 , 46 are pulled into the clamp assembly 12 . This causes the jaws 20 , 22 to close. Because the adjusting links 44 , 46 are pivotably coupled between the slider 62 and the jaws 20 , 22 , they come together within clamp assembly 12 . As an alternative to the embodiments shown in FIGS. 1-5 and 9 , movable jaws 20 , 22 may comprise a mandrel block and a rotating sleeve. Further, the first and second movable jaws may be provided with working surfaces generally conforming to a workpiece.
FIG. 11 illustrates a handle 16 as it is coupled to the threaded rod 64 in accordance with one embodiment of the present invention. Suitable mechanisms other than threaded structures may be used to operate the tool of the present invention. For example, as known to those skilled in the art, a ratchet arrangement or a rack and pinion system may alternately be used. In a threaded arrangement, as shown in FIG. 11 , an angled bar 82 may be attached to the extension tube 14 . The angled bar 82 includes a lower locking hole 84 that can be aligned with an upper locking hole 86 bored through handle 16 . When the two holes 84 , 86 are aligned a locking member such as a padlock or any securing member can be passed through both holes 84 , 86 and essentially lock the clamping tool 10 . When the clamping tool 10 is locked after a pipe has been sealed, the lock will prevent the clamping tool 10 from accidentally or unintentionally being opened. Of course, other suitable handle assemblies may be used with clamping tools in accordance with the present invention.
Although the present invention has been described with reference to preferred embodiments, persons 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 tool for gripping, clamping or holding an object, wherein the tool has a handle portion, a linkage portion and a working portion, and wherein the working portion includes two workpiece contacting surfaces, at least one of the surfaces shaped to generally conform to at least a portion of the outer surface of a workpiece to be clamped, gripped or held. In some embodiments, at least one of the workpiece contacting surfaces is adapted to provide a treatment to a workpiece being clamped, gripped or held. | 1 |
CROSS-REFERENCE TO RELATED APPLICATIONS
This continuation-in-part application claims the benefit of U.S. patent application Ser. No. 09/803,911 filed Mar. 13, 2001, abandoned Feb. 6, 2002; which is a division of U.S. patent application Ser. No. 09/433,711 filed Nov. 4, 1999, abandoned May 13, 2001; which application claims the benefit of U.S. Provisional Patent Application Serial No. 60/110,481, filed Dec. 1, 1998.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to sprint vehicle suspension systems incorporating an air bag in lieu of springs, torsion bars or a coil-over design. This application further modifies the aforementioned structural systems by having (1) the front axle supporting a pair of air bags mounted proximate each front wheel, and (2) the rear axle having bird cages mounted adjacent each rear wheel over the wheel bearings and the air bags mounted on extensions.
2. Description of the Related Art
Sprint cars and other open wheeled race cars typically use a swing arm suspension. A representative prior art view is shown in FIG. 3 of this application, wherein a rear axle 180 of a sprint car 18 has a carrier hub 310 connecting the suspension to the wheel. One end of the swing arms 140 and 350 is attached to a torsion bar 320 , and the other end is attached to a means of supporting a wheel, such as a carrier hub 310 on a live axle or the axle itself on a fixed axle. The torsion bar 320 is typically housed within a tubing in the frame 330 shown in shadow. The carrier hub 310 is attached to a swing arm 140 which is connected to a torsion bar 320 . If only one swing arm is utilized, the swing arm 140 may lead or trail its associated axle. Supplemental suspension linkages may be present for additional support to the axle 180 .
Exemplary patents of various suspension systems include the following patents and patent application publications.
U.S. Pat. No. 2,453,388 issued on Nov. 9, 1948, to Arthur G. Schramm describing a wheel suspension for trailers comprising wheels suspended on arms controlled by levers sprung to provide resiliency, and the arms being arcuately adjustable.
U.S. Pat. No. 3,063,733 issued on Nov. 13, 1962, to Bryan J. Morris describes an anti-roll vehicle suspension mechanism comprising a pair of cylindrical springs, a pair of levers pivotally connected to the chassis, axle and the springs.
U.S. Pat. No. 3,410,573 issued on Nov. 12, 1968, to Albert F. Hickman describes a vehicle spring suspension comprising an axle supporting a first arm fixed to a hub member or cross shaft. A second arm fixed to and projects radially from the hub member to bear compressively against a rubber body connected to the vehicle frame.
U.S. Pat. No. 3,822,908 issued on Jul. 9, 1974, to Rene Gouirand describing a suspension system using single or dual air bags having a tapered cross-section in the truck's longitudinal direction and supported by an upper plate and a pair of lower lever members or axle supports. The air bags are pressurized by an air pump.
U.S. Pat. No. 3,964,764 issued on Jun. 22, 1976, to Erik G. Rickardsson describes an air spring axle assembly for a spring suspension and sway resistance of a vehicle chassis comprising a U-shaped frame as a box girder spring-mounted and supporting a wheel axle.
U.S. Pat. No. 4,415,179 issued on Nov. 15, 1983, to Joseph A. Marinelli describes an axle and air bag suspension comprising a forward mounting portion and a front-to-rear trailing arm which has its forward end pivotally supported. The rear end portion of the arm is anchored to an axle by a bushed clamp sleeve. An air bag is mounted on a stationary mount portion. A Y-shaped stabilizer bar has its free ends pivoting from the forward chassis mount.
U.S. Pat. No. 4,418,932 issued on Dec. 6, 1983, to Paul W. Claar describes a front axle suspension system for a vehicle chassis comprising a first forward link and a second rearward link pivotally connected and extending down from the chassis and coupled to a third link. A spring and dampener mechanism interconnects the coupler link and chassis.
U.S. Pat. No. 4,733,876 issued on Mar. 29, 1988, to Merle J. Heider et al. describes a leaf spring supplemented with a pressure controllable air bag supplying variable spring adjustment, variable ride height, and stationary levelling of a motor home.
U.S. Pat. No. 4,842,297 issued on Jun. 27, 1989, to Mitsuo Takahashi describes a wishbone suspension system comprising upper and lower suspension arms with each arm having one end pin-connected to the vehicle body, and a knuckle member connected to a wheel axle. A connecting rod is connected at one end to an intermediate portion of one of the suspension arms, and a bell crank lever having a first end pin-connected to the other end. A second end pin is connected to one end of the knuckle member and a bent portion between these first and second ends. The bent portion is pin-connected to the other end of the suspension arms.
U.S. Pat. No. 4,858,210 issued on Aug. 22, 1989, to Donovan B. Wallace et al. describes a trailing arm suspension with a fixed cup communicating with a movable piston air spring mounted by a clamp in lateral juxtaposed relationship to a terminal end of the trailing arm assembly. A track bar with bushed joints at both ends interconnects the frame and the axle housing to provide lateral stability.
U.S. Pat. No. 4,923,210 issued on May 8, 1990, to Merle J. Heider et al. describes a leaf spring in conjunction with an air bag for motorhome levelling. A pneumatic control system communicates with the air bag to control the bag pressure.
U.S. Pat. No. 5,083,812 issued on Jan. 28, 1992, to Donovan B. Wallace et al. describes an air spring suspension system including trailing arms connecting the vehicle frame to a transverse beam connecting them with bushed articulating joints which permit the trailing arms to move with respect to each other. A stiffener arm is mounted at one end to each trailing arm by a bushed connection, and rigidly secured at the other end to the transverse beam. The system resists roll forces.
U.S. Pat. No. 5,265,907 issued on Nov. 30, 1993, to Ray Tostado describes a bolt on an auxiliary air bag suspension system, wherein the frame takes existing apertures provided in certain trucks, resulting in a removable supplemental suspension system that assists the factory suspension system.
U.S. Pat. No. 5,346,246 issued on Sep. 13, 1994, to Cecil Lander et al. describes an air bag suspension system controller for adjustment of spring rates of an air bag coupled in parallel with a leaf spring.
U.S. Pat. No. 5,366,238 issued on Nov. 22, 1994, to Donald L. Stephens describes a trailing arm suspension system having a tapered arm at a pivoting end so as to reduce arm weight in conjunction with an air spring at the opposite end.
U.S. Pat. No. 5,375,871 issued on Dec. 27, 1994, to James L. Mitchell et al. describes a vehicle suspension system comprising a wide base beam and an axle shell. The beam is mounted for pivoting movement to a hanger and securely to a vehicle axle. The beam is constructed with a laterally widening base as it extends longitudinally from the pivot mounting to the axle, and with an axle shell securing the beam to the axle to reduce stress on the axle.
U.S. Pat. No. 5,431,429 issued on Jul. 11, 1995, to Unkoo Lee describes a vehicle suspension system including a knuckle pivotally supporting a wheel with upper and lower control arms connecting upper and lower parts of the knuckle to the vehicle.
U.S. Pat. No. 5,584,497 issued on Dec. 17, 1996, to Cecil Lander et al. describes an air bag suspension controller system for automatic adjustment of spring rates of an air bag mechanically coupled in parallel with a leaf spring.
U.S. Pat. No. 5,639,110 issued on Jun. 17, 1997, to William C. Pierce et al. describes a trailing arm suspension for heavy duty vehicles comprising a fabricated beam of three pieces connected at two joints. A shock absorber bracket is integrally formed with the basic beam. A casting fixed in a preformed seat in the basic beam facilitates an axle connection.
U.S. Pat. No. 5,649,719 issued on Jul. 22, 1997, to Gareth A. Wallace et al. describes a weight-reducing, z-spring alternative in the form of an arm linkage and suspension system for heavy weight bearing vehicles featuring upper arms y-mounted to the frame sides and the axle center.
U.S. Pat. No. 5,711,544 issued on Jan. 27, 1998, to Reinhard Buhl describes an axle suspension for rigid vehicle axles comprising two longitudinal control arms connecting the vehicle body to the axle. A triangle pull rod is articulated to the axle and body centrally, and laterally offset. A stabilizer bar including a torsion spring bar counteracts lateral tilting by torsional stresses. The stabilizer bar is arranged directly between the longitudinal control arms, and its ends connected as a universal joint, but rotating in unison.
U.S. Pat. No. 5,765,859 issued on Jun. 16, 1998, to Corbett W. Nowell et al. describes a modular squatdown wheeled suspension system comprising air bags supported between pivoted bracket elements located adjacent the trailer wheels. An air supply system with an automatic locking arrangement allows the trailer deck to be lowered to a ground engaging position and raised back to the transport position.
U.S. Pat. No. 5,908,198, issued on Jun. 1, 1999, to Ervin K. VanDenberg describes a center beam and air spring suspension system comprising a central beam having a mounting flange on each side and pivotally mounted to a suspension frame at one end and rigidly attached to an axle at the other end. A control arm is pivotally mounted to each mounting flange at one end, and to the suspension frame at the other end. The pivot connection of the central beam may have a constant or varying air spring rate.
U.S. Pat. No. 5,988,672 issued on Nov. 23, 1999, to Ervin K. VanDenberg describes an air spring suspension system with an integral box beam comprising the box beam welded around the axle and having a pair of axially aligned and spaced apart pivots which include air springs having horizontal, vertical and axial spring rates.
U.S. Pat. No. 6,039,337 issued on Mar. 21, 2000, to Brian A. Urbach describes a vehicle suspension with a stroke-reducing linkage comprising a spring/damper assembly interposed between the control arm and the vehicle frame.
U.S. Pat. No. 6,070,861 issued on Jun. 6, 2000, to Jack D. Ecktman describes a bumper extension for use with a bumper on an air spring.
U.S. Pat. No. 6,089,583 issued on Jul. 18, 2000, to Erkki Taipale describes a vehicle stabilizer incorporating a torsion bar.
U.S. Pat. No. 6,092,614 issued on Jul. 25, 2000, to Tae-Hak Shin describes a structure for installing a conventional shock absorber for the rear suspension in a solar driven automobile.
U.S. Pat. No. 6,203,039 B1 issued on Mar. 20, 2001, to Marvin J. Gordon describes an independent suspension system for a four-wheeled trailer with an improved vertical alignment and range of travel which includes air bags at each end of the axle beams.
Canadian Patent Application No. 492,516 published on May 5, 1953, for Ernest E. Smith et al. describes a suspension system with an inelastic yet flexible inflatable conduit providing an air cushion.
Netherlands Patent Application No. 7612-924 published on May 23, 1978, for Dr. S. Rosenthal describes a swing arm suspension system having an air spring with the wheel situated at a fulcral point. The air spring may have an auxiliary spring of the diabolo type inside.
German Patent Application No. 3934-238-A1 published on Apr. 18, 1991, for Audi AG (Heinz Hollerweger et al.) describes a vehicle wheel suspension with an elastically mounted wheel guide and having a first variable volume chamber acted on by lateral wheel forces to create an under-steer effect on the wheel. The first chamber is pressurized by a second variable volume chamber operated by lateral wheel forces. The two chambers can be incorporated into one unit with no separate components required.
None of the above inventions and patents, taken either singularly or in combination, is seen to describe the instant invention as claimed. Thus, an air bag for sprint cars solving the aforementioned problems is desired.
SUMMARY OF THE INVENTION
The present invention relates to the field of vehicle suspension systems, specifically in the first two embodiments as an air bag spring-dampener on (1) a swing arm suspension with the spring-axle connected via a four-bar linkage and (2) two actuator arms and a rotating actuator shaft, wherein the air bag spring replaces traditional torsion bars or coil springs. These systems are particularly suitable for use on racing cars on dirt or rough surfaces, and more specifically, on an open wheeled sprint, midget, micro-sprint, mini-sprint, championship dirt car, micro-midget, super-modified, championship dirt car, and well-suited for heavier cars such as modified race cars. In competition, such race cars endure severe forces often resulting in loss of wheel to road surface contact, and resulting loss of traction, control and speed. A further refinement by a simplified third embodiment is presented having (1) the front axle supporting a pair of air bags mounted proximate each front wheel, and (2) the rear axle having bird cages mounted adjacent each rear wheel over the wheel bearings and the air bags mounted on extensions. An upper adjustable mount for the air bag having a clamp is welded onto the frame of a sprint car.
Accordingly, it is a principal object of the invention to provide an improved lightweight suspension system for a racing vehicle on a dirt track.
It is another object of the invention to provide an improved lightweight suspension system which is based on air springs mounted directly on the front axle.
It is a further object of the invention to provide an improved lightweight suspension system which is based on air springs mounted on extensions proximate the rear axle inside bird cages.
Still another object of the invention is to provide an improved lightweight suspension system having an upper adjustable mount for the air spring with a clamp affixed to the frame.
It is an object of the invention to provide improved elements and arrangements thereof for the purposes described which is inexpensive, dependable and fully effective in accomplishing its intended purposes.
These and other objects of the present invention will become readily apparent upon further review of the following specification and drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an environmental, perspective view of a first embodiment of an air bag suspension installed for a rear axle of a sprint race car shown in shadow according to the present invention.
FIG. 2 is a partially sectioned side elevational view of an air bag draped over its shaping cone and in contact with a four-bar linkage.
FIG. 3 is a perspective view of a swing arm suspension utilizing torsion bar springs in a prior art sprint car shown in shadow.
FIG. 4 is a top plan view of a sprint car shown in shadow equipped with four air bag springs and bar linkages.
FIG. 5 is a sectional side view of a prior art air bag spring as described by FIG. 8 in U.S. Pat. No. 4,858,949 to Wallace et al.
FIG. 6 is a sectional side view of a prior art GOODYEAR™ air spring 1S6-023.
FIG. 7 is a partially sectioned side view showing the direction of motion and the forces of an air bag spring being compressed by upward forces acting upon a wheel.
FIG. 8 is a side view showing the direction of motion and the forces acting upon a wheel being pushed down by an air bag spring.
FIG. 9 is a right side elevational view of a sprint car with a second embodiment of the innovative air springs installed in the front and rear.
FIG. 10 is a front elevational view of the second embodiment of the innovative air springs for the front axle in a sprint car.
FIG. 11 is a rear elevational view of the second embodiment of the innovative air springs for the rear axle in a sprint car.
FIG. 12 is an elevational side view of an actuator shaft in the second embodiment.
FIG. 13 is a schematic front elevational view of a third embodiment for a front axle, wherein the pair of air spring supports are directly connected by a lower mounting plate to the front axle housing and the bird cages with the adjustable upper mount movable in a clamp welded to the vehicle frame.
FIG. 14 is a schematic front view of the third embodiment for a rear axle, wherein the air springs are directly connected to the bird cages or housings for the wheel bearings.
Similar reference characters denote corresponding features consistently throughout the attached drawings.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The first embodiment 8 of the present system incorporates a four-bar linkage system connecting an axle swing arm suspension system to an air bag spring dampening system.
FIGS. 3, 5 and 6 depict prior art suspension systems with air bag springs. In FIG. 3, a sprint car 18 having a frame 330 supported in the rear by a rear axle 180 having a triangular carrier hub 310 at each end. A pair of torsion bars 320 are attached to one carrier hub 310 by a front swing arm 140 and a rear swing arm 350 . FIG. 5 illustrates an air bag spring assembly 22 comprising an air spring 72 having a top cover 73 and self-sealing beads 80 mounted on a movable piston 66 over a cup 64 which is attached to a top mounting plate 58 on a terminal end of a trailing arm 56 . FIG. 6 shows the aforementioned GOODYEAR™ air bag spring 1S6-023 as 24 in an air spring assembly 20 having a top cover 26 and a cup 28 secured by self-sealing tire beads 30 .
Turning to the first embodiment 8 of FIGS. 1, 2 and 4 , an air bag spring 150 is draped over an inverted cone 160 (FIG. 2) Such air bag springs 150 are available through GOODYEAR™ or FIRESTONE™ with GOODYEAR™ bag number 1S6-023 serving as an optimal choice. A wide variety of air bags are available with varying size and stiffness. The cone 160 provides support toward shaping and holding up the air bag. The draped air bag provides a spring resistance to an input link of a four-bar linkage, having four pivot joints interconnecting the four bars. The appearance of first, second, third and fourth structural members may be described out of numerical sequence for the sake of brevity and the sake of understanding of functional relationships.
The input link 110 has a first pivot joint 116 and has an end 117 in contact with the air bag spring 150 , the contact generally being located at the top of the air bag spring 150 . The input link 110 is in rotational contact about the first pivot joint 116 with the air bag spring 150 , whereby substantially antagonistic oppositional forces from the air bag 150 are applied against the input link 110 .
The input link 110 is attached, at the end 119 distant to the air bag, to a second pivot joint 118 . Connected to the second pivot joint 118 is a second coupler link 130 functioning as a push rod. Between the air bag spring 150 and the second pivot joint 118 is the first pivot joint 116 . The first pivot joint 116 serves as a second fulcral point. Pivotally attached at the first pivot joint 116 is a first coupler link 120 functioning as a pull rod. At the end 121 (FIG. 2) of the first coupler link 120 , distant from the input link 110 , is a third pivot joint 146 attached to the frame or chassis 170 of the vehicle. Also pivotally attached on the frame or chassis 170 at the third pivot joint 146 is a swing arm 140 . The distant end 141 of the swing arm 140 is attached to a carrier hub 310 (FIG. 3) on the vehicle axle for live axles or half shafts, or directly to the axles for wheels not attached to rotating axles. This attachment to the carrier hub 310 or axle 180 will generally be a pivotal link (not shown). Orienting the swing arm 140 longitudinally parallel to the chassis and perpendicularly to the respective axle simplifies chassis construction and facilitates suspension adjustment and maintenance, though swing arms may be oriented in numerous other directions. The front swing arm 140 has a fourth pivot joint 148 located between the third pivot joint 146 and the axle 180 . Pivotally attached at the fourth pivot joint 148 is the push rod coupler link 130 .
Referring to FIG. 7 which shows relative force vectors to describe the invention's action and reaction, a rise in the wheel relative to the chassis typically occurs due to an upward force 710 at the ground, resulting from factors such as (1) a rise in the surface such as a bump or hill, (2) a downward force on the chassis as the bottom of a hill, trough or hole, (3) the chassis rolling in the direction of the wheel in turning a corner, and (4) acceleration (rear wheels) or deceleration (front wheels). The forced rise in the wheel in turn forces (at 720 ) the swing arm 140 up at the axle connection, which in turn pushes (at 730 ) the second coupler link or push rod 130 up. The push rod 130 then pushes the attached end 119 of the input link 110 up, which forcibly pivots (at 740 ) the input link 110 about the first fulcral point (first pivot joint 116 ) resulting in the end of the input link 110 pressing down (at 750 ) in contact with the air bag spring 150 . The force 750 acts downwardly, allowing the arm of the input link 110 to continue to pivot until the opposing force vector associated with pressure in the air bag spring 150 is equalized. In other words, the rotational force from the input link 110 is antagonistically counteracted such that the forces come into balance and into fulcral equilibrium.
Alternately, as suggested by FIG. 8, weight may be transferred from the wheel 190 (FIG. 1) as the road drops away from it, such as by entering a hole, cresting a bump or hill, or the car rolling away from the wheel 190 during cornering, deceleration (rear wheels), or acceleration (front wheels). Such events all may result in a reduction in upward force at the wheel. This reduction in weight on the wheel permits the air bag to force (at 810 ) the arm of the input link 110 up, forcibly rotating (at 820 on the first coupler link 120 ) the input link 110 about the first fulcral point or the first pivot joint 116 , thereby transferring force along vector 830 down on the end of the input link 110 , opposite the force vector 810 of the expanding air bag spring 150 . This in turn results in a vector force 840 longitudinally directed down the push rod or second coupler link 130 , thereby forcing (at 840 ) the front swing arm 140 down. This force 840 in turn exerts a transferred downward force 850 onto the axle 180 (not shown), until such point as the force 810 exerted by the air bag spring 150 and the upward wheel force 710 (FIG. 7) are fulcrally balanced in equilibrium.
Additionally, the four-bar linkage achieves a positional offset for the point of contact with the air bag spring 150 . This permits the input link 110 of the four-bar linkage to come in contact with the air bag spring 150 at a point well clear of the ground.
As depicted in FIGS. 1 and 2, the four-bar linkage provides a means for adjusting spring coefficients independent of air pressure and air bag changes. The four-bar linkage can be used to increase or decrease the effective spring coefficient as seen at the axle by adjusting the travel of the input link adjoining the air bag. The effective spring coefficient is adjusted by the following equation with the angles and distances depicted in FIG. 2 .
F effective =( F actual )×(( A+B )/ B )×[cos (theta 1)]×([ C/D ) cos (theta 2)]
where:
A=the distance between the wheel center and the fourth pivot joint 148 ;
B=the distance between third pivot joint 146 and the fourth pivot joint 148 ;
C=the distance between the first pivot joint 116 and the second pivot joint 118 ;
D=the distance between the first pivot joint 116 and the air bag spring 150 ;
Theta 1=the angle formed by the swing arm 140 and the second coupler link 130 closest the air bag spring 150 about the inside of the fourth pivot joint 148 ; and
Theta 2=the inside angle formed by the second coupler link 130 and the input link 110 closest the air bag spring 150 about the inside of the second pivot joint 118 .
The linkage adjustments increase or reduce the force maintained on the axle with respect to axle travel. The linkage adjustment may be readily facilitated by drilling a plurality of holes 112 (FIGS. 1 and 2) in the input link 110 and repositioning the first pivot joint 116 , or fulcral point which in turn adjusts variables C, D and Theta 2 .
As a portion of the spring character of the airbag is obtained through air-compression and expansion, the airbag provides a non-linear resistance to the arm travel, thus creating an inherently damped spring due to energy losses associated with compression and expansion of gases.
Due to the relatively low viscosity of air, an airbag has a higher and broader frequency response than traditional dampening devices such as shock absorbers using high viscosity fluids. This results in a smaller portion of the high speed vibrations that are likely to be found on bumpy surfaces such as dirt courses to transfer via the suspension to the chassis as the suspension will flex with these high speed movements as contrasted with the slower suspension systems. Likewise, high frequency Fourier components of individual pulses and movements may be readily transferred to the air bag spring 150 , thereby resulting in lesser values for the derivatives of the displaced wheel distance with respect to time, such as acceleration and over the course of the travel of the swing arm 140 .
The second embodiment 10 illustrated in FIGS. 9-12 employs a first inside actuator arm 12 acting on an air bag spring 150 pressurized by an air hose 13 for each wheel 190 on the front axle 14 and the rear axle 16 of a sprint car 18 . The first inside actuator shaft 12 has a distal end connected directly to a hollow rotating actuator shaft 32 housed inside a horizontal frame tube 34 consisting of three separate frame supported sections. A second outside actuator arm 36 has a first end 38 connected to the housing of the axle 14 or 16 and a second end 40 connected to an outside end of the rotating actuator shaft 32 . The inside actuator arm 12 is provided with a splined hole which is slotted at the end of the arm for clamping with a bolt (not shown) onto one of the splined ends 33 of the rotating hollow shaft actuator shaft 32 and further protected by a bushing 42 as shown in FIG. 12 . The inside actuator arm 12 can have a series of holes for saving weight (not shown).
As shown in FIG. 10, an additional frame element 44 can be provided for supporting the air bag spring 150 on top and a circular support plate 46 on the bottom which is attached to the first inside actuator arm 12 . Thus, the second embodiment system 10 again provides a lightweight but durable suspension system for a sprint car.
In a third embodiment 49 illustrated in FIG. 13 (front axle 50 ) and FIG. 14 (rear axle 51 ), another support means is provided for the air bags 52 having air intake stems 68 . In FIG. 13 a clamp 53 having a ring 54 with an apertured extension 55 supports the upright post 57 having peripheral stops 59 of the circular upper mount 60 of the air bag 52 . The clamp 53 can be either welded or fastened tightly by fasteners (not shown) onto the frame 61 , and is utilized for supporting the air bags 52 for both the front axle 50 and rear axle 51 .
On the front axle 50 , the air bags 52 for the front wheels 69 are directly connected to circular metal plates 62 welded onto the axle 50 . For the rear axle 51 the bird cages or housings 63 hold the bearings 65 (hidden). The wheel bearings 65 are sealed roller bearings. A wedge shaped metal lower mount 67 extending from and welded to the bird cage 63 supports the air bag 52 for each rear wheel 70 . The wheel bearings 65 and bird cages 63 are attached to the rear axle 57 by sliding over the ends of the axle.
It should be noted that there is both a reduction in weight associated with the use of air bag springs over metal coils or torsion springs and a reduction in unsprung weight, both of which will improve the handling of the vehicle.
It is to be understood that the present invention is not limited to the embodiments described above, but encompasses any and all embodiments within the scope of the following claims. | A vehicle air bag spring suspension system utilizing a swing arm as a member of a four-bar linkage subsystem wherein the suspension system with the airbag spring is compressed by the linkage opposite the swing arm's fulcral point relative the supported wheel. The air bag further serves as an inherently, partially dampened spring having a non-linear spring compression rate, so as to firmly keep the vehicle tires firmly planted to a rough surface. A second embodiment employs two actuator arms per wheel, wherein one inside actuator arm contacts a fixed air bag spring and cooperates with the other outside actuator arm and a rotating actuator shaft inside a frame tube to dampen wheel movement. A third embodiment employs the air spring supports directly connected to the bird cages or the housings for the bearings for both the front and rear axles. | 1 |
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority of German application No. 102005021061.9 filed May 6, 2005, which is incorporated by reference herein in its entirety.
FIELD OF THE INVENTION
[0002] The invention relates to a method for tomographically displaying a cavity, preferably a blood vessel, by Optical Coherence Tomography (OCT), in that a scanning head with a catheter is inserted into the cavity to be optically scanned and the surroundings of the scanning head are displayed in a tomographical display on the basis of detected interferences and their intensities between a measuring light beam and reference light beam, wherein the path length of the measuring light beam in the catheter can change as a result of a movement of the catheter and brings about a change in the display scale.
[0003] The invention also relates to an OCT (=Optical Coherence Tomography) device for tomographically displaying an examined object, comprising a coherent laser light source, a splitter for splitting the light emitted by the laser light source, a length-adjustable reference light path into which the laser light source irradiates with a first portion of the emitted light (=reference light beam), a length-adjustable measuring light path in a catheter, into which the laser light source irradiates with a second portion of the emitted light (=measuring beam), comprising an optical scanning head which radially scans its surroundings at least in one plane, an interference detector with an input for the reference light path and the measuring light path, and a computing and display device for tomographically displaying the surroundings of the scanning head on the basis of the detected interference intensity between measuring beam and reference beam, wherein a part of the OCT device is visible in the tomographical display.
BACKGROUND OF THE INVENTION
[0004] The basic principle of OCT is based on white light interferometry. This method compares the propagation time of a signal using an interferometer, usually a Michelson interferometer. In this case an optical path with known optical wavelength, the reference path of the interferometer, is used as the reference for the measuring path. The interference of the signals from both paths produces a pattern, as a result of optical cross correlation, from which pattern the relative optical wavelength—an individual depth signal—can be read. In the one-dimensional grid method the beam is transversely guided in one or two directions, whereby a two-dimensional scan or a three-dimensional tomogram may be taken. The outstanding property of the OCT lies in the decoupling of the transversal resolution from the longitudinal resolution. In contrast thereto both the axial resolution—depth-wise—and the transversal—lateral—resolution depend on the focusing of the light beam in conventional light-optical microscopy.
[0005] The fields of application are primarily in medicine, in particular in ophthalmology, and in early cancer diagnosis, for skin examination or in the field of examination of vessels which is considered in particular here. Reflections on boundaries of materials with different refractive indices (membranes, cellular layers, organ boundaries) are measured in this case and thus a two- or three-dimensional image is reconstructed.
[0006] The use of OCT is limited by the penetration depth of electromagnetic radiation into the object being examined and by the bandwidth. Since 1996 sophisticated broadband [lasers] have enabled the development of UHR-OCT (Ultra High Resolution OCT) which has advanced the resolution from a few tens of micrometers (μm) to fractions of micrometers. Subcellular structures in human cancer cells can thus be displayed.
[0007] In the field of vessel examination OCT is used, as is described for example in WO 97/32182 A1, to generate images from the insides of the vessels using image-producing intravascular catheters. OCT is particularly suitable for example for qualitative plaque assessment. For this purpose OCT systems operate in a light wave range of approx. 1,300 nm. The light is emitted into the vessel wall from a catheter introduced into a vessel and the reflection from the vessel wall is registered in a depth-resolved manner, as described above, by means of interferometry. By translating the irradiated light beam information from various adjacent locations in the vessel wall can be obtained and compiled into a 2D image. The catheter can also be moved in the longitudinal axis of the vessel during image acquisition in order to sequentially display portions of the vessel that are located one behind the other.
[0008] The reflections of the various vessel wall layers carry the relevant image information and must be detected and displayed by the OCT device. The catheter itself has an internal structure which produces reflections, so the OCT system displays the catheter used in the image. OCT and the interferometry used for this purpose involve minimal differences in length which have to be detected. As, during catheter production, the manufacturing tolerances of the catheter length far exceed the differences in length that are to be measured, the OCT system must be re-calibrated for each new OCT catheter which is used as disposable material.
[0009] It is known here to make use of the autoreflections from the catheter itself. As the manufacturing tolerance of the diameter of the OCT catheter, which is visible in the center of the OCT image, is negligible compared with the differences in length that are to be measured, markings are usually displayed on the screen of the OCT system for calibration purposes, the spacing of which markings from each other corresponds to the known diameter of the OCT catheter. During calibration the user manually adjusts the length of the measuring path until the marking and the displayed reflection of the catheter match.
[0010] If the OCT catheter is advanced or withdrawn the optical fiber, which is part of the measuring path, in the catheter is compressed or elongated by a few micrometers. The changed length of the OCT catheter, or its core, changes the calibration, so length measurements in photographs which are caused by a movement of the catheter contain substantial errors and thus cannot be utilized for the examination. Manual recalibration is not possible as the catheter moves very quickly.
SUMMARY OF THE INVENTION
[0011] The object of the invention is therefore to develop a method which continuously recalibrates photographs which are produced during a longitudinal movement of the OCT catheter.
[0012] This object is achieved by the features of the independent claims. Advantageous developments of the invention are the subject of the subordinate claims.
[0013] The inventors recognized that it is automatically possible to directly influence both the change in the length of the optical fiber in a moved catheter as well as indirectly correct the effect of such changes in length in the generated image if, with the aid of image analysis, an object which is known in its dimension is continuously registered in the scanning region of the OCT catheter and the displayed dimension thereof is compared with the known actual dimension and is re-corrected according to a detected change in dimension. The correction measure can for example be a purely electronically executed change in the scale of the display of a scanned image, or one of the light paths of the measuring or reference beam can also be directly corrected in terms of its length. The delay time of the light through the measuring or reference path may also be influenced, and this also corresponds to a change in the length of the light path. A combination of a plurality of variants is also possible, in particular if the developments of the individual variants have different reaction times and adjustment speeds. Thus it may for example be advantageous to firstly electronically compensate, in the image itself, a change in the scale of the image display as soon as this is detected and to subsequently make a change in the mechanical length of a light path.
[0014] According to this basic idea the inventors propose improving the method, known per se, for tomographically displaying a cavity, preferably a blood vessel, by Optical Coherence Tomography (OCT), wherein, as is known, a scanning head with a catheter is introduced into the cavity to be optically scanned and the surroundings of the scanning head are shown in a tomographical display on the basis of detected interferences and their intensities between a measuring light beam and a reference light beam, wherein the path length of the measuring light beam in the catheter can change as a result of a movement of the catheter and brings about a change in the display scale. The improvement lies in the fact that a possible change in the path length of the measuring light beam in the event of a movement of the catheter is electronically determined and automatically compensated.
[0015] For this purpose there is the possibility of directly determining the change in the length of the measuring path interferometrically, preferably with the aid of an additional interferometer, and using it for calibration.
[0016] Alternatively, an object that is known by its dimension can also be scanned by the measuring light beam, be detected and measured in the tomographical display of this object by a continuous image analysis, and a correction can automatically be made with the aid of the detected dimension of the known object.
[0017] As a result of this continuous and automatic length tracking or calibration of the display, it is accordingly possible to maintain the display of the tomographic image such that it can be interpreted and utilized even during longitudinal movements of the catheter, for example during what is known as a pullback. It is therefore accordingly possible for the operator to assess the characteristic of a blood vessel with movement of the catheter much more easily.
[0018] In a particular embodiment a change in the length of the path of the measuring light beam and/or reference light beam is made as the correction. It is also possible, in addition or alternatively, to change the delay time of the reference light beam and/or measuring light beam, more precisely of the wave packet transported there, for the correction.
[0019] A further correction possibility consists in changing the scale of the display.
[0020] The catheter diameter in the region of the scanning head can preferably be used as the object whose dimensions are known for the above-mentioned measures. This can be seen in the display of the scan anyway and its diameter is known with a high degree of accuracy. On the other hand, an additional reference object in the scanning region of the scanning head can also be introduced and used for calibration as the object whose dimensions are known.
[0021] Such an object with a known dimension, preferably the diameter of the catheter located in the center of the image, can for example be determined by edge detection, so simple continuous calibration can be carried out.
[0022] In addition there is the possibility of directly determining the change in length or lengths of the measuring path by way of an interferometric measurement and of using these measured values for continuous calibration.
[0023] According to the above-described method, the inventors also propose the improvement in an OCT (=Optical Coherence Tomography) device for tomographically displaying an examined object, which contains:
a coherent laser light source, a splitter for splitting the light emitted by the laser light source, a length-adjustable reference light path into which the laser light source irradiates with a first portion of the emitted light (=reference light beam), a length-adjustable measuring light path, at least partially extending in a catheter, into which the laser light source irradiates with a second portion of the emitted light (=measuring beam), comprising an optical scanning head which radially scans its surroundings at least in one plane, an interference detector with an input for the reference light path and the measuring light path, and a computing and display device for tomographically displaying the surroundings of the scanning head on the basis of the detected interference intensity between measuring beam and reference beam, wherein a part of the OCT device, preferably a catheter end, is visible in the tomographical display.
[0030] The improvement according to the invention in the OCT device lies in the fact that the computing and display device contains a program code which during operation executes the steps of the method described above.
BRIEF DESCRIPTION OF THE DRAWINGS
[0031] The invention will be described in more detail hereinafter with reference to a preferred embodiment and using the figures, wherein only the features required for an understanding of the invention are illustrated. The following reference characters will be used: 1 : computing unit; 2 : OCT device; 3 : laser; 4 : semi-transparent mirror; 5 : mirror; 6 : catheter; 7 : scanning head; 8 : blood vessel; 9 : cutting plane; 10 : interferometer/detector; 11 : reference path; 12 : measuring path; 13 : outer edge of the catheter in the region of the scanning head/ring; 14 : second interferometer; 15 : second semi-transparent mirror; 16 : common light path; 17 : mirror; d: diameter of the catheter in the region of the scanning head; Prg 1 -Prg n : program for graphical display, evaluation of the tomographical display and calibration.
[0032] In the figures:
[0033] FIG. 1 shows a schematic diagram of an OCT device;
[0034] FIG. 2 tomographically shows a blood vessel with catheter;
[0035] FIG. 3 shows photographs from FIG. 2 but with extracted edges;
[0036] FIG. 4 shows an enlargement of a detail around the catheter from the photograph in FIG. 2 ;
[0037] FIG. 5 shows an enlargement of a detail around the catheter from the photograph in FIG. 3 ; and
[0038] FIG. 6 shows a schematic diagram of an OCT device with additional interferometer for measuring the length of the measuring path.
DETAILED DESCRIPTION OF THE INVENTION
[0039] FIG. 1 shows an OCT device known per se with a computing unit 1 and the actual OCT unit 2 . This is constructed from a laser 3 which, via a common light path 16 , emits coherent light radiation to a semi-transparent mirror 4 . At this semi-transparent mirror 4 a portion of the light is guided on the measuring path 12 to the scanning head 7 of the catheter 6 where the surroundings of the blood vessel 8 (schematically shown here) are scanned in a plane 9 . The reflected light is then returned to the measuring path 12 and reflected at the semi-transparent mirror to the subsequent detector 10 . At the same time, a decoupled portion of the light is conveyed to the reference path 11 at the semi-transparent mirror 4 . A mirror 5 , which conveys the light back and through the semi-transparent mirror 4 to the detector 10 , is located in this reference path 11 .
[0040] The two overlapping light beams are detected in the detector in the region of the scanning head 7 with respect to their interference intensity as a function of a variation in the length of the reference path and the respective angle of the emitted light, so, following an evaluation in the computing unit 1 , a tomographic image of the surroundings of the scanning head 7 can be created.
[0041] FIG. 2 shows an exemplary tomographical photograph of this type in the plane 9 of a blood vessel 8 in which a catheter 6 is located, wherein the outer edge of the catheter 6 is reproduced by the concentric circle 13 .
[0042] FIG. 3 situated below shows the same photograph but with the edges electronically emphasized, so simple detection of this diameter d of the catheter can be determined in the region of the scanning head 7 . The illustrated tomographic image of the blood vessel 8 may be calibrated using this displayed diameter d. According to the invention calibration takes place electronically and continuously during the examination, so the display can be utilized even in the event of movements of the catheter 6 in the blood vessel 8 .
[0043] For clarification FIG. 4 and 5 again show enlargements of details from the center of the diagrams of FIG. 2 and 3 , in which the surrounding area of the catheter 6 is shown with its diameter d.
[0044] Thus the catheter edge, which is shown as an emphasized ring 13 with diameter d, can be tracked in the images in order to obtain information about the compression or elongation of the display via the change in the radius of the ring. Alternatively other signals visible in the image may also be tracked. However the catheter ring 13 is expedient as the potential search space is much smaller than the entire image as the center of the ring is also always disposed in the center of the image and therefore the detail of the image to be scanned is known. This considerably simplifies automatic object finding.
[0045] Tracking of the ring 13 proves to be much simpler here than the “free” finding of any desired object in an image, primarily because both the previous position of the ring and the direction of movement are known. Thus when the catheter is advanced the ring becomes smaller and when the catheter is withdrawn the ring becomes larger. Algorithms for tracking the ring are generally known.
[0046] If the ring is found in the image its radius can be determined and thus the change in the calibration. This information is accordingly used to recalibrate adaptively, either in terms of hardware, for example by mechanical adjustment of the light run length of the catheter, or in terms of software, by way of a radial elongation or compression of the image.
[0047] In general the information about the change can be used to control the calibration device in the system and thus make the correction. In principle the correction may also be made via additional mechanisms. The length of the optical fibers can be changed, for example by additional opposing elongation/relaxation of the fibers or by insertion of an optical delay. An adjustment of the reference run length may also be made on the hardware side, for example by additional displacement of the reference mirror. A further possibility of calibration is radial correction of the image itself. In this case the pixels are either inwardly or outwardly displaced along the radius by a fixed offset, which corresponds to the elongation/compression of the catheter.
[0048] However there is a limitation to this method if, in the case of an advance, the compression of the catheter is larger than the radius of the ring to be tracked. The ring can possibly disappear in this case and thus no longer be tracked. Precise calibration is no longer possible. However the actual catheter movement is the “pullback”, in other words the controlled withdrawal of the catheter, in which the ring becomes ever larger. Tracking is thus not a problem in this case.
[0049] An alternative possibility of measuring the change in calibration consists in measuring signals not contained in the image and determining their change. A signal that is suitable for this purpose is for example the light which is reflected at the end of the optical fibers at the transition to the lens. In principle a portion of the light is reflected at each boundary that has a refractive index gradient. The light reflected at this boundary contains the information about the current length of the optical fibers. One possibility consists in fitting an additional interferometer and integrating the measuring beam into the device. The interferometry technique for exact length measurement is generally known. In principle other measuring techniques which can detect a change in the length of the optical fibers can also be used.
[0050] FIG. 6 shows an OCT device of this type according to the OCT device shown in FIG. 1 , although an additional interferometer 14 , for directly determining the length of the measuring path, is integrated and carries out a direct length measurement of the measuring path via an additional semi-transparent mirror 15 and a further mirror 17 .
[0051] It is understood that, in addition to the respectively disclosed combinations, the above-cited features of the invention can also be used in other combinations or alone without departing from the scope of the invention. | The invention relates to a method for tomographically displaying a cavity by optical coherence tomography (OCT) and to an OCT device, wherein the path length of a measuring light beam in the catheter can change as a result of a movement of the catheter and brings about a change in the display scale, wherein a possible change in the path length of the measuring light beam in the event of a movement of the catheter is electronically determined and automatically compensated. | 0 |
CROSS-REFERENCE TO RELATED APPLICATION
[0001] The present application is a continuation of U.S. patent application Ser. No. 10/844,302, filed May 12, 2004, which application claims the benefit of the filing date of U.S. Provisional Application No. 60/471,418, filed on May 16, 2003, the entire disclosures of which are hereby incorporated herein by reference.
BACKGROUND OF THE INVENTION
[0002] A pair of shoes is typically adapted for a specific use, with a person owning a number of different types of shoes for different purposes.
[0003] For example, different shoes may be used for walking, for hiking, for athletic activities, or for formal occasions. Even within each type of shoe category, a number of pairs of shoes may be required, such as a pair of hiking shoes suitable for snow, a pair for wet terrain, and a lightweight pair designed for greater comfort on long hikes over dry terrain. Similarly, formal footwear may include different colors and styles of shoes for different clothing, and different types of occasions.
[0004] The useful variety of available footwear poses particular problems for the traveler, who is frequently faced with the task of packing a variety of gear into one or two bags suitable for carrying. This problem is made worse by the fact that each shoe may be bulky and rigid, requiring significant space in a travel bag, and adding significant weight to the bag once it has been packed.
[0005] There remains a need for footwear that offers versatility to travelers in a compact form.
SUMMARY OF THE INVENTION
[0006] A modular shoe is provides which separates into components. The components may be interchangeable to provide versatility without requiring a large number of complete shoes. Each subcomponent may also be collapsible to provide for convenient packing in a travel bag or other location where space is limited.
[0007] In one embodiment, the shoe of this invention comprises the following components: a foot enclosure for receiving a foot, a chassis adapted to fit beneath the foot enclosure, and a shell surrounding the chassis and foot enclosure for engaging the foot while in use. These components are removable and replaceable to provide a variety of options for the wearer.
[0008] In another embodiment, the modular shoe of this invention includes a foot enclosure, a chassis and a shell, wherein the lower surface of the chassis has treads which protrude through one or more openings in the bottom of the shell.
[0009] In a further embodiment, the shoe of this invention includes a weatherproof barrier for protecting the foot of the wearer against adverse weather conditions, such as those resulting from rain, water, mud or snow.
[0010] In accordance with another embodiment of the present invention, an article of footwear is provided. The article of footwear comprises a shell and a chassis. The shell provides an opening for receiving a foot therein. The shell includes a ground contacting surface on a bottom thereof and a cinching mechanism for securing the foot within the opening. The chassis is adapted for removable insertion within the opening of the shell. The chassis provides a support surface for the foot, a rear surface connected to a heel section of the support surface, and a fold line for collapsing the chassis by folding along the fold line.
[0011] In one alternative, the fold line is disposed between the rear surface and the support surface. In another alternative, the rear surface of the chassis includes a protrusion thereon positioned for a facing arrangement with a rear portion of the shell. In this case, the rear surface of the chassis may comprise a rigid back surface that is collapsible along the fold line so that the chassis may be removed from the shell.
[0012] In accordance with a further embodiment of the present invention, an article of footwear is provided. The article of footwear includes a chassis and a shell. The chassis provides a support surface for a foot. The chassis including a protrusion thereon. The shell surrounds the chassis, and is adjustable to maintain the chassis in operative engagement with the foot while in use. The shell includes an opening in a heel area thereof. The chassis and the shell are removable and replaceable with respect to one another. The protrusion is suitable for gripping to apply a force to the chassis to disengage the chassis from the shell. The opening in the heel area of the shell is configured to engage with the protrusion on the chassis when the chassis is engaged with the shell.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] The foregoing and other objects and advantages of the invention will be appreciated more fully from the following further description thereof, with reference to the accompanying drawings, wherein:
[0014] FIG. 1 is a perspective view of a modular shoe.
[0015] FIG. 2 is a bottom view of a modular shoe.
[0016] FIG. 3 is a perspective view of modular shoe with a foot enclosure partially disengaged, depicting the disengagement of the shoe by a user.
[0017] FIG. 4 is a perspective view of a modular shoe without a foot enclosure.
[0018] FIG. 5 is a perspective view of a modular shoe with a chassis partially disengaged and depicting disengagement of the chassis.
[0019] FIG. 6 is a bottom view of a modular shoe with a chassis partially disengaged.
[0020] FIG. 7 is a top front view of the components of a modular shoe.
[0021] FIG. 8 is a front side view of components of a modular shoe.
DETAILED DESCRIPTION
[0022] To provide an overall understanding of the invention, certain illustrative embodiments will now be described, including a modular shoe with three components: a foot enclosure, a chassis, and a shell. However, it will be understood that the footwear systems described herein may have utility as a different number of components and subcomponents, such as treads, shell, chassis, and foot enclosure, and may employ components and subcomponents adapted for any number of aesthetic or functional purposes. All such footwear designs are intended to fall within the scope of the systems described herein.
[0023] FIG. 1 depicts a modular shoe. The shoe 100 may include a shell 102 with a cinching mechanism 104 , a chassis (not visible), and a foot enclosure 106 .
[0024] The shell 102 may be formed of conventional shoe materials, such as leather, vinyl, suede, woven material, rubber, or plastic, or combinations of these. The materials for the shell 102 may also be selected according to conventional footwear design constraints including aesthetics, durability, flexibility, or comfort. In general, the shell 102 may be any component providing an exterior surface to the shoe 100 described herein. Thus a number of shells may be carried by a traveler, with each shell serving a particular aesthetic or functional role for the traveler.
[0025] The cinching mechanism 104 may be shoe laces, Velcro straps, buckles or any other device or devices for securing the shoe 100 about the foot of a wearer. The cinching mechanism 104 of the shell 102 may be tightened to securely engage the shell 102 , the foot enclosure 106 , and the chassis about the foot of the wearer while the shoe 100 is in use. The cinching mechanism 104 may be loosened to permit removal and disassembly of the shoe.
[0026] The chassis, which will be discussed in further detail below, may provide a supportive bottom surface beneath the foot enclosure 106 , such as a rigid, semi-rigid, or flexible support surface, and may include padding along its top surface for the comfort of a wearer of the shoe 100 . In general, the chassis may be any component providing rigid support to the overall shoe 100 described herein.
[0027] The foot enclosure 106 may be positioned within the shell 102 , and is generally adapted to receive a foot of a wearer. In general, the foot enclosure 106 may be any component adapted to receive a wearer's foot. Where the foot enclosure 106 comes directly in contact with the foot, the foot enclosure 106 may have an interior surface comfortable for such direct contact. The foot enclosure 106 may include a padded bottom surface. The foot enclosure 106 may be formed of any suitable material including natural or synthetic woven materials, breathable membranes that are permeable to water vapor but not liquid, and/or an elastic material that stretches to adapt to the shape of a foot. The foot enclosure 106 may also include additional padding or a wear guard directly beneath the cinching mechanism 104 to provide additional comfort at this pressure point within the shoe, and/or to reduce wear on the foot enclosure 106 during repetitive tightening and loosening of the cinching mechanism 104 .
[0028] Although it is expected that the foot enclosure 106 will remain fixed within the shell 102 when a user's foot is inserted into and removed from the shoe 100 , the foot enclosure may further include a zipper (not shown) or other mechanism to facilitate insertion and removal of a foot directly from the enclosure 106 so that the foot enclosure may additionally serve as a slipper apart from the shell 102 . In one embodiment, the foot enclosure 106 may be positioned above the chassis. However, it will be appreciated that the foot enclosure 106 may instead enclose the chassis, in which case the chassis would preferably present an upper surface that comfortably engages the foot of the wearer. Further, while the foot enclosure 106 is depicted as a slipper or sock-like component that encloses most of a foot, other types of foot enclosures may be used, such as a strap or band of elastic material, a sandal-like configuration that slides between the toes, around the ankle, or some other portion or portions of the foot, or any other arrangement that operates to hold the foot securely within the shoe 100 . All such structures and configurations are intended to fall within the scope of the term “foot enclosure” 106 as that term is used herein, except where specifically described otherwise.
[0029] Each of the foot enclosure 106 , the chassis, and the shell 102 may be removable and replaceable so that the shoe 100 may be disassembled and reassembled. Or, one of the components may be removed and replaced with a different component. For example, a user may change from a brown shell 102 to a black shell 102 to match a change in clothing. Or the user may change to a chassis with a more aggressive tread before an off-road hike. Or the user may insert a new foot enclosure 106 or chassis after a day's use.
[0030] It will be readily appreciated that any number of different or additional components may be included with the shoe 100 described herein, and that the components may be differently arranged. For example, the chassis may be positioned within the foot enclosure 106 rather than between the foot enclosure 106 and the shell 102 , with suitable adaptations of padding, surface materials, and attachment mechanisms. All such arrangements are intended to fall within the scope of the footwear described herein.
[0031] FIG. 2 is a bottom view of a modular shoe. The shoe 200 may be the shoe 100 described above with reference to FIG. 1 . As visible from this perspective of the shoe 200 , the chassis 202 may form a portion of a bottom surface of the shoe 200 . The shoe 200 may include treads 204 on the chassis 202 and/or treads 206 on the shell 208 . The treads 204 may be of various shapes and sizes, with various gripping surfaces according to intended uses of the shoe 200 . For example, the treads 204 , 206 may be adapted for wet slippery surfaces as in a deck shoe, for comfortable use on dry level surfaces as in a walking shoe, or for traction on off-road terrain as in a hiking shoe. The bottom surfaces of the shell 208 and the chassis 202 may be formed of any conventional material used in a shoe outsole, such as molded rubber or plastic, or any other material suitable for use in a shoe outsole and treads. The chassis 202 may be friction-fit into the shell 208 or otherwise securely but removably affixed to the shell 208 , along with a gasket to seal a seam between the chassis 202 and the shell 208 to render the seam watertight.
[0032] It will be appreciated that, although not depicted here, in certain embodiments more or less of the surface of the bottom surface of the shoe 200 may be formed from the chassis 202 . In certain embodiments, the chassis 202 may not protrude through the shell 208 at all, with the shell 208 forming the entire bottom surface of the shoe 200 . However, combining treads 204 with the chassis 202 in an integrated subcomponent permits the nature of the treads 204 to match any interior padding in the chassis 202 so that both the interior cushioning and the treads may be conveniently matched to a particular use of the shoe, such as hiking.
[0033] FIG. 3 depicts a modular shoe with a foot enclosure partially disengaged. The shoe 300 includes a shell 302 , a chassis 304 , a foot enclosure 306 , a first attachment device 308 , and a second attachment device 310 . A tool 312 that mates with a groove 314 in the shell 302 may be provided to assist with disassembly of the shoe 300 . The shoe 300 may be any of the shoes described above.
[0034] The first attachment device 308 and the second attachment device 310 may include any mechanism for securing the foot enclosure 306 within the shell 302 and/or the chassis 304 . For example, the devices 308 , 310 may include mating Velcro strips on the foot enclosure 306 and the shell 302 , or a similarly positioned button and button hole, or a button and snap, or other device or mechanism for securing the foot enclosure 306 within the shoe 300 . Once the devices 308 , 310 have been detached from one another, the foot enclosure 306 may be withdrawn from the shell 302 as depicted. When the foot enclosure 306 is inserted into the shell, the devices 308 , 310 may be reattached to secure the foot enclosure 306 in place. Although the precise placement and nature of the devices 308 , 310 is not essential, it is preferred that the devices 308 , 310 are of the same type, and in the same location for different shells and foot enclosures, so that the modular nature of the shoe 300 is maintained.
[0035] The tool 312 may provide a surface against which a downward pressure may be conveniently exerted while pulling upward to withdraw the foot enclosure 306 from the shell 302 . The tool 312 may be generally U-shaped, and the groove 314 in a heel area of the shell 302 may mate with the tool 312 so that the tool 312 horizontally slides onto and off of the groove 314 . Any other tool or technique that provides a suitable surface for applying force counter to withdrawal of the foot enclosure 306 may be similarly employed.
[0036] FIG. 4 depicts a modular shoe without a foot enclosure. The shoe 400 may be any of the shoes described above, and may include a chassis 402 , a tab 404 , and a shell 406 . With the foot enclosure (not shown) removed, an upper surface of the chassis 402 is visible. The upper surface of the chassis 402 may be suitably padded, such as by provided extra padding in the heel area to absorb shock during walking. The tab 404 or other protrusion may extend from the chassis 402 in a manner suitable for gripping and pulling to withdraw the chassis 402 from the shell 404 . In lieu of a tab 404 , the protrusion may include a hook or other mechanical device suitable for gripping and withdrawal with an appropriate tool, although such a mechanical protrusion would preferably be positioned and configured to avoid discomfort to a wearer of the shoe 400 .
[0037] FIG. 5 depicts a modular shoe with a chassis partially disengaged. The shoe 500 may be any of the shoes described above, and may include a shell 502 with a groove 504 in the heel area and a chassis 506 with treads 508 , a gasket 510 , and a tab 512 . A tool 514 , such as the tool 312 described above with reference to FIG. 3 , may be provided that mates with the groove 504 to assist with disassembly of the shoe 500 .
[0038] The treads 508 , as noted above, may be configured to protrude through openings (not shown) in the shell 502 to provide a gripping surface while the shoe 500 is in use. As noted above, the tread type may vary according to an expected use for the chassis 508 , such as for sporting, outdoor, casual, or formal use. Any suitable padding or cushioning, such as foam or an air or gas bladder (or interconnecting or isolated groups of bladders) may be included in the chassis 506 to cushion areas, such as the heel for the user's foot.
[0039] The chassis 506 may also include uniform or varying reinforcements, or layers of stiff material, in order to impart a desired degree of stiffness to the entire chassis 506 , and individual areas thereof. For example, a stiff heel area may be desired to distribute the shock across a padded area of the chassis 506 when the heel strikes a surface during walking, whereas a more flexible area may be desired further forward in the shoe where the foot naturally flexes during walking motion.
[0040] The gasket 510 may be, for example, a rubber bead attached to the chassis 506 where the chassis 506 mates with the shell 502 . The frictional engagement of the chassis 506 to the shell 502 may secure the chassis 506 within the shell 502 , and provide a watertight seal to a bottom surface of the shoe 500 .
[0041] The tab 512 may align and further secure the chassis 506 within the shell 502 by mating with a corresponding slot (not shown) in the shell 502 .
[0042] FIG. 6 is a bottom view of a modular shoe with a chassis partially disengaged. The shoe 600 may be any of the shoes described above. From this perspective, two openings 602 , 604 are visible in the shell 606 , once the chassis 608 has been removed. The openings 602 , 604 are configured to receive tread portions of the chassis 608 , and include edges that mate with the gasket (not shown) on the chassis 608 . It will be appreciated that other arrangements of this construction are possible. For example, more or less openings may be provided in the shell 606 , and other securing and sealing mechanisms may be used, such as a gasket on the shell 604 instead of the chassis 608 .
[0043] FIG. 7 is a top front view of components of a modular shoe. The shoe 700 may be any of the shoes described above, and may include a shell 702 , a chassis 704 , and a foot enclosure 706 . Certain features of the shoe 700 are now described in more detail.
[0044] From this perspective, a slot 708 is visible on the rear surface of the shell 702 . A corresponding tab 710 is visible on the chassis 704 . In operation, the tab 710 is urged into an interlocking engagement with the slot 708 by a rigid back surface 712 of the chassis 704 when the chassis 704 is inserted into the shell 702 . In order to disengage the chassis 704 from the shell 702 , the rigid back surface 712 may be pressed toward the front of the shoe 700 so that the tab 710 releases from the slot 708 in the shell 702 . The heel portion of the chassis 704 may then be drawn upward and out of the shell 702 , as described above.
[0045] It will also be noted that a reinforced area 714 is provided on the foot enclosure 706 . This may prevent chaffing when this region of the foot enclosure 706 is aligned with laces 716 of the shell 702 . The reinforced area 714 may be rigid to distribute the pressure exerted by the laces 716 (or other cinching mechanism) against the foot enclosure 706 when the shoe 700 is in use.
[0046] FIG. 8 is a front side view of subcomponents of a modular shoe. The shoe 800 may be any of the shoes described above, and may include a shell 802 , a chassis 804 , and a foot enclosure 806 . In addition to many of the features described above, this view illustrates the treads 808 and lower surfaces 810 that protrude from the chassis 804 to fill mating openings in a bottom surface of the shell 802 .
[0047] Other additions and modifications may be made to the modular shoes described herein that are not depicted in the above drawings. For example, an optional or supplemental layer may be provided to be worn under certain weather conditions. This weatherproof layer may present a barrier to, for example, water, snow, or wind, so that a shoe additionally employing the weatherproof layer is specifically adapted for use in water, snow, or mud, or on surfaces such as ice, or in particular inclement conditions. The weatherproof layer may also be designed for other weather conditions, such as by fashioning the layer of an absorbing or wicking material for use in hot weather. The weatherproof layer may be disposed about the outside of the shell to provide an exterior barrier to such elements or conditions, or the weatherproof layer may be disposed between layers of the shoe, such as between the shell and the chassis, or between the chassis and the foot enclosure, or more generally anywhere between the shell and the foot enclosure of the shoes described above. The weatherproof layer may also be a sock, bootie, or similar sheath that serves as a foot enclosure in place of, or in addition to, the foot enclosures described above.
[0048] In certain embodiments, the components of the shoe may be collapsible to permit convenient stowage, such as in a travel bag or other location where space is limited. Non-rigid components may be collapsible in any convenient fashion. Relatively rigid components may include grooves, creases, or hinges to permit folding along certain lines into a more compact geometry suitable for packing or other stowage. Any one or more of the components may be collapsible in this fashion.
[0049] In various embodiments, the modular shoe described herein may provide a number of advantages over existing shoes. The modular shoe may be compact and lightweight, while providing the functional and stylistic variety of a number of different shoe types and colors. The relatively low weight and small size, when compared to numerous pairs of shoes that might otherwise be required or desired, may provide particular advantage to a traveler with limited luggage space for footwear. Furthermore, the shoe may be separated into components that may be more easily cleaned and dried, and components such as the foot enclosure or chassis may be refreshed and replaced conveniently to avoid wearing the same footwear over a number of days.
[0050] In certain embodiments, some or all of the components of the shoe may be washable to permit cleaning of shoes in a sink or, if machine washable, with other laundry. To this end, some or all of the components may be made of washable materials that can be cleansed with water and soap or other detergents or cleaning agents. Such materials may include a washable leather or any of a number of synthetic materials. The material(s) may be hydrophobic to facilitate drying and relatively quick reuse.
[0051] While the invention has been disclosed in connection with the preferred embodiments shown and described in detail, it will be understood that the invention is not to be limited to the embodiments disclosed herein, but is to be understood from the following claims, which are to be interpreted as broadly as allowed under the law. | A modular shoe separates into components. The components may be interchangeable to provide versatility without requiring a large number of single use shoes. Each shoe component may also be collapsible to provide for convenient packing in a travel bag or other location where space is limited. | 0 |
PRIORITY
[0001] This application claims benefit of U.S. Provisional Patent Application serial No. 60/446,502, filed Feb. 11, 2003.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates generally to trailer brake and remote control systems for automotive use, and more specifically to a independent brake operating system and remote trailer operating system for automotive trailers.
[0004] 2. Description of Related Art
[0005] Automotive trailers are a common part of our lives. We tow trailers behind virtually every type of vehicle known. We use trailers to carry a wide variety of items and we expect trailers to perform a wide variety of tasks. For the very heaviest of trailers, we rely on the fifth-wheel and pintle hitches. Two very common types of automotive trailers that use the fifth wheel and pintle hitches are heavy equipment trailers used on construction sites, and recreational vehicle trailers.
[0006] One type of heavy equipment trailer is a water trailer, also known as a water wagon. A water wagon is used frequently on construction sites. The water trailer is used to distribute water over a work site for such tasks as dust control, soil compaction, street cleaning, irrigation, fire prevention or control, and chemical delivery. In its basic form the water trailer is a large water tank mounted to a trailer frame. The water trailer is attached to a semi tractor to be pulled to or through the area where water is needed. A semi tractor is needed to supply pneumatic power for the water trailer's brakes. If no semi tractor is available, the water trailer cannot operate safely. This places a demand on an equipment fleet to have a dedicated semi tractor and available to operate the water trailer when it is needed. Additionally, a semi tractor driver needs a special driver license. This is wasted on a job site. There is no reason to have an special person at the site just to operate a water trailer.
[0007] When no water trailer is available, a water tank is sometimes placed into the bed of a dump truck to serve the same purpose. However, with either of these variations the water flow from the tank is controlled by pneumatics or by a cable. The driver must have compatible equipment in the truck's cab to operate the trailer's water distribution system. Regardless of the type of truck and trailer operations, this arrangement is inefficient.
[0008] Thus, what is needed is a trailer that can be remotely operated while the driver or operator is safely in the truck's cab or another safe location.
[0009] Some of the most specialized trailers and equipment are found in the construction industry. Often, these trailers are so large that the common American light duty pickup truck is incapable of towing them over the road. These trailers often require the capacity of a semi tractor, or similar towing vehicle. As a result of the trailers' size and weight, special dedicated braking systems and equipment are required to control them over the road.
[0010] Operating heavy trailers over the road requires special brake equipment due to Federal and state laws. The heavy equipment and recreational vehicle trailers can often be quite massive and require special, heavy duty coupling and braking systems to properly control the load. However, these legal restrictions may not apply to use of the trailers for off road purposes.
[0011] Typical trailer brakes are operated via pneumatic, electric or hydraulic power. In the standard arrangement, the power to operate the braking systems is supplied by the towing vehicle. The braking power, whether pneumatic, electric or hydraulic, is routed to a coupling at the rear of the towing vehicle. When the trailer is attached, the mating coupling from the trailer is attached to the towing vehicle's coupling to operate the trailer brakes and other systems. Such an arrangement requires that the towing vehicle be specially equipped to supply pneumatic, electric or hydraulic power as required by the trailer. As a result, both the trailer and the towing vehicle must be specially outfitted with compatible equipment. The added complexity can create a very expensive situation, especially where a large fleet of towing vehicles is maintained.
[0012] With respect to heavy trailers, one of the most common hitch mechanisms is the fifth wheel hitch. Fifth-wheel hitches are used for both commercial and recreational trucks and trailers. The trailer's hitch has a kingpin that protrudes downward from a hitch plate on the front of the trailer. This kingpin is inserted into the fifth wheel at the rear of the towing vehicle.
[0013] The towing vehicle's framework supports a fifth wheel hitch, which has a large plate with a mechanism for accepting and locking onto the kingpin from a trailer. Typical fifth wheel hitch components are rigidly mounted to the towing vehicle and the trailer. Once coupled, only a few degrees of movement between the towing vehicle and the trailer is allowed. In one variation of the fifth wheel hitch, the fifth wheel hitch frame of the towing vehicle is designed to rock side to side a few degrees to permit easier coupling where the towing vehicle and the trailer are on particularly uneven surfaces. However, this feature is utilized during coupling or uncoupling operations only. With all these special systems, the trailer hitches, brake and power couplings are built into the towing vehicles to meet the stringent legal requirements for over the road use. As a result, the towing vehicles become very expensive to operate and maintain. This places great demands on the trucks and reduces cost-effectiveness.
[0014] Thus, what is needed is a self-contained trailer braking system that requires no special dedicated equipment on the towing vehicle except for a trailer hitch to properly connect the trailer to the towing vehicle.
SUMMARY OF THE INVENTION
[0015] The device is a self-contained brake and remote control system for trailer operation. The system allows permits any truck with a trailer hitch to safely pull and stop a trailer without any coupling between the trailer and the towing vehicle except for the trailer hitch. In addition, the system allows the trailer's functions to be operated and controlled from a remote, safe location, such as the cab of the towing vehicle. The system also allows the trailer to be operated safely on a hazardous or unsafe work site by virtually any truck, bulldozer, grader, loader or other equipment with a compatible hitch, regardless of whether the vehicle has a Department of Transportation approved braking system, without risk to the operator or driver. For example, the trailer could be used by military units to pull heavy equipment through combat areas. By default, more towing vehicles, including tanks or other armored vehicles, are available. Other uses include off-road logging trailers or off-road delivery trailers that can be more safely operated with off-road towing vehicles. Additionally, these trailers could be used for fighting forest fires, pulled by proper off-road towing vehicles.
[0016] The trailer braking system includes a fifth-wheel trailer hitch, an energy transfer mechanism, a brake actuator, and a power generator all attached to a trailer with brakes. The remote trailer operating system includes a remote control transmitter, a remote control receiver, and power equipment mounted on the trailer and powered by the power generator for the braking system. Thus the trailer may function even if no towing vehicle or other power source is available.
[0017] The energy transfer mechanism includes a special hitch plate with a slot oriented fore and aft down through which a kingpin protrudes to engage the towing vehicle's fifth-wheel. The kingpin is fixed to a sliding plate immediately above and in contact with the hitch plate. A linkage is attached between the sliding plate and a brake actuator. The brake actuator is supplied with energy from the generator to operate the trailer's brakes. The brake actuator meters energy to the brakes in response to the position of the sliding plate.
[0018] In use, the hitch framework on the towing vehicle and the trailer are subject to a tremendous amount of force and energy due to dynamic trailer loads. The self-contained trailer brake system uses these forces to activate the trailer's braking system, eliminating the dependence on specialized towing vehicles with pneumatic, hydraulic, electric or cable-operated systems. As a result, virtually any vehicle with an appropriate hitch, such as a fifth-wheel or pintle hitch, can be a proper towing vehicle. This increases the flexibility of the truck and equipment owners and increases cost-effectiveness. Trucks having fifth wheels come in a variety of sizes. The trailer is produced in different sizes and scaled to be appropriate for towing vehicles from pickup trucks to the largest construction equipment.
[0019] Accordingly, it is a principal object of the invention to teach a trailer braking system that is completely self-contained.
[0020] It is another object of the invention to provide a trailer braking system that works with virtually any truck, bulldozer or other heavy equipment.
[0021] It is a further object of the invention to teach a trailer control system that may be operated from the cab of a truck, without any permanently installed equipment.
[0022] Still another object of the invention is to provide a wirelessly operated trailer control system.
[0023] It is an object of the invention to provide improved elements and arrangements thereof in an apparatus for the purposes described which is inexpensive, dependable and fully effective in accomplishing its intended purposes.
[0024] These and other objects of the present invention will become readily apparent upon further review of the following specification and drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0025] [0025]FIG. 1 is a perspective view of a trailer equipped with a self-contained brake and remote control system, according to the present invention.
[0026] [0026]FIGS. 2 and 3 are elevational views of the forward deck of a trailer equipped with a self-contained brake and remote control system, according to the present invention.
[0027] [0027]FIG. 4 is a view of the underside of the forward deck of a trailer equipped with a self-contained brake and remote control system, according to the present invention.
[0028] [0028]FIG. 5 is a perspective view of the rear of a trailer equipped with a self-contained brake and remote control system, according to the present invention.
[0029] Similar reference characters denote corresponding features consistently throughout the attached drawings.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0030] The present invention is a self-contained brake and remote control system. The trailer braking system includes a fifth-wheel trailer hitch, an energy transfer mechanism, a brake actuator, and a power generator all attached to a trailer with brakes. The remote trailer operating system includes a remote control transmitter, a remote control receiver, and a variety of power equipment mounted on the trailer and powered by the power generator.
[0031] The energy transfer mechanism includes a special hitch plate with a slot oriented fore and aft down through which a kingpin protrudes to engage the towing vehicle's fifth-wheel. The kingpin is fixed to a sliding plate immediately above and in contact with the hitch plate. A linkage is attached between the sliding plate and a brake actuator. The brake actuator is supplied with energy from the generator to operate the trailer's brakes. The brake actuator meters energy to the brakes in response to the position of the sliding plate. The trailer's brakes may be pneumatic, electric or hydraulically powered.
[0032] [0032]FIG. 1 is a perspective view of a trailer equipped with a self-contained brake and remote control system, according to the present invention. The trailer 10 resembles a standard trailer in many ways. A high-strength frame 12 runs the whole length of the trailer 10 and supports the load, in this case a water tank. 14 . A heavy-duty axle at the rear of the trailer 10 supports the tremendous weight of the fully loaded trailer and brakes incorporated into the axle. Two or more axles may be used, and flotation tires as well, to deal with a very heavy trailer or to minimize the impact on the ground surface. A stand is attached near the front of the trailer 10 to keep the trailer level when it is not attached to a towing vehicle. The stand can be raised and lowered via a crank mechanism visible just below the frame 12 ahead of the water tank 14 . A forward deck 16 area includes a fifth-wheel hitch 18 (see FIG. 4) as well as standard couplings and controls for pneumatic, electric or hydraulic power (see FIGS. 2 and 3). Other aspects of the trailer 10 are quite unique.
[0033] The trailer frame 12 is incorporated into and through the tank 14 , providing exceptional support to the tank 14 and protection for the frame 12 . The water tank 14 is used to supply water for a multitude of purposes. In this embodiment, virtually all of the plumbing, power conduits and control cables for the trailer 10 is routing through the tank 14 , protecting it from damage. A plurality of water couplings 20 are attached in various places around the tank 14 to permit the user to utilize the trailer 10 in the optimum manner. Each coupling 20 may include a power conduit 22 and a control cable 24 to permit the selective use of the any coupling 20 on the trailer 10 . A number of power accessories may be attached to the couplings 20 , such as a high-pressure water nozzle 26 . The couplings 20 are an industry standard size and will accept any number of common power accessories such as water cannons and other spray heads. The power conduit 22 is routed through the tank 14 to a power generator (see FIG. 5) in an engine bay 28 at the rear of the trailer 10 .
[0034] A fill port 30 is located atop the tank 14 and permits quick and easy filling of the tank 14 from a number of sources, including hydrants, water towers, ground water, ponds and virtually any other water source.
[0035] The trailer 10 is shown coupled to a bulldozer and a towing dolly 32 , but virtually any towing vehicle capable of supporting the weight of the trailer could be used, including rubber-tire loaders, earth movers, semi tractors and many other vehicles. In this embodiment, the bulldozer does not have a fifth wheel, but does have a pintle hitch instead. A towing dolly 32 is used to attach the trailer to the towing vehicle. The towing dolly 32 has a fifth-wheel which couples directly to the fifth-wheel hitch 18 on the trailer 10 . In another embodiment, the towing vehicle has a fifth wheel, such as a semi tractor. The typical dolly has an axle, or tandem axles, with one or more wheels at each end, similar to the axle on the trailer 10 . It has a ring or other compatible mechanism for coupling with the towing vehicle's pintle. Atop the axle is a fifth wheel, similar to that found on the semi tractor. Virtually every piece of heavy equipment found on construction sites has a pintle hitch. In this manner, the trailer 10 may be towed and operated on a job site even if no semi tractor is available. This greatly improves the flexibility of a work crew and, manager of a job site who can choose an available towing vehicle from a large number of available pieces of equipment.
[0036] [0036]FIGS. 2 and 3 are elevational views of the forward deck of a trailer equipped with a self-contained brake and remote control system, according to the present invention. FIGS. 2 and 3 are downward views, looking forward from the top of the tank 14 onto the forward deck 16 . FIG. 2 shows the operating mechanism for the self-contained brake system in the pulling or coasting position. FIG. 3 shows the operating mechanism for the self-contained brake system in the braking position.
[0037] The forward deck 16 is covered with plates, which are hinged to permit access to the self-contained brake system and other compartments. The deck 16 is shown with a pair of gladhands 40 and an electrical connector 42 for optional pneumatic and electric power from a towing vehicle. Also shown is a pneumatic isolator valve 44 that permits the user or operator to choose the source of power to operate the trailer's brakes, i.e., the towing vehicle or the power source on the trailer 10 . In one position, the isolator 44 permits energy from the towing vehicle to operate the trailer's brakes. In another position, the isolator 44 permits energy from the power generator 70 (see FIG. 5) to operate the trailer's brakes. When using braking energy from the towing vehicle, the trailer's brakes function as standard Department of Transportation (DOT) required brakes. When delivery of the trailer to and from the job site is on the road, the trailer must use the DOT-approved brake system. However, the semi tractor is unnecessary at the off-road job site for the duration of the work at the job site.
[0038] The operating system for the self-contained brake system is situated within the frame 12 beneath the forward deck 16 . A sliding plate 46 is the source of braking input to the self-contained brake system. The sliding plate 46 is capable of limited, generally horizontal movement between a forward stop 50 and a rear stop 52 and slides upon a floor plate 64 . The contacting surfaces of the sliding plate 46 and the floor plate 64 may be coated with an anti-friction substance, such as Teflon®. In FIG. 2 the floor plate 64 is visible between the rear stop 52 and the sliding plate 46 . In FIG. 3 the floor plate 64 is visible between the forward stop 50 and the sliding plate 46 . A pair of springs 48 bear against the sliding plate 46 and apply force against sliding plate 46 toward the forward stop 50 . In one embodiment, the springs 48 are coil springs. In other embodiments the springs 48 could be a torsion bar, leaf spring, or an air spring or airbag. Notice in FIG. 3 the springs 48 are compressed. The springs 48 are held in position by a set of keepers 54 . A set of dampers 56 moderates the action of the springs 48 in moving the sliding plate 46 against the forward stop 50 . A linkage 58 connects the sliding plate 46 to a brake actuator 60 . In one embodiment, the brake actuator 60 is supplied with pneumatic energy via an air hose 62 . In another embodiment, the brake actuator 60 is supplied with electric power via a power cable. The particular embodiment used depends upon the type of energy required by the trailer's brakes. In FIG. 3 the linkage 58 is fully extended and the springs 48 are compressed, thus maximum braking energy is conducted through the actuator 60 .
[0039] The self-contained brake system may be disabled with a brake lock mechanism 63 . The brake lock 63 mechanically locks the sliding plate 46 to the frame 12 , thus preventing any movement of the sliding plate 46 and subsequent trailer brake actuation. This is important where the trailer 10 is backing up an incline, and the trailer's own weight would actuate its brakes against the efforts of the towing vehicle. The brake lock 63 is also used where a standard DOT brake system is required.
[0040] [0040]FIG. 4 is a perspective view of the underside of the forward deck of a trailer equipped with a self-contained brake and remote control system, according to the present invention. The under side of the floor plate 64 has an aperture 68 through which the kingpin 66 protrudes. The kingpin 46 is fixed to the bottom of the sliding plate 46 which is visible through the aperture 68 . The aperture 68 is elongated along the longitudinal axis of the trailer 10 . This permits the sliding plate 46 and the kingpin 66 to move forward and aft in response to dissimilar trailer and towing vehicle speeds. The total amount of movement of the kingpin 66 permitted by the aperture 68 matches the amount of available movement of the sliding plate 46 between the forward stop 50 and the rear stop 52 . This arrangement limits the amount of stress experienced by the kingpin 66 .
[0041] Returning to FIGS. 2 and 3, the brake actuator 60 acts as a valve to supply variable amounts of energy to the trailer's brakes depending upon the position of the sliding plate 46 . When the sliding plate 46 is against the forward stop 50 , the actuator 60 supplies no energy to the trailer's brakes. The sliding plate 46 will be in this position when the trailer 10 is being pulled forward by the towing vehicle. When the sliding plate 46 is against the rear stop 52 , the actuator 60 supplies maximum energy to the trailer's brakes. The sliding plate 46 will be in this position when the towing vehicle is decelerating. Braking energy between these two extremes is supplied proportionally when the towing vehicle is braking at a rate which causes the sliding plate 46 to slide only part way between the forward stop 50 and the rear stop 52 .
[0042] In use, the trailer 10 is attached to a towing vehicle. As the towing vehicle accelerates or coasts, the sliding plate 46 is against the forward stop 50 due to the pulling force of the towing vehicle upon the kingpin 66 and the sliding plate 46 , or due to the action of the springs 48 . When the towing vehicle decelerates, the inertia of the trailer 10 causes it to catch up to the towing vehicle and moving the sliding plate 46 and compressing the springs 48 . As the sliding plate 46 moves, the linkage 58 operates the brake actuator 60 to supply braking energy to the trailer's brakes. The dampers 56 prevent excessive braking inputs particularly on uneven ground, where numerous undulations in the ground's surface would cause frequent acceleration and deceleration cycles.
[0043] [0043]FIG. 5 is a perspective view of the rear of a trailer equipped with a self-contained brake and remote control system, according to the present invention. The engine bay 28 houses a power generator 70 . The power generator 70 supplies all of the pneumatic, electric or hydraulic power necessary to operate the trailer's brakes and all other functions. In the preferred embodiment, the power generator 70 is an internal combustion engine, but it could also be a reservoir of compressed air with batteries. The power generator includes an electric generator (not shown) and may also include an air pump 72 or hydraulic pump, depending upon the power requirements of the trailer 10 , including the brakes. In the preferred embodiment, the power generator 70 is attached to an air pump 72 and a water pump 76 . The air pump 72 supplies all of the pneumatic energy required, and the electric generator meets all the electric requirements. Virtually all of the electrical cables and pneumatic lines are routed through the tank 14 and frame 12 for maximum protection and cooling.
[0044] The water pump 76 has multiple uses. It permits the trailer 10 to fill itself with water from virtually any available water supply, including ground water. In addition, it supplies water pressure to the plumbing system of the trailer 10 for water delivery through the water couplings 20 or other water valves 74 . The power generator 70 includes controls for manually starting and operating it, as well as a remote start and control capability through the remote operating system. A hydrant fill pipe 75 permits the tank 12 to be filled from any hydrant. This process does not require pumping due to the pressurized nature of hydrants. If the water supply is not pressurized, such as a ground water supply, then a self-load fill pipe (not shown) can be used. In this embodiment, the self-load fill pipe is located below the hydrant fill pipe 75 . The self-load fill pipe is connected to the water pump on the power generator 70 , and permits the trailer 10 to fill the tank 12 under its own power. A hose bib 77 or other hose coupling is provided for hose attachment.
[0045] The wireless remote operating system includes a remote control transmitter (not shown), a remote control receiver 78 and a power distribution unit 80 connected to the remote control receiver 78 . The remote control transmitter may be kept with the operator in the cab of the towing vehicle. The power distribution unit 80 distributes electrical power to operate various functions of the trailer 10 as commanded by the remote control transmitter through the remote control receiver 78 . The electrical power from the power distribution unit may in turn direct the operation of pneumatic- or hydraulic-powered features of the trailer 10 , depending upon the construction of the trailer 10 . For example, the electric power at the power distribution unit may trigger air valves within a pneumatic power system, or it may trigger hydraulic valves within a hydraulic system. Alternatively, the various functions of the trailer may all be electrically actuated and operated. There is no practical limit to the type and number of functions that could be actuated and operated in this manner.
[0046] Common powered functions include starting, stopping and adjusting the power output of the power generator 70 , pumping water through the plumbing system to fill or empty the tank 14 , and activation of a nozzle 26 or other equipment attached to a water coupling 20 .
[0047] The wireless remote control transmitter provides control for every function of the trailer 10 , including an emergency stop button, a generator start button, and accessory buttons to activate or deactivate the other powered functions of the trailer 10 , and many other functions. Each function of the trailer 10 is operable separately from the others via the remote control transmitter. A battery 88 and a fuel tank (not shown) provide independent trailer 10 operation for extended periods. A control panel may provide a keyed starter 82 and choke control 84 for the power generator 70 as well as a set of gauges may be provided to monitor electric power, such as a voltmeter an ammeter 86 , or other operating parameters.
[0048] In one embodiment, the trailer 10 includes all equipment required by Federal and state law for use on the road. The system permits the trailer 10 to be used by a wide variety of towing vehicles, even those that do not have proper over the road braking systems. A towing vehicle needs only a compatible hitch to properly attach and operate the self-contained trailer system. This trailer system greatly increases the flexibility of a fleet of trucks at an off road site. Numerous variations on this system are possible, including a trailer 10 with a completely conventional hitch frame, but where the towing vehicle's hitch is intended to slide or shift under a braking load to provide braking energy.
[0049] It is to be understood that the present invention is not limited to the sole embodiments described above, but encompasses any and all embodiments within the scope of the following claims. | A self-contained trailer braking system comprises a fifth wheel hitch attached to a trailer frame, where the trailer hitch further comprises a kingpin to engage a fifth wheel of a towing vehicle. A sliding mechanism is attached to the kingpin, where the sliding mechanism is slidingly captured within the trailer frame and can move between a forward position and a rear position. A spring is attached to the sliding mechanism and the trailer frame, where the spring biases the sliding member to the forward position. A brake actuator is mounted to the trailer frame and linked to the sliding mechanism. A brake assembly is attached to the brake actuator, and a power supply is attached to the brake assembly, where power is applied to the brake assembly when the sliding mechanism is away from the forward position. | 1 |
FIELD OF THE INVENTION
This invention relates generally to the mixing of particulate and/or other forms of material, including the mixing of dry particles or granules with one another and with liquids and paste-like plastic masses. More particularly, the invention relates to apparatus for accomplishing such mixing, and in particular to new and novel agitator structures for use in such mixing apparatus, especially mixers such as those used in the baking arts. Notwithstanding this, it should be understood that the apparatus and technology provided in accordance herewith is not limited to the field of baking and on the contrary is useful and advantageous in many other specific applications where generally analogous mixing tasks are required.
BACKGROUND OF THE INVENTION
To a considerable extent, the various requirements which are involved in the mixing operations of commercial bakeries are also encountered in other food-processing and/or commercial and industrial activities, although the difficulties and obstacles present in the baking art often exceed those present in other fields.
For example, in the mixing of different baking doughs the requirement for achieving complete and substantially uniform dispersion of different materials, such as dry particulate matter, throughout the mix is more apt to be merely the beginning requirement rather than the ultimate one. For example, the recipes for different baked products often call for specific sequences of ingredient addition, with continuous mixing being carried out so that the addition of each different component technically produces a different mixture at a different point in time, and each such mixture is a prerequisite for the addition of the next ensuing ingredient. At the same time, baking doughs involve the physical chemistry of hydration, since they typically combine dry ingredients with various different liquid ingredients of widely-varying viscosities (e.g. from water to various oils, etc.), as well as utilizing various pastelike materials such as solid shortenings and the like, all of whose mixing characteristics differ very substantially from one another. Furthermore, baking often involves other requirements such as the need to "cream" ingredient mixtures by uniformly dispersing wet and dry ingredients and then working the resulting mix so as to incorporate air into it, as well as the requirement for "developing" dough, which involves plastic deformation of a hydrated dough mass, frequently including the need for substantial amounts of shearing or kneading of the dough mass by the mixer blades.
Generally speaking, food mixers are predominantly of the "horizontal" type, i.e., having agitators which rotate about a horizontally-disposed axis, although there are also various vertical mixers and special purpose devices. As will be understood, commercial food and/or bakery-product mixers operate on dough masses of the same general type as those encountered in home baking where mixers are usually of the vertical type, but the need for quantity and speed are substantially different in commercial operations, and this substantially exacerbates the degree of difficulty in meeting functional requirements as well as the significance of power consumption and the importance of speed. Thus, a mixer which performs well in the home environment may very well not do so in the commercial environment, but a mixer which performs well in the commercial environment is practically assured of functional acceptability, and probably of functional superiority, in other environments.
In the past, the predominating type of horizontal commercial mixer utilized one or more agitator elements having long, thin mixer blades which were bent into a helically-curving, longitudinally twisted shape. Typically, such prior agitator structures had a pair of such helical blades, each extending longitudinally along approximately half the length of the agitator but disposed on opposite sides thereof and located along different axial portions, i.e., each blade extending generally from an opposite end of the agitator and toward its midsection. In such agitators, a radially-extending cross arm located generally centrally of the structure is used to interconnect and reinforce the two opposite helically-curved mixing blades because the latter must of necessity have thin cross sections and are comparatively weak. Because of this structural weakness, such agitators had to have a rigid center drive shaft disposed along the axis of rotation, which supported and rotatably drove the twisted, helical mixer blade sections during mixing activity.
Agitators of the type just described have become an industry standard over the many, many years in which they have been used, even to the extent of being taken for granted and thus foreclosing objective evaluation of their performance. In fact, while it has to a large extent been presumed that mixers utilizing such agitators provided desirable or even optimum results, the present inventors have determined that such is not always, or even usually, the actual result, and that on the contrary such agitators provide a great many areas of defective performance, depending upon the specifics of the mixing task involved, such as the type of media to be mixed, amount of development required, desired speed of the performance, etc. In addition, it is not unusual to experience torsional failure in such agitators, due to the inherent structural weakness noted above, at which time the helical blades become twisted and bent, in effect destroying the agitator.
In addition, the previously predominating type of agitator structure, as described above, also inevitably involves the very serious disadvantage of having a high degree of manufacturing difficulty, resulting in the near impossibility of precise duplication. That is, in order to obtain the helically-curving shape, the mixing blades of such agitators had to be formed from comparatively thin elongated sections of metallic plate stock, which could be bent into generally helical configuration by complex processes, usually involving hammering and forging, etc. In fact, this type of blade actually involved a double curvature, which incorporates a twisting moment. Such a structure inevitably requires substantial individual shaping steps and considerable custom work, machining, etc. Furthermore, while such a complex shape is producible by casting processes, this involves very substantial expense and, furthermore, also requires considerable finishing machining, in order to obtain the required final dimensions and shaping. Of course, manufacturing of such agitators also involve the requirement for mounting the curving, twisting, helical mixing blades upon the center support shaft, and rigidly securing the same thereto so that they may withstand the demanding structural requirements encountered in actual use.
Due to these extensive fabrication difficulties, agitators of the type described above could never be produced as efficiently and economically as desired, and each such twisted helical blade is not likely to be identical to the next, resulting in substantial difficulty in producing operationally-satisfactory mixers having multiple agitators. Additionally, these fabrication and design problems kept the manufacturers involved from developing an agitator structure which was sufficiently strong to eliminate the center support shaft, even though such shafts present substantial operational disadvantage because they inherently interfere with desirable mixing flow patterns and introduce "dead zones" in the mixer interior. Also, such center shafts tend to promote build-up of the mix media along them, and thus introduce cleaning problems.
THE PRESENT INVENTION
The present invention provides significant and extensive improvements for mixers of the general type described above, by way of a new concept in agitator structures for use in such mixers. In so doing, the invention provides for substantially improved results in mixing performance, as well as providing substantial improvements in manufacturability, thereby yielding commensurate advantages in both such areas. From the standpoint of mixing performance, improvements are provided in mixing speed as well as in the completeness and efficiency of achieving uniform component dispersion within the mix, including the substantial elimination of "dead zones," such as have virtually always been present in prior mixers, where little or no true mixing occurs and lack of homogeneity and uniformity in the resulting mix is therefore characteristically an inseparable adjunct of mixer performance.
From the standpoint of structural design and manufacturability, the novel agitator structure of the present invention may, and preferably does, comprise an assemblage of component parts which are individually manufactured by much more standardized processes from much more standardized stock than has been true heretofore, thereby eliminating both the attendant structural weakness and manufacturing expense which characterized prior agitators of the twisted helix type. At the same time, the novel agitator structure in accordance herewith provides the very desirable attribute of enhanced applications flexibility; i.e., agitators in accordance with the present invention have a high degree of scaleability and may readily be manufactured with various differing dimensions to satisfy particular applications and requirements. This desirable result may be achieved, in essence, simply by changing the dimensions of selected component parts without necessarily changing others, manufacture (assembly) of components into the operative agitator structure proceeding in substantially the same way and by the same procedure in each such instance, without extensive and costly special machining or assembly processes.
The foregoing objectives and advantages of the invention are provided by an agitator structure which is open and "shaftless" along its axis of rotation, and which incorporates straight and flat (i.e., planar) mixing blades rather than twisted or otherwise complexly-curved blades. This structure improves strength and performance as well as enhancing manufacture, since it may be accomplished by use of flat stock (e.g., metal plate) and does not require forging or hammering operations, or any need for complex castings. Furthermore, preferred embodiments of the new and novel agitator structure eliminate and/or change the basic componentry of known agitators, incorporating (for example) elements whose shape and location are different than those which have become the norm in the past. Such new and different structures not only improve mixing performance, as noted above, but also provide the manufacturing and applications advantages and economies which have also been noted.
The foregoing attributes and characteristics of the invention will become more apparent and better understood by reference to the ensuing description of certain preferred embodiments of the underlying concepts, particularly in contemplation of the appended drawings depicting such embodiments.
BRIEF DESCRIPTION OF THE DRAWINGS
In the drawings:
FIG. 1 is an overhead plan view of a first preferred agitator structure embodiment;
FIG. 2 is an end elevational view of the apparatus illustrated in FIG. 1;
FIG. 3 is a cross-sectional elevational view taken along the compound plane III--III of FIG. 1;
FIG. 4 is an overhead plan view of a second preferred embodiment for an agitator structure in accordance herewith;
FIG. 5 is an end elevational view of the agitator structure shown in FIG. 4;
FIG. 6 is a front perspective view of the agitator structure shown in FIGS. 4 and 5; and
FIGS. 7-11 inclusive are a series of overhead perspective views showing a pair of the agitator structures in accordance with FIGS. 1-3 operatively mounted in double-agitator configuration within a mixer body, i.e. "bowl," showing various relative positions of rotation for the two such agitators which occur during normal operation of such a mixer.
DESCRIPTION OF PREFERRED EMBODIMENTS
Referring now in more detail to the drawings, FIGS. 1-3 inclusive illustrate a first embodiment of an agitator structure 10 in accordance with the invention. As there illustrated, it will be seen that the agitator structure 10 embodies an open, shaftless design, having axially-aligned hub portions 12 and 14 at each opposite end, by which the agitator may be rotatively mounted upon appropriate trunnion shafts within a mixer housing. More particularly, each of the hubs 12 and 14 comprises a generally circular support boss 12a which is welded or otherwise secured to the inside face of a crank arm 16, 18, respectively, the resulting assembly being bored, and machined and assembled, to produce a pair of aligned mounting and driving apertures 20 having keyways 21, as illustrated (FIG. 2).
The crank arms, or drive arms, 16 and 18 extend in generally opposite radial directions from the axis of rotation, and each is secured to, and supports, one or the other of a pair of mixing blades 22, 24 respectively, which are preferably disposed generally parallel to one another and oriented at an acute angle "A" (FIG. 1) with respect to the drive axis (which is labeled "B" in FIG. 1). As further illustrated in FIGS. 1 and 2, the inboard portions of mixing blades 22 and 24 located centrally of the agitator 10 are interconnected by a center blade, or connector blade, 26, which extends generally transversely across the rotational axis B and is rigidly secured to each of the two respective mixing blades 22 and 24 to reinforce and support them.
Accordingly, it will be seen that the customary axial support shaft which has for so long been considered an inseparable part of conventional mixer agitators has been entirely eliminated, and a much different structural arrangement provided. Furthermore, it will be noted that the geometry of each of the mixing blades 22 and 24 is not of twisted-helix configuration, or even of helical configuration, but is instead generally planar. Thus, the mixing blades may advantageously be made from flat-sided plate-like stock which is cut into an arcuate overall shape and chamferred, or angled, along the top and bottom sides 22a, 22b and 24a, 24b, respectively. As may be seen in FIG. 3, these chamferred sides are disposed such that they converge toward one another (preferably, with a sharper angle on the top, or outer sides 22a, 24a), thereby giving the mixing blades a polygonal cross section, in particular, a trapezoidal cross section. As illustrated, arcuate or other slots 28 may be cut through the mixing blades to provide additional shearing effects where this is desired, although in many instances such slots will not be necessary.
Those who are skilled in the art and familiar with horizontal-axis mixers as have come to be known heretofore will immediately recognize the structural unconventionality of the mixing blades 22 and 24, both with respect to shape and size. That is, the thickness and massiveness of such mixing blades are striking in comparison to the typical twisted-helix type of mixer blade, as is the use of the flat blade configuration employed in accordance herewith, by which the relative high strength and rigidity are obtained. A further feature of this configuration should also be noted, however; i.e., the sweep angle, or mixing angle, "A" is continuous and uniform along the entire length of each mixing blade 22 and 24, and this feature provides substantially different and more desirable mixing action than that obtainable from known prior agitator structures. That is, the mixing action afforded by agitators in accordance herewith (whether employed in single or double-agitator mixers) is much more uniform and consistent, and may be optimized for a particular type of operation by selection of a particular desired mixing angle (different operations such as dispersion and development optimally requiring different mixing angles); moreover, the selected optimal mixing angle is maintained consistently and continuously along the entire length of each mixing blade. The continuous and consistent mixing action so produced is dramatically different, and superior, to that obtained from prior types of agitator structures, especially those of the twisted helix type, which provide differing mixing angles all along the length of their mixing blades.
It will further be noted that mixing blades 22 and 24 are positioned such that their respective leading edges move in the same rotational direction, but the angularity of the mixing blades is such that the mixing operation which they provide is, in effect, to continuously move a swept stream of the mix from opposite ends (actually, from opposite corners) of the mixer (viewed as an envelope which approximates the surface of revolution defined by agitator rotation) toward the center portion thereof, thus continuously combining and intermixing the particles or other media within the mixing chamber. In this respect, the silhouette presented by the outer periphery of each of the mixing blades 22 and 24 defines a circle, viewed from the end of the agitator Thus, upon rotation, the mixing blades define a uniform, right-circular cylinder of revolution, such that the edges of the blades continuously sweep along and closely adjacent to the inside periphery of the mixer housing over the length of the mixer blades The outer surfaces or faces 22a and 24a taper back somewhat more angularly than the corresponding inner surfaces 22b and 24b (note FIG. 3), to minimize cohesive build-up of the mix media along the outer such surfaces, where the maximum relative movement of the mix media occurs, thus keeping the agitator blades clear and clean, and enhancing thorough and complete mixing of the media.
Further with respect to the mixing pattern and mix media movement provided by the novel agitator structure in accordance herewith, it should be noted that the inboard end extremity of each of the mixing blades 22 and 24 preferably has an extension portion 23, 25, respectively (FIGS. 1 and 2), which protrudes beyond the intersection of the corresponding mixing blade with the center blade, or connector, 26. These extension portions, which as illustrated extend substantially beyond the midpoint of the agitator, provide very desirable additional mixing action in the center area of the agitator. Although not well appreciated heretofore, this center area has in fact long been the site of very imperfect, and incomplete, mixing performance, as is amply demonstrated by the development of observable lines of striation in the mix media (where multi-colored mix components are utilized) extending generally orthogonally to, and around the center area of, the agitator. Of course, such lines show that the media is simply being inadequately mixed in this area, leading to lack of homogeneity and, in many instances, incomplete development of baking dough. The presence of the extension portions 23 and 25, and the substantially enhanced mixing effects provided thereby, together with the results achieved by the center blade 26 (as described hereinafter), substantially eliminate this problem by achieving much more extensive and complete mixing throughout the central area of the agitator.
Due to the relative geometry of the agitators and the mixer housing, which is typically a uniform and continuous right circular cylinder, it is desirable that the outermost faces 23a and 25a (FIG. 1) of the corresponding mixing blade extension portions 23 and 25 be machined to have a cylindrical surface configuration which closely complements that of the inside of the mixer housing. This establishes and maintains the desired clearance between the mixer blade and the inside surface of the mixer housing (which is preferably on the order of about one-eighth inch). This, in turn, establishes and maintains an important parameter of the desired mixing operation, since if this clearance is too wide it will substantially diminish proper mixing action, whereas if it is too narrow it will damage and degrade the mixture in the affected area, even to the extent of causing localized burning of the mix due to friction. Thus, this clearance should be accurately established, and it should also be consistently maintained throughout the length of the blade. This has been a significant failure of prior agitators, but is a significant achievement obtained by the present invention.
In addition to the mixing blade extension portions 23 and 25, discussed above, mixing operation at the center area of the agitator 10 is also affected by the shape and position of the center blade, or connector, 26. That is, the shape and orientation of connector blade 26 (FIGS. 2 and 3) are preferably selected to enhance mixing operation, as well as to structurally support the mixing blades 22 and 24. Thus, while the connector blade 26 may advantageously be comprised simply of a section of bar or plate stock, having a rectangular cross section which is disposed with its longitudinal axis lying generally orthogonally across the axis of agitator rotation, the connector blade 26 is preferably canted laterally somewhat with respect to the longitudinal axis "B" (FIGS. 2 and 3), and also is preferably positioned to intersect the plane of each mixing blade 22 and 24 at an acute angle. Thus, connector blade 26 preferably rotates through the center area of the mixer in an angular disposition, having leading and trailing edges 26a and 26b, respectively, as well as leading and trailing surfaces 28a and 28b, respectively, which shear and impel the mix media as the agitator rotates, helping to move the media outwardly from the center area of the mixer in cooperation with the mixing blades themselves and, in particular, in cooperation with the extension portions 23 and 25 of the mixing blades. At the same time, cohesive build-up of the mix media upon the connector blade 26 is substantially reduced by the angulated structure just described.
As previously indicated, FIGS. 4, 5 and 6 illustrate an alternative preferred embodiment 110 of agitators in accordance with the invention, which also have highly advantageous attributes while at the same time embodying structural variations which further illustrate certain of the underlying concepts of the invention.
With further reference to FIGS. 4, 5 and 6, it will be noted that the agitator 110 shown there includes a pair of spaced end hubs 112 and 114, which are essentially like the hubs 12 and 14 described above in conjunction with the embodiment of FIGS. 1-3, and in the same analogous manner the agitator 110 includes a pair of mutually-spaced mixing blades 122, 124 which are connected by respective crank arms 116 and 118 to the aforementioned end hubs. While these components of the agitator 110 are quite similar to the corresponding structures of agitator 10, it will be noted that the agitator 110 does not have a center or connector blade such as the blade 26 of the first embodiment and, on the contrary, the mixing blades 122, 124 are 20 connected to strut-like support bars 126, 126', respectively, which extend from each respective mixing blade to the opposite end hub. This arrangement, of course, also provides a "shaftless" agitator structure which, as a result of the structural features just noted, is entirely open throughout its middle area. Nonetheless, the mixing action provided by the agitator 110 throughout the center area (as well as other areas) is vigorous and active, with little or no of the "dead zone" effect exhibited by most prior art horizontal agitators.
One reason underlying the highly effective iixing performance of the agitator 110 just noted is the structure embodied in the mixing blades 122, 124 (which are, as already indicated, essentially like blades 22 and 24 of agitator 10); however, the other structural attributes of agitator 110 are also significantly involved in the highly effective mixing performance of this embodiment. For example, the angular disposition of the struts, or connector bars 126, 126', together with the cross-sectional shape and the basic orientation of these bars with respect to the sweep motion of the associated mixer blades, also contributes substantially to the desirable mixing performance of this agitator. Thus, the angular position of rectangular cross section bars 126, 126' with respect to their associated mixing blades 122 and 124 provides a strong stirring, or mixing, action which is of a different nature than that provided by the mixing blades themselves, as well as being different from that provided by the center blade 26 which is present in the agitator 10 of FIGS. 1, 2 and 3. Furthermore, the relative angulation between the connecting bars 126, 126' and their associated mixing blades 122 and 124 provides, in effect, a plow-shaped structure on each opposite side of the agitator 110 which strongly moves the mix material away from the center area. In this regard, it should be noted that the two angularly-shaped such "plows" are preferably not directly aligned with one another across the axis of rotation, i.e., the mixing blades 122 and 124 are preferably longer than the struts or bars 126, 126'.
The novel type of agitator structures in accordance with the concepts of the present invention, as discussed above, are not only advantageous when used singly in an appropriate mixer housing but, in addition, may readily be used conjointly in pairs; in particular, both embodiments of such agitators may be used in pairs, to provide coordinated, interleaved, operation in which the outer surface of revolution defined by each mixing blade element enters into and passes through that of the corresponding mixing blade in the adjacent agitator. Such a combined, paired-agitator mixer is illustrated in FIGS. 7-11 inclusive, in which the two separate agitators of the type shown in FIGS. 1-3 inclusive (designated 10 and 10', respectively) are shown cooperatively mounted within a mixer housing 30.
As illustrated in FIGS. 7-11, the mixer housing 30 basically comprises an open-topped, laterally-enclosed vessel (often called a "bowl" even though not generally spherical, or semi-spherical in shape), defined by oppositely-spaced sidewalls 32 and 34 and end walls 38 and 40. The lower extremities of sidewalls 32 and 34 curve under and partially around the agitators 10, 10' and extend toward one another to form a ridge or peak 36 inside the mixer housing; i.e., the lower extremities of the sidewalls 32 and 34 comprise complementary longitudinal segments of a cylinder whose inner periphery approximates the lower part of the surface of revolution defined by the two agitators. These cylindrically-configured sidewalls are closed at each opposite end by flat end walls 38 and 40, to form an enclosing vessel around the sides and bottom of the agitators.
Within the mixer housing 30, the two agitators 10, 10' are disposed in side-by-side relation, with their corresponding hubs 12 and 14 mounted upon drive shafts or pivot axles extending through the end walls 38 and 40. As will be understood, the two such agitators may be rotatably driven by such axle members, either from one or both ends as the occasion may demand. Agitator structures in accordance with the present invention will typically have ample structural strength and rigidity to permit application of drive force from only one end, and a typical form of drive may utilize a drive gear (not specifically shown) which is secured to a drive shaft (not specifically shown) that extends from the hub portion of each of the two agitators outward through the adjacent end wall 38, either or both such drive gears being suitably engaged with another such gear (not specifically shown) for transmittal of the required drive forces. As will be appreciated, mutual engagement of such drive gears will establish and maintain the desired coordinated positioning of the two agitators relative one another as they are rotatably driven, although of course other types of engagement or drive structure may also be utilized to the same effect.
The various positions of coordinated rotation of the two agitators 10, 10' may be understood by considering FIG. 7 to represent the end of one complete revolution, and by considering FIGS. 8-11 as representing the sequential positions leading to that of FIG. 7. More particularly, in FIG. 8 it will be noted that the agitators 10, 10' are in essence reversed from the relative positions shown in FIG. 7; that is, in FIG. 8 mixing blades 24, 24', located at the right-hand side of the mixer, are disposed closely adjacent and generally parallel to one another, whereas the other two such mixing blades 24, 24' are spaced widely apart. In this relative position of the two agitator structures, the center blades 26, 26' thereof are disposed generally crosswise of one another, in a somewhat T-shaped arrangement.
As the two adjacent agitators 10, 10' rotate during normal operation of the mixer, they progress from the positional relationship shown in FIG. 8 through that of the succeeding FIGS. 9-11 inclusive, and from the position of FIG. 11 to that of FIG. 7. During this movement, the leading edges 21, 21' of mixing blades 24, 24' initially move downward toward the upraised central edge 36 extending along the bottom of the mixer housing, and away from one another, while the leading edges 27, 27' of mixing blades 24, 24' initially move upwardly within the housing and rotate toward one another. During this relative rotation, the inward end portions of mixer blades 22, 22' sweep across and approach reasonably closely to the oppositely-disposed center blades 26, 26' of the adjacent agitator, and as the agitators continue rotational movement from the positions generally shown in FIG. 7 back to those generally shown in FIG. 8, the inward end portions of mixing blades 24, 24' carry out an analogous sweeping movement with respect to the opposite side of the respective center blade 26, 26' of the adjacent agitator.
During the agitator motion just described, the inboard extension end portions 23 and 25 (and 23', 25') of each mixing blade sweep through that portion of the interior of the mixer housing, or bowl, which is located generally opposite the main (outboard) part of the other mixing blade of both agitators, in a counter-mixing motion. Also, the canted center blades 26, 26' are at the same time sweeping through and stirring the center area of the mixer, and the end result is a strong and vigorous composite mixing action in the center part of the housing. Additionally, it should be understood that during rotational movement of the two agitator structures 10, 10', the crank arms 16 and 18, and 16', 18', also perform a sweeping and mixing function in the area closely adjacent each of the end walls 38 and 40, and it should be further understood that in accordance with further aspects of the invention the leading edges and side surfaces of the crank arms may be angled and configured in a manner somewhat analogous to the center blades 26, 26', in order to bring about a specific mixing and media movement where that is desired.
It is to be understood that the above detailed description is merely that of certain exemplary preferred embodiments of the invention, and that numerous changes, alterations and variations may be made without departing from the underlying concepts and broader aspects of the invention. In particular, it should be understood that the component parts from which agitators in accordance with the invention are assembled are in the nature of standardized-type parts, and that any or all of these parts may be varied in size and shape from one specific agitator to another, to make the particular resulting agitator useful in a particular mixer arrangement or environment, even including those of the type known as "Steffan" mixers, and those known as "vertical mixers," which customarily utilize a somewhat spherically dished, bowl-like, mixer housing. Of course, as already stated hereinabove, the agitators themselves may be used either singly or in paired groupings, such as is illustrated, and the concept underlying the agitator will produce superior and desirable results in either such instance. Accordingly, the scope of the invention is to be understood as the same as set forth in the appended claims, which should be interpreted in accordance with the established principles of patent law, including the doctrine of equivalents. | An improved agitator structure for use in mixers for baking dough and other such food products and the like providing for improved mixing performance and speed, and useable in single-agitator or multiple-agitator embodiments, comprises an open, "shaftless" structure which incorporates straight and flat (i.e. planar) mixing blades as opposed to twisted or other complexly-curved blades, and incorporates a pair of mutually-spaced hubs aligned with one another along an axis of rotation, a pair of mutually-spaced mixer blades located generally on opposite sides of the rotational axis and extending generally longitudinally thereof along a different portion of such axis, with each such mixer blade disposed at a longitudinal angle with respect to such axis and each being connected to at least one of the hubs for rotation therewith about said axis. Each of the mixer blades comprises a generally planar member having a curved outer edge which lies substantially within the plane of its associated mixer blade, with the curved outer edge of the mixer blades defining a cylindrical service of revolution upon rotation of the blades about said axis. | 1 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a method of manufacturing a stamped part having extrusions, and an apparatus for manufacturing the part.
2. Background Art
The use of drawn structural extrusions as a means to reduce the cost of a finished part, particularly a stamped part, is well known. Typically these parts do not have the thickness of material required for the forming of threads, which would allow the part to be bolted directly into place. Attempts to solve this problem include the use of a separate fastener such as a threaded nut, or attaching additional material to the part in the area to be threaded—e.g., using a weld nut. A better alternative is to extrude and thread the part itself, thereby eliminating the cost of the additional components, and the cost of attaching the components.
Despite the overall cost benefit associated with extruding a stamped part, the extruding process itself remains a specialty. A great deal of expertise and experience is required to ensure that the extrusion that is formed is capable of being threaded and is strong enough to meet the customer's structural requirements. In addition, extruding a stamped component can significantly increase the processing cost. Two separate die assemblies are required: an extrusion die, which forms the extrusions, and a component die, which is used to form the workpiece into the finished part. Typically the extrusion die and the component die are part of the same die assembly. This significantly increases the size of the die assembly, which not only increases the cost of handling the die assembly within the processing facility, but also creates logistical problems and increases costs when the die assembly is transported to or from the customer's facility. This further limits the number of processing facilities that can perform this type of extrusion work. Not only must the processor have the requisite level of skill, but facilities and equipment capable of handling extremely large die assemblies must also be available.
One method used to overcome some of the problems associated with handling these larger die assemblies is to “split” the die between the extrusion and component portions. This has the advantage of making the die assembly easier to handle and less costly to transport; however, this method has inherent limitations of its own. Specifically, this type of “die splitting” increases the engineering costs associated with the design of the die assembly. Splitting the die makes it necessary to design two portions that can be separately attached to a press, and are capable of being properly aligned with one another once they are installed on the press. Additional costs are then incurred each time the die assembly is attached to the press, since the alignment of the extrusion portion and the component portion is critical. Therefore, neither of the two methods—using a single, extremely heavy but complete die assembly, or splitting the die and dealing with critical alignment issues—eliminates the problems inherent in the extrusion process.
Accordingly, it is desirable to provide a method of extruding a stamped part which overcomes the above referenced shortcomings of prior art methods, by reducing the cost of the extrusion process and at the same time eliminating the need to maneuver and transport extremely heavy die assemblies.
SUMMARY OF THE INVENTION
The present invention provides a method of manufacturing a stamped part with extrusions, such that the net costs to both the processor and the customer are reduced, and at the same time the ability to maneuver and transport the die assemblies is greatly increased. The present invention also provides for a method of doing business which utilizes the manufacturing method such that sales are increased and costs are lowered. Further provided in the present invention is an apparatus to be used in the manufacturing method.
Specifically, the manufacturing method dedicates a stamping press with a moveable ram and a stationary bolster plate to a particular set of finished parts. Each part in the set has extrusions that are similarly configured. Permanently attached to the ram and bolster plate of the press are upper and lower shoes that are configured to cooperate with replaceable die subassemblies.
The upper and lower shoes are weldments that are assembled prior to being permanently mounted on the stamping press. Each shoe comprises a plurality of nitrogen cylinders mounted between two sub-plates that are welded to a plurality of vertical support members. Once the shoes are assembled, the upper shoe is attached to the movable ram on the press, and the lower shoe is attached to the stationary bolster plate opposite the upper shoe.
An extrusion die sub-assembly is then assembled and configured for use with more than one type of finished part. Use of the extrusion die sub-assembly will result in some of its components, known as perishables, becoming worn and requiring replacement. However, the extrusion die sub-assembly itself is only replaced when the finished part changes significantly, such as when a finished part from a new product line is ordered. In a preferred embodiment, the extrusion die sub-assembly is assembled from components which are, to the extent possible, standard in both size and shape. This significantly reduces the cost of the extrusion die sub-assembly, by allowing the components to be purchased and/or manufactured in bulk quantities.
The method further requires the assembly of a component die subassembly designed to meet the customer's finished part specifications. The extrusion die sub-assembly is mounted to the upper and lower shoes, and the component die sub-assembly is directly mounted to the ram and bolster plate of the press. The two die sub-assemblies are then mounted in such a way they can be easily removed. Typically, the extrusion die sub-assembly is removed to replace its perishable components, and the component die-subassembly is completely replaced when a new finished part is ordered. A workpiece is fed into the stamping press where it is first extruded into a preform, and then formed into the finished part. The actual processing of the workpiece resembles a standard progressive die stamping process.
The business method utilizes the manufacturing method of the present invention to benefit both the manufacturer and the customer. A standard stamping operation does not utilize upper and lower shoes permanently attached to the press. Rather, only portions of the shoes are used in a standard operation, and these are part of the tooling costs paid for by the customer. Typical tooling costs include the cost of the extrusion die set and the component die set. Each time the customer orders a different finished part, new tooling is purchased. Hence, the cost of at least a portion of the shoes is a reoccurring cost for the customer-one that is often significant. In contrast to a standard operation, the present business method designates the shoes as capital equipment. This means that the stamping facility now bears this cost, but amortizes it over a long period of time. The net cost to the stamping facility is negligible compared to the increase in business resulting from significantly lowering customer tooling costs. As an alternative, the capitalized cost of the shoes can be added into the price charged for a finished part. This additional cost to the customer is minimal, since the same shoes are used for many different finished parts. Moreover, the same shoes can be used for parts made for different customers, further reducing the cost to an individual customer. Either method results in a net cost savings to the customer.
The business method also includes standardizing extrusion configurations in such a way that the needs of most customers are met by using one of the standard configurations. Further, performance and dimensional data for the standard configurations are published and made available to the customers. This allows the customers to have before them all the information they need to make an informed decision regarding the extrusions they choose for their parts. In addition, this allows the stamping facility to assemble standard extrusion die sub-assemblies from standard parts inventoried in bulk. This results in a net savings to both the customer and the stamping facility. Hence, capitalizing the upper and lower shoes, standardizing the extrusion configurations, and following the steps of the manufacturing method, results in a business method which benefits both the manufacturer and the customer.
Accordingly, one aspect of the present invention provides an improved method of manufacturing a customer's finished part such that costs to both the manufacturer and the customer are reduced.
One aspect of the invention is a method of manufacturing a finished part to a customer's specifications using a stamping press having upper and lower shoes. The method comprises attaching the upper shoe to a moveable ram of the press, and attaching the lower shoe to a stationary bolster plate of the press, the shoes being configured to cooperate with replaceable die sub-assemblies. An extrusion die sub-assembly is assembled and configured to extrude a workpiece into a preform for the finished part. This die sub-assembly is then replaceably attached to the upper and lower shoes. A component die sub-assembly is assembled based on the customer's finished part specifications. The component die sub-assembly is then replaceably attached to the ram and bolster plate of the press. Finally, a workpiece is fed into the stamping press where it is progressively formed: first by extruding it into a preform with the extrusion die sub-assembly, then by forming it into the finished part with the component die sub-assembly.
Another aspect of the invention is a method of doing business in a stamping facility whereby net costs are lowered for the stamping facility and its customers. The business method comprises capitalizing an upper shoe attached to a moveable ram of a press, and capable of cooperating with replaceable die subassemblies. Further, a lower shoe attached to a stationary bolster plate opposite the movable ram on press is also capitalized. Capitalizing the shoes removes their cost from the customer tooling by having the stamping facility bear the initial cost. Capitalizing the shoes also includes amortizing their cost over time, such that the cost is spread over many different finished parts. The business method further comprises standardizing extrusion configurations and inventorying a variety of different die components adapted to make the standard configurations. An extrusion die sub-assembly is assembled using at least some of the inventoried components; it is then replaceably attached to the upper and lower shoes. A component die subassembly is assembled based on the customer's finished part specifications; it is then replaceably attached to the ram and bolster plate of the press. Finally, the customer's finished part is manufactured by feeding a workpiece into the stamping press where it is first extruded into a preform by the extrusion die sub-assembly, and then formed into the finished part by the component die sub-assembly.
It is another aspect of the present invention to provide a modular progressive stamping die assembly which comprises a stamping press having a moveable ram for imparting a stamping force to a workpiece, and a stationary bolster plate located opposite the moveable ram. An upper shoe is attached to the ram and a lower shoe is attached to the bolster plate. Both shoes are capable of cooperating with replaceable die sub-assemblies. An extrusion die sub-assembly, replaceably attached to the upper and lower shoes, is configured to extrude the workpiece into a preform for a finished part. A component die sub-assembly, replaceably attached to the ram and bolster plate of the press in a position to receive the preform from the extrusion die sub-assembly, is configured to form the preform into at least a near net shape.
The above object and other objects, features, and advantages of the present invention are readily apparent from the following detailed description of the best modes for carrying out the invention when taken in connection with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a front view of stamping press with upper and lower shoes attached;
FIG. 2 shows a front view of the stamping press with an extrusion die sub-assembly and a component die sub-assembly attached to the press;
FIG. 3 shows a perspective view of an upper portion of the extrusion die sub-assembly;
FIG. 4 shows a perspective view of a lower portion of the extrusion die sub-assembly;
FIG. 5 shows a perspective view of the component die subassembly;
FIG. 6 shows a perspective view of the workpiece progressively extruded and formed to make successive pairs of finished parts; and
FIG. 7 shows a perspective view of a finished part after the extrusion and forming is complete.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 shows a front view of a stamping press 10 having a moveable ram 12 and stationary bolster plate 14 . Attached to the ram 12 of the press 10 is an upper shoe 16 . The upper shoe 16 includes sub-plates 18 and 20 that are welded to a plurality of vertical support members 22 . Also included in the upper shoe 16 is a plurality of nitrogen cylinders 24 . The nitrogen cylinders 24 act as springs to strip a workpiece from extrusion tooling shown in detail in FIG. 3 . Attached to the bolster plate 14 is a lower shoe 26 which includes sub-plates 28 and 30 welded to vertical support members 32 . The lower shoe 26 also includes a plurality of nitrogen cylinders 34 and a plurality of locating pins 36 that are used to accurately mount replaceable die sub-assemblies. The nitrogen cylinders 34 also aid in the removal of the workpiece from extrusion tooling shown in detail in FIG. 4 .
FIG. 2 shows a front view of the stamping press 10 with the extrusion die sub-assembly 38 mounted between the upper and lower shoes 16 , 26 , and a component die sub-assembly 40 mounted between the ram 12 and the bolster plate 14 . The extrusion die sub-assembly 38 includes perishable tooling 42 which is shown in greater detail in FIGS. 3 and 4. Also shown in FIG. 2 is the workpiece 44 feeding into the component die sub-assembly 40 from the extrusion die sub-assembly 38 . An alignment bar 46 provides a link between the extrusion die sub-assembly 38 and the component die sub-assembly 40 . The alignment bar 46 ensures that the two die sub-assemblies 38 , 40 are properly aligned when they are mounted on the stamping press 10 .
FIG. 3 shows the upper portion 48 of the extrusion die subassembly 38 . In this view the upper portion 48 is shown detached from the upper shoe 16 . Typically the upper portion 48 is bolted to the upper shoe 16 at bolt locations 50 . The upper portion 48 includes a plurality of punch retainers 52 which retain progressively sized punches 54 . Bushings 56 acts as guides for the nitrogen cylinders 24 in the upper shoe 16 . During the extrusion process the workpiece 44 may adhere to the punches 54 such that a stripping operation is required. The nitrogen cylinders 24 actuate a series of stripper pins 55 , shown in FIG. 2, which are used to help remove the workpiece 44 from the punches 54 . A stripper plate 57 , also shown in FIG. 2, is attached to the stripper pins 55 and contacts the workpiece 44 with a downward force provided by the nitrogen cylinders 24 such that the workpiece 44 is cleanly removed from the punches 54 .
The upper portion 48 of the extrusion die sub-assembly 38 includes additional tooling 58 that is located near the far end of the extrusion die subassembly 38 . The additional tooling 58 may or may not be utilized depending on the extrusion configuration of the particular part being manufactured. If the additional tooling 58 is needed, it is easily modified to accommodate a variety of different finished part configurations. Each of the four corners of the upper portion 48 includes a guide pin 60 . The guide pins 60 cooperate with guide bushings 62 which are located at the four corners of the lower portion 64 of the extrusion die sub-assembly 38 shown in FIG. 4 . The lower portion 64 is the counterpart to the upper portion 48 and together they form the extrusions in the workpiece 44 . The lower portion 64 is attached to the lower shoe 26 with bolts (not shown) at bolt locations 66 . The workpiece 44 moves through the extrusion die sub-assembly 38 along guide rails 68 . The guide rails 68 are vertically spring loaded such that they accommodate some up and down movement; however, they are rigidly affixed horizontally, to insure that the workpiece 44 remains properly aligned as it progresses through the extrusion die sub-assembly 38 .
The extrusion process is accomplished when the ram 12 of the press 10 moves the upper portion 48 down onto the workpiece 44 such that the punches 54 force some of the workpiece material into draw bushings 70 located on the lower portion 64 . The draw bushings 70 are progressively sized along the length of the lower portion 64 , such that they compliment the punches 54 located in the upper portion 48 . Additional tooling 72 is also provided in the lower portion 64 to compliment the additional tooling 58 located in the upper portion 48 . Use of the additional tooling 72 is dependent on the configuration of the finished part being manufactured, and the additional tooling 72 is easily modified to accommodate a variety of finished part configurations. As the extrusions are progressively stamped into the workpiece 44 , the workpiece material has a tendency to remain inside the draw bushings 70 , especially near the end of the extrusion process. That is why the nitrogen cylinders 34 are located in the lower shoe near the last of the draw bushings 70 . The nitrogen cylinders 34 force pins 74 , shown in FIG. 2, back up through the draw bushings 70 to eject the workpiece 44 .
Once the workpiece 44 has left the extrusion die sub-assembly 38 it is a preform ready to be received by the component die sub-assembly 40 . Shown in detail in FIG. 5, the component die sub-assembly 40 includes vertical support portions 76 and 76 ′. The vertical support portions 76 ′ include bolt locations 78 for mounting the component die sub-assembly 40 to the ram 12 and the bolster plate 14 of the press 10 . Like the extrusion die sub-assembly 38 , the component die subassembly 40 has guide pins 80 and guide bushings 82 to assist in the cooperation between the upper portion 84 and the lower portion 86 of the component die subassembly 40 . The alignment bar 46 is welded to one of the vertical support portions 76 ′ on the lower portion 86 of the component die sub-assembly 40 . The alignment bar 46 cooperates with locating pins 36 to insure that the two die sub-assemblies are properly aligned when they are mounted on the press 10 .
The elements of the component die sub-assembly 40 that form the workpiece 44 into the finished part 90 , shown in FIG. 7, are representative of a typical component die sub-assembly. However, it should be noted that these elements will change for any given finished part. Returning to FIG. 5, the workpiece 44 goes through three stages as it is progressively formed in the component die sub-assembly 40 . In the first stage, piercing and trimming tooling 85 punctures and removes material from the workpiece 44 so that it is properly formed by forming tools 86 in the second stage of the process. Finally, the workpiece 44 reaches cut-off tooling 88 where the finished part is severed from the remainder of the workpiece 44 .
FIG. 6 shows the workpiece 44 progressively extruded and formed to make successive pairs of finished parts 90 . For clarity, the workpiece 44 is shown on its side, though in the process described above, the extrusions are formed downward as the punches 54 force material into the draw bushings 70 . The workpiece 44 , shown in FIG. 6, has three distinct areas. The first is the extruding area, showing the extrusions as they are progressively formed. The second area is a relatively short length where the workpiece is between the extrusion die subassembly 38 and the component die sub-assembly 40 . Last is the forming area, which shows the workpiece 44 as it is cut and formed into the finished part 90 . FIG. 7 shows the finished part 90 after the extrusion and forming is complete. The component die sub-assembly 40 forms the finished part 90 and cuts it to its final size. Hence, the only remaining operation is the threading of the extrusions 92 which allows the finished part 90 to be bolted into its assembled position without the use of external fasteners.
While embodiments of the invention have been illustrated and described, it is not intended that these embodiments illustrate and describe all possible forms of the invention. Rather, the words used in the specification are words of description rather than limitation, and it is understood that various changes may be made without departing from the spirit and scope of the invention. | A method of manufacturing a stamped, extruded finished part includes permanently attaching upper and lower shoes to a moveable ram and a stationary bolster plate of a dedicated stamping press. A replaceable extrusion die sub-assembly is mounted between the upper and lower shoes for extruding a workpiece into a preform. A component die sub-assembly is replaceably attached to the ram and bolster plate of the press for processing the preform into the finished part. The workpiece is progressively extruded then stamped into the finished part. Only the component die sub-assembly and the perishable components of the extrusion die sub-assembly are replaced when a different finished part is ordered. | 1 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] The present application claims the priority benefit of U.S. Provisional Patent Application Ser. No. 62/104,998, filed Jan. 19, 2015, entitled ATTENUATED VACCINES TO PROTECT AGAINST TICK-BORNE EHRLICHIA SPECIES INFECTIONS
FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0002] This invention was made with government support under PHS grant # A1070908 from the National Institute of Allergy and Infectious Diseases. The United States government has certain rights in the invention.
SEQUENCE LISTING
[0003] The following application contains a sequence listing in computer readable format (CRF), submitted as a text file in ASCII format entitled “47025-PCTSequenceListing,” created on Jan. 19, 2016, as 1,526 KB. The content of the CRF is hereby incorporated by reference.
BACKGROUND OF THE INVENTION
Field of the Invention
[0004] The present invention relates to vaccines against Ehrlichia and Anaplasma species infections in vertebrate animals and people and the development of a new class of drugs.
Description of Related Art
[0005] Ehrlichia chaffeensis is an obligate intracellular gram-negative species of rickettsial bacteria. E. chaffeensis is an Amblyomma americanum tick-transmitted rickettsial pathogen causing persistent infections in people and several other vertebrate animals. The disease caused by E. chaffeensis in people is referred as the human monocytic ehrlichiosis (HME). People with HME may exhibit flu like symptoms. HME in people can cause a life-threatening febrile illness and is associated with significant morbidity, especially in people with compromised immunity. About 40-60% of cases of HME require hospitalization, and fatality rates are estimated to be around 3%. White-tailed deer is the reservoir host for the pathogen, while humans, dogs and other vertebrate hosts, such as coyotes and goats, are regarded as the incidental hosts, similar to humans.
[0006] E. chaffeensis infections are a major concern for people with compromised immunity, as they develop a more severe disease which also results in a higher case-fatality rate. Further, because E. chaffeensis infects monocytes and macrophages and the pathogen is viable in refrigerated blood, people undergoing blood transfusions and organ transplantations are also at high risk in acquiring the pathogen and can develop a severe life threatening HME disease. The limited therapeutic option of only a single class of antibiotics and the non-availability of vaccines to prevent the infection are the added challenges for both humans and companion animals. The vaccine development is complicated due to limited understanding of the influence of the host on the pathogen phenotype and immunogenicity, and the limited knowledge about the pathogen antigens involved in stimulating protective immunity. Deer, dog and A. americanum tick infection studies are ideal for mapping genes essential to E. chaffeensis growth and persistence in vertebrate and tick hosts as they are recognized as the reservoir, an incidental host and the tick vector, respectively. In particular, the dog is an ideal incidental host model similar to humans in acquiring infections with E. chaffeensis from an infected A. americanum tick. E. chaffeensis infections in deer and dog are very similar in exhibiting clinical symptoms, rickettsemia levels and in their antibody responses.
[0007] To date, there are no reports in the literature which describe the vaccine development against E. chaffeensis infections in humans and dogs. Currently, treatment with the only available antibiotic class and the supporting care are the only options of controlling the disease in people or dogs.
SUMMARY OF THE INVENTION
[0008] The present invention relates to the development of a new class of drugs derived from targeting gene regions in Ehrlichia species. The invention broadly includes the methodology for generating attenuated mutant strains of organisms. The utility of these attenuated organisms comes from their application as a new class of vaccines to protect people and other vertebrate animals against infection. Herein, we disclose the methodology involved in developing these mutant organisms, how these modifications result in attenuated strains, a description of the pathogen-specific antibody and CD4 + T cell responses they elicit, and the resultant protective immunity against secondary challenges.
[0009] Described herein are immunogenic compositions useful to elicit an immune response against Ehrlichia infection (e.g., tick-transmitted E. chaffeensis infection or other rickettsial infections) in a subject. The compositions generally comprise live, attenuated E. chaffeensis dispersed in a pharmaceutically-acceptable carrier. The live, attenuated E. chaffeensis comprises a mutation in one or more target genes that results in attenuated growth of the bacterium in a vertebrate host organism.
[0010] Methods of inducing an immune response against Ehrlichia infection in a subject are also described herein. The methods generally comprise administering an immunogenic composition according to any one of embodiments described herein to the subject, for protection and/or treatment against tick-transmitted E. chaffeensis infection or other rickettsial infections.
[0011] Also described herein are kits for inducing an immune response against Ehrlichia infection in a subject. The kits generally comprise an immunogenic composition according to any one of embodiments described herein, instructions for administering the immunogenic composition to the subject.
[0012] Use of an immunogenic composition according to any one of embodiments described herein for inducing an immune response against Ehrlichia infection in a subject is also described herein.
BRIEF DESCRIPTION OF THE DRAWING FIGURES
[0013] The patent or application file contains at least one drawing executed in color. Copies of this patent or patent application publication with color drawing(s) will be provided by the Office upon request and payment of the necessary fee.
[0014] FIG. 1 is (A) an illustration of the insertions and (B) verification of clonal purity amongst five mutant strains by Southern blot;
[0015] FIG. 2A is an illustration for the insertion and transcriptional analysis of genes neighboring transposon insertion sites by semi-quantitative RT-PCR;
[0016] FIG. 2B is an illustration for the insertion and transcriptional analysis of genes neighboring transposon insertion sites by semi-quantitative RT-PCR;
[0017] FIG. 2C is an illustration for the insertion and transcriptional analysis of genes neighboring transposon insertion sites by semi-quantitative RT-PCR;
[0018] FIG. 2D is an illustration for the insertion and transcriptional analysis of genes neighboring transposon insertion sites by semi-quantitative RT-PCR;
[0019] FIG. 2E is an illustration for the insertion and transcriptional analysis of genes neighboring transposon insertion sites by semi-quantitative RT-PCR;
[0020] FIG. 3A shows representative Cell Trace Violet dilution profiles, gated on total live cells and total CD3 + CD4 + T cells;
[0021] FIG. 3B shows the percentage of CD4 + T cells that have proliferated in response to E. chaffeensis antigens as measured over the course of the experiment. Each line is representative of a single animal;
[0022] FIG. 4A shows representative flow plots of mock and antigen-stimulated CD4 + T cells gated on IFNγ + cells from animals in groups 1, 2 and 3, gated on total live cells and total CD3 + CD4 + T cells;
[0023] FIG. 4B shows the percentage of IFNγ + cells of total CD4 + T cells in the blood;
[0024] FIG. 5A shows data from CD8 + T cells were analyzed by flow cytometry for proliferation as measured by Cell Trace Violet dilution at day 5 of culture;
[0025] FIG. 5B shows data from intracellular production of IFNγ at day 5;
[0026] FIG. 6 is data from cell culture supernatants collected and analyzed by Enzyme-linked immunosorbent assay (ELISA) measuring PBMC production of (A) IFNγ and (B) IL-17 following vaccination, challenge, and +/− stimulation with host-cell free E. chaffeensis lysate;
[0027] FIG. 7A shows data from an ELISA measuring Pathogen-specific total IgG response in deer infection following vaccination, challenge, and +/− stimulation with host-cell free E. chaffeensis lysate for wild type E. chaffeensis or mutant Ech_0284;
[0028] FIG. 7B shows data from an ELISA measuring Pathogen-specific total IgG response in deer infection following vaccination, challenge, and +/− stimulation with host-cell free E. chaffeensis lysate for mutant Ech_0379 or Ech_0660;
[0029] FIG. 7C shows data from an ELISA measuring Pathogen-specific total IgG response in deer infection following vaccination, challenge, and +/− stimulation with host-cell free E. chaffeensis lysate for the control, and a graph including comparison of the IgG responses;
[0030] FIG. 8A is data from an ELISA measuring Pathogen-specific total IgG response in deer following vaccination and subsequent challenge for Ech_0379;
[0031] FIG. 8B is data from an ELISA measuring Pathogen-specific total IgG response in deer following vaccination and subsequent challenge for Ech_0660;
[0032] FIG. 9A is data from an ELISA measuring Pathogen-specific total IgG response in dogs following vaccination and subsequent challenge for Ech_0379;
[0033] FIG. 9B is data from an ELISA measuring Pathogen-specific total IgG response in dogs following vaccination and subsequent challenge for Ech_0660;
[0034] FIG. 10A is data from an ELISA measuring Pathogen-specific total IgG response in deer following vaccination and subsequent challenge delivered by injection vs tick for Ech_0660;
[0035] FIG. 10B is data from an ELISA measuring Pathogen-specific total IgG response in deer following vaccination and subsequent challenge delivered by injection vs tick for Ech_0480;
[0036] FIG. 11A is an illustration of genomic locations for transposon mutation in E. chaffeensis; and
[0037] FIG. 11B is an illustration of genomic locations for transposon mutation in E. chaffeensis.
DETAILED DESCRIPTION
[0038] In more detail, the invention is concerned with attenuated Ehrlichia strains. In one or more embodiments, the invention is concerned with attenuated E. chaffeensis . In particular, the invention is concerned with live attenuated mutant E. chaffeensis strains, and corresponding immunogenic compositions for eliciting immune responses against Ehrlichia infection, and particularly tick-transmitted E. chaffeensis infection. In one or more embodiments, the live attenuated mutants are E. chaffeensis str. Arkansas (Genbank CP000236.1, incorporated by reference herein, SEQ ID NO:1). In one or more embodiments, the attenuated mutant strain of E. chaffeensis comprises a mutation in one or more genes that results in attenuated growth of the bacterium in a vertebrate host organism. In one or more embodiments, the mutation is an insertion in gene protein coding region of a target gene itself or in sequences responsible for, or involved in, controlling gene expression. In another aspect, the mutation results in an insertion in the gene, wherein the insertion causes altered expression of a gene product encoded by the genes near the insertion causing an inactive gene product encoded by the mutated gene. In one or more embodiments, the attenuated mutant strain of E. chaffeensis comprises an insertion mutation in one or more genes that results in attenuated growth of the bacterium in the host organism. In one or more embodiments, the mutation is stably incorporated into the mutant strain's genome. In one or more embodiments, the insertion mutation is transposon-based, random mutagenesis generating a stable insertion mutation in one or more E. chaffeensis genes. In one or more embodiments, the mutation causes transcriptional inactivation of a bacterial membrane protein gene in the mutated strain.
[0039] In one or more embodiments, the gene is selected from the group consisting of Ech_0660 (SEQ ID NO:2), Ech_0379 (SEQ ID NO:4), and Ech_0230 (SEQ ID NO:6). In one or more embodiments, the attenuated mutant strain of E. chaffeensis comprises a mutation in the phage-like structure connector protein encoding gene, Ech_0660 (SEQ ID NO:2). In one or more embodiments, the attenuated mutant strain of E. chaffeensis comprises an insertion mutation in the phage-like protein encoding gene, Ech_0660 (SEQ ID NO:2), and more preferably a transposon (random) insertion mutation in Ech_0660 (SEQ ID NO:2). In one or more embodiments, the attenuated mutant strain of E. chaffeensis comprises an insertion mutation in the putative Na+/H+ antiporter protein encoding gene, Ech_379 (SEQ ID NO:4), and more preferably a transposon (random) insertion mutation in Ech_0379 (SEQ ID NO:4). In one or more embodiments, the attenuated mutant strain of E. chaffeensis comprises an insertion mutation in the putative membrane protein encoding gene, Ech_0230 (SEQ ID NO:6), and more preferably a transposon (random) insertion mutation in Ech_0230 (SEQ ID NO:6). In one or more embodiments, the mutation results in inhibition and/or inactivation of transcription and/or translation of a gene product (protein) selected from the group consisting of SEQ ID NO:3 (Genbank ABD45123.1), SEQ ID NO:5 (Genbank ABD44646), and SEQ ID NO:7 (Genbank ABD45256.1).
[0040] In one or more embodiments, the insertion sequence comprises at least one heterologous sequence, and preferably at least one reporter stably incorporated therein. In one or more embodiments, the heterologous sequence comprises an in vivo inducible promoter, and preferably a promoter related to a heterologous transcription regulator gene, such as from a different Ehrlichia strain or species or Anaplasma species. In one or more embodiments, the heterologous sequence is a promoter from Anaplasma marginate transcription regulator gene. In one or more embodiments, the heterologous sequence is fused to at least one reporter gene, such as a fluorescence gene, antibiotics resistance gene, and the like. Reporter genes assist in identification of successfully generated mutant strains from the wild type (wt) by making the mutant bacteria resistant to an antibiotic (e.g., Streptomycin/Spectinomycin resistance gene) or give off a fluorescence signal (e.g., mCherry fluorescence gene, GFUuv fluorescence gene). In one or more embodiments, the insertion sequence is engineered by molecular cloning of these fragments into a plasmid vector, followed by replication to obtain a large quantity of the engineered plasmid. This plasmid can then be used to generate the mutant strain. In one or more embodiments, the mutation comprises insertion of SEQ ID NO:8 into the target gene. In one or more embodiments, the mutation comprises insertion of SEQ ID NO:9 into the target gene.
[0041] In one or more embodiments, the attenuated mutant strain of E. chaffeensis is generated by transpositional insertion causing altered expression of several genes positioned upstream and downstream to the insertion sites. In one or more embodiments, the attenuated mutant strain of E. chaffeensis comprises one or more mutated genes selected from the group consisting of SEQ ID NO:10 (mutated sequence for Ech_0660), SEQ ID NO:11 (mutated sequence for Ech_0379), and SEQ ID NO:12 (mutated sequence for Ech_0230; note that the insertion mutant in Ech_0230 is inserted 17 nt downstream from the wild type stop codon). The effect of the inactivation of these genes causes attenuation of the organism's growth in vertebrate hosts, but does not impact its acquisition and persistence in ticks. In one or more embodiments, the invention is concerned with other live attenuated mutant strains of Ehrlichia canis, Ehrlichia ewingii, Ehrlichia muris, Ehrlichia muris -like agent infectious to humans, Anaplasma phagocytophilum, Anaplasma marginate , and/or Anaplasma platys. The mutants comprise a mutation in a gene homologous to E. chaffeensis gene Ech_0660, Ech_0379, or Ech_230, which results in attenuated growth of the bacterium in a vertebrate host organism.
[0042] Regardless, the resulting mutant E. chaffeensis can be used in immunogenic compositions to elicit an immune response against Ehrlichia infection in a subject. In some embodiments, the mutant E. chaffeensis can be used as a vaccine for immunizing a subject against Ehrlichia infection. The term “vaccine” is used interchangeably herein with “immunogenic composition” and refers to compositions capable of eliciting partial or complete immunogenic protection against a disease or condition in the subject to which it has been administered. Although vaccines are generally considered prophylactic, the vaccines may be used for therapeutic treatment of a disease or a condition. The terms “prophylactic” or “prevent,” as used herein, refer to vaccines that are intended to inhibit or ameliorate the effects of a future infection or disease to which a subject may be exposed (but is not currently identified as having been infected with). In other words, for prophylactic use, the subject generally does not (yet) show observable signs/symptoms of infection prior to administration of the immunogenic composition. In some cases the vaccine may prevent the development of observable morbidity from infection (i.e., near 100% prevention). In other cases, the vaccine may only partially prevent and/or lessen the extent of morbidity due to the infection (i.e., reduce or mitigate the severity of the symptoms and/or effects of the infection, and/or reduce or mitigate the duration of the infection/symptoms/effects). In either case, the vaccine is still considered to “prevent” the target infection or disease in the context of this disclosure. Conversely, the terms “therapeutic” or “treat,” as used herein, refer to vaccines that are intended to produce a beneficial change in an existing condition (e.g., infection, disease) of a subject, such as by reducing the severity of the clinical symptoms and/or effects of the infection, and/or reducing the duration of the infection/symptoms/effects.
[0043] The vaccines comprise the mutant E. chaffeensis strain(s) described herein dispersed in a pharmaceutically-acceptable carrier. The term carrier is used herein to refer to diluents, excipients, vehicles, and the like, in which the mutant E. chaffeensis strain(s) may be dispersed for administration. Suitable carriers will be pharmaceutically acceptable. As used herein, the term “pharmaceutically acceptable” means not biologically or otherwise undesirable, in that it can be administered to a subject without excessive toxicity, irritation, or allergic response, and does not cause unacceptable biological effects or interact in a deleterious manner with any of the other components of the composition in which it is contained. A pharmaceutically-acceptable carrier would naturally be selected to minimize any degradation of the mutant E. chaffeensis strain(s) or other agents and to minimize any adverse side effects in the subject, as would be well known to one of skill in the art. Pharmaceutically-acceptable ingredients include those acceptable for veterinary use as well as human pharmaceutical use, and will depend on the route of administration. For example, compositions suitable for administration via injection are typically solutions in sterile isotonic aqueous buffer. Exemplary carriers include aqueous solutions such as normal (n.) saline (˜0.9% NaCl), phosphate buffered saline (PBS), sterile water/distilled autoclaved water (DAW), aqueous dextrose solutions, aqueous glycerol solutions, ethanol, normal allantoic fluid, various oil-in-water or water-in-oil emulsions, as well as dimethyl sulfoxide (DMSO) or other acceptable vehicles, and the like.
[0044] The vaccine can comprise a therapeutically effective amount of live attenuated mutant E. chaffeensis dispersed in the carrier. As used herein, a “therapeutically effective” amount refers to the amount that will elicit the biological or medical response of a tissue, system, or subject that is being sought by a researcher or clinician, and in particular elicit some desired protective effect as against the infection by priming or stimulating an immune response specific for one or more strains of E. chaffeensis . One of skill in the art recognizes that an amount may be considered therapeutically “effective” even if the condition is not totally eradicated or prevented, but it or its symptoms and/or effects are improved or alleviated partially in the subject. In some embodiments, the composition will comprise from about 5% to about 95% by weight of a mutant E. chaffeensis described herein, and preferably from about 30% to about 90% by weight of the mutant E. chaffeensis , based upon the total weight of the composition taken as 100% by weight. In some embodiments, combinations of more than one type of the described E. chaffeensis mutants can be included in the composition, in which case the total levels of all such mutant E. chaffeensis strains will preferably fall within the ranges described above. Such multi-valent vaccines are preferred for use in vaccination in some embodiments. In some embodiments, modifications may be made to the insertions, such as deletions of the antibiotic cassette or creation of new targeted insertions within the genes Ech_0660, Ech_0379, or Ech_0230 to improve the vaccine effectiveness. In some embodiments, similar mutations may be made in other Ehrlichia and Anaplasma species pathogens impacting the health of people and dogs upon their infections and they will be used similarly as vaccines.
[0045] Other ingredients may be included in the composition, such as adjuvants, other active agents, preservatives, buffering agents, salts, other pharmaceutically-acceptable ingredients, including residual amounts of ingredients used in vaccine manufacturing. The term “adjuvant” is used herein to refer to substances that have immunopotentiating effects and are added to or co-formulated in the vaccine composition in order to enhance, elicit, and/or modulate the innate, humoral, and/or cell-mediated immune response against the vaccine components. Suitable adjuvants include: aluminum salts, such as aluminum hydroxide, aluminum phosphate, alum (potassium aluminum sulfate), or mixed aluminum salts, peptides, oil or hydrocarbon emulsions, or any other adjuvant deemed suitable for human or animal use. In some embodiments, the vaccine is substantially free of any adjuvants, where the term “substantially free” means that the ingredient is not intentionally added or part of the composition, although it is recognized that residual or incidental amounts or impurities may be present in low amounts (e.g., less than about 0.1% by weight and preferably less than about 0.01% by weight, based upon the total weight of the composite taken as 100% by weight). Other active agents that could be included in the composition include antiviral compounds or any immunogenic active components (e.g., antigens) such as those that resemble a disease-causing microorganism or infectious agent, and/or are made from weakened or killed forms of the same, its toxins, subunits, particles, and/or one of its surface proteins, such that it provokes an immune response to that microorganism or infectious agent. In addition to live, modified, or attenuated vaccine components, active agents using recombinant or synthetic peptides/proteins, carbohydrates, or antigens can also be used, including those targeted to the gene products of Ech_0660, Ech_0379, and/or Ech_0230. Antibiotics can also be used as part of vaccine production and may be present in small amounts in the vaccine, such as neomycin, polymyxin B, streptomycin and gentamicin. In some embodiments, the vaccine composition is substantially free of any other active (immunogenic) agents, other than the mutant E. chaffeensis and optional adjuvant, dispersed in the carrier.
[0046] In use, the vaccine composition is administered to a subject. Various routes of administration can be used depending upon the particular carrier and other ingredients used. For example, the vaccine can be injected intramuscularly, subcutaneously, intradermally, or intravenously using a needle and syringe, or a needleless injection device. The vaccine can also be administered mucosally, such as intranasal administration. For intranasal administration, the vaccine composition is usually administered through the nasal passage as drops, large particle aerosol (greater than about 10 microns), or spray into the upper respiratory tract. While stimulation of a protective immune response with a single dose is preferred, additional dosages can be administered, by the same or different route, to achieve the desired prophylactic or therapeutic effect. The vaccine can also be administered using a prime and boost regime if deemed necessary. In some embodiments, the methods described herein are useful for preventing the occurrence or incidence of Ehrlichia infection and/or preventing the effects of Anaplasma infection, as described above.
[0047] In some embodiments, the vaccine can be provided in unit dosage form in a suitable container. The term “unit dosage form” refers to a physically discrete unit suitable as a unitary dosage for human or animal use. Each unit dosage form may contain a predetermined amount of the vaccine (and/or other active agents) in the carrier calculated to produce the desired effect. In other embodiments, the vaccine can be provided separate from the carrier (e.g., in its own vial, ampule, sachet, or other suitable container) for on-site mixing before administration to a subject. A kit comprising the vaccine is also disclosed herein. The kit further comprises instructions for administering the vaccine to a subject. The virus can be provided as part of a dosage unit, already dispersed in a pharmaceutically-acceptable carrier, or it can be provided separately from the carrier. The kit can further comprise instructions for preparing the virus for administration to a subject, including for example, instructions for dispersing the virus in a suitable carrier.
[0048] Advantageously, vaccination with live, attenuated mutant E. chaffeensis induces pathogen-specific humoral and cellular immunity, and protection from tick-transmitted E. chaffeensis infection in a physiologic host. In one or more embodiments, vaccination with live, attenuated mutant E. chaffeensis generates a host response that is protective against infection in both the reservoir host (deer) and in an incidental host (dogs). In one or more embodiments, vaccination is completely protective against infection (Ech_0660 mutation). In one or more embodiments, vaccination is at least partially protective against infection (Ech_0379 mutation). In some embodiments, the immunogenic composition comprises a mixture of mutated E. chaffeensis strains comprising at least a mutation in Ech_0660 in one strain and a mutation in Ech_0379 in a second strain.
[0049] In one or more embodiments, administering the immunogenic composition to a subject will result in reducing rickettsemia when the subject is exposed to Ehrlichia , and/or artificially challenged with a wild type infection. In one or more embodiments, administering the immunogenic composition to a subject will result in complete clearance of the pathogen from both reservoir and incidental hosts. In one or more embodiments, administering the immunogenic composition to a subject will result in a rise in E. chaffeensis -specific antibody titers in the subject. In one or more embodiments, administering the immunogenic composition to a subject will result in a significant Th1 response in peripheral blood of the subject as measured by E. chaffeensis antigen-dependent CD4+ T cell proliferation and IFNγ production. In one or more embodiments, administering the immunogenic composition to a subject will result in a significant IL-17 production by peripheral blood leukocytes in the subject. In one or more embodiments, administering the immunogenic composition to a subject will does not result a significant antigen-dependent CD8+ T cell response in the subject.
[0050] Using the methodology and technology described herein, different attenuated Ehrlichia and/or Anaplasma vaccines can be developed and used for canines, and other species including, but not limited to human, equine, cervus (deer), feline, goats, non-human primate, and the like.
[0051] The methods can be also applied for clinical research and/or study. Thus, kits for study and/or generation of additional mutant Ehrlichia strains are also described herein. The kits comprise vectors (plasmids) as described herein encoding for the insertional mutations. The kit can also include vectors encoding for the target genes. Alternatively, such sequences can be determined by the end-user. The kit may include plasmids for subsequently inserting the insertional mutation sequences for generation of the mutant Ehrlichia strains. The kit may further include additional components, including cells, culture medium, buffers, along with instructions for their use to generate the mutant Ehrlichia strains.
[0052] The methods can also be applied towards developing drugs targeting the gene products of genes Ech_0660, Ech_0379, and Ech_0230, and their homologs of other related rickettsial pathogens to inhibit or reduce the effects, severity, or symptoms of Ehrlichia or Anaplasma infections.
[0053] Additional advantages of the various embodiments of the invention will be apparent to those skilled in the art upon review of the disclosure herein and the working examples below. It will be appreciated that the various embodiments described herein are not necessarily mutually exclusive unless otherwise indicated herein. For example, a feature described or depicted in one embodiment may also be included in other embodiments, but is not necessarily included. Thus, the present invention encompasses a variety of combinations and/or integrations of the specific embodiments described herein.
[0054] As used herein, the phrase “and/or,” when used in a list of two or more items, means that any one of the listed items can be employed by itself or any combination of two or more of the listed items can be employed. For example, if a composition is described as containing or excluding components A, B, and/or C, the composition can contain or exclude A alone; B alone; C alone; A and B in combination; A and C in combination; B and C in combination; or A, B, and C in combination.
[0055] The present description also uses numerical ranges to quantify certain parameters relating to various embodiments of the invention. It should be understood that when numerical ranges are provided, such ranges are to be construed as providing literal support for claim limitations that only recite the lower value of the range as well as claim limitations that only recite the upper value of the range. For example, a disclosed numerical range of about 10 to about 100 provides literal support for a claim reciting “greater than about 10” (with no upper bounds) and a claim reciting “less than about 100” (with no lower bounds).
EXAMPLES
[0056] The following examples set forth methods in accordance with the invention. It is to be understood, however, that these examples are provided by way of illustration and nothing therein should be taken as a limitation upon the overall scope of the invention.
INTRODUCTION
[0057] In a recent study, we described nine transposon insertion mutations in E. chaffeensis (Cheng et al., Targeted and Random Mutagenesis of Ehrlichia chaffeensis for the Identification of Genes Required for In vivo Infection PLOS Pathogens, Vol. 9, Iss. 2 (2013), incorporated by reference herein) (see FIG. 11 ). Genomic locations of the insertion sites and the genes at or near the insertions, as per the whole genome data (GenBank # CP000236.1) are shown in FIG. 11 . E. chaffeensis genomic DNAs from three independent transformations with mCherry (one transformation) and GFPuv (two transformations) Himarl transposon plasmids were used to determine the integration locations by inverse PCRs and ST-PCRs followed by DNA sequence analysis. Genomic locations of the insertion sites and the genes at or near the insertions were presented. The gene expression data assessed by RT-PCR are also included in the figure (E, expressed gene; m, in macrophage culture; t, in tick cell culture; No, gene not expressed). The insertions in mCherry transformants are shown on the left, and insertions in GFPuv transformants are depicted on the right. Numbers 6-8 are the first GFPuv transformants, and number 10 is the second GFPuv transformant).
[0058] In the current study, we investigated the impact of the insertion mutations in the pathogen's growth in an incidental host, tick and in altering transcriptional activities of genes near to the insertion sites. The potential of attenuated mutants to confer protection against infection challenge was also investigated. We present the first evidence that transposon mutations in E. chaffeensis cause polar effects in impacting gene expression from the nearby genes, in addition to disrupting gene functions for mutations existing within a gene. Further, we report that the transposon insertion mutation within the Ech_0660 gene causes attenuation and offers protection against infection challenges in both deer and dogs.
[0059] The E. chaffeensis Arkansas isolate (wild type and the mutants) and E. canis Oklahoma strain were continuously cultivated in the macrophage like cell line (DH82) for use in examples described below. Animal experiments with deer and dogs were performed by complying with the Public Health Service (PHS) Policy on the Humane Care and Use of Laboratory Animals, the US Department of Agriculture's (USDA) Animal Welfare Act & Regulations (9CFR Chapter 1, 2.31), and with approvals of the Oklahoma State University (OSU) and Kansas State University (KSU) Institutional Animal Care and Use Committees (IACUC), and as per the guidelines of the protocols. Laboratory-reared deer and pure-bred laboratory-reared dogs were used for conducting infection experiments. Purebred beagle dogs of 5-6 months of age of either sex were obtained from Covance Research Products (Denver, Pa.). Infection experiments were done according to established protocols.
[0060] The quantitative IgG ELISA data were analyzed using the 2-tailed unpaired Student t test (GraphPad software; http://www.graphpad.com/, La Jolla, Calif.). Statistical significance was set for differences between the experimental groups at P≦0.05. To maximize power to detect differences, T cell and antibody responses were compared using an analysis of variance accounting for the repeated measures on animals over time and the nesting of animals within each infection group was performed as previously described. For cytokine assays, ELISA results on cell culture supernatants from day 7-post infection were analyzed using a 1-way ANOVA with Bonferri post-test analysis.
[0061] Example 1 illustrates the clonal purification and verification of E. chaffeensis mutants. Example 2 illustrates the impact of mutations on the transcriptional activities of genes near the insertion sites by RT-PCR analysis. Example 3 illustrates the infection of animals with strains of mutant or wild type E. chaffeensis and the impact of these mutations on E. chaffeensis growth in an incidental host. Example 4 illustrates the needle infection of A. americanum ticks with mutants or wild type E. chaffeensis cultures. Example 5 illustrates the antibody, CD8+, and CD4+ T Cell responses to vaccination and challenge. Example 6 illustrates that attenuated mutants confer protection against wild type infection challenge in deer and dogs
Example 1
Clonal Purification and Verification of E. chaffeensis Mutants
[0062] Transposon mutants of E. chaffeensis were clonally purified by limiting dilution Briefly, host cell-free E. chaffeensis mutant pools were prepared, the numbers of organisms were estimated using a hemocytometer, and diluted to generate about one infected cell to be transferred per chamber in a 48-well plate containing confluent DH82 cells and incubated at 37° C. When the infectivity reached to −80%, 0.7 ml culture from each well was harvested for genomic DNA isolation. The remaining culture was transferred to a T25 flask containing confluent DH82 cells for expanding the culture growth. Clonal purity of mutants was assessed by PCR targeting to each insertion region and by performing Southern blot analysis with genomic DNA digested with Bgl II and hybridized with insertion-specific spectinomycin (aad) probe. Blots were assessed for the presence of single predicted DNA fragments for each clonal mutant.
[0063] To characterize the mutant organisms, we clonally purified five mutants by limiting dilution technique; Ech_0202, Ech_0284, Ech_0379, Ech_0480, and Ech_0660; clonal purity of mutants was verified by Southern blot analysis ( FIG. 1 ). Expected genomic DNA fragments for the Bgl II restriction endonuclease digestion, estimated from the position of transposon insertions, were calculated ( FIG. 1A ) and observed in DNA of each purified mutant as illustrated by agarose gel electrophoresis ( FIG. 1B ). Lanes 1-5 represent the mutants Ech_0202, Ech_0284, Ech_0379, Ech_0480 and Ech_0660, respectively.
Example 2
Impact of Mutations on the Transcriptional Activities of Genes Near the Insertion Sites by RT-PCR Analysis
[0064] Total RNA, free of contaminated genomic DNA, was isolated as according to standard protocols. RNA concentrations from wild type and clonal mutants were equalized and semi-quantitative RT-PCR targeting E. chaffeensis genes surrounding the transposon insertion sites was performed by 35 cycles of amplification using the gene specific primer sets described in Table 1.
[0000]
TABLE 1
Primers used for RT-PCR of genes
surrounding the insertion sites
Primer
Gene
Amplicon
name
target
size (bp)
Primer sequence
RRG1382
Ech_0202
314
5′-ttg ctg ata gtg tgg cag ctg aag (SEQ ID NO: 13)
RRG1383
5′-tct cca tct tgg ata aca gca gg (SEQ ID NO: 14)
RRG1384
Ech_0203
175
5′-tgt gtc ctg ttg tta tgg gtt ctc (SEQ ID NO: 15)
RRG1385
5′-tcc cta agt aat atg gaa cca tct gca c (SEQ ID NO: 16)
RRG1370
Ech_0284
380
5′-tct gct aga agt gct act cta gg (SEQ ID NO: 17)
RRG1371
5′-tcc cac agt gta gct ctc tgc (SEQ ID NO: 18)
RRG1372
Ech_0285
417
5′-atg act gct gcc att aca gtt ggg (SEQ ID NO: 19)
RRG1373
5′-cct cat cac ttg ttc ctc ctt c (SEQ ID NO: 20)
RRG1632
Ech_0378
446
5′-tgc tat agg gat acc tgt agc ttt tgc (SEQ ID NO: 21)
RRG1633
5′-gca aga cca tcg tac gta cta ggt g (SEQ ID NO: 22)
RRG1276
Ech_0379
373
5′-cta agg ttg tag gga atg caa cc (SEQ ID NO: 23)
RRG1277
5′-aca agg taa gta cct tgc ttg ctc (SEQ ID NO: 24)
RRG1634
Ech_0380
161
5′-atg tgc tct gta tca att gct tg (SEQ ID NO: 25)
RRG1635
5′-aac aaa gaa gta aaa aga cat aca tg (SEQ ID NO: 26)
RRG1374
Ech_0479
357
5′-act cct tgg caa tgg tgt gta g (SEQ ID NO: 27)
RRG1375
5′-aat cgc tct aga caa cac tga agg (SEQ ID NO: 28)
RRG1376
Ech_0480
368
5′-tat gta act tct ttg cct ctt atg (SEQ ID NO: 29)
RRG1377
5′-atg aaa tct tta gtg act cga cc (SEQ ID NO: 30)
RRG1636
Ech_0659
224
5′-act aga tga att tga cta tac aat tga tg (SEQ ID NO: 31)
RRG1637
5′-ttt aag ctt tgt aag ctg tta gaa t (SEQ ID NO: 32)
RRG1344
Ech_0660
265
5′-tgt acc tgt atc ctc acc tat cac c (SEQ ID NO: 33)
RRG1345
5′-cta tca att ctt cac ttc cat ttg tgt g (SEQ ID NO: 34)
RRG1638
Ech_0661
155
5′-atc tac tgc tac caa ccc aat ac (SEQ ID NO: 35)
RRG1639
5′-tag tgc ata tgc aat ttc att gtg c (SEQ ID NO: 36)
[0065] Insertional mutations within Ech_0230, Ech_0379 and Ech_0660 caused transcriptional inactivation from these genes. To assess the polar effects in altering transcriptional activities of genes surrounding the insertions, we evaluated transcription from genes located immediately upstream and downstream to insertion sites for the five clonally purified mutants ( FIG. 2 ). Total RNA isolated from wild-type E. chaffeensis (lane 1) and clonal mutants (lane 2) was assessed for the genes 5′ and 3′ to insertion sites by semi quantitative RT-PCR. FIGS. 2A-2D have the cartoons depicting the insertions within the genome and the genes near the insertions 111, along with corresponding RT-PCR products resolved on agarose gels for each of the respective genes. No template controls (lane 3) and wild type genomic DNA template reactions (lane 4) were included to serve as negative and positive controls, respectively for each reaction. M represents 1 kb plus DNA ladder (Life Technologies Inc. Carlsbad, Calif.). With exception of the intergenic mutation downstream to Ech_0202, all other mutations influenced the transcript levels from the genes immediately upstream and/or downstream to the insertion sites. The insertion 3′ to Ech_0284 caused an enhancement of gene expression from the Ech_0285 gene. Similarly, mutation within Ech_0379 caused decline of the transcription to undetectable levels from the upstream gene, Ech_0378, similar to the loss of transcription from Ech_0379 gene previously published, while not impacting the transcript level for the downstream gene, Ech_0380. The mutation 3′ to Ech_0479 enhanced transcription from this gene and also activated the transcriptionally silent gene, Ech_0480. Mutation within Ech_0660 resulted in the decline in transcription to undetectable level from Ech_0659, similar to transcript knockdown from Ech_0660 gene. This mutation had no impact on the transcript level of Ech_0661.
Example 3
Infection of Animals with Strains of Mutant or Wild Type E. chaffeensis and the Impact of these Mutations on E. chaffeensis Growth in an Incidental Host
[0066] Animals were injected with transposon mutants as a pool, clonally purified organisms, or with wild type E. chaffeensis . Inocula were prepared and inoculated with an estimated concentration of ˜2×10 8 Ehrlichia organisms in 1 ml. The presence of mutants and wild type organisms in an animal was assessed in blood drawn several days post infection by performing culture recovery or by nested PCR analysis.
[0000]
TABLE 2
Verification of the E. chaffeensis infection status by nested PCR targeting
to the transposen insertion sites in mutant pool infected dog blood #
Days post infection
Insertion site
0
2
5
7
9
12
14
16
19
21
29
35
44
Dog 1
Ech_0202
−
−
−
−
−
−
−
−
−
−
−
−
−
Ech_0230
−
−
−
−
−
−
−
−
−
−
−
−
−
Ech_0379
−
−
−
−
−
−
−
−
−
−
−
−
−
Ech_0480
−
+
+
+
+
+
−
+
−
−
+
+
+
Ech_0490
−
−
−
−
−
−
+
+
+
−
+
−
−
Ech_0601
−
−
−
−
−
−
−
−
−
−
−
−
+
Ech_0660
−
−
−
−
−
−
−
−
−
−
−
−
−
Ech_0760
−
−
−
−
−
−
+
−
−
−
+
−
−
Dog 2
Ech_0202
−
−
−
−
−
−
−
−
−
−
−
−
−
Ech_0230
−
−
−
−
−
−
−
−
−
−
−
−
−
Ech_0379
−
−
−
−
−
−
−
−
−
−
−
−
−
Ech_0480
−
+
+
+
−
−
+
−
−
−
+
+
+
Ech_0490
−
+
−
−
−
−
−
−
−
−
−
−
−
Ech_0601
−
−
−
−
+
−
−
−
−
−
−
−
−
Ech_0660
−
−
−
−
−
−
−
−
−
−
−
−
−
Ech_0760
−
−
−
−
−
−
−
−
−
−
−
+
+
Dog 3
Ech_0284
−
−
−
−
−
−
+
+
+
+
+
−
+
# The signs − and + refer to samples tested negative or positive by culture recovery and/or nested PCR, respectively.
[0067] E. chaffeensis transposon mutants grew well under in vitro culture conditions, while their growth and persistence in the reservoir host, white-tailed deer, was variable; insertions causing transcriptional inactivation from three putative membrane protein encoding genes Ech_0230, Ech_0379 and Ech_0660 resulted in the attenuated growth in deer. To examine if the mutations similarly impacted the pathogen's growth in an incidental host, we conducted experimental infection studies in three dogs. Infection progression in the dogs was followed for 44 days by sampling blood once every 2-7 day intervals. The dogs tested positive for the mutants similar to our prior observations in deer when assessed by culture recovery and/or insertion-specific PCRs at various time points post infections (Table 2). As in deer, dogs tested negative for the same three insertion mutations at Ech_0230, Ech_0379 and Ech_0660 genes. In addition, the mutant near Ech_0202 gene was undetectable. Evaluation Ech_0202, Ech_0601 and Ech_0760 mutants in vivo was assessed for the first time. Ech_0601 is an intragenic mutation, while Ech_0202 and Ech_0760 mutations are intergenic mutations downstream from the coding sequences of Ech_0202 and Ech_0760 genes, respectively. As the mutants' progression in dogs is similar to deer for the previously assessed six mutants, we reasoned that the infection progression with Ech_0202, Ech_0601 and Ech_0760 mutants in deer will also be similar to dogs. We followed infection for two months in a deer with a pool of these three mutants (Table 3). As in dogs, Ech_0202 mutant was undetectable in deer, while Ech_0601 and Ech_0760 mutants persisted.
[0068] Mutants with attenuated growth in vertebrate host species were considered vaccine candidates.
[0000]
TABLE 3
Infection status in deer blood with mutant pool
containing Ech_0202, Ech_0601 and Ech_0760 #
Days post infection
Insertion site
0
5
6
8
10
14
18
21
28
32
35
39
42
46
49
52
59
63
Ech_0202
−
−
−
−
−
−
−
−
−
−
−
−
−
−
−
−
−
−
Ech_0601
−
−
+
−
−
+
+
+
+
−
−
−
−
−
−
−
−
+
Ech_0760
−
+
−
−
+
−
+
+
−
−
−
−
−
−
−
−
−
−
# The signs − and + refer to samples tested negative or positive by culture recovery and/or nested PCR, respectively.
Example 4
Needle Infection of A. americanum Ticks with Mutants or Wild Type E. chaffeensis Cultures for Assessing the Impact of Mutations on E. chaffeensis Growth in the Tick Vector
[0069] A. americanum nymphal ticks experimentally fed and dropped after completing a blood meal from a naïve sheep were used in this study. Fed nymphs were purchased from the Oklahoma State University tick facility. Within 24-48 h post blood meal, nymphs were injected with about 5 μl of 10 fold concentrated cultured E. chaffeensis (mutants or wild type). Briefly, culture in PBS was used for needle puncture inoculation into the ventral side of ticks. Ticks were allowed to molt to adults at room temperature. Total genomic DNA from ticks was individually isolated, resuspended into 100 μl of nuclease-free water and 2 μl each of the DNA was used as template for PCR analysis. The presence of E. chaffeensis (wild type or mutant organisms) was determined by nested PCR assays as described in Example 1 above.
[0070] Infection of A. americanum ticks by needle inoculation method with E. chaffeensis mutants demonstrated that the mutated genes were essential only for survival in the vertebrate host but not for the organism's persistence in its tick vector. Four groups of engorged nymphal ticks were included in this experiment; group 1 received wild-type E. chaffeensis , group 2 received a pool of five mutants grown together (Ech_0230, Ech_0284, Ech_0379, Ech_0480 and Ech_0490), group 3 received an equal mixture of five individually cultured mutants (Ech_0202, Ech_0284, Ech_0379, Ech_0480 and Ech_0660) and group 4 contained five sub-groups inoculated with mutants individually cultured (the same five mutants used in group 3 experiment). Following molting of nymphs to adults, total genomic DNA was recovered from randomly selected ticks of both sexes from each group (14-21 ticks per group/subgroup) and assessed for infection rates by wild type or mutant-specific nested PCR assays, data summarized in Table 4. Infection with wild type E. chaffeensis (group 1) was 9.5%. Infection rates with the mutants were variable for each mutant in groups 2-4. The highest infection rate was observed for Ech_0480 mutant and its infection rates were very similar in all three groups of ticks at 50-57%. The Ech_0379 mutant infection in groups 2-4 was also very similar at 28-30%. Ech_0202 infection was undetectable in a pool containing equal mixture (group 3); however, it was detected in one tick in the subgroup of group 4 receiving the mutant alone as the inoculum. These results illustrate the unexpected result that, contrary to the attenuated growth in deer and dogs, Ech_0230, Ech_0379 and Ech_0660 mutants showed no survival disadvantage in ticks.
[0000]
TABLE 4
Infection rate of needle injected A. americanum ticks
Group 2
Group 3
Group 4
Group 1
(mutant
(equal mixture
(individual
(wild type)
pool)
of mutants)
mutants)
wild type
9.5% (2/21)
Ech_0202
0% (0/14)
4.7% (1/21)
Ech_0230
20% (4/20)
Ech_0284
5% (1/20)
57.1% (8/14)
23.8% (5/21)
Ech_0379
30% (6/20)
28.5% (4/14)
28.5% (6/21)
Ech_0480
50% (10/20)
57.1% (8/14)
57.1% (12/21)
Ech_0490
50% (10/20)
Ech_0660
7.1% (1/14)
23.8% (5/21)
Example 5
Antibody, CD8+, and CD4+ T Cell Responses to Vaccination and Challenge
[0071] PBMCs were isolated by density centrifugation from buffy coat fractions of peripheral blood collected into 2× acid citrate dextrose. Cells were washed and resuspended in complete RPMI composed of RPMI-1640 (Gibco, Carlsbad, Calif.) supplemented with 2 mM L-glutamine, 25 mM HEPES buffer, 1% antibiotic-antimycotic solution, 50 mg/mL gentamicin sulfate, 1% nonessential amino acids, 2% essential amino acids, 1% sodium pyruvate, 50 μM 2-mercaptoethanol, and 10% (v/v) fetal bovine serum. For lymphocyte proliferation assays, cells were labeled with 1 μM CellTrace Violet (Life Technologies Inc.) per manufacturer's instructions. Cells were cultured for 5 days at 37° C. with 4×10 5 cells/well in 96-well plates and were stimulated with 10 μg/mL host cell-free E. chaffeensis whole-cell lysate that was grown in ISE6 tick cells. As a positive control, cells were stimulated with 5 μg/mL Concanavalin A (Sigma-Aldrich). For proliferation and intracellular cytokine staining data, background (mock) responses were subtracted from the response to antigen and results are presented as change over mock.
[0072] For surface staining of cells for flow cytometry, cells were resuspended at 10 7 cells/mL in FACS buffer (0.1% NaN 3 , 10% fetal calf serum, PBS) and incubated for 20 minutes at 4° C. with 10 μg/mL primary antibodies or as recommended by the manufacturer (mouse anti-canine CD3-FITC (clone CA17.2112), CD4-RPE or APC (clone YKIX302.9), CD8 RPE or APC (YCATE55.9) all from AbD Serotec (Raleigh, N.C.)). Cells were washed and fixed in BD FACS Lysis buffer (BD Biosciences).
[0073] Flow cytometry data were collected on a BD LSR Fortessa X-20 flow cytometer and analyzed using FlowJo software (Tree Star Inc., San Carlos, Calif.). Antigen-dependent CD4 + T cells were identified based upon proliferation in response to E. chaffeensis antigen as determined by dilution of the Cell Trace Violet dye.
[0074] We next measured E. chaffeensis -specific CD4 + T cell recall responses in peripheral blood from vaccinated and control dogs. PBMC were labeled with Cell Trace Violet, stimulated with host cell-free E. chaffeensis whole cell lysate and then analyzed by flow cytometry. Antigen-dependent CD4 + T cells were identified based upon proliferation in response to E. chaffeensis antigen as determined by dilution of the Cell Trace Violet dye. Data in FIGS. 3A and 3B represent PBMC from dogs vaccinated with Ech_0660 and challenged with wild-type E. chaffeensis via needle inoculation (group 1, left panels), vaccinated with Ech_0660 and challenged with wild-type E. chaffeensis via tick inoculation (group 2, middle panels), or unvaccinated and infected with wild-type E. chaffeensis or Ech_0480 via tick inoculation (group 3, right panels) were labeled with Cell Trace Violet, then cultured for 5 days at 4×10 6 cells/mL in the presence or absence of 10 ug/mL E. chaffeensis host-cell free lysate grown in the tick ISE6 cell line. On day 5, CD4 + T cells were analyzed by flow cytometry for Cell Trace Violet dilution as a measure of proliferation. FIG. 3A shows representative dilution profiles of mock and antigen-stimulated CD4 + T cells from one representative animal per group on day 7 post-secondary challenge. The numbers depicted in FIG. 3A represent the percent of proliferating CD3 + CD4 + cells contained within each gate. FIG. 3B shows the percentage of CD4 + T cells dividing in response to antigen that was measured in all animals over the course of the experiment. Background levels of proliferation were subtracted from these values and results represent change in proliferation over mock stimulated cultures.
[0075] We observed an increase in the percentage of CD4 + T cells that divided in response to E. chaffeensis antigen in PBMC collected on day 14-17 post inoculation with the Ech_0660 mutant. This percentage was further increased on day 7-14 following wild type E. chaffeensis challenge, consistent with a recall response. Vaccinated animals displayed significantly higher percentages of proliferating E. chaffeensis antigen-dependent CD4 + T cells compared to unvaccinated dogs ( FIG. 3B , p=0.0081).
[0076] We also measured antigen-dependent IFNγ production by CD4 + T cells in the blood using intracellular cytokine staining. Protocol for harvest and surface staining was performed as described above with the addition of mouse-anti-bovine IFNγ-RPE (clone CC302) also from AbD Serotec (Raleigh, N.C.). The bovine IFNγ-specific clone CC302 has been previously demonstrated to cross-react with canine IFNγ. Intracellular cytokine staining for IFNγ was carried out using the BD Fixation and Permeabilization Solution kit (BD Biosciences). Cells were cultured with antigen for 5 days, and then Brefeldin A was added for the last 5-6 hours of incubation. Cells were surface stained and then fixed, permeabilized and stained for intracellular IFNγ (Clone CC302, 10 μg/mL) per manufacturer's instructions.
[0077] FIG. 4 presents PBMC from dogs vaccinated with the Ech_0660 mutant and challenged with wild-type E. chaffeensis (groups 1-3, as in FIG. 2 ) were cultured for 5 days at 4×10 6 cells/mL in the presence or absence of 10 ug/mL E. chaffeensis host-cell free lysate grown in the tick ISE6 cell line. On day 5, brefeldin A was added for the last 6 hours of culture. CD4 + T cells were stained for intracellular expression of IFNγ and analyzed by flow cytometry. FIG. 4A shows representative flow plots of mock and antigen-stimulated CD4 + T cells gated on IFNγ + cells from animals in groups 1, 2 and 3, gated on total live cells and total CD3 + CD4 + T cells. FIG. 4B shows the percentage of IFNγ + cells of total CD4 + T cells in the blood measured over the course of the experiment. Background was subtracted from mock stimulated samples as above. We observed significantly increased percentages of CD4 + T cells producing IFNγ in response to E. chaffeensis antigen in samples from vaccinated animals, compared to unvaccinated controls ( FIG. 4B , p=0.0025).
[0078] FIG. 5 presents CD8 + T cell proliferation and IFNγ production were measured using similar approaches as in FIGS. 3 and 4 . PBMC from dogs in groups 1-3 were cultured for 5 days at 4×10 6 cells/mL in the presence or absence of 10 ug/mL E. chaffeensis host-cell free lysate. On day 5 of culture, CD8 + T cells were analyzed by flow cytometry for proliferation as measured by Cell Trace Violet dilution, illustrated in FIG. 5A ; and intracellular production of IFNγ, illustrated in FIG. 5B . The frequencies of responding CD8 + T cells were measured over the course of the experiment. Results were gated on total live cells and total CD3 + CD8 + T cells. Background was subtracted as above.
[0079] Neither vaccination nor infection with wild type E. chaffeensis induced a significant CD8 + T cell response as measured by proliferation or IFNγ.
[0080] ELISAs were performed to measure cytokines using PBMC culture supernatants collected after 5 days of stimulation with 10 μg/mL host-cell free E. chaffeensis lysate. IL-4, IFNγ, and IL-17A protein concentrations were determined by commercial ELISA kit (R&D Systems, Minneapolis, Minn.) per manufacturer's instructions to measure Th1, Th2 and Th17 cytokines secreted by PBMC in recall responses to E. chaffeensis antigen.
[0081] FIG. 6 presents PBMC from dogs vaccinated with Ech_0660 and challenged with wild-type E. chaffeensis (groups 1-3, as in FIG. 2 ) were collected on day 7 post-secondary challenge with wild-type E. chaffeensis . PBMC were cultured for 5 days at 4×10 6 cells/mL in the presence or absence of 10 ug/mL E. chaffeensis host-cell free lysate grown in the tick ISE6 cell line. On day 5, cell culture supernatants were collected and later analyzed by ELISA for secretion of (A) IFNγ, (B) IL-17, and IL-4 (not shown). Each bar is representative of a single animal. PBMC from Ech_0660 vaccinated animals secreted IFNγ (Th1) in response to E. chaffeensis antigen ( FIG. 6A ); and this response was significantly increased over the response from unvaccinated control dogs. We did not observe appreciable IL-4 (Th2) production by PBMC from vaccinated or control dogs (data not shown); however, all three groups mounted a vigorous IL-17 response to E. chaffeensis antigen ( FIG. 6B ). IL-17 production by cells from Ech_0660 vaccinated dogs was significantly increased over unvaccinated controls.
Example 6
Attenuated Mutants Confer Protection Against Wild Type Infection Challenge in Deer and Dogs
[0082] We reasoned that the attenuation in vertebrate hosts with three gene disruption mutations is the result of the pathogen's inability to maintain replication cycle continuously. We then hypothesized that the attenuated mutants induce sufficient host response to protect against infection challenge with wild type E. chaffeensis . We tested this hypothesis with two clonally purified attenuated mutants with insertions within Ech_0379 and Ech_0660 genes, as these mutations caused the loss of gene activity from putative Na + /H + antiporter and phage like structure protein, respectively. Five groups of deer were used (three animals each in groups 1, 3 and 4, and two animals each in groups 2 and 5): group 1 received wild type E. chaffeensis infection; group 2 received clonally purified Ech_0284 mutant, as it is similar to wild type in causing persistent infection and can serve as a syngeneic positive control for other mutants; groups 3 and 4 received infections with clonally purified Ech_0379 and Ech_0660 mutants, respectively; and group 5 received no infection to serve as non-infection controls. Infection in all five groups was monitored in blood sampled frequently for 31-41 days and by performing nested PCRs on DNA recovered or by culture recovery method (Table 5). Infection was detected frequently and persisted very similar in groups 1 and 2 animals (59% and 61% of the samples tested positive, respectively), while detected less frequently (19% of the time) in Ech_0379 mutant infected (group 3) animals; detected in one animal on day 4 and 28, on day 35 in the second animal, and on day 7 in the third animal. Infection was undetectable throughout the study in group 4 (Ech_0660 mutant group) and group 5 deer (controls).
[0000]
TABLE 5
White tailed deer Infection status with three different
clonally purified mutants or with wild type E. chaffeensis #
Days post infection*
0
4
11
18
22
24
27
30
37
41
Group 1
wt-1
−
−
+
+
+
+
+
+
+
+
wt-2
−
−
−
−
+
+
+
+
+
−
wt-3
−
+
−
−
−
+
+
−
−
−
0
3
5
8
10
14
21
23
28
31
Group 2
Ech_0284-1
−
−
+
+
+
+
+
−
−
−
Ech_0284-2
−
−
−
+
+
+
+
+
−
+
0
4
7
12
14
21
28
35
Group 3
Ech_0379-1
−
+
−
−
−
−
+
−
Ech_0379-2
−
−
−
−
−
−
−
+
Ech_0379-3
−
−
+
−
−
−
−
−
0
3
5
8
10
14
21
23
28
31
Group 4
Ech_0660-1
−
−
−
−
−
−
−
−
−
−
Ech_0660-2
−
−
−
−
−
−
−
−
−
−
Ech_0660-3
−
−
−
−
−
−
−
−
−
−
Group 5
Control-1
−
−
−
−
−
−
−
−
−
−
Control-2
−
−
−
−
−
−
−
−
−
−
# The signs − and + refer to samples tested negative or positive by culture recovery and/or nested PCR, respectively.
*Samples were collected on different days post infection for each group.
Total average positives in groups 1-5 are 59%, 61%, 19%, 0% and 0%, respectively (0 day data were not included in this calculation).
[0083] Plasma samples from all deer in groups 1-5 were evaluated by ELISA for the total IgG antibody response against E. chaffeensis whole cell antigens ( FIG. 7 ).
[0084] ELISA was performed using a preparation of host cell-free E. chaffeensis lysate. Plasma samples from deer or dogs collected prior to infection and several days following infections were assessed by ELISA for the presence of the pathogen-specific IgG.
[0085] FIGS. 7A-7C present E. chaffeensis -specific IgG response in deer infected with wild-type and mutant E. chaffeensis . Groups 1-5 represent the ELISA analysis performed on animals infected with wild-type, Ech_0284, Ech_0379, Ech_0660 and non-infected controls, respectively. Line graphs within each group represent the IgG responses for individual animals {data presented as mean values±standard deviation (SD) from triplicate samples}. In FIG. 7C , the comparison of IgG data for each group for the last day of sample analysis is shown on the right. Significant IgG differences (P≦0.05) observed between groups are identified with asterisks. Error bars for this graph represent mean values±SD for animals within each group.
[0086] Deer in groups 1 and 4 (wild type and Ech_0660 mutant infected groups, respectively) had IgG responses, whereas the Ech_0379 infected group 3 and control group 5 had no IgG responses. The Ech_0284 infected group 2 had a weaker response. The IgG levels are higher in wild type infected group which steadily increased with time post infection. The IgG responses were similar for wild type and Ech_0660 infected animals. The IgG levels for these two groups were not significantly different, as judged by comparing the IgG data for each group for the last day of the sample analysis, while IgG in Ech_0284 and Ech_0379 mutant infected animals were significantly lower compared to wild type. Similarly, Ech_0379 and Ech_0660 mutant infected animals differed significantly (P≦0.05).
[0087] To determine if the Ech_0379 and Ech_0660 mutants confer protection, deer infected with these mutants (groups 3 and 4, respectively) were intravenous infection challenged with wild type E. chaffeensis after about a month and the infection was monitored in blood by nested PCR and by in vitro culture recovery methods for 32 days (group 3) or 44 days (group 4) (Table 6). To serve as a positive control, infection in deer with the wild type E. chaffeensis infection (group 1 above) was carried out with this challenge experiment using the inoculum used from same batch of culture. All three challenged animals in the Ech_0660 group tested negative for the organism for the entire 44 days, while one animal in the Ech_0379 group tested positive on day 7 post challenge (Table 6). In toto, prior exposure of animals with the attenuated mutants; Ech_0379 or Ech_0660, reduced E. chaffeensis circulating in blood when challenged with wild type organisms. Tissue samples (liver and spleen) collected at the end point of the study were assessed for the presence of E. chaffeensis by nested PCR. DNA was isolated from about 20 mg each of a tissue sample and nested PCR assays were performed as described above in Example 1 above.
[0000]
TABLE 6
Assessing Ech_0379 and Ech_0660 mutant in conferring
protection against E. chaffeensis challenge in white-tailed deer #
Days post challenge
4
7
12
19
23
32
Group 3
Ech_0379-1
−
+
−
−
−
−
Ech_0379-2
−
−
−
−
−
−
Ech_0379-3
−
−
−
−
−
−
4
11
18
22
24
27
30
34
37
41
44
Group 4
Ech_0660-1
−
−
−
−
−
−
−
−
−
−
−
Ech_0660-2
−
−
−
−
−
−
−
−
−
−
−
Ech_0660-3
−
−
−
−
−
−
−
−
−
−
−
# The signs − and + refer to samples tested negative or positive by culture recovery and/or nested PCR, respectively.
[0088] Animals in group 4 (Ech_0660 group) and non-infected controls (group 5) tested negative, while deer in groups 1 and 3 (wild type and Ech_0379 groups) tested positive in one or both tissues (Table 7, annotated as above). The group 3 (Ech_0379 group) animals receiving E. chaffeensis challenge had a very little change in the antibody response, while two of the three challenged animals in group 4 (Ech_0660 group) had a steady rise in the antibody response ( FIG. 8 ). Specifically, FIGS. 8A-8B present E. chaffeensis -specific IgG changes in deer receiving Ech_0379 ( FIG. 8A ) or Ech_0660 ( FIG. 8B ) mutant followed by challenge with wild-type infection. IgG levels were assessed in animals receiving mutant inoculated and challenged with wild-type for several days post infection. The data were plotted as in FIG. 3 . The day of challenge is identified with down arrows.
[0000]
TABLE 7
Infection status of tissue samples in deer (Note:
the deer numbers are the same as in Table 5) #
Deer Group
1 (wild type)
3 (Ech_0379)
4 (Ech_0660)
5 (Control)
Tissue
1
2
3
1
2
3
1
2
3
1
2
Spleen
+
+
−
+
+
−
−
−
−
−
−
Liver
+
+
+
+
−
−
−
−
−
−
−
# The − and + signs refer to samples tested negative or positive by nested PCR, respectively.
[0089] The infection and challenge experiment was repeated in dogs using mutant/vaccine candidates Ech_0379 and Ech_0660. Tick transmission protocol was performed as follows. E. chaffeensis infected A. americanum adult ticks were used for the tick-transmitted challenge. The tick infection was conducted as previously described. Briefly, nymphal ticks were needle-inoculated with 5 μl of concentrated bacterial culture containing of 5,000 wild-type E. chaffeensis or virulent Ech_0480 mutant. Nymphs were allowed to molt into adults at room temperature in a humidified chamber with 14 h daylight and 10 h darkness cycles. The infection status of the needle-inoculated ticks was verified by nested PCR targeting to the Ech_1136 gene encoding for the p28-Omp 14 protein as previously described. A small area on the back of the dog was shorn and a tick containment cell was affixed. Twenty-five pairs of adult ticks per dog were placed in the tick containment cell and permitted to feed for 6-7 days before removal.
[0090] Two dogs each were infected with the two mutants or with wild type E. chaffeensis and two dogs were kept as uninfected controls. Infection with wild type and uninfected controls were as previously described. Infection in blood was monitored by nested PCR and culture recovery methods. The wild type E. chaffeensis infected dogs were persistently positive (83% of the time), while the uninfected controls tested negative for the same time period. One dog receiving infection with the Ech_0379 mutant tested positive on days 3, 7 and 10 and the second dog tested positive on days 3, 10, 15, 30, 32 and 35 (Table 8).
[0000]
TABLE 8
Assessing Ech_0379 and Ech_0660 mutants in conferring protection against wild type E. chaffeensis challenge in dogs #
Days Post Infection
Days Post Challenge
0
3
7
10
15
18
22
24
30
32
35*
2
8
10
17
24
31
38
Ech_0379-1
−
+
+
+
−
−
−
−
−
−
−
+
+
+
−
−
−
−
Ech_0379-2
−
+
−
+
+
−
−
−
+
+
+
−
+
+
+
−
−
−
0
5
7
9
12
14
16
19
21
26
29*
5
8
10
14
20
22
28
35
42
49
56
64
Ech_0660-1
−
+
+
−
−
−
−
−
−
−
+
+
−
−
−
−
−
−
−
−
−
−
−
Ech_0660-2
−
−
+
−
−
−
−
−
−
−
−
−
−
−
−
−
−
−
+
−
−
−
−
# The signs − and + refer to samples tested negative or positive by culture recovery and/or nested PCR, respectively.
[0091] Both the dogs receiving Ech_0660 mutant infection tested positive only for the first week after receiving the inoculum (positives detected on days 2 and 7 for one dog and day 7 for the second dog) (Table 8). One dog infected with Ech_0660 mutant also tested positive by culture recovery on day 29 post infection. Dogs infected with Ech_0379 and Ech_0660 mutants were challenged after about a month with wild type E. chaffeensis.
[0092] The infection was monitored in blood sampled up to 38 days (Ech_0379 mutant group) or 64 days (Ech_0660 mutant group) (Table 8). The Ech_0660 mutant group tested negative all days after infection challenge, except for the first week in one dog, while the Ech_0379 mutant group challenged dogs tested positive more frequently for the first 17 days post-challenge. DNA recovered from spleen and liver samples from the challenged group dogs at the end point of the study for both the groups tested negative for the organism, while dogs received only wild type infection tested positive (not shown). FIGS. 9A-9B illustrate E. chaffeensis -specific IgG response in dogs with Ech_0379 ( FIG. 9A ) or Ech_0660 ( FIG. 9B ) mutant followed by challenge with wild-type E. chaffeensis . IgG levels assessed in animals receiving mutant inoculated and challenged with wild-type for several days post infection. The data were plotted as in FIG. 3 . The day of challenge is identified with down arrows; dogs in both groups had a rise and fall in pathogen-specific IgG responses following mutant infections; and the responses were boosted initially with wild type infection challenges and then declined with time.
[0093] To determine if the Ech_0660 mutant is protective in a physiologic setting of tick-transmitted challenge, we vaccinated dogs with the mutant and then performed secondary challenges on day 31-post infection. Four control dogs remained unvaccinated. Seven dogs were vaccinated i.v. with the Ech_0660 mutant organisms. Animals were monitored for the presence of Ehrlichia in the blood following Ech_0660 vaccination by PCR and culture recovery methods (Table 9).
[0000]
TABLE 9
Infection status of dogs vaccinated with attenuated mutant Ech_0660
Days Post Vaccination
0
3
8
11
14
21
28
31
Ech_0660_1 a
−
−
−
−
−
−
−
−
Ech_0660_2
−
−
−
−
−
−
−
−
Ech_0660_3
−
c b
−
−
−
−
−
−
Ech_0660_4
−
−
−
−
−
−
−
−
Ech_0660_5
−
−
−
−
−
−
−
−
Ech_0660_6
−
c
−
−
−
−
−
−
Ech_0660_7
−
c
−
−
−
−
−
−
a Seven dogs were inoculated i.v. with 2 × 10 8 E. chaffeensis mutant Ech_0660 organisms.
b Dogs were tested at the indicated time points for E. chaffeensis organisms in the blood by PCR (p) and culture recovery methods (c) as previously described.
[0094] We have shown previously that the Ech_0660 mutant is highly attenuated and rapidly cleared from the canine host. In agreement with our prior studies, the Ech_0660 mutant was detected in only three animals on day 3 post vaccination. Thirty-one days after vaccination, dogs were divided into groups. Two Ech_0660 vaccinated dogs were challenged with wild-type E. chaffeensis via needle inoculation (group 1). Three vaccinated dogs were challenged with wild-type E. chaffeensis by tick transmission (group 2). The four unvaccinated control dogs were challenged via tick transmission with wild-type E. chaffeensis (n=2) or a wild-type like, isogenic mutant strain Ech_0480 (n=2) (group 3). We have previously demonstrated that the Ech_0480 mutant behaves like the wild-type strain of E. chaffeensis , displaying similar persistence in the vertebrate host; therefore we have combined the data for these two control groups (group 3).
[0095] E. chaffeensis infection in dogs varies from subclinical infection to severe systemic disease. Mild clinical signs may manifest as low-grade fever or thrombocytopenia, as others and we have previously reported. In this experiment, we did not observe significant clinical disease in vaccinated or control dogs (data not shown). E. chaffeensis infection was monitored in the blood after secondary challenge using nested PCR and culture recovery methods. The results are shown in Table 10. Dogs that were vaccinated and challenged with wild-type E. chaffeensis by needle inoculation (group 1) were protected from infection, as evidenced by testing positive for infection in the blood only twice in one animal on days 8 and 11 post challenge (12.5% of the time), and testing negative for the organism in the spleen and liver at the time of necropsy. Vaccinated dogs that were challenged via tick-transmission (group 2) were also protected from secondary challenge. This group tested positive for Ehrlichia in the blood 29.1% of the time (7 out of 24 total blood samples tested). However, no blood positives were obtained after day 15 post challenge, and all animals were also negative for the organism in the spleen and liver at the time of necropsy. This result suggests that while dogs may develop ehrlichemia early following infection, vaccination with the Ech_0660 mutant promotes protection from long-term pathogen persistence in the blood and organs. In contrast, unvaccinated control dogs (group 3) displayed persistent infection, testing frequently positive for the organism throughout the 31 days of assessment (about 34.3% of the time: 11 out of 32 samples tested) and moreover testing positive for the organism in the tissues at necropsy.
[0000]
TABLE 10
Infection status of Ech_0660 vaccinated dogs and unvaccinated
control dog following wild type E. chaffeensis challenge
Days Post Challenge: WT
E. chaffeensis by needle transmission
Necropsy e
Group 1 a
0
4
8
11
15
22
29
36
blood
sp
liv
Ech_0660_1
−
−
−
−
−
−
−
−
−
−
−
Ech_0660_2
−
−
p d
c
−
−
−
−
−
−
−
Days Post Challenge: WT
E. chaffeensis by tick transmission
Group 2 b
0
4
8
11
15
22
29
36
blood
sp
liv
Ech_0660_3
−
−
c
−
c
−
−
−
−
−
−
Ech_0660_4
−
−
c
−
c
−
−
−
−
−
−
Ech_0660_5
−
−
p/c
p
c
−
−
−
−
−
−
Days Post Infection (non-vaccinated
control group): WT E. chaffeensis
or Ech_0480 by tick transmission
Group 3 c
0
3
7
10
14
17
24
31
blood
sp
liv
Wild-type_1
−
−
p
−
c
−
−
p
−
−
+
Wild-type_2
−
−
p
−
c
p
−
−
−
−
−
Ech_0480_1
−
−
−
−
c
−
−
−
−
−
+
Ech_0480_2
−
p
−
−
c
−
p
p
−
+
−
a Dogs from Table 9 were challenged 31 days after vaccination. Animals were challenged via i.v. inoculation with 2 × 10 8 wild type E. chaffeensis organisms;
b Dogs from Table 9 were challenged 31 days after vaccination. Animals were challenged via tick-transmission with wild type E. chaffeensis organisms;
c Unvaccinated control dogs were challenged with 2 × 10 8 wild type E. chaffeensis organisms or 2 × 10 8 Ech_0480 mutant E. chaffeensis organisms;
d Dogs were tested at the indicated time points for E. chaffeensis organisms in the blood by PCR (p) and culture recovery methods (c) as described. Animals testing positive by both methods are indicated by (p/c);
e Animals were euthanized and necropsied on day 39 post challenge.
[0096] To determine if Ech_0660 mutant inoculation protects dogs against a heterologous challenge, we challenged the remaining two Ech_0660 vaccinated animals with a closely related Ehrlichia organism, E. canis , by needle inoculation (group 4). One unvaccinated control animal was also infected with wild-type E. canis by needle inoculation. Dogs in group 4 tested positive for infection in the blood 81.2% of the time (13 out of 16 samples tested), similar to the unvaccinated control animal (Table 11). Importantly, as only two animals were included in this group, additional experiments will be necessary to confirm this result and to achieve statistical significance.
[0000]
TABLE 11
Infection status of Ech_0660 vaccinated dogs and unvaccinated
control dog following wild-type E. canis challenge
Days Post Challenge: WT
E. canis by needle transmission
Necropsy d
Group 4 a
0
4
8
11
15
22
29
36
blood
sp
liv
Ech_0660_6
−
−
p/c c
p/c
p/c
p/c
p/c
p/c
p/c
−
+
Ech_0660_7
−
−
p/c
−
p/c
p/c
p/c
p/c
p/c
−
−
Days Post Challenge: WT
E. canis by needle transmission
Control b
0
3
7
10
14
17
24
31
blood
sp
liv
E_canis_1
−
p/c
p/c
p/c
p/c
p/c
p/c
p/c
p/c
+
+
a Dogs from Table 9 were challenged 31 days after vaccination. Animals were challenged i.v. with 2 × 10 8 wild-type E. canis organisms;
b Unvaccinated control dog was challenged with ~2 × 10 8 wild-type E. canis organisms;
c Dogs were tested at the indicated time points for E. canis organisms in the blood by PCR (p) and culture recovery methods (c). Animals testing positive by both methods are indicated by (p/c);
d Animals were euthanized and necropsied on day 39 post challenge.
[0097] A subsequent analysis of the E. chaffeensis —specific IgG response of vaccinated vs unvaccinated animals followed by challenge with wild type organisms was performed. Vaccination revealed a pathogen-specific IgG response in 4 of 5 animals ( FIG. 10 ). Both vaccinated and unvaccinated animals exhibited pathogen-specific IgG responses following challenge.
[0098] FIG. 10A illustrates total E. chaffeensis -specific IgG measured in the plasma at multiple time points by ELISA in dogs vaccinated with the Ech_0660 mutant and challenged with wild type E. chaffeensis via needle inoculation (group 1) or vaccinated with Ech_0660 and challenged with wild type E. chaffeensis via tick-transmission (group 2). FIG. 10B illustrates unvaccinated control dogs infected with wild type E. chaffeensis or the non-attenuated Ech_0480 mutant via tick-transmission (group 3). Each line is representative of a single animal | Attenuated vaccines to protect vertebrate animals and people against tick-born rickettsial, Ehrlichia and Anaplasma species infections is disclosed. Also disclosed are methods to modify the organism to achieve the desired immunity through the modification of a novel genetic region involved in pathogenesis. These compounds represent a needed vaccine against an organism causing life-threatening febrile illness in humans and animals, and also represent the potential to develop new classes of drugs targeting the gene products of genes Ech_0660, Ech_0379, and Ech_0230, and their homologs of other related rickettsial pathogens. | 0 |
STATEMENT REGARDING RELATED APPLICATIONS
This application is a continuation of application Ser. No. 08/874,018, filed Jun. 12, 1997, now U.S. Pat. No. 5,875,981 which was a continuation of application Ser. No. 08/733,315, filed Oct. 17, 1996, now abandoned, which was a divisional of application Ser. No. 08/617,346, filed Mar. 18, 1996, now U.S. Pat. No. 5,718,390.
BACKGROUND OF THE INVENTION
The invention relates generally to a gyratory or cone crusher.
Gyratory crushers or cone crushers are characterized by crushing heads having a generally cone-shaped outer surface, which are mounted to undergo gyratory motion. The cone-shaped crushing head of a gyratory crusher is generally centered about a cone axis that is angularly offset from a vertical crusher axis generally centered through the crusher. The outer surface of the head is protected by a replaceable mantel.
The crushers are further characterized by a bowl-shaped member, sometimes referred to as a concave or bonnet, disposed in an inverted position generally over the cone-shaped crushing head and centered on the vertical crusher axis. The inner surface of the bowl-shaped member is protected by a replaceable bowl liner. The outer dimensions of the head and mantel are smaller than the corresponding inner dimensions of the bowl liner. The head is mounted such that there is a space between the mantel and the bowl liner, sometimes referred to as the "crushing chamber" or "crushing cavity". The volume of the crushing cavity can be increased by altering the shape of the exposed surface of the bowl liner and/or the shape of the exposed surface of the mantel. It can also be increased or decreased by vertically adjusting the separation between the mantel and the bowl liner. The bowl-shaped member has an upper opening through which material to be crushed can be fed into the crushing cavity.
The smallest distance between the mantel and the bowl liner at the bottom of the crushing cavity is called the "closed side setting" or "setting" of the crusher. The width of the setting determines the size of crushed materials operably produced by the crusher. The setting can be enlarged to increase the size of the crushed material produced by the crusher, and can be decreased to reduce the size of the crushed material produced by the crusher. The setting can be adjusted by simply raising or lowering the elevation of the bowl liner relative to the elevation of the cone head. The setting of some cone crushers is adjusted by raising or lowering the head. The difference between the width of the closed side setting and the spacing between the mantel and the bowl liner at the bottom of the crushing cavity directly opposite from the closed side setting, sometimes called the "open" side or "open side setting", is called the "throw" or "stroke" of the crusher.
The small angular offset of the cone axis relative to the vertical crusher axis is provided by mounting the head on an eccentric element, or other suitable mounting. The head is caused to gyrate relative to the bowl-shaped member by rotating that mounting or eccentric element. As the eccentric element rotates, one side of the head is caused to approach the bowl liner until it attains the closed side setting while the opposite side of the head recedes from the bowl liner until it simultaneously attains the open side setting. The closed side setting and open side setting operably travel around the periphery of the lower end of the crushing cavity as the eccentric element is rotated, each making a complete revolution around the cone head for each revolution on the eccentric element. The magnitude of the gyration is determined by the angle that the cone axis is offset from the crusher axis and by the location of the point at which those two axes most closely approach or intersect.
State-of-the-art gyratory or cone crushers are generally driven by a horizontally disposed countershaft which radially extends into a lower part of a generally cylindrical crusher housing. An inner end of the countershaft is coupled through a pinion and ring gear to the eccentric element to rotatably drive the eccentric element.
A motor (either electric or combustion) is used to drive the crusher. The speed of the motor, the size ratio of the pulleys on the motor and the crusher, and the gearing of the eccentric element determine the speed at which the head gyrates, sometimes referred to as the "gyrational speed". The gyrational speed selected for each crusher depends on the particular application for which the crusher is to be used. Increasing or decreasing the gyrational speed is usually a matter of changing the speed of the motor, changing the relative sizes of the pulleys on the motor and the crusher, and/or changing the gear ratios for the eccentric.
The gyratory or gyrating motion of the cone-shaped crushing head performs a material comminution action on material, such as rock, ore, coal and other hard substances, as the material is fed through the bowl opening into the crushing cavity. The material typically moves by gravity through the annular space between the exposed surface of the stationary bowl liner and the exposed surface of the cone-shaped mantel. As the gyrating head approaches the liner, it crushes the material; as it recedes from the liner, the material falls farther down the crushing cavity to undergo further crushings during subsequent revolutions of the eccentric member and as the separation between the bowl liner and the head gradually decreases from top to bottom. This progressive crushing action repeatedly occurs until the crushed material is discharged from the bottom of the crushing cavity.
A continuing problem with prior art cone crushers is the provision of reliable and inexpensive dust seals to prevent dust and grit, that is invariably generated in abundance during the crushing operation, from gaining access to critical moving parts. The problem arises from the need to attach one side of such a seal to a portion of a crusher that moves relative to another portion of the crusher to which the other side of the seal must be attached.
Another problem with cone crushers is the external plumbing used for tramp iron relief systems for automatically processing uncrushable material through the crushing chamber. The plumbing, being exposed on the exterior of the crushers, is largely unprotected and prone to accidental damage and disruption.
A further desirable improvement for a cone crusher would be the provision of a self-contained lubricating system whereby auxiliary equipment located externally to the crusher could be eliminated. A related desirable improvement would be to provide a more reliable and simpler method of supporting the gyrating head of the crusher and distributing lubricating oil within the crusher.
Another problem with prior art cone crushers is the thermal stresses that develop within the lower frameworks of the crushers. The thermal stresses arise due to the difference in temperature of the working parts of the crushers during the crushing operation relative to the temperature of the outer walls of the lower framework. The temperature difference is acerbated by the crushed material being discharged against and sliding down the outer walls of the lower framework thereby cooling those walls, sometimes to a temperature lower than ambient.
Another desirable improvement for a cone crusher would be to accurately and precisely locate the eccentric element thereof whereby the drive assembly associated therewith could be simplified without sacrificing long-wear characteristics and reliability.
What is needed is a gyratory crusher that has a dust seal that reliably and inexpensively prevents dust and grit from gaining access to critical moving parts of the crusher; that has a tramp iron relief system without external plumbing; that has a self-contained lubricating system; that has a simpler and more reliable cone head mounting and supporting system; that has a precisely and accurately located eccentric element, even during the crushing operating; that allows simplification of the drive arrangement thereof; that has a thermal relief system whereby temperature differences between moving parts of the cone head supporting system and walls of the lower framework of the crusher are reduced; and that has easily replaceable parts that minimize maintenance costs.
SUMMARY OF THE INVENTION
An improved gyratory crusher is provided for crushing rock, ore, coal and other hard substances. The gyratory crusher includes a lower frame portion, an upper frame portion supported by the lower frame portion, and a bonnet supported by the upper frame portion. The bonnet has an upper opening for receiving the material to be crushed.
The gyratory crusher also includes an eccentric member and a conically shaped crusher head. The eccentric member is pivotally mounted on the lower frame portion about a crusher axis spaced centrally and vertically relative to the lower frame member. The crusher head is pivotally mounted on the eccentric member about a cone head axis spaced generally centrally and vertically relative to the lower frame portion wherein the cone head axis is angularly offset from the crusher axis and intersects the crusher axis above the crusher head. A crushing chamber is formed between the crusher head and the bonnet.
The mounting arrangement of the gyratory crusher also includes a plurality of hydrostatic bearings for operably supporting the crusher head, a pair of taper bearings configured to operatively provide rotational displacement of the eccentric member about the crusher axis, and a spherical bearing configured to operatively provide rotational displacement of the crusher head about the cone head axis. The crusher head is mounted on a main shaft having a tapped partial bore adapted to threadably receive a mantel stud. One or more partial bores spaced across the threads of the tapped partial bore and the threads of the mantel stud are each adapted to receive a dowel pin as the mantel stud is in threaded engagement with the tapped partial bore. The dowel pin or pins prevent overtightening of the self-tightening mantel stud during crushing operations of the gyratory crusher.
The gyratory crusher also includes a flexible seal that is configured to operatively protect moving components thereof from dust and grit generated during crushing operations. An outer edge of the flexible seal is secured to the crusher head and an inner edge of the flexible seal is secured to an outer race of a ball bearing seal, the inner race of which is secured to non-rotating members of the mounting arrangement.
The gyratory crusher also includes a hydraulic tramp iron relief system that is configured to automatically allow uncrushable material to pass through the crushing chamber. The tramp iron relief system includes channels formed internally within the structure of the lower frame portion to connect cylinders and accumulators of the tramp iron relief system in high-pressure hydraulic fluid flow communication.
The gyratory crusher also includes a self-contained lubricating system configured to operatively lubricate the moving components and sliding interfaces thereof, and to operably transfer thermal energy from the moving parts of the mounting arrangement to the lower frame portion to thereby reduce thermal stress within the crusher.
A driving arrangement, including a bevel gear centered about the crusher axis and secured directly to the eccentric member, provides power for operating the crusher.
PRINCIPAL OBJECTS AND ADVANTAGES OF THE INVENTION
The principal objects and advantages of the present invention include: providing a gyratory crusher that has a flexible dust seal arrangement; providing such a gyratory crusher that has a tramp iron relief system without external plumbing interconnecting cylinders and accumulators thereof; providing such a gyratory crusher that has a self-contained lubricating system; providing such a gyratory crusher that has a hydrostatically supported cone head; providing such a gyratory crusher that has a precisely and accurately located eccentric element relative to lower framework of the crusher; providing such a gyratory crusher that has a drive arrangement attached directly to an eccentric element of the crusher; providing such a gyratory crusher that has a thermal relief system whereby thermal energy from moving parts of a cone head supporting arrangement of the crusher is transferred to a lower framework of the crusher; providing such a gyratory crusher that has easily replaceable parts to minimize maintenance costs; and generally providing such a gyratory crusher that is efficient in operation, capable of long operating life, and particularly well adapted for the proposed usages thereof.
Other objects and advantages of this invention will become apparent from the following description taken in conjunction with the accompanying drawings wherein are set forth, by way of illustration and example, certain embodiments of this invention.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a fragmentary, side elevational view of a gyratory crusher including an elevating arrangement and cylinders and accumulators of a tramp iron relief system thereof, according to the present invention.
FIG. 2 is a fragmentary, partially cross-sectional view of the gyratory crusher, taken along line 2--2 of FIG. 1.
FIG. 3 is an enlarged and fragmentary, side elevational view of the gyratory crusher, showing one of the plurality of cylinders of the tramp iron relief system with portions broken away to reveal details thereof.
FIG. 4 is a further enlarged and fragmentary, side elevational and cross-sectional view of one of the plurality of cylinders of the tramp iron relief system of the gyratory crusher, taken along line 4--4 of FIG. 3.
FIG. 5 is an enlarged and fragmentary, top plan view of one of the plurality of accumulators of the tramp iron relief system of the gyratory crusher taken along line 5--5 of FIG. 2, with portions broken away to reveal details thereof.
FIG. 6 is a fragmentary top plan view of the gyratory crusher taken along line 6--6 of FIG. 2 with a portion cut away to reveal details thereof, showing a thermal stress relief arrangement thereof.
FIG. 7 is a further enlarged and fragmentary, partially cross-sectional and side elevational view of a stop pin arrangement of the gyratory crusher.
FIG. 8 is an enlarged and fragmentary, partially cross-sectional and side elevational view of a fluted bowl liner of the gyratory crusher.
FIG. 9 is a further enlarged and fragmentary, partially cross-sectional view of the gyratory crusher, showing a mantel stud thereof.
FIG. 10 is a yet further enlarged and fragmentary, partially cross-sectional view of the gyratory crusher, showing a dust seal arrangement thereof in the vicinity of a closed side setting of the gyratory crusher.
FIG. 11 is a fragmentary view of the gyratory crusher, similar to that of FIG. 10 but showing the dust seal arrangement in the vicinity of an open side setting of the gyratory crusher.
FIG. 12 is a yet further enlarged and fragmentary view of the gyratory crusher, similar to that of FIG. 10 but showing an alternate dust seal arrangement.
FIG. 13 is a schematic representation of a lubricating system of the gyratory crusher, according to the present invention.
FIG. 14 is a fragmentary and further enlarged plan view of the elevating arrangements of the gyratory crusher.
FIG. 15 is a partial exploded and perspective view of accumulator attaching means of the gyratory crusher, according to the present invention.
DETAILED DESCRIPTION OF THE INVENTION
As required, detailed embodiments of the present invention are disclosed herein; however, it is to be understood that the disclosed embodiments are merely exemplary of the invention, which may be embodied in various forms. Therefore, specific structural and functional details disclosed herein are not to be interpreted as limiting, but merely as a basis for the claims and as a representative basis for teaching one skilled in the art to variously employ the present invention in virtually any appropriately detailed structure.
The reference numeral 1 generally refers to a gyratory crusher in accordance with the present invention, as shown somewhat simplified to highlight particular features of the present invention in FIGS. 1 through 15. The crusher 1 includes frame means 3, head mounting means 5, adjusting means 7, lubricating means 9, thermal stress relief means 11, dust seal means 13, and a tramp iron relief system 15.
The frame means 3 includes a lower frame portion 21 and an upper frame portion 23. A "V-seat" arrangement 25, as shown in FIG. 7, is peripherally situated between the lower frame portion 21 and the upper frame portion 23, similar to that disclosed in U.S. Pat. No. 4,773,604 entitled "Seat Member for Gyratory Rock Crusher Bowls" and issued Sep. 27, 1988. A bowl, concave or bonnet 31 is mounted on the upper frame portion 23 by threads 33. A bowl liner 35 having an exposed surface 37 is replaceably mounted on the bonnet 31 by liner connectors 39. The bowl liner 35 is a wear item that is replaceable while the crusher 1 is shut down during maintenance periods. The upper frame portion 23, the bonnet 31 and the bowl liner 35, which may be collectively referred to herein as an upper assembly 41, are all centered about a vertically oriented crusher axis 51, located centrally through the crusher 1. The bowl liner 35 has the general shape of a hollow truncated pyramid with a generally circularly shaped upper opening 53 and a wider, generally circularly shaped lower opening 55. The upper opening 53 provides a material feed or intake opening for the crusher 1.
Partially located within the bowl liner 35, and extending through the lower opening 55 into the space encompassed by the bowl liner 35, is a crusher head or cone head 61 of the crusher 1. The cone head 61 is generally conically shaped. A mantel 63, replaceably mounted on the cone head 61, provides a conical upwardly facing crushing surface 65 for the cone head 61. The cone head 61 is centered about a generally vertically oriented cone head axis 67, which is disposed and supported at an angle of deviation, as indicated by the numeral 69 in FIG. 2, with respect to the crusher axis 51. The cone head axis 67 and the crusher axis 51 intersect at an apex of gyration or apex 71 that lies centrally above the crusher 1. During the operation of the crusher 1, the cone head 61 gyrates about the apex 71 with respect to the bonnet 31.
The head mounting means 5 includes a main shaft 81, centered about the cone head axis 67, for receiving the cone head 61, as shown in FIG. 2. An upper end 83 of the main shaft 81 has a tapped partial bore 85 for threadably receiving a mantel stud 87, as shown in FIG. 9.
The mantel stud 87 has an inner threaded portion 89 for mating with the partial bore 85 and an outer threaded portion 91 for mating with a mantel nut 93 as hereinafter described. The handedness of the inner threaded portion 89 and the outer threaded portion 91 is such that the mantel stud 87 and the mantel nut 93 are self-tightening. The threads of the inner threaded portion 89 and the outer threaded portion 91 have an appropriate pitch, such as four threads per inch for the outer threaded portion 91 and six threads per inch for the inner threaded portion 89.
At least one, preferably two or more, partial bores 95, axially aligned with the cone head axis 67, are located across the mated threads of the partial bore 85 and the inner threaded portion 89 for receiving a respective dowel pin 97 therein. The dowel pins 97 are adapted to prevent over-tightening of the mantel stud 87 during the crushing operation and to thereby facilitate subsequent removal or replacement of the mantel stud 87, thereby allowing low-cost replacement of a corresponding thread system that holds a mantel bolt 99 without having to remove or replace the main shaft 81.
The mantel 63 is attached to the cone head 61 by placing the mantel 63 on the cone head 61 and placing a mantel washer or "torch ring" 111 over the outer threaded portion 91. The mantel nut 93 is threadably advanced along the outer threaded portion 91. The mantel nut 93 has outwardly tapered shoulders 113 which, in conjunction with the torch ring 111 and an appropriately sized and shaped orifice 115 through the mantel 63, centers and secures the mantel 63 to the cone head 61. A mantel cap 117 is secured to the mantel nut 93 by the bolt 99 to protect the mantel nut 93 and the torch ring 111 from material falling through the upper opening 53.
The head mounting means 5 also includes an eccentric member 131 mounted within an encasement portion 133 of the lower frame portion 21. Rotational movement of the eccentric member 131 relative to the encasement portion 133 is provided by a pair of taper bearings 135, 137 centered about the crusher axis 51, as shown in FIG. 11.
A cavity 139, formed within the eccentric member 131, is configured to provide the angular offset 69. Rotational movement of the cone head 61 relative to the eccentric member 131 is provided by a spherical bearing 141 centered about the cone head axis 67. A bushing 143 and a spacer 145 about the main shaft 81 appropriately locate the spacing of the spherical bearing 141 relative to the main shaft 81. Counterweight 147 can be attached to the eccentric member 311 to balance the gyratory forces, as needed.
To provide adequate mounting for the taper bearings 135, 137 while also providing added support for the substantial stress forces generated during the crushing operating, the cone head 61 is mounted in abutting engagement with a plurality of hydrostatic bearings 161, mounted on thrust seats 163 equidistantly spaced around the crusher axis 51. A bottom surface 165 of the cone head 61 is spherically shaped with the center of curvature thereof located at the apex 71 whereby the abutting engagement between the hydrostatic bearings 161 and the surface 165 form a sliding interface as the cone head 61 gyrates during the crushing operation.
The thrust seats 163 are mounted on and jointly supported by an upper side 167 of the encasement portion 133 and the taper bearings 135, 137. The primary purpose for partially supporting the cone head 61 by the taper bearings 135, 137 is to "load" the taper bearings 135, 137. In so doing, the eccentric member 131 is precisely located, both axially and radially, relative to the encasement portion 133. Selected ones of a plurality of shims 169 having different thicknesses provide the desired loading of the taper bearings 135, 137.
By precisely mounting and locating the eccentric member 131 relative to the encasement portion 133 with the taper bearings 135, 137, a gear 181, such as a spiral bevel gear, can be centered about the crusher axis 51 and attached directly to the eccentric member 131, thereby eliminating the more complicated, more expensive and higher maintenance gear arrangements of the prior art arrangements. A drive train or drive pinion arrangement 183, meshed with the gear 181 and connected to a sheave 185 or other suitable means, provides means for powering the crusher 1.
The crushing operation is effected by the spacing between the cone head 61 and the bonnet 31 or, more particularly, the spacing between the mantel 63 and the bowl liner 35. A releasable clamping arrangement 187 jams the opposing threads 33 against each other to prevent relative rotation of the threads 33 except when desired. Preferably, the clamping arrangement 187 is activated by hydraulically operated by appropriately spaced cylinders 189. Alternately, the clamping arrangement 187 may be activated by utilizing bolts and nuts 190.
Wear occurring on the respectively exposed mantel surface 65 and the bowl liner surface 37 tends to increase the spacing therebetween. Consequently, the adjusting means 7, which provides periodic corrective adjustments of the spacing between the mantel 63 and the bowl liner 35, includes the threads 33 which permit continuous adjustment of the axial position of the bonnet 31 in a step-less up or down displacement by rotating the bonnet 31 about the crusher axis 23 with respect to the upper frame portion 7, the ring gear 191, and a pair of drive motors 193, as shown in FIG. 1.
The adjusting means 7 also includes a plurality, four for example, of vertically oriented cleats 195 secured to a wall 197 of the upper frame portion 23. The ring gear 191 has a corresponding plurality of vertically oriented grooves 199. The ring gear 191, cleats 195 and grooves 199 are configured whereby the ring gear 191 can be displaced vertically alongside the wall 197 but cannot be horizontally rotated relative to the wall 197 due to interaction between the cleats 195 and the grooves 199, as shown in FIG. 14.
The drive motors 193 are mounted on the lower frame portion 21. A plurality of rollers 201, supporting the ring gear 191, are also mounted on the lower frame portion 21 whereby the ring gear 191 is maintained in gearing engagement with the drive motors 193.
To adjust the separation between the mantel 63 and the bowl liner 35, the hydraulic cylinders 189 are bled whereby the jamming pressure between the opposing threads 33 is reduced allowing the drive motors 193 to displace the mating surfaces of the threads 33 relative to each other. Then, the drive motors 193 are activated whereby the ring gear 191 is horizontally rotated. If it is desired to increase the separation between the bowl liner 35 and the mantel 63, the drive motors 193 are operated in unison to cause the upper frame portion 23 to be threadably advanced upwardly. Conversely, if it is desired to decrease the separation between the bowl liner 35 and the mantel 63, the drive motors 193 are operated in unison in the opposite direction to cause the upper frame portion 23 to be threadably advanced downwardly. After attaining the desired separation between the bowl liner 35 and the mantel 63, forces exerted by the clamping arrangement 187 are increased to maintain the newly established separation.
Included conical angles of the bowl liner 35 and the mantel 63 are configured to provide an annular space or crushing chamber 211 between the bowl liner surface 37 and the mantel surface 65, the width thereof generally decreasing downwardly. An annular gap 213 at the lower opening 55 between the bowl liner 35 and the mantel 63 constitutes an annular material discharge opening 215 from the crushing chamber 211. During operation of the crusher 1, material is fed into the crushing chamber 211 through the upper opening 53, which material is gravitationally urged downwardly through the annular crushing chamber 211 and is reduced in size through repeated crushing contacts between the adjacent surfaces 37 and 65 of the bowl liner 35 and the mantel 63.
The maximum size of material that can be crushed by the crusher 1 is determined by the spacing between the uppermost ends of the bowl liner surface 37 and the mantel surface 65, as indicated by the phantom circle designated by the numeral 217 in FIG. 8. If desired, a plurality of flutes 219 may be formed in the bowl liner surface 37, as shown in FIG. 8, whereby occasional oversized material may be received by the crushing chamber 211 to thereby increase the maximum opening of the crushing chamber 211 without increasing the size of the crusher 1.
The lubricating means 9 of the crusher 1 is self-contained and includes a first pumping arrangement 231 for circulating oil through the crusher 1 for lubricating the various moving parts thereof.
Oil for the first pumping arrangement 231 is contained in an oil pan 233. The first pumping arrangement 231, as schematically illustrated in FIG. 13, draws oil from the oil pan 233 by a lubricating portion 235 of a pump 237 and directs that oil by an oil line 239 through a high-pressure filter 241, a pressure transducer 243 and a flow divider 245. If a failure should occur whereby oil pressure should unexpectedly drop at the pressure transducer 243, such as a broken oil line, the pressure transducer 243 is adapted to signal shut-down controls 247, which immediately shut-down operation of the crusher 1. If, instead, oil pressure in the oil line 239 should exceed a certain pre-determined level, oil will be bled from the oil line 239 by a relief valve 249 and routed back to the oil pan 233.
The flow divider 245 distributes oil flowing therethrough separately to each of the hydrostatic thrust bearings 161 and to the drive pinion arrangement 183, from where the oil gravitationally returns to the oil pan 233, as indicated by the arrow designated by the numeral 251 in FIG. 13. The flow divider 245 also distributes oil to the drive train 183, as indicated by the dashed line designated by the numeral 252.
Monitoring means 253 monitors the volume of oil being processed through the flow divider 245. If oil flow to the hydrostatic thrust bearings 161 or the drive pinion arrangement 183, as evidenced by a reduction in volume of oil flow therethrough as determined by the monitoring means 253, the monitoring means 253 will signal the shut-down controls 247 to immediately shut-down operation of the crusher 1.
Pressurized oil is conveyed from the flow divider 245 to the interface between the hydrostatic bearings 161 and the bottom surface 165 of the cone head 61 by oil channels 255 for lubrication purposes. The oil is sufficiently pressurized whereby the cone head 61 is slightly elevated and supported on a thin film of oil on each of the hydrostatic bearings 161. Oil sprays outwardly from the interface between the hydrostatic bearings 161 and the bottom surface 165 of the cone head 61 and, as it cascades downwardly, lubricates the other moving parts of the head mounting means 5 therebelow. Spring loaded wiper rings 257 cause oil sprayed radially outwardly from the hydrostatic bearings 161 to be directly downwardly onto a seal bearing 259. Weep holes 261 drain oil from the seal bearing 259 and other pockets for gravitational return to the oil pan 233.
The thermal stress relief means 11 is also self-contained and includes a second pumping arrangement 281. The second pumping arrangement 281 draws oil from the oil pan 233 by a cooling portion 283 of the pump 237 and directs that oil through oil line 285 and a filter 287. If the oil temperature should be lower than a pre-determined temperature, a bypass valve 289 diverts the oil from the oil line 285 to the oil pan 233. When the oil in oil line 285 reaches or exceeds that pre-determined temperature, oil is no longer diverted by the bypass valve 289 but, instead, is directed through half-collars 291 abutting a wall 293 of the lower frame portion 21 and into the oil pan 233. The half collars 291, as shown in FIG. 6, and the oil circulated therethrough are adapted to elevate the temperature of the wall 293 to a temperature more closely approximately the temperatures in the head mounting means 5 to reduce thermal stresses within the lower frame portion 21 of the crusher 1.
Actually, the thermal relief means 11 serves a dual purpose. In addition to relieving the thermal stress, the thermal relief means 11 also serves as a cooling means for the lubricating oil.
The dust seal means 13 is adapted to isolate inner moving components, such as the interface between the hydrostatic bearings 161 and the bearings 135, 137 and 141, from abrasive contamination arising from the ubiquitous dust and grit generated during the crushing process. The dust seal means 13 includes a flexible seal 301 having an outer edge 303 secured to a lower extremity 305 of the cone head 61 and an inner edge 307 secured to an outer race 309 of the seal 259, an inner race 311 of which is secured to the thrust seats 163. Bearing balls 312 are captured between the inner race 311 and the outer race 309 in peripheral grooves thereof.
To provide the flexibility needed to compensate for the oscillatory displacement of the cone head 61 due to the gyratory motion thereof, the flexible seal 301 generally has a single-wall construction with a corrugation-like cross-sectional configuration, as shown in FIG. 10. As the separation between the mantel 63 and the bowl liner 35 at a particular point along the gap 213 approaches the closed side setting, the corrugations or fingers 313 widen to compensate for the corresponding increasing separation between the lower extremity 305 and the seal bearing 301. Similarly, as the separation between the mantel 63 and the bowl liner 35 approaches the open side setting, the fingers 313 become narrower to compensate for the corresponding decreasing separation between the lower extremity 305 and the seal bearing 301.
To compensate for rotation of the cone head 61 relative to the bowl liner 35 during a crushing operation, the outer race 309 rotates with the cone head 61, peripherally relative to the inner race 311.
Alternatively, the dust seal means 13 may include a flexible seal 321 having a double-wall construction that forms a bladder 323 therebetween, as shown in FIG. 12. For some applications, it may be desirable to pressurize the bladder 323, such as between one to five pounds per square inch.
The tramp iron relief system 15 includes a lower radial member 331 secured to and spaced radially outwardly from an upper end 333 of the wall 293 of the lower frame portion 21. A peripheral groove 335 is formed in an outer edge 337 of the lower radial member 331. A plurality of equidistantly spaced partial bores 341 extend radially inwardly from the groove 335, as shown in FIG. 2. For example, the tramp iron relief system 15 may include eight of the partial bores 341.
In addition, a port 343 is provided from each of the partial bores 341 through a lower surface 345 of the lower radial member 331, as shown in FIG. 3. The ports 343 are spaced outwardly from the wall 293 whereby a cylinder 347, can be connected to and suspended downwardly from a respective one of each of the ports 343. If desired, the cylinders 347 may be connected to the ports 343 by inserts 349, as shown in FIG. 3, preferably constructed of a dissimilar metal, such as brass or other suitable material to minimize or eliminate galling when removing the cylinders 347 from the ports 343. The cylinders 347 are spaced in close proximity to the wall 293.
The tramp iron relief system 15 also includes a skirt 351 secured to the lower radial member 331 as shown in FIG. 4. The skirt 351 extends downwardly from the lower radial member 331 to provide some protection for the cylinders 347. If desired, a groove 353 may be provided along an inner peripheral surface of the skirt 351 to complement and provide greater flow capacity for hydraulic fluid being conveyed along the groove 335.
A piston rod 355 extends downwardly from each of the cylinders 347 and connects to a respective one of a plurality of rocker arm arrangements 357. Each of the rocker arm arrangements 357 has an extension 359 extending through a respective one of a plurality of guides 361. A pair of opposing pull rods 371 extend upwardly from each end of a respective one of the rocker arm arrangements 357, through corresponding openings 373 in the lower radial member 331, and through additional corresponding openings 375 in an upper radial member 377, secured to and spaced radially outwardly from the wall 197 of the upper frame portion 23. Split keepers 379 connected to upper ends of each of the pull rods 371 provide means for hydraulically providing substantial hold-down forces between the upper frame portion 23 and the lower frame portion 21.
The tramp iron relief system 15 also includes a plurality of accumulators 385. For example, the crusher 1 may have one of the accumulators 385 positioned in every other space between the cylinders 347. Each of the accumulators 385 are connected in flow communication with the groove 335, similarly to that provided by the ports 343 and the partial bores 341 for the cylinders 347 and, preferably, by inserts similar to the inserts 349. An appropriately spaced input port 387 is provided for injecting hydraulic fluid into the tramp iron relief system 15 from an external hydraulic source 388, as schematically shown in FIG. 1.
Each of the accumulators 385 are affixed to the wall 293 by accumulator attaching means, comprising a pair of opposing locators 389 and an interconnecting hanger 391. Each of the locators 389 is spaced outwardly from the wall 293 by standoffs 392. The locators have a pair of slots in a base 393 thereof that allows a cylindrical edge 394 thereof to be placed and affixed in abutting engagement with the respective accumulator 385, as shown in FIGS. 5 and 15. The hanger 391 has a threaded connector 395 at each end thereof to clamp the accumulator 385 against the cylindrical edges 394.
One of the distinct advantages provided by the present invention is the elimination of all external plumbing of a hydraulic system for tramp iron relief purposes.
In an application of the present invention, hydraulic fluid is injected into the system to pressurize the hydraulics of the tramp iron relief system 15 to a selected pressure; for example, 2,000-2,400 psi or other suitable pressure as appropriate to clamp the upper frame portion 23 to the lower frame portion 21, particularly across the V-seat arrangement 25.
The closed side setting is adjusted by displacing the bowl liner 35 upwardly or downwardly as needed by clockwise or counterclockwise rotation of the elevating ring gear 191 as appropriate. The first pumping arrangement 231 is activated to provide lubricating oil to the hydrostatic thrust bearings 161 and the drive pinion arrangement 183. The second pumping arrangement 281 is activated to provide oil to the half collars 291 after the oil reaches or surpasses a pre-determined temperature. A prime mover 397, as schematically indicated in FIG. 2, is drivingly engaged with the sheave 185 to initiate gyration of the cone head 61 relative to the bowl liner 35.
Rock, ores or other material are dropped through the upper opening 53 of the bowl liner 35 and are crushed between the mantel 63 and the bowl liner 35 as the material being crushed is gravitationally urged through the crushing chamber 211 to be discharged through the gap 213 thereof. As the crushing operation progresses, the temperature of the oil increases until the pre-determined temperature setting of the bypass valve 289 is reached or exceeded. Then, the bypass valve 289 directs the oil passing through the second pumping arrangement 281 to and through the half collars 291.
The trajectory of crushed material being discharged from the gap 213, which is generally much cooler than the oil, bearings and other moving parts of the crusher 1, causes the crushed material to impact with the wall 293, thereby cooling the wall 293. Due to the temperature difference between the cooled wall 293 and that of the moving components of the crusher 1, prior art crushers endure thermal stresses in addition to the substantial physical stresses inherent in the crushing process. In the present invention, however, the oil circulated through the half collars 291 warms the wall 293, thereby counteracting the cooling effect of the crushed material impacting with the wall 293. As a result, thermal stresses in the crusher 1 of the present invention are substantially reduced from those of prior art crushers.
As non-crushable material that is too large to be processed through the crushing chamber 211, sometimes referred to as "tramp iron", is dropped into the crushing chamber 211, a portion of the bowl liner 35 and the association portion of the upper frame portion 23 are forced upwardly from the cone head 61, causing the corresponding portion of the V-seat arrangement 25 to separate. As the upper frame portion 23 is forced upwardly, corresponding ones of the pull rods 371, which are secured to the upper radial member 377 by the split keepers 379, and the rods 355 connected to the pull rods 371 by the rocker arm arrangements 357 are also forced upwardly.
As the rods 355 are forced upwardly, pistons 399 push hydraulic fluid thereabove into the enclosed peripheral groove 335. The hydraulic fluid flows along the groove 335 to each of the plurality of accumulators 385 connected in flow communication with the groove 335. As the added pressure in the hydraulic fluid is conveyed to the accumulators 385, compressed bladders 401 within the accumulators 385 are further compressed to temporarily store the added mechanical energy caused by the tramp iron passing through the crushing chamber 211.
Immediately after the tramp iron has worked its way through the crushing chamber 211 and dropped from the gap 213, thereby relieving the upwardly thrusting forces previously exerted by the tramp iron, the extra pressure stored in the bladders 401 is dissipated as the upper frame portion 23, which was forced upwardly, returns to its rest position about the V-seat arrangement 25, also returning the pistons 399, the piston rods 355, the rocker arm arrangements 357, and the pull rods 371 to their rest positions. As the V-seat arrangement 25 is disturbed, such as during passage of tramp iron or "bowl float", stop pins 403 prevent rotation of the upper frame portion 23 relative to the lower frame portion 21. Sleeves or inserts 405 are readily removable to facilitate replacement of worn parts interacting with the stop pins 403 and of the pins 403 themselves to thereby minimize maintenance costs.
It is to be understood that while certain forms of the present invention have been illustrated and described herein, it is not to be limited to the specific forms or arrangement of parts described and shown. | A gyratory crusher with a tramp iron relief system having an annular manifold is disclosed. The gyratory crusher includes a frame, with the frame including a circumferential manifold ring having an internal hydraulic channel. A bonnet and a gyratory head are supported by the frame, with the gyratory head being spaced relative to the bonnet such that a crushing chamber is formed therebetween. The bonnet is adjustably mounted to the frame to permit relative vertical movement between the bonnet and the gyratory head. A hydraulic relief system is provided and includes at least one hydraulic cylinder operatively interconnecting the bonnet and the frame and being in flow communication with the hydraulic channel. The hydraulic relief system is arranged to allow uncrushable material to automatically pass through the crushing chamber. | 1 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to separable slide fasteners and more particularly to reinforcing tapes to be applied fast to the terminal parts of the fastener tapes, particularly the terminal parts of dyed fastener tapes, to which a separable insertion joint is attached. This invention further relates to a method for forming fastener tapes having a reinforced terminal part.
2. Description of the Prior Art
The conventional reinforcing tapes to be applied fast to the terminal parts of dyed fastener tapes have included those which, for the sake of obviating the necessity of preparing reinforced tapes dyed specially in various colors matched to the colors of the aforementioned dyed fastener tapes and consequently saving such time and labor as would otherwise be incurred in the inventory control, use transparent synthetic resin films in a superposed manner so as to show the colors of the dyed fastener tapes therethrough. For example, the reinforcing pieces which are formed of two superposed transparent synthetic resin films having different melting points and are adapted to be applied fast to fastener tapes by melting that of the two films having a lower melting point as disclosed in Japanese Utility Model Publication No. 44-25,843 and the lateral application tapes which are formed by superposing on one side of a transparent film of nylon 6 or nylon 6,6 a transparent polyester copolymer film having a melting point in the range of 80° to 200° C. so as to show the color of the base fabric of fastener tapes therethrough as disclosed in published Japanese Patent Application, KOKAI (Early Publication) No. 62-149,780 have been known to the art.
Since the conventional reinforcing tapes use a crystalline synthetic resin film in the surface layer thereof as described above and, therefore, are hard from the material point of view, they cannot be easily shaped by bending in conformity with the shape of the core parts of fastener tapes to which such fitting metal pieces as are used for a separable insertion joint are attached. As a result, it is difficult to impart an accurate outer shape to the core parts of the fastener tapes. The conventional reinforcing tapes pose yet other problems. When they are bent repeatedly, the bent parts thereof ultimately cause whitening possibly to the extent of impairing the overall appearance of the reinforcing tapes. Since their surface layers made of synthetic resin film have a highly glossy surface, the color of the dyed fastener tapes appears in a different tint as seen through the reinforcing tapes.
SUMMARY OF THE INVENTION
It is, therefore, an object of the present invention to eliminate the problems suffered by the conventional slide fasteners as mentioned above.
A more specific object of the present invention is to provide a reinforcing tape for a slide fastener which can be easily shaped in conformity with the outer shape of a core part of a fastener tape intended for attachment thereto of a fitting metal piece and, therefore, easily impart an accurate outer shape to the core part of the fastener tape.
A further object of the present invention is to provide a reinforcing tape and a slide fastener having the reinforcing tape attached thereto at a terminal part thereof, which allow the color of a dyed fastener tape to be seen therethrough faithfully.
A still further object of the present invention is to provide a method of forming a slide fastener tape having a reinforced terminal part.
To accomplish the objects mentioned above, the first aspect of the present invention consists in providing a reinforcing tape for a slide fastener, which comprises a transparent elastomer film and an adhesive layer superposed on the reverse side of the elastomer film.
In accordance with the second aspect of the present invention, there is provided a slide fastener which comprises a pair of dyed fastener tapes each having a row of coupling elements attached to the fastener tape along a longitudinal edge thereof and at least a pair of reinforcing tapes attached to a terminal part of each of the fastener tapes, characterized in that each of the reinforcing tapes comprising a transparent elastomer film and an adhesive layer superposed on the reverse side of the elastomer film is attached by welding or fusion bonding to the terminal part of the dyed fastener tape through the medium of the adhesive layer and has a knurled surface at the welded part.
In accordance with the third aspect of the present invention, there is provided a method of forming a fastener tape having a reinforced terminal part, which comprises the steps of providing a reinforcing tape formed of a transparent elastomer film and an adhesive layer superposed on the reverse side of the eleastomer film, thermally welding the reinforcing tape to a terminal part of a fastener tape through the medium of the adhesive layer, and knurling a surface of the welded part of the reinforcing tape.
In a preferred embodiment of the present invention, a reinforcing tape formed of a transparent polyester elastomer film and a modified polyester film superposed on the reverse side of the elastomer film is thermally welded to the terminal part of a dyed fastener tape formed of woven or knitted synthetic polyester fibers, and the welded part of the reinforcing tape is knurled.
BRIEF DESCRIPTION OF THE DRAWINGS
Other objects, features, and advantages of the invention will become apparent from the following description taken together with the drawings, in which:
FIG. 1 is a fragmentary plan View showing the lower part of a slide fastener provided with reinforcing tapes of the present invention;
FIG. 2 is a fragmentary plan view showing the lower part of the slide fastener of FIG. 1 held in a separated state;
FIG. 3 is a fragmentary cross-section view of the lower end part of a fastener tape provided with a reinforcing tape of the present invention; and
FIG. 4 is an enlarged fragmentary cross-section view of a fastener tape provided with a knurled surface.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Now, a preferred embodiment of the present invention will be described below with reference to the accompanying drawings. FIG. 1 and FIG. 2 each show the lower part of a slide fastener 1 having the reinforcing tapes 3a and 3b of the present invention provided in the parts used for attachment of a separable insertion joint at the lower end parts of a pair of fastener tapes 2a and 2b. FIG. 2 shows the lower part of the slide fastener which is held in a separated state.
The slide fastener 1 shown in FIG. 1 includes a pair of fastener tapes 2a and 2b, a pair of reinforcing tapes 3a and 3b which are welded or fused to the lower end parts of the respective fastener tapes 2a and 2b, rows of coupling elements 4a and 4b, such as spiral coil coupling elements, attached to the inner longitudinal edges of the respective fastener tapes 2a and 2b, a slider 5, and a separable insertion joint or pin-and-box separator composed of an insertion member or hinge bar 6, a box bar 7, and a box member 8, these members being secured to the inner edges of the reinforcing tapes 3a and 3b which are welded to the lower end parts of fastener tapes 2a and 2b. The slider 5 is slidably mounted on the rows of coupling elements 4a and 4b for engaging and disengaging the coupling elements 4a and 4b. FIG. 1 shows the slide fastener 1 in a closed state and FIG. 2 shows it in an opened state.
The fastener tapes 2a and 2b to which the coupling elements 4a and 4b are attached are manufactured by weaving or knitting a fibrous material formed of such synthetic fibers as polyester, nylon, etc. or such natural fibers as cotton. To the lower end parts of the pair of fastener tapes 2a and 2b, the reinforcing tapes 3a and 3b are respectively welded or fused through the medium of an adhesive layer as explained hereinafter. The insertion member 6 which is one of the fitting metal pieces for the separable insertion joint is secured to the inner edge of one, 3a, of the opposed reinforcing tapes and the box member 8 for admitting the insertion member 6 and the box bar 7 therefor are secured to the opposite inner edge of the other, 3b, of the reinforcing tapes. The insertion member 6 is releasably engageable in a slot in the box member 8.
The reinforcing tapes 3a and 3b according to the present invention are each formed of two layers as shown in FIG. 4. A surface layer 9 is made of a film of an elastomeric polymer, or an elastomer, of a transparent amorphous highly elastic synthetic resin. Since the elastomer is amorphous and therefore highly elastic, it displays highly satisfactory modulus in flexure and allows easy bending even after adhesion to a fastener tape. Even when it is repeatedly bent, it retains the transparency thereof because the bent part does not cause whitening. The present invention specifically uses a transparent polyester elastomer as the material for the surface layer 9. The surface layer 9 of the elastomer film has a thickness in the range of 150 to 200 μm. It is provided on the reverse side thereof with an adhesive layer 10. A commonly used adhesive agent may be used as the material for the adhesive layer. A hot-melt adhesive is particularly advantageously used as the material for the adhesive film. In the present embodiment, a modified polyester is used as the hot-melt adhesive. It exhibits particularly high adhesiveness when the fastener tapes 2a and 2b are made of polyester fibers. The optimum thickness of the adhesive layer 10 is in the range of 50 to 60 μm.
The reinforcing tapes 3a and 3b are respectively applied fast to the fastener tapes 2a and 2b by fusing the adhesive layer 10 by such hot-pressing means as hot plate pressing or ultrasonic pressing. By knurling the surface layer 9 at the same time that the reinforcing tapes 3a and 3b are welded to the fastener tapes 2a and 2b, knurls 11 are formed at a pitch of not more than 1 mm (0.5 mm optimally) on the surface of the surface layer 9 to erase the surface gloss proper for the synthetic resin film.
FIG. 3 shows a cross section of the portion of the fastener tape 2a which has the reinforcing tape 3a welded thereto and the insertion member 6 further attached thereto. In the inner longitudinal edge of the fastener tape 2a, a protruding core part 12 is formed as with a core cord. The reinforcing tape. 3a is bent inwardly so as to cover the core part 12 and is welded to both the obverse and the reverse side of the fastener tape 2a so as to reinforce the part to which the insertion member 6 is attached. In the lower terminal part of the fastener tape 2b on the opposite side, the box bar 7 of the box member 8 for admitting the insertion member 6 is attached in the same manner as the aforementioned insertion member 6 as shown in FIG. 2, though omitted from illustration in a cross section. In addition to the lower terminal parts to which the separable insertion joint for the fastener tapes 2a and 2b is attached, the reinforcing tapes 3a and 3b may be welded in the upper terminal parts in the same manner as in the lower terminal parts.
The reinforcing tapes 3a and 3b are formed of a transparent elastomer film of elastic polymer. When they are welded or fused to the surfaces of the dyed fastener tapes 2a and 2b, therefore, the color of the fastener tapes is seen faithfully therethrough. Further since the reinforcing tapes 3a and 3b have no conspicuous surface gloss, they appear in substantially the same color as the dyed fastener tapes 2a and 2b and cannot impair the appearance.
As described above, since the reinforcing tape has the surface layer formed of a transparent elastomer film which is more elastic and flexible than most crystalline synthetic resins of the ordinary grade, it allows the core part to which the separable insertion joint is attached to be shaped accurately and easily. Even when the reinforcing tapes of the present invention are repeatedly bent, the bent parts do not cause whitening. Owing to this feature coupled with the meager surface gloss, the reinforcing tapes show the color of the dyed fastener tapes faithfully therethrough and appear to be intimately merged with the fastener tapes and cannot impair the appearance. Since the reinforcing tapes are consequently capable of matching the fastener tapes which generally come in numerous colors, they serve the purpose of obviating the necessity of preparing reinforcing tapes specially matching numerous colors and avoiding the complicated management of inventory.
By thermally welding reinforcing tapes formed of a surface layer of a polyester elastomer film and an adhesive layer of a modified polyester to fastener tapes which are formed of polyester fibers as mentioned above, a slide fastener which is reinforced by the reinforcing tapes possessing such excellent adhesiveness as prevents the adverse phenomena like separation and wear of the reinforcing tapes due to the impacts of the friction of a slider, the laundering, etc. and which produces no feeling of extraneousness of color, therefore, can be obtained.
While a preferred embodiment has been disclosed herein, the invention may be embodied in other specific forms without departing from the spirit or essential characteristics thereof. The described embodiment is 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 slide fastener comprises a pair of dyed fastener tapes each having a row of coupling elements attached to the fastener tape along a longitudinal edge thereof and at least a pair of reinforcing tapes attached to a terminal part of each of the fastener tapes. The reinforcing tape comprising a transparent elastomer film and an adhesive layer superposed on the reverse side of the elastomer film is attached by welding or fusion bonding to the terminal part of the dyed fastener tape through the medium of the adhesive layer and has a knurled surface at the welded part. | 0 |
FIELD OF THE INVENTION
This invention relates to equipment for positioning material dispensers, and, more particularly, to an apparatus carrying at least two dispensers supplied with material from a single feed line wherein the position of at least one of the dispensers is quickly and easily adjusted with respect to the other dispenser.
BACKGROUND OF THE INVENTION
Many applications require the use of multiple dispensers positioned at different locations relative to an article of given size which discharge adhesives, paint, powder coatings or other materials onto the article. For example, hot melt adhesive dispensers are employed in the cartoning and packaging industry to assemble the cartons or packages, and to adhere objects to the exterior of such packages. In one particular application, water-tight cardboard boxes for various beverages are assembled with hot melt adhesive, and then a pattern of three dots of adhesive is applied to the outside of the water-tight box to secure a straw thereto for use in drinking the beverage from the container In this application, and other cartoning applications, it is desirable to have the capability of accommodating boxes of different height with a minimum of down time of the cartoning line. In order to properly position the dots on the exterior of the water-tight cardboard box in the above-described example, the position of the adhesive dispensers must be adjusted to a height corresponding to that of the box and the straw sized for use with such box.
Positioners which are capable of adjusting the location of adhesive dispensers with respect to an article such as a box or package are well known and widely used in industry. One problem with many positioners for dispensers is that they are capable of handling one or more adhesive dispensers each having its own adhesive supply line, temperature control equipment and operating air lines. In the application described above, a total of three adhesive dispensers and associated adhesive supply lines and air lines are required to apply the desired pattern of dots to the water-tight carton. In this and many other cartoning and packaging applications, the space available for heated hot melt adhesive supply lines and/or air control lines is very limited, and separate supply lines for each adhesive dispenser is unacceptable
SUMMARY OF THE INVENTION
It is therefore among the objectives of this invention to provide an apparatus for adjusting the position of two or more dispensers relative to one another which provides for quick and easy adjustment of the relative position of the dispensers which is compact in construction, which employs a single material supply line and which is substantially leak free during adjustment and operation.
These objectives are accomplished in an apparatus for positioning two or more dispensers for hot melt adhesive, or other materials, comprising a first module adapted to connect to a source of adhesive, and a second module which is axially movable with respect to the first module. The first and second modules each mount at least one adhesive dispenser such that an adhesive passageway formed in each module is connected to a discharge bore formed in each adhesive dispenser The adhesive passageways in the first and second modules, in turn, are interconnected by a pair of pivot arms arranged in a scissors-like configuration which extend between the modules and are movable between an extended and retracted position in response to movement of the second module.
This invention is predicated upon the concept of permitting adjustment of the relative position of multiple adhesive dispensers while supplying all of the dispensers with hot melt adhesive or other material from a single supply line. This is achieved by the pivot arms which interconnect the first and second modules, wherein each pivot arm is formed with a connector passage providing a flow path for the adhesive from the first module connected to a single adhesive supply line, to the second module. This configuration permits quick and easy adjustment of the relative location of the adhesive dispensers carried on the two modules so that the location of the adhesive discharged therefrom can be varied as required.
In the presently preferred embodiment, the dispenser positioner apparatus of this invention includes a fixed module which mounts a first adhesive dispenser and a movable module which mounts two adhesive dispensers side-by-side. Both the fixed and movable modules are carried on a slider rod, and the movable module is formed with a throughbore to receive the slider rod and permit axial movement therealong. In order to effect movement of the movable module along the slider rod, a partially threaded shaft extends between a bore formed in the fixed module and a nut carried by the movable module. Rotation of the shaft causes the movable module to slide toward or away from the fixed module upon the slider rod, and thus position the side-by-side dispensers carried by the second module at the desired location relative to the dispenser mounted to the first module.
With the modules adjusted to the desired relative position, adhesive from a single supply line is introduced into the adhesive passageway formed in the fixed module. This adhesive passageway connects to the adhesive dispenser carried by the fixed module, and is also directed into the connector passage of one of the pivot arms. The adhesive is transmitted along such pivot arm, through a pivotal connection joining the two pivot arms and then into the connector passage of the other pivot arm which is connected to the movable module. The adhesive passageway in the movable module receives the adhesive from the connector passage in the pivot arm and transmits it to each of the two adhesive dispensers carried on a movable module. Preferably, the pivotal connections between the pivot arms and modules, and between the two pivot arms themselves, are made by pivotal elements such as plugs or connectors having O-rings which seal such pivotal connections against leakage. Adhesive is thus transmitted from a single supply line to both of the modules and all of the adhesive dispensers regardless of the relative position of the movable module and fixed module, and their associated dispensers.
Another important aspect of this invention is that the two modules and their associated pivot arms are all heated by a single cartridge heater carried in the slider rod. Each module is mounted to the slider rod, and the pivot arms are connected to the modules such that a large surface area of contact is provided therebetween. A heat transfer path is thus created from the slider rod, through the modules and to the pivot arms which transmits sufficient heat to each element to maintain hot melt adhesive transmitted between the modules at the desired temperature.
DESCRIPTION OF THE DRAWINGS
The structure, operation and advantages of the presently preferred embodiment of this invention will become further apparent upon consideration of the following description, taken in conjunction with the accompanying drawings, wherein:
FIG. 1 is a front view of the apparatus herein in which the modules are shown in a partially retracted position;
FIG. 2 is a rear view of the apparatus shown in FIG. 1;
FIG. 3 is a cross sectional view of the adhesive flow path between the modules and pivot arms taken generally along line 3--3 of FIG. 2;
FIG. 4 is a cross sectional view of the adhesive passageway in the fixed module, taken generally along line 4--4 of FIG. 3;
FIG. 5 is a cross sectional view of the adhesive passageway in the movable module, taken generally along line 5--5 of FIG. 3;
FIG. 6 is an elevational view of the fixed module herein as seen generally along line 6--6 of FIG. 3;
FIG. 7 is an elevational view of the movable module of this invention as seen generally along line 7--7 of FIG. 3;
FIG. 8 is a schematic view of a small, water-tight cardboard box having a pattern of adhesive applied by the apparatus of this invention for attaching a straw thereto; and
FIG. 9 is a view similar to FIG. 8 except with a larger water-tight cardboard box and straw.
DETAILED DESCRIPTION OF THE INVENTION
Referring now to the FIGS., a multiple dispenser positioner 10 is illustrated comprising a fixed module 12 which mounts an adhesive dispenser 14, and a movable module 16 which mounts two adhesive dispensers 18, 20 side-by-side. The movable module 16 is axially movable toward and away from the fixed module 12. Structure is provided to effect such axial movement of module 16, and to permit the transmission of adhesive between the fixed and movable modules 12, 16 so that a single adhesive supply line 22 connected to the fixed module 12 can be employed to supply adhesive to all of the dispensers 14, 18 and 20. The module adjustment structure and adhesive flow paths are described separately below.
Adjustment Structure
In the presently preferred embodiment, the fixed module 12 has a bore 24 which receives a relatively large diameter slider rod 26 fixedly mounted thereto. This slider rod 26 extends through a throughbore 28 formed in the movable module 16, and then into a support block 30 wherein the slider rod 26 is fixed in place. A cartridge heater 27 is carried within the slider rod 26 to provide heat to the modules 16, 16, as described more fully below. The movable module 16 is illustrated in an intermediate position and is axially slidable along the slider rod 26 between a retracted position (not shown) in FIGS. 1 and 2, and an extended position (see phantom lines 16p).
The movable module 16 is slid along the slider rod 26 by operation of a shaft 32 formed with external threads 34 along a portion thereof. The fixed module 12 is formed with a throughbore 36 which receives an unthreaded portion 38 of shaft 32 terminating with flats (not shown) which mount a knob 40. The portion of shaft 32 formed with threads 34 extends into a nut 42 carried between a pair of flanges 44, 46 formed in the movable module 16. Each flange 44, 46 is formed with a throughbore 45 to permit passage of the shaft 32 therethrough. The threaded portion 34 of shaft 32 extends through the bore 45 in the flange 44 into the support block 30 where it is carried in a journal 48.
In response to rotation of the shaft 32, the movable module 16 is moved along the shaft 32 and slider rod 26 toward or away from the fixed module 12 depending upon the direction of rotation of shaft 32. The relative spacing between the adhesive dispenser 14 carried on the fixed module 12, and the adhesive dispensers 18, 20 carried on the movable module 16, is thus variable as required in a particular application.
Adhesive Flow Path
As mentioned above, an important aspect of this invention is the provision of structure capable of transmitting adhesive between the fixed module 12 and movable module 16 from a single adhesive supply line 22 throughout the movement of the movable module 16 between an extended and retracted position. This flow path is formed by adhesive passageways in both the fixed module 12 and movable module 16, described below, and connector passages formed in a pair of pivot arms 50 and 52 which are pivotally interconnected to one another and to the fixed and movable modules 12, 16, respectively.
With reference to FIGS. 2-7, and FIG. 3 in particular, the adhesive flow path through the fixed module 12 into pivot arms 50 and 52 is illustrated. Preferably, the fixed module 12 is formed with an adhesive inlet 54 connected to the adhesive supply line 22 from a source of adhesive 23. The adhesive inlet 54 is connected to a first passageway 56 which transmits adhesive to the adhesive dispenser 14. The adhesive dispenser 14, as well as dispensers 18, 20, form no part of this invention per se and are of the type disclosed, for example, in U.S. Pat. No. 4,785,996, owned by the same assignee as this invention, the disclosure of which is incorporated by reference in its entirety herein. Each dispenser 14, 18 and 20 has a discharge passage (not shown) connected to a nozzle 21 having a discharge outlet 25, and are supplied with operating air through an air passage 27 formed in each module 12, 16 connected to a source of pressurized air (not shown). See FIGS. 6 and 7.
The fixed module 12 is formed with a stepped bore 58 connected to an L-shaped second passageway 60 which extends to the adhesive inlet 54. This stepped bore 58 has a threaded portion which mounts a pivot plug 62 having an internal bore 64 which is generally L-shaped defining a longitudinal portion 66 and a transverse portion 68 as viewed in the FIGS. The transverse portion 68 of internal bore 64 terminates within an annular groove 69 formed in the outer end of pivot plug 62. An inner O-ring 70 is carried on the inner end of pivot plug 62 upstream from second passageway 60, and a pair of O-rings 71 are carried on the outer portion of pivot plug 62 on either side of annular groove 69.
As illustrated in FIG. 3, the outer portion of pivot plug 62 mounts the lower end 72 of pivot arm 50 so that the pivot arm 50 is pivotal with respect to the fixed module 12. A castle nut 74 is threaded onto the outermost end 76 of pivot plug 62, and retained thereon by a cotter pin 77, to mount the pivot arm 50 upon the pivot plug 62. As shown in FIG. 3, the pivot plug 62 is positioned with respect to the pivot arm 50 such that a connector passage 78 formed in the pivot arm 50 aligns with the annular groove 69 in the pivot plug 62. An adhesive flow path is therefore formed through the fixed module 12 into the pivot arm 50 defined by the adhesive inlet 54, a portion of passage 56 and second passageway 60 within the fixed module 12, the internal bore 64 and annular groove 69 in the pivot plug 62 and the connector passage 78 in the pivot arm 50. Because of the O-rings 70 and 71 carried by the pivot plug 62, rotation of the pivot arm 50 with respect to the fixed module 12 is permitted without any leakage of adhesive from the above-defined adhesive flow path.
Referring again to FIG. 3, an adhesive flow path is illustrated from the pivot arm 50, through the pivot arm 52 and then into the movable module 16. As viewed at the middle portion of FIG. 3, the pivot arms 50, 52 are interconnected by a pivot arm connector 84. The pivot arm connector 84 has an outer portion 86 which is received within a throughbore 88 formed in pivot arm 52. The pivot arm connector 84 is also formed with an inner portion 90 which is received within a throughbore 92 formed in the pivot arm 50. In the assembled position shown in FIG. 3, the pivot arms 50, 52 are pivotal upon the connector 84 and are retained thereon by snap rings 95 located on opposite ends of the connector 84.
In the presently preferred embodiment, the connector 84 is formed with an internal passage 94 having one end connected to an annular, recessed groove 96 formed in the pivot arm 52, and an opposite end connected to an annular, recessed groove 98 formed in the pivot arm 50. The annular groove 96 in pivot arm 52 communicates with a connector passage 100 formed therein, and the annular groove 98 formed in pivot arm 50 communicates with the connector passage 78 formed therein. A pair of O-rings 106 are carried by the pivot arm connector 84 on either side of the annular groove 96 and connector passage 100, and a second pair of O-rings 108 are located on either side of the annular groove 98 and connector passage 78. This provides a leak-proof seal between the pivot arms 50, 52 at the connector 84.
With reference to the top portion of FIG. 3 and FIG. 7, the movable module 16 is formed with a stepped bore 110 which is joined to a bore 112 connected to a U-shaped transfer passage 113 having a first leg 114 which transmits adhesive to the adhesive dispenser 18, and a second leg 115 which transmits the adhesive into the other adhesive dispenser 20.
Adhesive is transmitted from the pivot arm 52 into the movable module 16 to bore 112 through a pivot plug 118 which is threaded into the stepped bore 110 of movable module 16. The pivot plug 118 is formed with an internal bore 122 having a longitudinal portion 124 connected to the stepped bore 110, and a transverse portion 126 which terminates at an annular groove 127 formed in the outer portion of pivot arm 52. The upper end of pivot arm 52 as viewed in FIG. 3 is pivotally mounted on the outer portion of pivot plug 118, and retained thereon by a castle nut 129 and cotter pin 130, such that the connector passage 100 in pivot arm 52 aligns with the annular groove 127 formed in the pivot plug 118. A pair of O-rings 128 are located on either side of the connection between connector passage 100 and the annular groove 127 to provide a seal therebetween. Additionally, an O-ring 132 is carried on the inner end of pivot plug 118 within the stepped bore 110 of movable module 16 upstream from the bore 112 to provide a seal thereat. A substantially leak-free adhesive flow path is thus provided from the pivot arm connector 84, through the pivot arm 52 and movable module 16, to each of the dispensers 18, 20 for discharge onto a substrate.
An important aspect of this invention is to maintain the hot melt adhesive at the desired temperature throughout its passage through the above-described adhesive flow path, without requiring the use of heaters and associated electrical wiring in either of the modules 12, 16 or the pivot arms 50, 52. This is accomplished herein by providing a large diameter, stationary slider rod 26 having a cartridge heater 27 which is effective to heat the slider rod 26 to a relatively high temperature. Heat from the slider rod 26 is transmitted directly to each of the modules 12 and 16 connected thereto which eliminates the need for separate heaters in such modules 12, 16. In addition, as shown in FIG. 3, the pivot plugs 62 and 118 which pivotally mount pivot arms 50 and 52 to modules 12 and 16, respectively, are each located at the far corner of such modules 12, 16. This ensures that each pivot arm 50 and 52 has a relatively large surface area of contact with modules 12, 16, respectively, to obtain good heat transfer therebetween. As a result, the cartridge heater 27 in slider rod 26 effectively heats modules 12, 16 and pivot arms 50, 52 so that the temperature of the hot melt adhesive is maintained in the course of its passage from module 12, to module 16.
Operation
The multiple gun positioner 10 of this invention is particularly useful in applications of the type illustrated in FIGS. 8 and 9 wherein an adhesive pattern must be supplied to boxes 134 and 136 of different height. As viewed in FIG. 8, the box 134 is relatively short and requires the adhesive dispensers 18 and 20 carried on the movable module 16 to be located in a position to apply two adhesive dots 139 and 140 onto the top portion of the side edge 142 of box 134 while the dispenser 14 on the fixed module 12 applies an adhesive dot 144 onto the bottom of the side edge 142. This particular pattern of adhesive dots 139, 140 and 144 is intended to affix a plastic straw 146 to the exterior of box 134 which is later used to drink the liquid contents from the box 134.
In order to effect movement of the movable module 16 to a position for the application of adhesive dots 139 and 140, the shaft 32 is rotated to slide the movable module 16 along slider rod 26 until the discharge outlets 25 of adhesive dispensers 18, 20 are located at the appropriate position with respect to side edge 142 of box 134. Adhesive is transmitted into the fixed module 12 and transferred to the adhesive dispenser 14 thereon, and to the adhesive dispensers 18, 20 carried by the movable module 16, along the adhesive flow path through the modules 12, 16 and pivot arms 50, 52 described above.
In order to accommodate the taller box 136, the shaft 32 is rotated in a direction to slide the movable module 16 away from the fixed module 12 so that the adhesive dispensers 18, 20 are placed at the desired location relative to box 136. The adhesive dots 139 and 140 are applied at the appropriate position along the taller side 148 of box 136 in order to secure a large straw 150 thereto. The bottom adhesive dot 144 discharged from the dispenser 14 carried by fixed module 12 is located at essentially the same position on box 136 as on box 134. The adjustment of the position of dispensers 18, 20 is thus accomplished quickly and easily with the positioner 10 of this invention, and the desired pattern of adhesive dots is obtained from multiple adhesive dispensers 14, 18 and 20 supplied by a single adhesive supply line 22.
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.
For example, relative movement of the fixed and movable modules 12, 14 is illustrated in the FIGS. as being effected by rotation of a threaded shaft 32. It is contemplated, however, that the movable module 16 could be slid along the slider rod 26 by essentially any means including pneumatic or hydraulic cylinders or the like. In this connection, it is also contemplated that the adhesive dispensers 18, 20 carried on the movable module 16 could be operated to discharge adhesive in the course of movement of the movable module 16 to obtain an elongated pattern of adhesive as opposed to the adhesive dots illustrated in the particular application of FIGS. 8 and 9.
In the embodiment of positioner 10 illustrated in the FIGS., the module 12 is fixed to the slider rod 26 whereas the module 16 is movable therealong. It is contemplated, however, that both modules 12, 16 can be moved toward and away from one another along the slider rod 26, if desired. The heated adhesive supply line 22 connected to the fixed module 12 is relatively flexible and can withstand at least some movement along the slider rod 26 if it was determined desirable to move both the module 12 and module 16. Moreover, the adhesive supply line 22 can be mounted to the movable module 16 or at a location along either of the pivot arms 50, 52, e.g., at the pivot arm connector 84, in order to supply adhesive to the dispensers 14, 18 and 20. It should also be understood that the number of adhesive dispensers illustrated in the FIGS. is intended for purposes of illustration only, and it is contemplated that essentially any number of dispensers could be employed as desired.
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. | An apparatus for adjusting the relative position of two or more material dispensers comprises a first module adapted to connect to a source of material, and a second module which is axially movable with respect to the first module. The first and second modules each mount at least one material dispenser such that a material pasageway formed in each module is connected to a discharge bore formed in each material dispenser. The passageways in the first and second modules, in turn, are interconnected by a pair of pivot arms arranged in a scissors-like configuration which extend between the modules, and are movable between an extended and retracted position in response to movement of the second module, so that each dispenser can be supplied with material from a single supply line. | 1 |
CROSS-REFERENCE TO RELATED APPLICATIONS
This application claims priority from U.S. Serial No. 60/309,640 filed Aug. 2, 2001.
BACKGROUND OF THE INVENTION
The present invention relates to measuring ventricular function.
Ventricular function is often measured by researchers in an isolated heart, such as an isolated rat heart. The use of an isolated heart allows a broad spectrum of biochemical, physiological, morphological, and pharmacological indices to be measured without the presence of confounding effects of other organs, the systemic circulation, and peripheral complications. One method that researchers often use is the Langendorff method. In the Langendorff method, a balloon attached to a cannula is inserted into the heart and attached to a reservoir containing oxygenated perfusion fluid. The fluid is delivered down the aorta in a retrograde direction at either a constant flow rate or at a constant hydrostatic pressure. The aortic valves are forced shut and the perfusion fluid is directed into the coronary ostia, perfusing the entire ventricular mass of the heart and draining into the right atrium via the coronary sinus.
Although the size of an isolated heart changes under many conditions, such as with ischemia, reperfusion, or drug treatment, in the traditional Langendorff method, any changes in the size of the heart are not taken into account. The result is the incorporation of a systematic error into repeated measurements of ventricular function following interventions. The present invention takes the changing size of the heart into account in calculating ventricular function, yielding accurate measurements.
SUMMARY OF THE INVENTION
In one embodiment, the invention relates to a method of measuring ventricular function in an isolated, perfused heart using an intraventricular balloon connected to a plumbing circuit containing a fluid, the plumbing circuit including (a) a valve for selectively opening the plumbing circuit to (i) atmospheric pressure or (ii) a pressure control circuit of a pressure control apparatus or (b) a pressure control apparatus which can be selectively connected to the plumbing circuit, including the steps of establishing a base pressure by (1) opening the valve to atmospheric pressure or the pressure control circuit or (2) operating the pressure control apparatus, after equalization of the pressure within the intraventricular balloon with the base pressure, closing the valve or stopping operation of the pressure control apparatus, following the closing of the valve, measuring ventricular function as a function of a titrated infusion of fluid into the plumbing circuit and intraventricular balloon, performing an intervention, and repeating at least the first three steps.
In another embodiment, the invention relates to a system for measuring ventricular function in an isolated, perfused heart, including an intraventricular balloon adapted to be inserted into the isolated heart, a plumbing circuit containing a fluid, connected to the intraventricular balloon, a pressure transducer connected to the plumbing circuit, a pump, and a three-way valve connected to the plumbing circuit, the pump, and to the atmosphere, wherein opening the three-way valve to the atmosphere causes atmospheric pressure to be exerted by the intraventricular balloon on the isolated heart, and wherein subsequently opening the three-way valve to the pump causes the pressure exerted by the intraventricular balloon on the isolated heart to be equal to the sum of the atmospheric pressure and the pressure exerted by an infused volume of fluid.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 illustrates a system in accordance with an embodiment of the present invention.
FIG. 2 illustrates a method in accordance with an embodiment of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
The following terms shall have, for the purposes of this application, the respective meanings set forth below.
Bioactive Agent: A bioactive agent is a substance such as a chemical that can act on a cell, virus, tissue, organ or organism, including but not limited to insecticides or drugs (i.e., pharmaceuticals) to create a change in the functioning of the cell, virus, organ or organism. Preferably, the organism is a mammal, more preferably a human or a mammal whose heart is traditionally used as model for human heart function.
Intervention: An intervention is any type of physical, physiological or pharmacological intervention in the function of a heart. Additions of bioactive agents to the fluid perfusing the heart is one example. Another example is surgical intervention to cause an ischemic event. Still another example is an alteration of nutrient or specific salt levels in the fluid perfused through the heart vasculature.
Referring to FIG. 1, isolated heart 100 , which can be a rat, mouse, guinea pig, or other small mammal heart, is perfused with an oxygenated fluid (not shown). The oxygenated fluid can be an oxygenated (95% O 2 , 5% CO 2 , pH 7.4) Krebs-Henseleit solution comprised of 112 mM NaCl, 25 mM NaHCO 3 , 5 mM KCl, 1 mM KH 2 PO 4 , 1.2 mM MgSO 4 , 5.5 mM dextrose, and between 0.2 and 4.0 mM calcium. Intraventricular balloon 110 , which can be a water-filled latex balloon fashioned for example from a latex finger cot (available from VWR Scientific of S. Plainfield, N.J. as part 55613-413), is attached to a cannula, such as a stainless steel cannula (of which model LL2 available from Hugo Sachs of March-Hugstetten, Germany is a suitable example). The cannula-balloon assembly is inserted into isolated heart 100 and connected to plumbing circuit 160 , which can be comprised for example of polyethylene tubing. Plumbing circuit 160 is filled with a liquid, such as a saline solution. Pressure transducer 130 , which can be model P23 available from Gould Instruments of Valley View, Ohio, is attached to plumbing circuit 160 and is used to measure intraventricular balloon pressure. Plumbing circuit 160 is also connected to three-way valve 150 , which is also connected to pump 140 and stand pipe 170 . Pump 140 can be for example a programmable infusion withdrawal pump, such as Harvard apparatus model 44 (Natick, Mass.).
Stand pipe 170 is open to atmospheric pressure and is positioned with its top preferably at the same height as isolated heart 100 . The height is typically aligned with the top of the isolated heart. More importantly, even if there are inaccuracies in the alignment, the relative height is maintained through iterations of the method. The cross-section of the stand pipe is selected to be wide enough that variations in volume at the intraventricular balloon 110 provide only modest variations in column height, such as less than 0.5%. Other relative heights can be selected if they provide appropriate starting or base pressures for tests of ventricular function. A pressure other than atmospheric pressure can be utilized in an appropriate case as the base pressure, so long as such pressure is a constant pressure that can be repeatedly applied to plumbing circuit 160 .
When three way valve 150 is open to stand pipe 170 , atmospheric pressure is exerted on the fluid in plumbing circuit 160 , which in turn exerts atmospheric pressure on intraventricular balloon 110 in isolated heart 100 . When three way valve 150 is open to pump 140 , it can be operated to force a volume of fluid into intraventricular balloon 110 , thereby exerting a pressure on intraventricular balloon 110 different from atmospheric pressure.
Referring to FIG. 2, a method in accordance with an embodiment of the present invention is illustrated. Prior to the performance of step 200 , an intraventricular balloon is inserted into an isolated heart, such as a rat, mouse, or guinea pig heart, or the heart of another small mammal, and connected to a system such as the one illustrated in FIG. 1 . Further details of one example are disclosed in exhibit A attached hereto. In step 200 , plumbing circuit 160 is filled with a fluid. In an exemplary embodiment, the entire plumbing circuit is filled with a saline solution and all air in the plumbing circuit is flushed out.
In step 202 , the three-way valve is set to direct the flow of fluid within the plumbing circuit to the stand pipe, thereby causing atmospheric pressure to be exerted on the intraventricular balloon. The beating of the isolated heart will in turn cause the intraventricular balloon to be resized so as to exert atmospheric pressure on the isolated heart. Typically the volume of the intraventricular balloon after resizing by the beating of the isolated heart will constitute between about 20% and about 40% of the volume of the left ventricle cavity. Optionally, the atmospheric pressure can be recorded at this time (either manually or using a pressure transducer) in order to allow verification of the lack of any meaningful changes in atmospheric pressure during the course of an experiment.
In other embodiments of the present invention, in lieu of utilizing a stand pipe to exert atmospheric pressure on the intraventricular balloon, a pump or other mechanism can be utilized to exert a fixed pressure on the intraventricular balloon. In this embodiment, any pump operable with the appropriate feedback to stably maintain an appropriate base or initial pressure for ventricular function measurements can be used. The pump can be, for example, a Harvard Apparatus Model 44 infusion/withdrawal Pump (available from Harvard Apparatus of South Natick, Mass.), a positive displacement pump (such as a piston, diaphragm pump or vane pump), a kinetic pump (such as a volute pump), or any other appropriate pump known in the art. Among positive displacement pumps, for the present purpose a single piston can operate to create pressure, with the displacement head sized to provide appropriate pressure responsiveness. The feedback can be provided by a pressure transducer fitted to measure pressure in the plumbing. Based on the pressure measurements, an operator can manually adjust the pump. Alternatively, the pressure transducer can send the pressure measurements to a controller operating the pump and appropriate adjustments can be made automatically. Methods known in the art can be used to control for pressure measurement oscillations from the transducer, such as integration, averaging of minima, maxima or transition points in the output values, or other noise reducing methods. Such a pump and pressure feedback apparatus is referred to herein as a pressure control apparatus. Feedback can also be provided through measurements of delivered volume.
Preferably, the pressure control apparatus includes plumbing independent of the plumbing that extends to the intraventricular balloon, such that it can be constantly self adjusting to the base pressure. As with the use of atmospheric pressure, a valve preferably connects or disassociates the two systems. Preferably, the volume of the pressure control apparatus is high enough that connection to the first plumbing circuit does not create a marked change in the pressure of the pressure control apparatus. If there is a change on connection, the feedback control can be allowed time to re-establish the base pressure.
In step 204 , the three way valve is set to direct the flow of fluid within the plumbing circuit to the pump. In step 206 , a volume of fluid is pumped into the plumbing circuit by the pump, thereby increasing the pressure exerted on the isolated heart by the intraventricular balloon (if the volume of fluid pumped in is positive). In step 208 , one or more measurements of ventricular function, such as contractile function, are made.
In step 210 , an intervention is optionally performed. For example, a bioactive agent, such as isoproterenol, can be pumped into a nutrient fluid perfused through the isolated heart. Step 210 can be performed at any time prior to the performance of step 212 , can be performed multiple times within one iteration of steps 202 through 210 , and can be performed in multiple iterations of steps 202 through 210 (and can be performed only within selected iterations of steps 202 through 210 ). Although in some experiments, performing an intervention only after measurements of ventricular function at fixed, reproducible pressures have been performed is desirable, in other experiments interventions can be performed prior to measurements of ventricular function and even prior to the establishment of a fixed pressure.
In step 212 , steps 202 through 210 are repeated until all desired measurements and interventions have been performed. By repeating step 202 following each intervention, changes in the size of the isolated heart caused by interventions are taken into account and measurements taken at a common infused volume prior to and following changes in the size of the heart caused by interventions are taken at a common pressure and are hence more meaningfully comparable. If step 202 is omitted following an intervention that changes the size of the isolated heart, measurements taken thereafter include distortions of a magnitude that can be difficult to determine and the measurements may be of reduced value.
In interpreting the results of the use of the present invention, the following equations are useful. First, the relationship between end-diastolic pressure and end-diastolic balloon volume is extremely well described by the following equation:
EDP=aV
2
+bV+c
where EDP is balloon end-diastolic pressure (mmHg), V is balloon volume (μl), and a, b, and c are curve fitting parameters. The positive root of this quadratic formula has the units of μl and yields the unloaded volume for any particular heart and balloon combination as defined by the following well known equation: V = - b ± b 2 - 4 a c 2 a
Relative changes in ventricular end-diastolic volume can be obtained by comparing the positive root from serial EDP-balloon volume curves for the same heart and balloon combination for each intervention. The absolute shift in the unloaded ventricular volume for each heart can be expressed as the change (μl) relative to the control value.
Diastolic chamber stiffness (dP/dV) can be estimated, as explained in the attached exhibit A, as the slope of the best linear fit of the EDP-balloon volume data according to the following equation:
EDP=mV+b
where EDP is the end-diastolic pressure, V is the balloon volume, m is the chamber stiffness constant, and b is a curve fitting parameter. Linear fits where r 2 ≧0.95 can be assured by restricting the stiffness data to infused balloon volumes between 40 and 100 μl. In order to accommodate physical differences in each balloon and heart combination, all stiffness values can be normalized, and expressed as a percent of their respective control values.
Prior to analysis, raw end-systolic pressures (0.5 μl balloon resolution) can be corrected for any balloon offset due to changes in ventricular diastolic volume according to the following equation:
ESP c =ESP exp −( EDP exp −EDP ref )
where ESP c is the corrected end-systolic pressure, ESP exp is the raw experimental ESP, EDP exp is the raw experimental end-diastolic pressure, and EDP ref is the reference EDP (control). The corrected data can then be submitted for classic end-systolic pressure-volume relation (ESPVR) analysis. ESPVR can be assessed as the best linear fit of the end-systolic pressure and balloon volume data as described by the following equation:
ESP
c
=mV+b
where ESP c is the corrected end-systolic pressure, V is the infused balloon volume, b is a curve fitting parameter, and m is the slope (end-systolic elastance; F es ).
While this invention has been described with an emphasis upon preferred embodiments, it will be obvious to those of ordinary skill in the art that variations in the preferred devices and methods may be used and that it is intended that the invention may be practiced otherwise than as specifically described herein. Accordingly, this invention includes all modifications encompassed within the spirit and scope of the invention as defined by the claims that follow. | A system and method for measuring ventricular function in an isolated, perfused heart using an intraventricular balloon connected to a plumbing circuit containing a fluid, the plumbing circuit including (a) a valve for selectively opening the plumbing circuit to (i) atmospheric pressure or (ii) a pressure control circuit of a pressure control apparatus or (b) a pressure control apparatus which can be selectively connected to the plumbing circuit, including the steps of establishing a base pressure by (1) opening the valve to atmospheric pressure or the pressure control circuit or (2) operating the pressure control apparatus, after equalization of the pressure within the intraventricular balloon with the base pressure, closing the valve or stopping operation of the pressure control apparatus, following the closing of the valve, measuring ventricular function as a function of a titrated infusion of fluid into the plumbing circuit and intraventricular balloon, performing an intervention, and repeating at least the first three steps. | 0 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a rotary seat and more specifically to a seat rotatable even within a narrow space. For instance, this rotary seat is suitable for use as an assistant driver's seat for an automotive vehicle, which can be rotated to such a position where the assistant driver can sit facing passengers in the rear seats. These rotary seats are mounted in general passenger cars of the sedan type.
2. Description of the Prior Art
The background of the present invention will be explained with respect to its application to rotary seats for automotive vehicles. In general, a seat cushion is fixed to a turntable, and the turntable can be rotated when a latch mechanism arranged on the turntable is released, to such a position that a passenger taking the rotary seat can sit facing other passengers taking rear seats.
When the prior-art rotary seat is mounted in a relatively large automotive vehicle, no problems will arise. However, when the prior-art rotary seat is arranged and rotated in a relatively limited space within a passenger compartment, there exists a problem in that the rotary seat will interfere with other adjacent elements such as a console box, seat belt fixtures, etc.
To overcome the above-mentioned problem, it may be possible to reduce the size of the rotary seat. In this case, however, another problem will arise in that sitting comfort becomes degraded.
Further, it may be possible to design the seat cushion to lift up before seat rotation. In this case, however, since the entire seat cushion must be supported on the turntable via hinges, for instance, there arises another problem in that the seat frame structure is complicated and the rigidity of each part is reduced. .In addition, since it is necessary to lift up the seat cushion before rotating the seat, the turning operation of the rotary seat is complicated and therefore troublesome.
SUMMARY OF THE INVENTION
With these problems in mind, therefore, it is the primary object of the present invention to provide a single-touch rotary seat which becomes rotatable when a part of seat cushion is pivoted upward by a single operation, without having to shifting up the entire seat cushion and without being subjected to interference with other adjacent elements.
To achieve the above-mentioned object, a rotary seat according to the present invention comprises (a) turntable means rotatable relative to the floor; (b) thigh support frame means pivotally supported on both sides of said turntable means; (c) hip support cushion means, disposed on said turntable means, for constituting a substantially middle seat cushion; and (d) thigh support cushion means, disposed on said thigh support frame means, for constituting substantially front and side portions of the seat cushion; when said thigh support frame means is pivoted down, said hip and thigh support cushion means being combined into a single complete seat cushion, and when said thigh support frame means is pivoted up, said thigh support cushion means being separated upward away from said hip support cushion means before seat rotation.
The rotary seat further comprises latch means for latching the turntable means to the floor, when said thigh support frame means is pivoted down to at least two predetermined latch positions after seat rotation; and release means for releasing said latch means from the floor, simultaneously when said thigh support frame means is pivoted up.
In the rotary seat according to the present invention, the seat cushion is divided into two, hip support and thigh support, cushions under due consideration of sitting comfort (driver's weight distribution). Further, the hip support cushion is supported on the turntable, and the thigh support cushion is supported on the thigh support frame pivotally supported on both sides of the turntable.
Therefore, it is possible to form the rotary seat on the basis of a simple structure without weakening the rigidity of the turntable or the thigh support frame.
In a seat turning operation, when only the thigh support cushion is pivoted upward, since the latch mechanism is released via the latch releasing mechanism, the seat becomes rotatable. Further, when the thigh support cushion is pivoted downward at a newly reversed position, the turntable is latched to the floor.
BRIEF DESCRIPTION OF THE DRAWINGS
The features and advantages of the rotary seat according to the present invention will be more clearly appreciated from the following description taken in conjunction with the accompanying drawings in which like reference numerals designate the same or similar elements or sections throughout the figures thereof and in which:
FIG. 1A is a perspective view showing a non-rotary driver's seat and rotary assistant driver's seat of the present invention, in which both seats are placed at ordinary seat positions;
FIG. 1B is a similar perspective view showing a pair of the same seats, in which only the rotary assistant driver's seat of the present invention is rotated somewhat;
FIG. 2A a perspective, partially cutaway, view showing a seat cushion of the rotary seat of the present invention, in which a thigh support cushion is pivoted downward;
FIG. 2B is a similar perspective view showing the same seat cushion, in which a thigh support cushion is pivoted upward;
FIG. 3 is a schematic view showing a frame structure of the rotary seat of the present invention;
FIG 4 is a side view showing the same frame structure;
FIG. 5A is a perspective view showing the ordinary position of the rotary seat, in which the thigh support frame is pivoted downward and the turntable is positioned to set the seat frontward;
FIG. 5B is a perspective view showing the upward pivoted position of the rotary seat, in which only the thigh support frame is pivoted upward from the state shown in FIG. 5A;
FIG. 5C is a perspective view showing the upward pivoted and turned position of the rotary seat, in which the turntable is turned from the state shown in FIG. 5B, with the thigh support frame kept pivoted upward;
FIG. 5D is a perspective view showing the reversed position of the rotary seat, in which the thigh support frame is pivoted downward and the turntable is positioned to set the seat rearward;
FIG. 6 is a perspective view showing a latch mechanism and a release mechanism incorporated in the rotary seat; and
FIG. 7 is an enlarged exploded view of the latch mechanism.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
With reference to the attached drawings, an embodiment of the rotary seat for an automotive vehicle according to the present invention will be described by way of example.
The first feature of the rotary seat of the present invention is to pivot upward only a part of the seat cushion to prevent the seat from interfering with other adjacent elements when rotated.
The second feature of the rotary seat of the present invention is to divide the seat cushion into a hip support cushion and a U-shaped thigh support cushion under due consideration of sitting comfort, frame strength, and frame structure simplification, and to pivot upwardly only the divided thigh support cushion before seat rotation.
The third feature of the rotary seat of the present invention is to provide a latch mechanism for the turntable in such a way as to be released from the floor when only the U-shaped thigh support cushion is pivoted upward before seat rotation.
FIGS. 1A and 1B show a pair of front seats 1. The front seats 1 include a driver's seat 1A and an assistant driver's seat 1B. The two seats 1A and 1B are arranged on a floor with a console box 4 (including a shift lever 2 and a hand brake lever 3) intervening between the two seats 1A and 1B.
Each front seat 1A and 1B is composed of a seat cushion 1a and a seat back 1b arranged at the rear portion of the seat cushion 1a. The seat cushion 1a is divided into a hip support cushion 1a-1 mounted on a turntable 5 and a thigh support cushion 1a-2 surrounding the front and both side portions of the hip support cushion 1a-1 and mounted on a thigh support frame 6 (FIG. 2A). As depicted in FIGS. 2A and 2B, the thigh support cushion 1a-2 is formed into a roughly U-shape and supported by the thigh support frame 6 pivotally supported via pivotal axles 11 (described later) on both the side portions of the turntable 5.
Further, the seat cushion is made up of a pad 7 and a decorative material 8 for wrapping the outer surface of the pad 7. Since only the thigh support cushion 1a-2 can be pivoted upward and then rotated as shown in FIG. 1B, it is possible to rotate the seat without interfering with other elements (i.e., the console box 4, the shift lever 2, the hand brake lever 3, etc.)
Although seat cushions have never previously been divided, sitting comfort and seat rotation mobility are very important factors for dividing the seat cushion.
The shape of the seat cushion can be partitioned into a hip support cushion for mainly supporting a driver's weight and a thigh support cushion positioned a little higher than the hip support cushion so as to surround the front and both side portions of the hip support cushion. This tendency is prominent, in particular, in bucket type seats, when body weight distribution is taken into account.
With reference to FIGS. 3 and 4, the structure of the seat cushion frame will be described in further detail hereinbelow. The turntable 5 is rotatably mounted on a base frame 9 fixed to a floor. In more detail, a shallow-cylindrical bearing boss portion 9a is fixed at the center of the base frame 9; and a ring-shaped boss portion 5a fixed to the turntable 5 is rotatably engaged with the bearing boss portion 9a, as depicted in FIG. 5A, in such a way that the ring-shaped boss portion 5a is fitted to the inner circumference of the bearing boss portion 9a. Further, although not shown, some blocks are attached to the under surface of the flange portion of the bearing boss portion 9a to prevent the turntable 5 from being disengaged from the bearing boss portion 9a of the base frame 9.
Also as depicted in FIG. 5B, the thigh support frame 6 is pivotally supported via two pivotal axles 11 at two supporting portions 5A formed on both side portions of the turntable 5.
Further, a shallow U-shaped auxiliary frame 12 is provided along the front portion of the frame 6 so as to extend in the width direction of the seat. When the middle portion of this auxiliary frame 12 is elastically engaged with an engage stopper member 14 fixed at the front end of the turntable 5, the thigh support frame 6 can be retained flush with the turntable 5.
As depicted in FIG. 5A, a latch plate 15 is fixed on the upper surface of the ring-shaped boss portion 5a. A latch mechanism 16 of the turntable 5 is arranged under this latch plate 15.
FIGS. 6 and 7 show this latch mechanism 16 for latching the turntable 5 to the bearing boss portion 9a of the base frame 9 by means of a striker 19 at appropriate angular positions at which the rotary seat is fixed.
In more detail, the latch mechanism 16 comprises a bracket 17 fixed to the lower surface of the latch plate 15; a shaft 18 pivotally supported by a pair of semicircular pin support portions 17a formed in the bracket 17; a striker 19 slidably inserted into square holes 17A formed in the bracket 17 and under the shaft 18 so as to cross the shaft 18; a pin 20 for connecting the striker 19 to the shaft 18; and a coil spring 21 disposed on the outer circumference of the shaft 18.
One end of the coil spring 21 is engaged with the pin 20 and the other end thereof is engaged with the semicircular pin support portions 17a, as shown in FIG. 6. Therefore, the shaft 18 is urged in the counterclockwise direction in FIG. 6, so that the striker 19 is urged through the square holes 17A formed in the bracket 17 into engagement with a latch slot LS (shown in FIG. 4) formed in the bearing boss portion 9a of the base frame 9. A plurality of latch slots LH (e.g. two) are formed at regular angular intervals (e.g. 180 degrees) along the inner circumference of the bearing boss portion 9a. Therefore, when the striker 19 is engaged with a latch slot LH, the turntable 5 can be latched at the latch position.
On the other hand, this striker 19 can be disengaged from the latch slot LH when the thigh support frame 1a-2 is pivoted upward. To accomplish this, one end of a release wire 22 is connected to one end of the striker 19 and the other end of the wire 22 is connected to the lower end of an unlatch arm 23 disposed coaxially with the pivotal axle 11 of the thigh support frame 6, as depicted in FIG. 6. This release wire 22 is arranged on the rear part of the seat as shown in FIG. 3. Further, the upper end 23A of the unlatch arm 23 is bent into an L-shape, so as to be stopped by one edge of the thigh support frame 6 when the frame 6 is pivoted upward.
The operation of the rotary seat according to the present invention will be described hereinbelow with reference to FIGS. 5A to 5D.
When the seat cushion 1a is located in its normal (forward) position, the striker 19 of the latch mechanism 16 is engaged with a front latch slot LS formed in the bearing boss portion 9a of the base frame 9, as shown in FIGS. 3 and 5A, so that the turntable 5 is fixed to the base frame 9. Further, in this normal position, the auxiliary frame 12 of the thigh support frame 6 is elastically engaged with the engage stopper member 14.
To reverse the seat 1 when the front edge of the thigh support portion 1a-2 is first pivoted upward, as shown in FIG. 2B, the auxiliary frame 12 is disengaged from the engage stepper member 14. Since the thigh support frame 6 is pivoted upward, as shown in FIG. 5B, about the pivotal axles 11, the upper end 23A of the unlatch arm 23 is pivoted rearward by the thigh support frame 6 together therewith, as depicted in FIG. 6. Therefore, the release wire 22 is pulled to disengage the striker 19 from the latch slot LS formed in the bearing boss portion 9a of the base frame 9 against an elastic force of the coil spring 21, so that the latch mechanism is released, accompanied with a clicking sound. Therefore, the seat 1 can be rotated freely with the thigh support cushion 1a-2 pivoted upward, without interference with other adjacent elements, as shown in FIG. 5C.
When the seat 1 is rotated by 180 degrees, for instance, the thigh support cushion 1a-2 is pivoted downward horizontally to such an extent that the auxiliary frame 12 of the thigh support frame 6 is elastically engaged again with the engage stopper member 14, again with a click sound. Under these conditions, since the unlatch arm 23 is release from the thigh support frame 6, the striker 19 is urged by an elastic force of the coil spring 21 into reengagement with another latch slot LS formed on the rear side of the bearing boss portion 9a of the base frame 9, so that the turntable 5 is fixed to the base frame 9 at the reversed position, as shown in FIG. 5D.
In the same way as described above, the seat can be returned from the reverse (rearward) position to the normal (forward) position.
In the above description, the present invention is disclosed with respect to its application as an assistant driver's seat for an automotive vehicle. Without being limited thereto, however, it is possible to apply the present invention to any other seats for an automotive vehicle or other vehicles or to other special seats, for instance, those seats whose heights can be adjusted. When the present invention is applied to a height adjustable seat, the mechanism of the present invention is easily coupled to a mechanism for adjusting the height of the thigh support frame.
Further, since the seat is divided, it is possible to change the color of the external decorative material of the hip support cushion from that of the thigh support cushion to diversify color variations.
As described above, in the rotary seat according to the present invention, since the seat can be reversed by simply lifting the front edge of the thigh support cushion before turning it, it is possible to prevent the seat from interfering with other adjacent elements when being rotated, in spite of the simplified turning operation.
Further, since only the thigh support cushion is lifted upward, it is possible to simplify the structure of the frame. Further, since the seat cushion is divided into two parts, on the basis of body weight distribution, it is possible to pivot upward only a part of the seat cushion (thigh support cushion) without exerting adverse affects upon sitting comfort. Furthermore, since the latch mechanism of the rotary seat can automatically be released for rotation when only the thigh support cushion is pivoted up, it is possible to turn the seat by a single operation. | To turn a seat to a reverse position within a narrow space, a rotary seat is composed of a turntable, a thigh support frame, a hip support cushion disposed on the turntable, and a thigh support cushion disposed on the thigh support frame. Simultaneously when the thigh support frame is pivoted upwardly from an original position together with the thigh support cushion, a latch mechanism is released via a latch releasing mechanism, and the turntable and the thigh support frame become rotatable with the thigh support cushion remaining pivoted upwardly. The turntable is then latched into a reversed position when the thigh support frame is pivoted back down to the original position. | 1 |
The invention relates generally to a novel method of preparing cycloalkylacetylenes. More specifically, the invention concerns the synthesis of cycloalkyacetylenes by reacting an alkynyl halide with a dialkylaminomagnesium halide compound such as diisopropylaminomagnesium chloride or a bis(dialkylamino)magnesium compound, such as bis(diisopropylamino)magnesium.
Cycloalkylacetylenes (CAA's) such as ethynylcyclopropane (cyclopropylacetylene) have previously been synthesized by reacting 2.4 equivalents of n-butyllithium (n-BuLi) in tetrahydrofuran (THF) with one equivalent of 5-chloropentyne. The yield of ethynylcyclopropane obtained by this method is temperature dependent, with lower temperatures resulting in higher yields due to less intermolecular head-to-tail coupling of the reaction intermediates. Yields range from 60% to 80% when the reaction is conducted at temperatures from 5° C. to -40° C., respectively.
Although n-BuLi is frequently used to carry out the aforementioned reaction, it is both expensive and pyrophoric. Thus, n-BuLi is not an ideal reagent because its use increases costs of production and presents significant safety hazards for users unfamiliar with the handling of pyrophoric materials.
In an effort to overcome the shortcomings associated with the use of n-BuLi, reactions have also been carried out using lithium diisopropylamide (LDA). LDA possesses a number of advantages over n-BuLi as a reagent in the aforementioned reactions. LDA is commercially available as a non-pyrophoric solution. It has also been found that when the aforementioned reaction is conducted with LDA in place of n-BuLi, a yield of 80% ethynylcyclopropane could be obtained at a temperature of 0° C., while the method utilizing n-BuLi as a reagent required a temperature of -40° C. to achieve such a yield.
Although LDA does obviate some of the problems associated with the use of n-BuLi, it still possesses a number of shortcomings. For example, stable and non-pyrophoric formations of LDA are relatively expensive. Furthermore, the reaction temperature must be maintained below 5° C. because tetrahydrofuran, the preferred solvent medium, is not stable in the presence of LDA at higher temperatures.
Accordingly, a need exists for a method of preparing cycloalkylacetylene compositions that gives good yields (e.g., in excess of 80%) at ambient temperatures or above, uses readily-available and inexpensive materials, requires standard laboratory or processing equipment, can be completed in a substantially short period of time (e.g. cycle times <24 hours), and which utilizes materials that do not present potentially grave safety hazards for the user (e.g., are not pyrophoric).
SUMMARY OF THE INVENTION
The process of the invention provides cycloalkylacetylene compounds having 5 to 20 carbons. Broadly, the process reacts an alkynyl halide with a dialkylaminomagnesium halide compound of the form R 2 NMgX or a bis(dialkylamino)magnesium compound of the form (R 2 N) 2 Mg to produce the desired cycloalkyacetylene compound.
The compounds produced by this process are cycloalkylacetylene compounds having the formula ZCHC 2 H where Z is a divalent alkylene bridge of the formula --(CH 2 ) n -- and n is equal to 2 to 17 units. These compounds are produced by the cyclization of alkynyl halides having the general formula X(CH 2 ) n C 2 H where n is equal to 3 to 18 units and X is Cl, Br, or I. The process is especially useful to produce cyclopropylacetylene.
The process can be carried out in an ether, (e.g., tetrahydrofuran (THF), dibutyl ether, etc.) an ether/hydrocarbon mixture, or a hydrocarbon medium where the hydrocarbons can be either aromatic (e.g., benzene, toluene, xylene, etc.) or linear or branched alkanes (e.g., Isopar C, Isopar G, Isopar H, etc.). The preferred solvent is tetrahydrofuran (THF). It has been determined experimentally that THF is stable to dialkylaminomagnesium halides and bis(dialkylamino)magnesium compounds for hours at reflux (64° C.). Depending on the specific CAA being formed, a higher boiling medium may be preferred in order to speed up the cyclization process or to aid in the isolation of the product. Thus, the choice of other solvents or solvent mixtures may prove more desirable. The process can be carried out at temperatures as low as -5° C. and is typically limited by the stability of the dialkylaminomagnesium halides/bis(dialkylamino)magnesium compounds and the amount of dehydrohalogenated by-products which can form at elevated temperatures. For example, the preparation of cyclopropylacetylene requires a reaction temperature of less than 40° C. in order to minimize the amount of dehydrohalogenated by-products.
The R 2 NMgX compounds are readily obtained by reacting a dialkylamine (R 2 NH where R is a branched, linear, or cyclic alkyl substituent having 1 to 6 carbon atoms or where the R substituents combine to form a heterocyclic alkyl amine having 3 to 6 carbon atoms) with a Grignard (R'MgX where R' is a 1°, 2° or 3° alkyl substituent and X is Cl, Br, or I) at ambient or slightly elevated temperatures (<64° C.). For the present, the structures of the dialkylaminomagnesium halides are given on the assumption of metathesis reactions. No consideration of complexation, aggregation, or other complication is included.
The bis(dialkylamino)magnesium compounds (R 2 N) 2 Mg are readily obtained by reacting the dialkylaminomagnesium halide with the desired lithium amide (R 2 NLi where R is a branched, linear, or cyclic alkyl substituent having 1 to 6 carbon atoms or where the R substituents combine to form a heterocyclic alkyl amine having 3 to 6 carbon atoms). Alternatively, the bis(dialkylamino)magnesium compounds can also be prepared by refluxing the appropriate dialkylamine (R 2 NH where R is defined as above) with a dialkylmagnesium compound (e.g., with dibutylmagnesium) in an ether, or ether/hydrocarbon mixture, or a hydrocarbon medium where the hydrocarbons can be either aromatic (e.g., benzene, toluene, xylene, etc.) or linear or branched alkanes (e.g., Isopar C, Isopar G, Isopar H, etc.). The bis(dialkylamino)magnesium compounds differ from the dialkylaminomagnesium halides in that they are more soluble in hydrocarbon solvents and are stronger bases. For the present, the structures of the bis(dialkylamino)magnesium compounds are given on the assumption of metathesis reactions. No consideration of complexation, aggregation, or other complication is included.
The preferred dialkylaminomagnesium halides for use in the present invention include diisopropylaminomagnesium bromide (DAMB), diisopropylaminomagnesium chloride (DAMC), 2,2,6,6-tetramethylpiperidinomagnesium bromide (TMPMB), and 2,2,6,6-tetramethylpiperidinomagnesium chloride (TMPMC). Preferred bis(dialkylamino)magnesium compounds for use in the present invention include bis(2,2,6,6-tetramethylpiperidino)magnesium (BTMPM) and bis(diisopropylamino)magnesium (BDAM).
DETAILED DESCRIPTION OF THE INVENTION
The present invention will be understood more fully from the description which follows, and from the accompanying examples, in which particular embodiments of the process of the invention are shown. It is understood at the outset, however, that persons of skill in the appropriate arts may modify the invention herein described while still achieving the favorable results thereof. Accordingly, the description and examples which follow are to be understood as being a broad teaching disclosure directed to persons of skill in the appropriate arts, and are not to be understood as limiting upon the present invention. The scope of the invention is to be determined by the appending claims.
The process is initiated by reacting a secondary amine (R 2 NH as previously defined) with an alkylmagnesium halide (i.e. a Grignard reagent of the form R' MgX where R' is typically a primary, secondary to tertiary alkyl group) to produce a reaction mixture containing the dialkylaminomagnesium halide compound of the form R 2 NMgX. The alkynyl halide is then added to the reaction mixture. Generally, the reaction is conducted at ambient temperatures (e.g., 20 to 30° C.) or above for a period of about 12 to 24 hours. The reaction mixture is preferably carried out in an ethereal solvent such as tetrahydrofuran (THF), or a hydrocarbon/ether mixture where the hydrocarbons can be either aromatic (i.e. benzene, toluene, xylene, etc.) or linear or branched alkanes (i.e. Isopar C, Isopar G, Isopar H, etc.).
The process of the invention is preferably initiated by reacting an excess of alkylmagnesium halide (i.e. a Grignard reagent such as ethylmagnesium bromide) with the secondary amine (e.g., diisopropylamine (DIPA)) in THF to form a reaction mixture containing a dialkylaminomagnesium halide (e.g., diisopropylaminomagnesium bromide (DAMB)). The amine is typically present in the reaction mixture when the Grignard is formed. Thus, the diisopropylamine reacts with the ethylmagnesium bromide as it is produced in situ to form the DAMB according to Equation (1): ##STR1##
The 5-chloropentyne is then added to the reaction mixture, where it is cyclized: ##STR2##
Advantageously, the amount of secondary amine (i.e., DIPA) used to produce the reaction mixture can be less than one stoichiometric equivalent because the dialkylaminomagnesium halide of the form R 2 NMgx is regenerated after the cyclization reaction by reaction of the amine released according to equation (2) with the excess alkylmagnesium halide present in solution. The amount of the amine realtive to the alkynyl halide can range from a catalytic amount to a stoichiometric amount, but the reaction proceeds smoothly with less than a stoichiometric amount, e.g., about 50% of a stoichiometric amount is typically used. The metalated cyclic acetylene produced by this process is readily released via a dilute acid or water quench, as is customary when performing Grignard reactions. ##STR3##
The molar ratio of alkyl Grignard to alkyne preferably exceeds the stoichiometric amount of 2:1 and is typically about 2.4:1. Using a 20% excess of alkyl Grignard in the reaction insures complete consumption of the alkyne and allows for a less than theoretical yield of the alkyl Grignard. Our results have shown that one byproduct in the Grignard formation is a tertiary amine. This tertiary amine presumably arises from the reaction of the dialkylaminomagnesium halide formed in situ with the unreacted alkyl halide present in the Grignard. This tertiary amine is not detrimental to the follow on chemistry.
When using THF as a solvent, the molar ratio of alkyne to the dialkylaminomagnesium halide is typically 2 to 1 respectively. If more dialkylaminomagnesium halide is used, the reaction mixture becomes very thick due to the low solubility of the dialkylaminomagnesium halide. If less dialkylaminomagnesium halide is used, the reaction times become extended due to the fact that there is a reduced amount of the cyclizing reagent (i.e. dialkylaminomagnesium halide) present in solution. Based upon these considerations the molar ratio could be higher than 2 to 1 such as up to 3 to 1.
The same process can be used to prepare other CAA's such as cyclobutylacetylene by cyclizing 6-chlorohexyne, Equation (4): ##STR4##
The process of the invention can also be initiated by reacting dibutylmagnesium (Bu) 2 Mg (1.0 M in heptanes) with a secondary amine (e.g. diisopropylamine (DIPA)) in THF at reflux to form a reaction mixture containing a bis(dialkylamino)magnesium (e.g., bis(diisopropylamino)magnesium (BDAM)). Equation (5). The bis(dialkylamino) magnesium has been shown to be stable toward THF at these temperatures. ##STR5##
The 5-chloropentyne is then added to the mixture where it is cyclized. ##STR6##
Advantageously, the amount of the bis(dialkylamino)magnesium used to produce the reaction mixture can be less than two stoichiometric equivalents because the byproduct from the cyclization reaction is a dialkylaminomagnesium halide which can in turn react with the metallated 5-chloropentyne. Equation (7). ##STR7##
The ratio of bis(dialkylamino)magnesium to alkyne is typically about 1.7 to 1 respectively. As in the case of the dialkylamino halide, the amount of the bis(dialkylamino)magnesium is a function of solubility and reaction time considerations.
The metalated cyclic acetylene produced by this process is readily released via a dilute acid or water quench, as is customary when performing Grignard reactions. Equation (8). ##STR8##
The same process can be used to prepare cyclobutylacetylene by cyclizing 6-chlorohexyne, Equation (9): ##STR9##
The invention is further explained by the following illustrative Examples:
EXAMPLE 1
Preparation of diisopropylaminomagnesium bromide (DAMB)
Into a 1 liter round bottom flask equipped with an addition funnel and a reflux condenser were placed magnesium turnings (24.3 g, 1.0 mol), diisopropylamine (20.2 g, 0.2 mol) and THF (500 ml). Bromoethane (120.0 g, 1.1 mol) was added dropwise to this mixture via the addition funnel at such a rate as to maintain a refluxing solution. Ethane was evolved during the addition. The reaction was determined to be complete once all of the magnesium was consumed. This process produced a solution containing EtMgBr and DAMB.
EXAMPLE II
Preparation of diisopropylaminomagnesium chloride (DAMC)
Preparation of DAMC was performed in a manner similar to that of Example I, except that this process employed chloroethane in place of bromoethane. This reaction produced a solution containing EtMgCl and DAMC.
EXAMPLE III
Cyclization of 5-chloropentyne to cyclopropylacetylene with DAMB
5-Chloropentyne (41.0 g, 0.4 mol) was added dropwise to the reaction mixture (containing EtMgBr and DAMB) of Example I at such a rate as to not exceed a reaction temperature of 30° C. After the addition was complete, the reaction mixture was allowed to stir for an additional 18 hours (<30° C.) in order to complete the cyclization. Upon completion the mixture was quenched with dilute acid (0.5 N HCl) in order to release the desired product. The crude reaction mixture was subjected to GC-FID analysis, which showed a yield of >95% of cyclopropylacetylene.
EXAMPLE IV
Cyclization of 6-chlorohexyne to cyclobutylacetylene with DAMB
Preparation of cyclobutylacetylene was performed in a similar manner to that of Example III, except that 6-chlorohexyne rather than 5-chloropentyne was added to the reaction mixture of Example I and solvent reflux was required in order to afford the cyclization. The reaction mixture was quenched with dilute acid and subjected to GC-FID analysis, which showed a yield of >90% of cyclobutylacetylene.
EXAMPLE V
(Comparison)
Reaction performed without dialkylaminomagnesium halide compound
The cyclization process was performed in a manner similar to that of Example III, except that 5-chloropentyne was added to EtMgBr in THF, but with no dialkylaminomagnesium halide compound present (e.g., DAMB or its precursor DIPA). The reaction mixture was quenched with dilute acid and subjected to GC-FID analysis, which showed no detectable trace of cyclopropylacetylene. Thus, in the absence of the dialkylaminomagnesium halide compound, cyclization does not occur.
EXAMPLE VI
Cyclization of 5-chloropentyne to cyclopropylacetylene with DAMC
5-Chloropentyne (41.0 g, 0.4 mol) was added to the reaction mixture (containing EtMgCl and DAMC) of Example II at such a rate as to maintain the reaction temperature below 30° C. The reaction mixture was allowed to stir for an additional 10 hours while maintaining a reaction temperature below 30° C. in order to complete the cyclization. The reaction mixture was quenched with dilute acid to release the product and subjected to GC-FID analysis, which showed a yield of >95% of cyclopropylacetylene.
EXAMPLE VII
Cyclization of 6-chlorohexyne to cyclobutylacetylene with DAMC
Preparation of cyclobutylacetylene was performed in a similar manner to that of Example VI, except that 6-chlorohexyne instead of 5-chloropentyne was added to the reaction mixture of Example II. Because the reaction was slow, solvent reflux (64° C.) was used to afford the cyclization. The reaction mixture was quenched with dilute acid and subjected to GC-FID analysis which showed a yield of >90% of cyclobutylacetylene.
EXAMPLE VIII
Cyclization of 5-chloropentyne to cyclopropylacetylene with TMPMB
Preparation of cyclopropylacetylene is performed in a manner similar to that of Example III, except that 5-chloropentyne is added to a reaction mixture containing EtMgBr and TMPMB instead of the reaction mixture of Example I. The reaction mixture was quenched with dilute acid and subjected to GC-FID analysis, which showed a yield of >90% of cyclopropylacetylene.
EXAMPLE X
Cyclization of 5-chloropentyne to cyclopropylacetylene with BTMPM
In a 100 mL round bottom flask equipped with a reflux condenser was placed dibutylmagnesium (3.46 g, 0.025 mol, 25 mL, 1.0 M in heptanes), THF (25 mL), and 2,2,6,6-tetramethylpiperidine (7.05 g, 0.05 mol). This mixture was then heated to reflux for 3 hours to form bis(tetramethylpiperidino)magnesium. This mixture was then cooled to 30° C. and 5-chloropentyne (1.506 g, 0.0147 mol) was added dropwise over a five minute period. The resulting mixture was then allowed to stir for an additional 1 hour. The reaction mixture was quenched with dilute acid and subjected to GC-FID analysis, which showed a yield of >90% of cyclopropylacetylene.
EXAMPLE XI
Cyclization of 6-chlorohexyne to cyclobutylacetylene with BTMPM
Preparation of cyclobutylacetylene is performed in a manner similar to that of Example X, except that 6-chlorohexyne is used in place of the 5-chloropentyne and the reaction mixture was heated to reflux for 18 hours to afford the cyclization. The reaction mixture was quenched with dilute acid and subjected to GC-FID analysis, which showed a yield of >70% of cyclobutylacetylene.
EXAMPLE XII
Cyclization of 5-chloropentyne to cyclopropylacetylene with BDAM
Preparation of cyclopropylacetylene is performed in a manner similar to that of Example X, except that diisopropylamine was used in place of 2,2,6,6-tetramethylpiperidine. The reaction mixture was quenched with dilute acid and subjected to GC-FID analysis, which showed a yield of >90% of cyclopropylacetylene.
EXAMPLE XIII
Cyclization of 6-chlorohexyne to cyclobutylacetylene with BDAM
Preparation of cyclobutylacetylene was performed in a manner similar to that of Example XI, except that diisopropylamine was added to a reaction mixture instead of the 2,2,6,6-tetramethylpiperdine. The reaction mixture was quenched with dilute acid and subjected to GC-FID analysis, which showed a yield of >70% of cyclobutylacetylene.
Having described the invention in detail it will be apparent that numerous modifications and variations are possible without departing from the spirit and scope of the following claims. | The process of invention reacts an alkynyl halide with a mixture that includes a dialkylaminomagnesium halide or a bis(dialkylamino)magnesium compound to produce a cycloalkylacetylene compound. Preferably, the dialkylaminomagnesium halide compound is of the general formula R 2 NMgX (where R is a linear, branched, or cyclic alkyl substituent or R 2 N represents a heterocyclic alkyl amine and X is Cl, Br, or I) and the bis(dialkylamino)magnesium compound is of the general formula (R 2 N) 2 Mg (where R is a linear, branched, or cyclic alkyl substituent or R 2 N represents a heterocyclic alkylamine). In a preferred method of the invention, the reaction is conducted at moderate temperatures for a period of about 12 to 24 hours. The reaction mixture preferably includes tetrahydrofuran (THF), or a hydrocarbon, or a hydrocarbonether mixture. The preferred compounds produced by this process are cycloalkylacetylene compounds having 5 to 20 carbons, such as cyclopropylacetylene and cyclobutylacetylene. | 2 |
BACKGROUND OF THE INVENTION
A folding mechanism for a multiple section implement wherein a pair of links are utilized together with a hydraulic actuator to fold an outer wing section to an inverted overhead position above an inner wing section is shown in U.S. Pat. No. 3,948,327. The folding mechanism of this before-mentioned patent utilizes a pair of links having a lost motion connection.
SUMMARY OF THE INVENTION
The folding mechanism of the present invention has particular utility in a foldable, multiple section agricultural implement of the type having at least a pair of horizontally aligned sections with ground wheels and depending earthworking tools wherein the sections are pivotally interconnected on longitudinal folding axes permitting one section to pivot relative to the other section between an extended working position in which the sections are horizontally aligned to a folded position in which one section is in an inverted position above the other with its tools projecting upwardly. The folding mechanism includes a first link having one end pivotally connected to one section of the implement on a first axis which is spaced from the folding axis, a second link which has one end pivotally connected to the other section of the implement on a second axis spaced from the folding axis and from the first axis, a lost motion connecting means pivotally interconnecting the other ends of the links to one another including a slot in the other end of the first link, the slot being elongated lengthwise of the first link and a pin part secured to the other end of the second link and operatively disposed in the slot and a linear actuating means connected to the second link which is operable to pivot the one section relative to the other section from the working position to a balanced overhead position and to a folded position. The actuating means includes a component pivotally connected to the other end of the second link which has an abutment shoulder in thrust transmitting engagement with the other end of the first link when the one section is in its overhead and folded positions. The pivot part may take the form of a pivot pin which may be connected to the component of the actuating means. The component may be a clevis having a base part from which a pair of legs extend and the abutment shoulder may be formed on a crotch plate disposed between the legs. The linear actuating means may take the form of a hydraulic jack comprised of piston and cylinder components, one of which is connected to the other section of the implement.
When the outer section is foled to a balanced overhead position, the abutment shoulder is in abutment with the end of the first link and this abutting relationship continues to exist as the outer section is folded to its inverted transport position. Thus, the lost motion between the links, which allows relative movement between the sections during working, is eliminated as the outer section is folded through its overhead balanced position to its inverted folded position.
BRIEF DESCRIPTION OF THE DRAWINGS
The foldup implement using the invention is illustrated in the drawings in which:
FIG. 1 is a partial top view of a five section agricultural implement;
FIG. 2 is an enlarged partial top view of two pivot joints between sections of the implement shown in FIG. 1;
FIG. 3 is a partial rear view of the implement shown in FIG. 1 showing an outer wing section folded to an inverted position above an inner wing section;
FIG. 4 is a rear view of the implement shown in FIG. 1 showing the implement completely folded for transport;
FIG. 5 is an enlarged section view taken on the line V--V in FIG. 1;
FIG. 6 is a top view of the pivot joint and fold-up mechanism shown in FIG. 5;
FIG. 7 is an enlarged rear view of part of the folding mechanism when the latter is in its folded position;
FIG. 8 is a section view taken along the line VIII--VIII in FIG. 7; and
FIG. 9 illustrates a modified form of clevis for the hydraulic actuator of the folding mechanism.
DETAILED DESCRIPTION OF THE INVENTION
Referring to FIGS. 1 and 2, a multiple section agricultural implement in the form of a folding field cultivator 11 includes a central section 12 having a draft structure 13 adapted for connection to a towing tractor (not shown). The central section 12 includes wheeled support structures, 14, 16 having offset dual wheels 17, 18, and 19, 21, respectively. The frame 34 of an inner wing section 26 is pivotally connected on a horizontal, longitudinal axis 27 to the frame 15 of the central section 12 by pivot means including four pivot pins 28, 29, 30, 31. Pivot pin 28 pivotally connects a diagonal tension bar 32 to a laterally extending brace structure 33 rigidly secured to the draft structure 13. A wheeled support structure 36 with dual wheels 37, 38 is provided at the laterally outer end of the inner wing section 26. The frame 48 of an outer wing section 41 is pivotally connected to the laterally outer side of the frame 34 of the inner wing section 26 on a horizontal, longitudinal axis 42 by pivot pins 43, 44, 45, 46. Pivot pin 43 pivotally interconnects the diagonal tension bar 32 to a draft bracket 47 rigidly secured to the frame 48 of the outer wing section 41. A wheeled support structure 51, with a pair of dual wheels 52, 53, is connected to the laterally outer part of the outer wing section frame 48. It will be noted that the diagonal tension bar 32 is connected only by the pins 28, 43. In other words, there is no direct connection between the diagonal tension bar 32 and the inner wing section 26; however, it remains generally coplanar therewith in all working and folded positions.
Referring also to FIGS. 3 and 4, the frame 55 of an inner wing section 56 is pivotally connected to the frame 15 of the central section 12 on a horizontal, longitudinal axis 57 by pivot pins 58, 59, 60, 61 and the frame 66 of an outer wing section 62 is pivotally connected to the inner wing section frame 55 on a longitudinal axis 65. The outer wing section 62 and the inner wing section 56 are reverse images of the wing sections 41 and 26, respectively. All of the sections 12, 26, 41, 56 and 62 carry earthworking members 63, which are secured to the frames 15, 34, 48, 55, 66 by suitable clamps 67. Dual wheel support structures 68 and 69 are mounted on frames 55 and 66, respectively. All the support structures 14, 16, 36, 51, 68, 69 are adjustable, relative to the frames of the field cultivator sections on which they are mounted, by suitable power means (not shown) so as to act as guage wheels during cultivation and as support wheels when the frames are raised.
A power operated folding mechanism 71 is provided for folding the inner wing section 26 relative to the central section 12 which includes a linear actuating means in the form of a double acting hydraulic jack 81 having its cylinder component pivotally connected to an upstanding bracket 82 of the frame 15 by a pivot pin 83. The rod end of the hydraulic jack 81 includes a pin 84 at its outer end which is slideably mounted in aligned slots 86, 87 in longitudinally spaced parallel brackets 91, 92. This provides a lost motion connection permitting the inner wing section 26 to float relative to the central section 12.
Referring also to FIGS. 5 through 8, a folding mechanism 96 for folding the outer wing section 41 relative to the inner wing section 26 about axis 42 includes a link 101 having its lower end pivotally connected by a pin 97 to a pair of upstanding, parallel, longitudinally spaced flanges 102, 103 for swinging movement about a longitudinal axis 104. The flanges 102, 103 are secured as by welding to a transverse member 105 of the frame 48 of the outer wing section 41. The folding mechanism 96 includes a second link 106 which has its lower end pivotally connected to a pivot bracket 107 by a longitudinally extending pivot pin 108 for pivotal movement about a horizontal longitudinal pivot axis 109. The link 106 includes a pair of legs 111, 112 which are rigidly interconnected by a longitudinally extending plate 113 secured as by welding to the confronting sides of the legs 111, 112. The upper ends of the links 101, 106 are pivotally connected to one another by a lost motion connecting means which includes a slot 116 formed in the upper end of link 101, the slot being elongated lengthwise of the link 101. In other words, the slot 116 extends radially from the pivot axis 104 of pivot pin 97. The lost motion connecting means includes a longitudinally extending pivot part in the form of a pin 118, with an axis 119, which is connected to the upper end of link 106 and extends longitudinally through the slot 116 for cooperating sliding engagement therewith. The upper ends of the flanges 102, 103 and bracket 107 are pivotally interconnected by the longitudinally extending pivot pin 45. When the wing sections are in their extended working positions, as shown in FIGS. 1, 5 and 6, the axis 104 of pivot pin 97 is spaced below and laterally outward of the folding axis 42, the axis 109 of pivot pin 108 is spaced below and laterally inward of the folding axis 42 and the axis 119 of pivot pin 118 is spaced above the folding axis 42. In the position illustrated in FIGS. 5 and 6, the outer wing section 41 is in an extended working position and is free to swing in a 30 degree arc about the folding pivot axis 42 between a position 15 degrees above the horizon to a position 15 degrees below the horizon. The swinging or floating movement is permitted by the lost motion connection represented by the slot 116 and the pin 118. The folding mechanism 96 is completed by a linear actuating means in the form of a double acting hydraulic jack 121 which has a piston component 122 which includes a clevis 123 secured to the end of its rod 129. The clevis 123 includes a base part 124 from which a pair of legs 126, 127 extend. The base part is secured by a pin 128 or other suitable means to the rod 129 of the piston component 122.
As shown in FIG. 3, the wing folding mechanism 96 is in its folded transport position wherein the outer wing section 41 has been pivoted to an inverted position above the inner wing section 26 in which condition the tools 63 extend in an upward direction. The hydraulic jack 121 has been contracted and an abutment arm 131 on the outer wing section 41 rests on the top of an abutment arm 132 on the inner wing section 26. The hydraulic jack 121 has its cylinder component pivotally connected to a bracket 130 secured as by welding to the frame 34 of the inner wing section 26.
Referring to FIGS. 7 and 8, the clevis 123 includes a crotch plate 141 which has laterally outwardly extending flanges 142, 143, 144, 146. Flanges 142, 143 have threaded openings 147, 148 in which set screws 151, 152 are threaded to secure the crotch plate 141 to the legs 126, 127 of the clevis 123. The crotch plate 141 includes an outwardly facing concave bearing surface 156 which is complementary to a convex bearing surface 157 on the upper extremity or end of link 101. The distance betwen the cylindrical peripheral surface of pivot pin 118 and the concave surface 156 of the crotch plate 141 is substantially equal to the distance between cylindrical surface 162 at the upper end of the slot 116 and the convex surface 157. In the folded position of the folding mechanism 96, the abutting engagement between surfaces 156 and 157 prevents the pin 118 from moving from the upper end of the slot 116. The crotch pad 141 is made of a suitable wear resistant material and should it become excessively worn it may easily be replaced by loosening the set screws 151, 152 and removing the pin 118.
FIG. 9 shows a clevis 223 which is an alternate construction for the clevis 123. The clevis 223 is made of suitable wear resisting material and includes a concave bearing surface 256 formed on the crotch area of its base part 224 between the legs 226, 227. The clevis 223 requires fewer parts and is less costly to manufacture.
OPERATION
When it is desired to fold the multi-sectioned implement from its extended earthworking position shown in FIG. 1 to the completely folded position shown in FIG. 4, the operator will first cause the double acting hydraulic jack 121 to be contracted by operating an appropriate hydraulic control (not shown). As the jack 121 is contracted, the outer wing section 41 will be pivoted in a clockwise direction, as viewed in FIG. 5, to a balanced overhead position shown in broken lines 161. In this overhead position the pin 118 will have moved to the upper end of the slot 116 where it abuts against the cylindrical end surface 162 and the pin 118 is locked in such position at the end of the slot 116 by the abutting engagement of the curved surfaces 156, 157 on the link 101 and clevis 123. Further contraction of jack 121 will fold the outer wing section 41 to an inverted transport position as shown in FIG. 3 and by broken lines 171 in FIG. 5. In this inverted position, the outer wing section 41 has been pivoted slightly less than 180 degrees from its horizontal working position. In this transport position, the pin 118 remains locked in the end of the slot 116 remote from pin 97 by the abutment of the thrust transmitting complementary curved surfaces 156, 157. In summary, as the outer wing section 41 approaches its balanced overhead position, the surfaces 156, 157 come into engagement to prevent further lost motion movement of the pin 118 in the slot 116 as the outer wing 41 moves through the balanced overhead position to the inverted transport position. Thus, the lost motion permitted during a field operation is automatically eliminated as the outer wing is folded up.
After the outer wing 41 is folded, the operator will cause, through appropriate control means (not shown), the jack 81 to contract thereby pivoting the inner wing section 26 to an upright transport position as shown in FIG. 4. In this position, the ends of the abutment arms 131, 132 will come to rest on a third abutment arm 173 secured to and extending upwardly from the frame 15 of the central section 12. If desired, the abutment arms 131, 132 may be locked to abutment arm 173 during transport of the implement. | A multiple section agricultural implement having laterally inner and outer wing sections on laterally opposite sides of a central section for relative folding movement about longitudinal axes by hydraulically powered folding mechanisms. The lost motion connections in the folding mechanisms permit the implement sections to float relative to one another during use of the implement thereby assuring proper position of the tools when traversing uneven ground. The hydraulic jack of the folding mechanism between the outer and inner wing sections includes a clevis which presents a shoulder in abutting relation to an upper, slotted end of a link connected to the outer wing section when the latter is folded to approximately an overhead balanced position. This abutting relationship, which continues to be present as the outer wing section is folded from its overhead balanced position to its inverted transport position, prevents uncontrolled movement of the outer wing section when the latter swings through its balanced overhead position. | 0 |
RELATED APPLICATIONS
The present invention was first described in U.S. Provisional Patent Application No. 61/567,905 filed on Dec. 7, 2011, the contents of which are incorporated herein by reference.
FIELD OF THE INVENTION
The present invention relates generally to a vehicle restraint belt and, more particularly, to a restraint belt system which can be selectively operated manually or automatically.
BACKGROUND OF THE INVENTION
Seatbelts are a ubiquitous feature in vehicles of all types, and in particular are installed in all modern automobiles. Seatbelts are such an important safety feature that in many locations their use is mandated by law.
Due to educational awareness programs and state laws, most people today automatically buckle up their seatbelt upon entering a motor vehicle. Such use has undoubtedly saved countless lives and will continue to do so into the future. However, a portion of the population sometimes seen not wearing seatbelts are those of law enforcement officers and military personnel who frequently need to exit a motor vehicle in an emergency situation. The extra seconds taken to release a seatbelt system are often seen as a detriment to their safety. Accordingly, there exists a need for a means by which seatbelt systems can be automatically and quickly released in a simultaneous manner as the vehicle door being opened to address the situation described above.
Having recognized the abovementioned problems, the inventor observed there remains a need for a means by which seatbelt systems can be quickly released in an automatic manner to address the situation described above.
Several attempts have been made in the past to provide such an automatic belt restraint release device. U.S. Pat. No. 3,840,249, in the name of Strom, discloses an assembly for positioning safety belts in restraining and non-restraining positions with pivoting arm mounted along the floor of the vehicle in response to opening and closing of the door. The Strom invention utilizes mechanical coupling between the door and the release mechanism whereas the present invention relies upon electrical signals.
U.S. Pat. No. 3,963,090, issued in the name of Hollins, describes an automatic seat belt buckle unlatching mechanism for when the engine of the vehicle is stalled. Unfortunately, this does not fall under the overall scope of the present invention.
U.S. Pat. No. 4,553,625, issued in the name of Tsuge et al., U.S. Pat. No. 4,432,119 issued in the name of Schwark et al., and U.S. Pat. No. 7,275,613, issued in the name of Park, each disclose similar automatic seat belt unbuckling mechanisms.
None of the prior art particularly describes a device that provides such a release mechanism for a shoulder belt assembly and lap belt assembly restraint in a vehicle. Accordingly, there is a need for a means by which one can quickly remove such belt restraint assemblies during an emergency or need for quick exit of a vehicle, such as emergency or law enforcement personnel.
SUMMARY OF THE INVENTION
In view of the foregoing disadvantages inherent in the prior art, it has been observed that there is need of a means provide a selectively manual or automatic release of a belt assembly in a motor vehicle.
An object of the present invention is to provide an automatic restraint belt release system comprising a buckle assembly, a shoulder belt assembly comprising a shoulder belt and a shoulder recoil unit, a lap belt assembly comprising a lap belt and a lap recoil unit, a latch switch mounted within a door of the vehicle, and a power switch mounted within the door.
A further object of the present invention is to provide such a belt buckle assembly comprising a control module configured to be affixed to a floor of a vehicle, a bracket hingedly attached to the control module, a belt buckle affixed to the bracket, and a release mechanism integral with the belt buckle and in electrical communication with the control module. The power switch activates the control module. The latch switch, which is connected to the existing door opening switch, automatically activates the control module to actuate the release mechanism.
Another object of the present invention is to provide such a control module having an enclosure rigidly mounted to the floor housing a control means for operating the releasing mechanism. The control means is in electrical communication with both the latch switch and the power switch.
Yet another object of the present invention provides for the shoulder recoil unit to be mounted to the door frame and the lap recoil unit to be mounted to the floor of the vehicle.
Yet another object of the present invention provides for the shoulder belt assembly to further comprise a length of shoulder belting affixed to the shoulder recoil unit, a shoulder clasp affixed to the shoulder belting, a shoulder belt bracket with a shoulder roller unit integral thereto, a shoulder mounting bracket attached to the vehicle and attached to the shoulder belt bracket via a shoulder spring hinge, and a shoulder stop bar slidably attached to the shoulder belting.
Yet another object of the present invention provides for the lap belt assembly to further comprise a length of lap belting affixed to the lap recoil unit, a lap clasp affixed to the lap belting, a lap belt bracket with a lap roller unit integral thereto, a lap mounting bracket attached to the vehicle and attached to the lap belt bracket via a lap spring hinge, and a lap stop bar slidably attached to the lap belting.
Yet another object of the present invention provides for the belt brackets of the shoulder belt assembly and said lap belt assembly to be each attached to the door frame of the vehicle.
Yet another object of the present invention provides the release mechanism to further comprise a release button supported by a first spring within the belt buckle and extending outward therefrom, a release solenoid in electrical communication with the control means, a belt latch operably coupled to the release solenoid via connecting linkage and supported by a second spring, and a linkage support mounted within the belt buckle such that the connecting linkage is pivotally connected thereto. The release button manually releases the belt latch from the shoulder clasp and lap clasp
Still yet another object of the present invention is to provide an alignment tab on the shoulder clasp to removably connect to an alignment slot of the lap clasp to enable simultaneous insertion of the shoulder clasp and lap clasp within the belt buckle.
BRIEF DESCRIPTION OF THE DRAWINGS
The advantages and features of the present invention will become better understood with reference to the following more detailed description and claims taken in conjunction with the accompanying drawings, in which like elements are identified with like symbols, and in which:
FIG. 1 is an environmental view of an automatic restraint belt release system 10 depicting an in-use state, according to a preferred embodiment of the present invention;
FIG. 2 is a close-up view of a shoulder belt assembly portion 50 of the automatic restraint belt release system 10 , according to a preferred embodiment of the present invention;
FIG. 3 is a section view of a linear buckle portion 22 of the automatic restraint belt release system 10 taken along section line A-A (see FIG. 1 ), according to a preferred embodiment of the present invention; and,
FIG. 4 is an electrical block diagram of the automatic restraint belt release system 10 , according to a preferred embodiment of the present invention.
DESCRIPTIVE KEY
10 automatic restraint belt release system
20 belt release mechanism
22 linear buckle
24 a release solenoid
24 b solenoid shaft
25 release plate
26 belt release bracket
27 spring hinge
28 control module housing
30 door latch switch
32 power switch
36 wiring
40 belt latch
41 linkage support
42 solenoid linkage
43 first spring
44 second spring
50 shoulder belt assembly
52 shoulder belting
53 a alignment slot
53 b alignment tab
54 a shoulder belt clasp
54 b lap belt clasp
55 a shoulder clasp aperture
55 b lap clasp aperture
56 stop bar
58 a shoulder belt bracket
58 b lap belt bracket
59 roller unit
60 first recoil unit
62 roller
66 mounting bracket
80 lap belt assembly
82 lap belting
86 second recoil unit
100 vehicle seat
105 vehicle
107 door frame
108 floor
110 door latch
115 fastener
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
The best mode for carrying out the invention is presented in terms of its preferred embodiment, herein depicted within FIG. 1 through 4 . However, the invention is not limited to the described embodiment, and a person skilled in the art will appreciate that many other embodiments of the invention are possible without deviating from the basic concept of the invention and that any such work around will also fall under scope of this invention. It is envisioned that other styles and configurations of the present invention can be easily incorporated into the teachings of the present invention, and only one particular configuration shall be shown and described for purposes of clarity and disclosure and not by way of limitation of scope.
The terms “a” and “an” herein do not denote a limitation of quantity, but rather denote the presence of at least one of the referenced items.
Referring now to FIG. 1 , an environmental view of the automatic restraint belt release system (herein described as the “system”) 10 , which provides automatic release of restraining belt portions and enables quick exiting from a vehicle 105 , being particularly useful for use by law enforcement and military personnel. The system 10 comprises an electrically released linear buckle 22 which provides a three-point restraint mechanism, coincidentally anchoring both a shoulder belt assembly 50 and a lap belt assembly 80 via respective clasp portions 54 a , 54 b . The linear buckle 22 is in mechanical communication with a chassis portion of the vehicle 105 via an anchoring structure comprising an arcuate belt release bracket 26 and a control module housing 28 being affixed to a center floor area 108 of the vehicle 105 . The belt release bracket 26 and the control module housing 28 are joined to form a structure being capable of withstanding tensile forces associated with conventional seat belt systems. The control module housing 28 comprises a heavy-duty metal enclosure being rigidly mounted to said floor portion 108 using a plurality of anchoring fasteners 115 . The control module housing 28 provides mounted containment and protection of electrical and electronic controlling portions of the system 10 (see FIG. 4 ). The control module housing 28 provides a pivoting attachment means to the belt release bracket 26 via a spring hinge 27 . The belt release bracket 26 in turn is integrally joined to the linear buckle 22 . The outwardly biased spring hinge 27 causes the linear buckle 22 to pivot away from the user automatically upon detachment of the shoulder 50 and lap 80 belt assemblies, thereby providing unimpeded exit of the user from the vehicle 105 .
The system 10 provides automatic detachment of the shoulder 50 and lap 80 belt assemblies via a door latch switch 30 , a power switch 32 , and interconnecting wiring 36 . The door latch switch 30 is to be mounted and positioned within a door portion of the vehicle 105 and being in mechanical communication with a door latch mechanism portion 110 of said door so as to cause electrical actuation of the door latch switch 30 upon opening the door. The power switch 32 is envisioned to be conveniently located along an inner door panel portion, thereby allowing selective activation or de-activation of the system 10 by the user. Upon opening a door portion of the vehicle 105 while the system 10 is activated, the electrical door latch switch 30 conducts an electrical signal via the wiring 36 to the control module housing 28 . The control module housing 28 in turn provides power to an integral release solenoid 24 within the linear buckle 22 to disengage the linear buckle 22 , thereby automatically releasing the belt assemblies 50 , 80 and allowing the user to freely and quickly exit the vehicle 105 . When the system 10 is deactivated using the power switch 32 , the first buckle 22 and belt assemblies 50 , 80 are envisioned to operate manually, similar to a conventional seat belt system by pressing a release button portion 25 located along a top surface of the linear buckle 22 .
The system 10 is preferably incorporated into the construction of new vehicles 105 ; however, it is understood that various models of the system 10 may be packaged as an aftermarket kit for installation within various vehicles 105 without deviating from the teaching of the system 10 , and as such, should not be interpreted as a limiting factor of the system 10 . It is further understood that the system 10 may be configured in a “mirror-image” manner for implementation on a right-side seat portion 100 within the vehicle 105 without being interpreted as a limiting factor of the system 10 as well.
Referring now to FIG. 2 , a close-up view of shoulder and lap belt assembly portions 50 , 80 of the system 10 , according to a preferred embodiment of the present invention, is disclosed. The shoulder 50 and lap 80 belt assemblies each comprise a length of shoulder belting 52 and lap belting 82 , respectively, being made using strong textile strapping material commonly associated with seat belt construction, being introduced in various vehicle interior-matching colors. Said belt assemblies 50 , 80 further comprise respective clasps 54 a , 54 b at proximal ends being sewn or otherwise ruggedly joined to end portions of the belting 52 , 82 . A distal end portion of said shoulder belt 50 is attached to a door frame portion 107 of the vehicle 105 via a shoulder belt bracket 58 a , spring hinge 27 , and mounting bracket 66 . Similarly, the lap belt 80 is attached to a door frame portion 107 of the vehicle 105 via a lap belt bracket 58 b , thereby providing similar pivoting function as the aforementioned belt release bracket 26 . Additionally, said shoulder 50 and lap 80 belt assemblies comprise respective first recoil 60 and second recoil 86 units being mounted to door frame 107 and floor 108 portions, respectively, in a conventional manner. Said recoil units 60 , 86 are envisioned to be similar to conventional inertial-operating units found within many popular vehicles. Said recoil mechanisms 60 , 86 are envisioned to work in conjunction with respective roller units 59 being integrated into upper edge portions of the aforementioned shoulder belt and lap belt brackets 58 a , 58 b . Each roller unit 59 comprises a cylindrical-shaped metal enclosure which axially supports an internal metal roller 62 to smoothly redirect the shoulder 52 and lap 82 belting portions downwardly into the recoil units 60 , 86 during release and retraction of said belt assemblies 50 , 80 . Said belt assemblies 50 , 80 are also envisioned to utilize common adjustable friction stop bars 56 which limit retraction of said belt assemblies 50 , 80 when released.
Referring now to FIG. 3 , a section view of the linear buckle portion 22 of the system 10 taken along section line A-A (see FIG. 1 ), according to a preferred embodiment of the present invention, is disclosed. The first clasp 54 a comprises a recessed alignment slot 53 a and the second clasp 54 b comprises a matching and inserting alignment tab 53 b . Said alignment slot 53 a and alignment tab 53 b act to interlock and align the clasps 54 a , 54 b prior to, and during insertion into the linear buckle 22 . The linear buckle 22 comprises a manual release button portion 25 being supported by a first spring 43 , which enables manual operation in a conventional manner. Additionally, the linear buckle 22 provides a means of electrical release via an internal release solenoid 24 a which when electrically actuated by the control module 28 , causes disengagement of an internal belt latch portion 40 to release the belt assemblies 50 , 80 . The solenoid 24 a preferably comprises a linear electromagnetic unit having a reciprocating solenoid shaft portion 24 b . The solenoid shaft 24 b is in mechanical communication with the belt latch 40 via connecting linkage 42 which acts to motion said belt latch 40 . The connecting linkage 42 is supported within the linear buckle 22 via a linkage support 41 . The belt latch 40 is supported by a second spring 44 , thereby being normally engaged within respective clasp aperture portions 55 a , 55 b of each clasp 54 a , 54 b to secure the belt assemblies 50 , 80 within the linear buckle 22 . Actuation of the solenoid 24 a pivotingly motions the belt latch 40 via the connecting linkage 42 to release the belt assemblies 50 , 80 , allowing the user to freely and quickly exit the vehicle 105 . When the system 10 is electrically deactivated using the power switch 32 , the linear buckle 22 and belt assemblies 50 , 80 are envisioned to operate in a conventional manual manner by pressing the release button 25 .
Referring now to FIG. 4 , an electrical block diagram of the system 10 , according to a preferred embodiment of the present invention, is disclosed. Electrical power to the system 10 is provided via connection of wiring 36 between the control module housing 28 to an un-switched circuit portion of the vehicle's 105 12-volt electrical system. The control module housing 28 contains electrical and electronic equipment such as, but not limited to: printed circuit boards, microprocessors, relays, embedded software, and the like, being necessary to the automatic operation of the system 10 . Said control module housing 28 receives input signals from the door latch switch 30 and the power switch 32 , and in turn provides power to the releasing solenoid 24 a based upon software instructions, thereby releasing the belt assemblies 50 , 80 .
It is envisioned that other styles and configurations of the present invention can be easily incorporated into the teachings of the present invention, and only one particular configuration shall be shown and described for purposes of clarity and disclosure and not by way of limitation of scope.
The preferred embodiment of the present invention can be utilized by the common user in a simple and effortless manner with little or no training. After initial purchase or acquisition of the system 10 , it would be installed as indicated in FIG. 1 .
The method of installing the system 10 (when procured in a retrofit kit form), may be achieved by performing the following steps: removing original personal restraining equipment including the shoulder belt, seat belt, recoiling devices, and anchoring means from the vehicle 105 ; anchoring the control module housing 28 to a middle floor portion 108 of the vehicle 105 using the fasteners 115 ; anchoring the first 60 and second 86 recoil units to the existing original equipment mounting features at door frame 107 and floor 108 areas of the vehicle 105 using fasteners 115 ; mounting the door latch switch 30 so as to be in mechanical communication with the door latch mechanism 110 ; mounting the power switch 32 upon the inner door panel portion of the vehicle 105 ; routing and connecting wiring 36 discreetly between the door latch switch 30 and power switch 32 portions, and the control module housing 28 ; and, routing and connecting additional wiring 36 from the control module housing 28 to an existing un-switched 12-volt circuit within the vehicle 105 . The system 10 is ready for operation.
The method of utilizing the system 10 may be achieved by performing the following steps: occupying a vehicle seat 100 within the vehicle 105 ; engaging alignment slot 53 a and alignment tab 53 b portions of the respective first 54 a and second 54 b clasps; inserting clasp portions 54 a , 54 b of the shoulder 50 and lap 80 belt assemblies into to the linear buckle 22 ; activating the system 10 by selecting the “ON” position upon the power switch 32 ; driving the vehicle 105 to a destination in a normal manner; utilizing the automatic release feature of the system 10 by grasping and motioning the door latch 110 , activating a signal from the door latch switch 30 to the control module housing 28 causing actuation of the linear solenoid 22 and release of the belt assemblies 50 , 80 ; exiting the vehicle 105 in an expeditious manner without having to attend to the manual releasing of the belt assemblies 50 , 80 ; and, benefiting from timely exiting from a vehicle 105 afforded a user of the present invention 10 .
The preferred embodiment of the system 10 may also be utilized in a deactivated or manual mode, thereby functioning in a similar manner as a conventional mechanical seat belt system by performing the following steps: selecting an “OFF” position upon the power switch 30 ; releasing the shoulder 50 and lap 80 belt assemblies by lifting the release plate portion 25 of the linear buckle 22 . The automatic features of the system 10 are especially useful to law enforcement officers and/or military personnel who need to frequently and quickly exit a vehicle 105 .
The foregoing descriptions of specific embodiments of the present invention have been presented for purposes of illustration and description. They are not intended to be exhaustive or to limit the invention and method of use to the precise forms disclosed. Obviously many modifications and variations are possible in light of the above teaching. The embodiment was chosen and described in order to best explain the principles of the invention and its practical application, and to thereby enable others skilled in the art to best utilize the invention and various embodiments with various modifications as are suited to the particular use contemplated. It is understood that various omissions or substitutions of equivalents are contemplated as circumstance may suggest or render expedient, but is intended to cover the application or implementation without departing from the spirit or scope of the claims of the present invention. | An automatic seatbelt release system includes an electrically-released buckle which engages a shoulder belt and a lap belt. When engaged, the system provides the protection and functionality of a common three-point seatbelt. When a user opens a vehicle door, an electric switch within the door handle provides a signal to disengage the buckle causing both the shoulder and lap belts to retract, enabling the user to exit the vehicle in an expedient manner. The system is particularly useful for law enforcement officers or military personnel who need to frequently and quickly exit a vehicle. A power switch is provided to deactivate the system. | 1 |
BACKGROUND OF THE INVENTION
This invention relates to article display and vending devices which typically are usable in retail stores to display cigarette packages or other similarly packaged, stackable articles, for example, soap, photographic film, etc.
Retail stores and particularly supermarkets display for sale at the check-out counter a variety of items including cigarettes. A number ot types of cigarette display and vending racks have been used. In the most common type of installation, the rack is a simple cabinet having a number of vertical dividers which define a plurality of parallel vertical slots in which the cigarette packages may be stacked. The rack often is placed on the check-out counter facing the customer and facing away from the cashier. Experience has indicated a very high rate of pilferage from these devices. In addition, they are limited in size for a number of reasons, one of which being that if made too large the rack may obstruct the cashier's view. Thus, the typical self-service type of cigarette rack holds relatively few packages of cigarettes and must be replenished often. Also, because of the generally small size of the rack, the variety of cigarette brands often must be limited.
Pilferage is a substantial problem and a number of efforts have been made to locate cigarette racks remotely from the customer, for example, by placing a cigarette rack on top of the cash register where it can only be reached by the cashier. This type of installation also presents some difficulties. For example, a rack so located sometimes is difficult and awkward to refill because it may be difficult to reach. In addition, placement of the cigarette rack over the cash register obstructs a substantial portion of the cashier's view. Also, such racks are quite limited in size, for example, to the width of the register.
In addition to the above, prior racks have presented still further difficulties. For example, it is not uncommon for an entire stack of cigarettes to fall out of its vertical channel. Also, with typical prior art cigarette racks, each vertical channel is dimensioned to receive only one size of cigarette package (e.g., "regular", "king size", or "one hundred millimeter length"). This requires some care in loading the rack to assure that the correct size cigarette package is placed in the proper vertical channel. It is somewhat of a nuisance and is time consuming. Also among the difficulties is that when the bottom package in the stack is withdrawn from the rack it sometimes happens that more than one package is drawn out. This is somewhat inconvenient and, in some instances, the disruption at the bottom end of the stack can cause the entire stack to become unstable and fall out of its vertical channel.
It is among the objects of the invention to provide an improved display and vending device which overcomes the foregoing and other difficulties.
SUMMARY OF THE INVENTION
The device may be formed in one or more sections which may be arranged in a straight line, L-shaped configuration or otherwise as desired. Each section has a generally rectangular frame which is suspended overhead from the ceiling structure. The frame extends generally parallel to the check-out counter and above the inside edge of the counter. The side which faces the customer is closed by a transparent panel to enable the customer to see the articles in the device. The other side of the frame, which faces the cashier is open to enable the device to be filled and to enable easy withdrawal of the articles by the cashier. A plurality of vertical dividers are horizontally spaced within the frame and extend from top to the bottom to define a plurality of vertical article-receptive channels. A supporting shelf rests on the bottom of the frame inside the device and defines a platform for the lowest article in each vertical stack, the remaining articles in each vertical channel being stacked one atop each other. The shelf has inclined surfaces which tilt the lowest aticle and, therefore, the rest of the articles in the stack to retard their falling out or being drawn outwardly with the lowest article in the stack. The shelf also includes a lip having a plurality of spaced cut-outs therein, there being one cut-out associated with each vertical channel. The lip facilitates retention of a variety of sizes of cigarette packages and the cut-outs facilitate easy grasping of the individual bottom package in the stack. Each frame also has associated with it, at the open face thereof, a horizontally extending bar located above the support shelf to insure that the cigarette packages or other articles will be in proper alignment as they gravitate toward the shelf.
It is among the objects of the invention to provide an improved display and vending rack.
A further object of the invention is to provide an improved check-out counter configuration for a retail type of establishment embodying an improved overhead display and vending rack.
Another object of the invention is to reduce pilferage of cigarettes or the like at the check-out region of a retail store.
A further object of the invention is to provide a display and vending rack which has a substantially increased capacity.
Another object of the invention is to provide an article display and vending rack which is easy to load and in which removal of the individual articles is facilitated.
A further object of the invention is to provide a vending rack for stackable articles which displays the articles to the customer but which does not permit the customer to actually reach the articles.
Another object of the invention is to provide a cigarette vending and display rack which can accommodate substantially all commercially available lengths of cigarette packages.
A further object of the invention is to provide a display and vending device for use in the cashier region of a retail establishment which does not obstruct the cashier's view.
Another object of the invention is to provide an improved display and vending rack in which any of the vertical channels can receive substantially any size or brand of commercially available cigarette packages.
Still another object of the invention is to provide an improved display and vending device which results in more usable space at the counter level of a check-out counter.
DESCRIPTION OF THE DRAWINGS
The foregoing and other objects and advantages of the invention will be understood more fully from the following further description thereof, with reference to the accompanying drawings wherein:
FIG. 1 is an illustration of an L-shaped display and vending rack as might be seen by the customer;
FIG. 2 is a segmented plan illustration of the rack shown in FIG. 1;
FIG. 3 is a front elevation of the device as seen from the customer's side;
FIG. 4 is an elevation of the device as seen from the cashier's side;
FIG. 5 is a side elevation of an end portion of the frame of the device as seen along the line 5--5 of FIG. 4;
FIG. 6 is a sectional elevation of the device as seen along line 6--6 of FIG. 4;
FIG. 7 is a partial plan sectioned illustration of the device as seen along line 7--7 of FIG. 5; and
FIG. 8 is a somewhat diagrammatic plan illustration of a typical check-out counter employing the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
FIGS. 1 and 8 show an embodiment of the invention and the manner in which it may be installed with respect to a typical check-out counter, for example, as in a supermarket. FIG. 1 shows an embodiment in which the device is formed from two sections 10, 12 which are suspended overhead from the ceiling structure by suspension rods 14. The sections 10, 12 are substantially identical in construction except that in the embodiment shown the section 10 is longer than the section 12. As shown, sections 10, 12 may be supported in an L-shaped configuration. FIG. 8 illustrates, diagrammatically, a desired relative location in plan, of the rack with respect to a typical check-out counter as is found in a supermarket. The generally L-shaped check-out counter shown includes the counter portion 16 on which the cash register 18 is placed. The sections 10, 12 of the device similarly are arranged in an L-shaped configuration and are suspended so that they extend along the inside regions of the check-out counter, where the cashier is located. The sections 10, 12 are suspended at an elevation in which the bottom of the sections 10, 12 are well above the cashier's head so that they do not obstruct the cashier's view.
As shown in FIGS. 2, 3 and 4 each of the sections includes a generally rectangular frame defined by an upper frame section 20, a lower frame section 22 and a pair of side frame sections 24, 26, all of which preferably are fabricated from sheet metal. For ease in description, the frame will be considered as having an outwardly or rearwardly facing side (the side facing the customer as seen in FIG. 1) and an inwardly or forwardly facing side (as would be seen by the cashier). The upper and side frame sections 20, 24 and 26 are of generally channel-shaped cross-section having flanges 28 extending longitudinally along their edges. The lower frame section 22 also has a flange 30 extending longitudinally and upwardly along its outwardly disposed edge. The frame sections 20, 22, 24 may be joined together where they meet at the corners by appropriate sheet metal fastening techniques. The outward face of each section is covered by a transparent panel (e.g., plastic) 32 which fits whithin the frame and is retained by the flanges 28, 30. The transparent panel 32 serves as a completely closed rear wall but enables the customer to view articles carried in the section.
The articles to be displayed and sold, such as cigarette packages, are exposed on the cashier's side of the panel 32 and are supported on a transversely extending shelf, indicated generally at 34 in FIGS. 4-6. The shelf 34 extends the full width of the section, from one of the side frame sections 24 to the other 26. The shelf 34 is generally concave, or V-shaped and also is fabricated from sheet metal bent to define (as seen in cross section) a rear leg 36, a downwardly and forwardly inclined rear shelf portion 38, a forwardly and upwardly inclined front shelf portion 40, a reverted forwardly and upwardly inclined lip 42 and a downwardly extending front leg portion 44. The configuration of these parts of the shelf 34 is such that the junction 46 of the rear leg 36 and rear shelf portion 38 is disposed above the other portions of the shelf 34. The rear shelf portion 38 preferably makes an angle with the rear leg portion 36 of no more than approximately 45°, and the front shelf portion 40 and extension defining the lip 42 make an angle with the rear shelf portion of at least more than 90° and, preferably of the order of 120°. The shelf 34 is self supporting in the device and the rear leg 36 bears against the inwardly facing surface of the transparent panel 32 to retain the panel in place. The legs 36, 44 bear directly on the lower frame section 22. Also, the shelf 34 preferably is constructed so that the outermost edge of the lip 42 lies below the height of the juncture 46. As will be described, the configuration of the support shelf 34 serves to present the lowermost pack of cigarettes to the cashier in a manner which facilitates its removal.
The lower frame section 22 may have, at its forward edge, an upwardly extending lip, indicated in phantom at 23 in FIG. 5, to engage the leg portion 44 of the shelf. Alternatively, the lip 23 may be omitted and the forward edge of the lower frame section 22 may have a channel-shaped extension depending therefrom, as defined by panels 25 and 27, shown in solid in FIG. 5. This latter configuration further strengthens the structure.
The interior of the rectangular section 10 is divided into a plurality of vertically extending channels indicated generally by the reference character 48 to separate the vertical stacks of articles from each other. The vertical channels 48 are defined by a plurality of dividers 50 which extend from the upper frame section 20 downwardly to the shelf 34. The dividers 50 may also be fabricated from sheet metal having vertical front and rear edges 52, 54 (FIG. 6) and a lower edge 56 which is inclined downwardly and rearwardly and rests on the front shelf portion 40 of the shelf 34. The dividers are retained in place by means of tabs 58, 60 which extend through forwardly-rearwardly extending slots 62, 64 formed in the upper frame section 20 and front shelf portion 40, respectively. By way of example, a typical section may include 24 vertical channels 48. In the embodiment shown the dividers 50 are evenly spaced and the channels 48 which they define of equal width.
This configuration is suited particularly for use in connection with vending of cigarette packages which, typically, all are of substantially the same width and thickness. Cigarette packages, however, do differ in length and a number of cigarette lengths are commercially available such as "regular size" (approximately 70 millimeters), "king size" (approximately 85 millimeters) and "100 millimeter" size. The invention is able to accommodate any of these sizes in any of the vertical channels 48. The depth of the channel and, particularly, the configuration of the shelf 34 are such that the smallest length package will be easily accessible while the longest length package will not protrude excessively from the device. FIG. 5 illustrates the manner in which the cigarette packages, indicated in phantom at 66, may be stacked within one of the channels 48. The lowermost package, indicated at 66', will protrude well beyond the other packages in the stack sufficiently so that it can be grasped easily by the cashier. This results from the configuration of the shelf 34. As it can be seen from FIG. 5, when the lowest package 66' is removed, the remaining packages in the stack above will fall of their own weight. The rear shelf portion 38 which is inclined forwardly and downwardly will guide the lowest package in the stack forwardly to the position suggested at 66'. The lowest pack 66' which rests on the shelf portion 40 and lip portion 42 is supported so that its forward end is in a forwardly and upwardly inclined attitude which causes the remaining packages stacked above also to assume the inclined attitude suggested in FIG. 5. That attitude tends to preclude the cigarette packages from falling out of the channels 48 in that each of them tends to slide downwardly and rearwardly toward and against the transparent rearward wall 32.
The forward shelf portion 40 and forwardly extending lip 42 are sufficiently deep (as measured from the forward edge 67 of the lip to the juncture 70 of shelf portions 38 and 40) to be able to provide a firm support surface for the full range of package sizes. As illustrated, the depth of the shelf portion 40 and lip 42 is greater than the length of "regular" size cigarette packages but is less than the length of "100 millimeter" size cigarette packages.
In order to be able to easily grasp all of the commercially available sizes of cigarette packages, the lip 42 is provided with a plurality of cut-out regions 68, there being one cut-out associated with each vertical channel 48. The cut-out region 68 is sufficiently deep so that when even the smallest length of cigarette package is supported on the shelf 34 (with its lower rearward corner disposed at the corner 70 of the shelf 34) the forwardmost end of the lowest cigarette package 66' will project forwardly beyond and overlap the cut-out 68 as suggested in phantom at 72' in FIG. 5. The reference character 72 illustrates the location of the forwardmost end of the next adjacent cigarette pack in the stack.
The invention also includes a horizontal aligning bar indicated at 74 mounted to the front side of the device above the shelf 34 and extending transversely across the entire width of the device. The horizontal bar 74 is secured by appropriate means to the side frame sections 24, 26. The bar 74, is employed to urge any of the cigarette packages in the stack which may be protruding too far forwardly, back into the device to maintain the stability of the stack and also to insure that the cigarette packages will engage the shelf 34 and be properly positioned on the shelf 34 for removal. To this end, the horizontal bar 74 includes a downwardly and rearwardly inclined flange 76 which extends from the upper edge of the bar as shown. As indicated at 66", a cigarette package which may have been improperly placed in the device and which extends too far forwardly will engage the bar and will be guided back into the channel as the package 66" slides along the flange 76. The horizontal bar 74 also aids in rigidifying the device. The bar 74 may be secured to the frame, for example, at the side frame sections 24, 26 by bolts 71. The bar 74 may be fabricated from sheet metal and, in the illustrative embodiment, is bent along its length to define a bottom panel 73, a front panel 75, and the downwardly and rearwardly inclined flange 76. The transverse ends of the bottom panel 73 may have an upwardly extending tab 77 which bears against the forwardly facing flange 28 of the side frame sections 24, 26 to facilitate securing the bar 74 in place. The bolts 71 may be passed through aligned holes in the front panel 75 and tabs 77 as shown.
The device may be hung from an appropriate overhead support, such as the ceiling grid or ceiling structure, by brackets 78 secured to the side frame sections which receive suspension rods 14. Where two sections are arranged in an L-shaped configuration as shown it is desirable to connect the adjacent ends of the sections as by an additional bracket 80 connected to the upper ends of each of the sections 10, 12. If desired, an additional L-shaped connector bracket 82 may be passed through the adjacent channels defined by the bars 74 where those bars mate as suggested at 84 in FIG. 1.
The device is capable of handling a large inventory of cigarette packages encompassing the full range of commercially available cigarettes. In this regard, it may be noted that the frame section 10, for example, may be approximately 41 inches wide and 24 inches high and approximately 51/2 inches deep. A section having these dimensions is capable of holding 24 different brands totalling approximately 650 individual packages. The total weight of such a substantial number of cigarette packages is significant and the construction of the device is such that it can hold such a load without deformation which might have an adverse affect on its operation.
While the invention has been described primarily in connection with a device for displaying and vending cigarette packages it should be understood that it is usable to display and vend other types of packages or articles. It will be appreciated that the invention enables a substantial number of articles to be displayed while enabling them to be readily available for sale. Moreover, these objectives are achieved without interfering with the cashier's view and in a manner which also results in increased usable counter space. In addition, losses from pilferage necessarily are significantly reduced.
It should be understood that the foregoing description of the invention is intended merely to be illustrative thereof and that other modifications and embodiments may be apparent to those skilled in the art without departing from its spirit. | A display and vending device for stackable articles such as cigarette packages or the like is suspended from overhead supports, for example, at the check-out counter of a retail store. The articles contained in the device are accessible only to the cashier but are visible to the customer. The device includes a frame having a plurality of vertical dividers which separate the stacks of articles and which enable the articles to be gravity fed. Means are provided for displacing the lowest article in each stack so that it projects from the stack and is easily grasped by the cashier. | 0 |
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