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TEPZZ 

7_9544A_T
(19)

(11) EP 2 719 544 A1


(12) EUROPEAN PATENT APPLICATION

(43) Date of publication: (51) Int Cl.:


16.04.2014 Bulletin 2014/16 B41N 1/20 (2006.01) B41C 1/18 (2006.01)
C25D 5/34 (2006.01) C25D 7/00 (2006.01)
(21) Application number: 12187941.5

(22) Date of filing: 10.10.2012

(84) Designated Contracting States: (72) Inventor: Ioannou, Ioannis


AL AT BE BG CH CY CZ DE DK EE ES FI FR GB 14574 Rodopoli Attikis (GR)
GR HR HU IE IS IT LI LT LU LV MC MK MT NL NO
PL PT RO RS SE SI SK SM TR (74) Representative: Nollen, Maarten Dirk-Johan et al
Designated Extension States: Arnold & Siedma
BA ME Sweelinckplein 1
2517 GK Den Haag (NL)
(71) Applicant: Icr Ioannou Abee
32011 Oinofyta Viotias (GR)

(54) Method of manufacturing rotogravure cylinders

(57) The present invention describes a method for hesion of the copper substrate and better dimensional
manufacturing rotogravure cylinders with a cylinder base accuracy.
made of aluminum. The method involves the coating of The advantage of this method is the elimination of
the cylinder surface with high velocity spraying, the cop- the surface roughening process and the elimination of
per plating in an appropriate solution, the engraving of the pre-plating process. In addition, the end plates are
the cylinder, and the hardening of the cylinder by chro- manufactured partly from aluminum and partly from steel
mium plating. which further reduces the total weight of the cylinder. The
The spraying process is accomplished by High-Ve- elimination of these processes reduces the weight of the
locity Air-Fuel or High-Velocity Oxygen-Fuel thermal cylinder and the overall manufacturing time considerably.
spraying which leads to less surface porosity, better ad-
EP 2 719 544 A1

Printed by Jouve, 75001 PARIS (FR)


1 EP 2 719 544 A1 2

Description derlying cylinder is increased by a mechanical means,


such as sand paper, sandblasting. Thereafter, a copper
FIELD OF THE INVENTION coating of 10-50 mm thickness is deposited in a thermal
spraying process. The copper coating is considered to
[0001] The present invention refers to a method for 5 be the substrate for subsequent electroplating. Another
manufacturing rotogravure or gravure cylinders. surface treatment with sandpaper is then carried out.
[0002] The invention also relates to the thus obtained [0010] In the fourth step, a pre-copper plating step is
rotogravure cylinders carried out, wherein a layer of copper of about 100-300
[0003] The invention further relates to the use of the mm is plated. The copper is plated without hardener, re-
rotogravure cylinders in the printing industry for the print- 10 sulting in a Vickers hardness of 100-120 HV.
ing of packaging materials (by transfer of ink from the [0011] This step is followed by another copper plating
printing cylinder to the packaging material), such as for step, using a bath that includes a hardener, so as to obtain
instance Intaglio printing processes. a copper engraving layer with preferably a Vickers hard-
ness of 200-240 HV. Such a Vickers hardness is known
BACKGROUND OF THE INVENTION 15 to be optimal for engraving; at lower values, the engraved
cell pattern loses definition. In addition, if the hardness
[0004] Gravure cylinders consist of the base of the cyl- exceeds 240 HV, the lifetime of the diamond styli often
inder (see Figure 1 which shows such a cylinder), which used to engrave the cylinders during electronic engraving
is usually made of steel or aluminum (1, Figure 1 and 1, may be reduced. The copper engraving layer of
Figure 2), a copper layer (2, Figure 1 and 2, Figure 2) 20 W02011/073695 is deposited in a thickness of about 200
usually 0.5 to 1mm thick and a protection layer, which is mm. Finally, a polishing step is carried out to achieve a
usually a chromium layer typically of 6 to 8mm thick (3, predetermined surface roughness, suitably in the range
Figure 1 and 3, Figure 2). of 0.03-0.07 mm.
[0005] The copper layer is electroplated on the base [0012] According to this method, the very hard copper
of the cylinder and forms the surface which is engraved 25 engraving layer is supported with a stack that is less hard.
or etched either by chemical or electromechanical (dia- As is well-known, the Vickers hardness of aluminium or
mond) or electronic (laser) method with the pattern which an aluminium alloy is relatively low; a medium strength
will be printed (transferred) on the packaging material aluminium alloy such as aluminium alloy 6082 is known
(paper, plastic film, aluminum foil, etc.). The copper is to have a Vickers hardness of 35 HV. The copper support
the dominant surface used for engraving, because it is 30 comprising the copper adhesion layer and particularly
easy to engrave. The chromium layer on the engraved the preplated layer therewith has an intermediate hard-
cylinder protects the surface of the cylinder from the pres- ness between the aluminium base and the hard copper
sure exerted by the doctor blade on the printing cylinder layer. Moreover, in accordance with this method, about
during the printing process (transfer of ink onto the pack- half of the at least 0.5 mm copper layer is present as
aging material). 35 support. This layer thickness is needed, so as to obtain
[0006] The cylinder body is usually made of steel which an appropriately homogeneous layer microstructure on
satisfies the requirements for precision and small deflec- top of which the hard copper can be grown.
tion required in the printing process. Alternatively for the [0013] In further investigations on the cylinders man-
printing industry, the cylinder body can be manufactured ufactured in accordance with W02011/073695A2 it was
from a light weight metal like aluminum or an aluminum 40 however observed that the reliability of the cylinders was
alloy. Aluminum has specific weight of about 2700kg/m3, less than desired. Particularly, about 1-5% of the cylin-
while steel has a specific weight of about 7800kg/m3. ders turned out defect relatively quickly after use by the
Using aluminum as the cylinder base results in a lighter customer. However, the defects came irregularly, in an
rotogravure cylinder (by about one third) which means unpredictable manner. Such defect clearly resulted in a
significant reduced transportation costs and safer han- 45 need for replacement of the defect cylinders, which is
dling during production phases. undesired.
[0007] However, aluminum is an electrochemically
passive material and it is quite challenging to electro- SUMMARY OF THE INVENTION
copper plate it. This has limited the use of aluminium for
the base of the cylinder. To the extent that aluminium is 50 [0014] It is therefore an object to overcome the known
used, it requires a plurality of process steps so as to ob- drawbacks from the prior art and to provide a manufac-
tain a suitable copper surface for the aluminium body. turing method of a rotogravure cylinder with an aluminium
[0008] One method for the manufacture of rotogravure base, a copper support and a hard copper layer with good
cylinders comprising an aluminium base, a copper sur- reliability.
face and a chrome protection layer is known from 55 [0015] It is a further object to provide a resulting roto-
W02011/073695A2. The copper surface is created in a gravure cylinder with improved properties and the use of
process that comprises no less than six steps. such improved cylinder for printing processes.
[0009] In a first step, the surface roughness of the un- [0016] According to a first aspect of the invention, a

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method of manufacturing rotogravure cylinders is provid- spraying process is used. In such a process, the particles
ed, wherein a copper support is provided onto a cylindri- are applied with a high speed such as at least 300 m/s
cal base, and a copper engraving layer is electroplated onto the cylinder. Suitably, the cylinder herein rotates
on the copper support, and wherein the copper engraving during the deposition process. The particles will impact
layer is thereafter engraved according to a desired pat- 5 on the cylindrical base, which results in liberation of a
tern and protected with a protection layer. Herein the pro- significant amount of energy in the form of heat. This heat
vision of the copper support comprises the formation of will warm up the particles so as to melt at least partially.
a copper layer circumferential to the base through at least [0024] It is an advantage of the invention that the cop-
partial melting of deposited copper particles per support layer and the copper engraving layer may be
[0017] According to a second aspect of the invention, 10 thin, preferably less than 100 mm each. This is made
an intermediate product is provided, comprising a cylin- possible in that the formed circumferential copper layer
drical base of aluminium onto which a circumferential has a very low porosity, suitably less than 1.0%, prefer-
copper layer extends, the base and the circumferential ably less than 0.5% or even less than 0.2%. This is in
copper layer having a mutual interface, wherein the cir- contrast to the prior art copper support layer of
cumferential copper layer is obtained with inherent com- 15 W02011/073695A2. Analysis of the rotogravure cylin-
pressive stress onto the underlying base and acts as a ders made in accordance with the prior art demonstrated
support for an electroplated copper engraving layer. a large porosity, with a significant spread between indi-
[0018] According to a third aspect of the invention, a vidual cylinders, which was merely overcome through
method of providing a rotogravure cylinder is provided deposition of a thick preplating layer.
comprising the steps of engraving the engraving layer of 20 [0025] In one embodiment, the circumferential layer
the intermediate product with a predetermined pattern has a thickness of at least 50 mm, more preferably at
and subsequent deposition of a protection layer. least 60 mm. This has the advantage that the circumfer-
[0019] According to further aspects of the invention, ential layer may have a thickness substantially corre-
provided are a rotogravure cylinder therewith obtainable sponding to the thickness of the subsequently deposited
and the use of such rotogravure cylinder for the printing 25 copper engraving layer.
of packaging materials by transfer of ink from the roto- [0026] In an alternative, preferred embodiment, the cir-
gravure cylinder to the packaging material. cumferential layer is provided in a thickness of less than
[0020] It was found in investigations leading to the in- 50 mm, preferably less than 40 mm or even at most 30
ventions that the defects resulted from an insufficient ad- mm. A suitable circumferential layer with such a small
hesion. Surprisingly, this adhesion could be improved 30 thickness is achieved with a high velocity spraying step
strongly with the improved process of the invention, in followed by a grinding step.
which the copper was at least partially melted. It was [0027] Most suitably, the circumferential layer is after
moreover unexpected that the improved process result- formation even thinned back. This thinning is for instance
ed in a continuous circumferential layer, so as to give carried out by sawing. A lubricant solution may be applied
rise to compressive stress. 35 simultaneously with the cooling. This process further-
[0021] It is an advantage of the present invention that more results in a suitable polishing of the surface of the
the manufacturing process of gravure cylinder with alu- circumferential layer. The polished circumferential layer
minum base is simplified. Particularly, the roughening is then suitable for the electroplating of the copper en-
treatment of the cylinder surface could be eliminated in graving layer.
comparison to the soft copper surface plating as de- 40
scribed in the above mentioned prior art method of BRIEF INTRODUCTION OF THE FIGURES
W02011/073695.
[0022] More precisely, the invention allows the crea- [0028] These and other aspects of the invention will be
tion of a copper support that may consist of a single layer, further elucidated with respect to the following figures,
and nevertheless matches the difference in properties 45 wherein:
between the base, which is particularly of aluminium, and
the copper engraving layer with a high hardness. This is Fig. 1 shows a diagrammatical bird’s eye view of a
achieved in that the copper support comprises a copper rotogravure cylinder;
layer that extends circumferentially around the base and Fig. 2 shows a diagrammatical cross-sectional view
includes a compressive stress. This compressive stress 50 of the rotogravure cylinder;
more particularly results from cooling down of the circum- Fig. 3 shows a diagrammatical view of end plates for
ferential layer after at least partial melting. The layer the rotogravure cylinder
therein has a inherent tendency to contract, and more
than the underlying base. This is suitably achieved there- ILLUSTRATED DISCUSSION OF DETAILED EMBOD-
in that the copper particles are heated up more than any 55 IMENTS
the cylindrical base.
[0023] The copper particles are suitably deposited in [0029] The figures 1, 2 and 3 are not drawn to scale
a spraying process. More preferably a high velocity and they are only intended for illustrative purposes. Equal

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reference numerals in different figures refer to identical base.


or corresponding figures. [0037] In one preferred embodiment, a gravure cylin-
[0030] The term ’rotogravure cylinders" relates herein der with an aluminium base was produced from an alu-
to rotogravure cylinders and/or any gravure cylinders minum tube to the desired dimensions. Thereafter, a high
used in the printing industry, particularly for the printing 5 velocity spraying process was used for spraying of cop-
of packaging materials. The length of such cylinders is per particles. Use was made of a gun as available from
typically at least 1.0 meter, more preferably in the order UniqueCoat Technologies, LLC, as sold as M3. The cop-
of 1.5-2.5 meter. per particles, with an average diameter of less than 50
[0031] The term ’cylindrical base’ as used in the con- mm, preferably in the range of 40-45 mm, were sprayed
text of the present invention does not require the base 10 with a jet velocity of 1,200-1,400 m/s, resulting in a par-
to be a block-like material. Rather the base may be hol- ticle velocity of 900-1000 m/s. During the spraying proc-
low. Alternatively, the base may comprise several layers, ess, the cylinder was rotated. Impact of the substantially
such as a steel core and an aluminium top layer. pure copper particles onto the cylinder resulted in defor-
[0032] The term aluminum in the present invention re- mations in the aluminum cylinder, and in heating up of
fers to pure aluminum, aluminum with small addition of 15 the particles, to the extent of at least partial melting. This
other materials or aluminum alloys. Likewise, the term melting resulted in formation of a single layer extending
copper refers to pure copper, copper with small addition circumferential around the base. Compressive stress de-
of other materials or copper alloys. Most suitably, how- veloped in the course of cooling down. This cooling down
ever, in the process in accordance with a preferred em- was achieved by waiting in one embodiment; in an alter-
bodiment of the invention, particles are sprayed that con- 20 native embodiment, jetted air was sprayed onto the cyl-
tain at least 99% copper, more preferably at least 99,5% inder with the circumferential layer. For the jet spraying,
copper or more. the same gun as mentioned above was used, but this is
[0033] The term high velocity spraying relates to a not considered essential.
spraying process wherein particles are sprayed with a [0038] In one embodiment, the resulting layer had a
velocity of at least 300 m/s, more preferably at least 500 25 thickness of approximately 125 mm. This layer was there-
m/s, at least 800 m/s or even at least 1,000 m/s. Prefer- after thinned and polished, by means of a sawing proc-
ably, use is made of a jet with a velocity above the said ess. Use was made of a diamond saw, as known for the
particle velocity. Generation of a supersonic jet is con- sawing of copper or copper-containing elements. A lu-
sidered most advantageous. Herein, the jet velocity may bricant was sprayed while sawing so as to prevent too
be higher than 1,400 m/s. 30 much heating of the copper layer. Moreover, herewith a
[0034] High velocity spraying may for instance be im- polishing was achieved as well. The sawing resulted in
plemented with High-Velocity Air Fuel (HVAF) technolo- removal of about 50 mm thickness of copper. The copper
gy and guns as commercially available from UniqueCoat support, here consisting of the copper circumferential lay-
Technologies, LLC from Oilville, VA 23129, USA. er, was therewith ready. It is however not excluded that
[0035] The term ’at least partial melting’ refers to a 35 additional layers are deposited.
process wherein at least the surface of individual parti- [0039] In an alternative embodiment, the deposited
cles is melted so as to create a homogeneous layer. It is layer had a thickness of 40-80 microns, for instance about
not excluded that inner cores of the said particles remain 50 microns. This layer was thereafter thinned, for in-
in solid form. It is moreover not excluded that the circum- stance with 40-60%. Use was made herein of grinding
ferential layer created by melting of copper particles is 40 with a conventional grinding machine with grinding and
actually an alloy with some aluminium of the underlying polishing stones.
cylindrical base. Such an alloy may well be created, par- [0040] The resulting surface roughness Rz, as for in-
ticularly close to the interface with the cylindrical base. stance achieved with the latter embodiment with a final
The composition of the circumferential layer further away layer thickness between 20 and 40 microns, was suitably
from the cylindrical base may thus be different from the 45 less than 0.5 mm. As known to the skilled person, various
composition near to said interface. parameters of surface roughness exist, which have been
[0036] In the preferred embodiment wherein the cop- defined in norms DIN EN ISO 4287:1998 and DIN EN
per particles are sprayed onto the base in a high velocity ISO 4288: 1998. The surface roughness Rz, also known
process, it is foreseen that the impact of the copper par- as the (average) surface roughness depth or the ten-pint
ticles onto the base may result in deformation and frac- 50 mean roughness. It is defined as the arithmetic mean
ture of the top layer of the base. Such deformation is value of the single roughness depths of consecutive sam-
deemed beneficial so as to obtain a larger interface area pling lengths. More suitably the surface roughness Rz
and/or some mechanical anchoring of the copper into the was less than 0.4 mm, for instance between 0.2 and 0.4
aluminium. The subsequent melting and furthermore the mm, and in one preferred embodiment close to 0.3 mm
thinning step are highly suitable in combination therewith, 55 (i.e. 0.25-0.35 mm).
so as to ensure appropriate dimensions and particularly [0041] In a subsequent step, a copper engraving layer
appropriate roundness when seen in cross-sectional with a high hardness, suitably in the range of 200-240
view perpendicular to an axial direction of the cylindrical HV, was deposited. The layer was deposited in a thick-

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ness of 60-100 mm, for instance 75 mm. In one embodi- percentage of aluminum used. The idea is to keep the
ment, a layer thickness was chosen that was substan- steel part at minimum weight.
tially corresponding to the layer thickness of the copper [0046] The manufacturing of the end plates are made
support. However, thicker layers are not excluded. The using the following simple steps:
deposition process for such an engraving layer is known 5
per se and involves electroplating. Use was made in one a) The outer diameter of the aluminum end plate part
embodiment of a solution of copper sulfate (200 - 230 gr (4, figure 3) is manufactured to fit the internal diam-
CuSO4 X 5H2O) and sulfuric acid (60 - 65 gr H2SO4 per eter of the cylinder base. The inner diameter of the
liter of solution) and a catalyst for hardness. The catalyst aluminum end plate part is made to fit the outer di-
does not have any particular properties and can be found 10 ameter of the steel end plate part.
easily in the market. During the plating, the cylinder is b) The outer diameter of the steel end plate part (5,
revolved with a speed of about 100 rpm. The current den- figure 3) is manufactured to fit the inner diameter of
sity during electroplating in this phase ranges from 20 to the aluminum end plate part.
25 amps/dm 2 for about 80-100min and with a solution c) The assembly of the aluminum and the steel part
temperature maintained at about 30°C. Further details in 15 of the end plates are is accomplished simply by heat-
relation to this process are known from various patents, ing (normal or induction heating) and press fitting the
such as U.S. Pat. No. 4,334,966, No. 4,781,801, two parts.
5,417,841 and 7,153,408, which are herein included by
reference. [0047] Although the above description is the recom-
[0042] In an alternative embodiment, which was tested 20 mended methodology for the manufacturing of a light
particularly in combination with a ground and thin circum- weight gravure cylinder with a base made of aluminum
ferential layer as discussed above, the copper engraving and end plates made from aluminum and steel, it is ap-
layer was formed by deposition and subsequent thinning parent to the experts of the field that small deviations or
and polishing. Here again, a thinning to approximately alterations or modifications can be implemented without
half of the deposited thickness turned out suitable in prac- 25 significant deviations from the present invention.
tice. However, it is not excluded that the thinning removes
merely 20-40% of the deposited thickness. TEST RESULTS
[0043] Thereafter, the cylinder was polished to achieve
desired surface roughness (usually Rz is between [0048] Semimanufactured cylinders made in accord-
0,03mm and 0,07mm) 30 ing with the prior art of W02011/073695A2 and in accord-
[0044] The intermediate product was therewith ready. ance with the invention were subjected to a bond strength
In a subsequent step, this intermediate product was en- test. The semimanufactured cylinders had an aluminum
graved in accordance with a desired and predefined pat- base, a copper support and a copper engraving layer.
tern. Use could be made of any engraving technique No engraving was applied in the copper engraving layer.
known per se, including so called electronic engraving. 35 A protection layer was not applied. The cylinder base in
Use of a laser appears beneficial. The engraving could both semi-manufactured cylinders was identical; merely
be carried out in a different location if so desired. After the manufacture of the copper support differed.
the engraving, a protection layer was applied. This pro- [0049] Bond strength tests were carried out using a
tection layer is suitably a chromium coating layer of about universal testing machine (as supplied from TLCLO,
6 to 10 mm, and was produced by plating in a chromium 40 Dartec Ltd, Stourbridge, England). Therein, shear force
oxide solution (250 - 280 gm of Cr2O3 per solution liter) was applied as close as possible to the aluminum-copper
and sulfuric acid (2.5 - 2.8 gm of H2SO4 per solution liter) interface at a crosshead speed of 1 mm/min. The ultimate
for about 30 min. load to failure was recorded in Newton (N), and repeated
[0045] In order to further reduce the weight of the gra- several times to ensure sufficient statistics. Table 1 pro-
vure cylinder, the end plates of the gravure cylinders (typ- 45 vides the results. It is clear therefrom that the bond
ical cross sections of an end plate is shown in figure 3) strength has been significantly improved. Whereas the
are made of two materials, one light weight (4, figure 3), prior art cylinders had a bond strength that was close to
e.g. aluminum and steel (5, figure 3). The typical thick- the limit or even below the limit of 15 N, the bond strength
ness of the end plates is 25mm.The steel is used for the in the invention is such that any variation does not matter
part of the end plate which comes into contact with the 50 any longer.
support of the printing machines because steel has better
wear resistance and higher strength compared to alumi- Table 1
num. sample preparation bond strength (N)
The dimensions of the end plate are determined by the
customer specifications. This is why the dimensions (and 55 W02011/073659A2 12 N
the keyway) are not shown in Figure 3. The proportion invention 70 N
of aluminum to steel is determined by the dimensions of
the end plate. The bigger the end plate the higher the

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Claims 12. The intermediate product as claimed in any of the


preceding claims 10-11, as obtainable with the meth-
1. Method of manufacturing rotogravure cylinders, od of claims 1-9.
wherein a copper support is provided onto a cylin-
drical base, and a copper engraving layer is electro- 5 13. Use of the intermediate product as claimed in any of
plated on the copper support, and wherein the cop- the Claims 10-12 for the engraving a predetermined
per engraving layer is thereafter engraved according pattern into the engraving layer and subsequent dep-
to a desired pattern and protected with a protection osition of a protection layer.
layer, wherein the provision of the copper support
comprises the formation of a copper layer circumfer- 10 14. A rotogravure cylinder comprising a cylindrical base,
ential to the base through at least partial melting of a circumferential copper layer extending aroung the
deposited copper particles. base, wherein the circumferential copper layer is ob-
tained with inherent compressive stress onto the un-
2. The method as claimed in Claim 1, further compris- derlying base and acts as a support for an electro-
ing the step of cooling down the created circumfer- 15 plated copper engraving layer, that is engraved in
ential copper layer, resulting in compressive stress. accordance with a predefined pattern and protected
with a protection layer, particularly as obtainable in
3. The method as claimed in Claim 1 or 2, wherein the accordance with the method of any of the claims 1-9
copper particles are deposited in a high velocity ther- and 13.
mal spraying process, for instance with a velocity of 20
at least 300 m/s. 15. Use of the rotogravure cylinder as claimed in Claim
14 for the printing of packaging materials by transfer
4. The method as claimed in any of the claims, wherein of ink from the rotogravure cylinder to the packaging
the circumferential copper layer is subsequently material.
thinned, for instance by sawing. 25

5. The method as claimed in Claim 4, wherein the saw-


ing process further results in polishing of the copper
support.
30
6. The method as claimed in Claim 4, wherein the cir-
cumferential layer is thinned by grinding to a surface
roughness Rz of less 0.5 mm.

7. The method as claimed in any of the preceding 35


claims, wherein the resulting copper support has a
thickness of at most 100 mm,

8. The method as claimed in Claim 4 or 6, wherein the


copper engraving layer is formed by deposition fol- 40
lowing by thinning.

9. The method as claimed in any of the preceding


claims, wherein the base comprises an aluminum
body. 45

10. An intermediate product comprising a cylindrical


base of aluminium onto which a circumferential cop-
per layer extends, the base and the circumferential
copper layer having a mutual interface, wherein the 50
circumferential copper layer is obtained with inherent
compressive stress onto the underlying base and
acts as a support for an electroplated copper engrav-
ing layer.
55
11. The intermediate product as claimed in Claim 10,
wherein the circumferential copper layer has a thick-
ness of at most 100 mm, preferably less than 50 mm.

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REFERENCES CITED IN THE DESCRIPTION

This list of references cited by the applicant is for the reader’s convenience only. It does not form part of the European
patent document. Even though great care has been taken in compiling the references, errors or omissions cannot be
excluded and the EPO disclaims all liability in this regard.

Patent documents cited in the description

• WO 2011073695 A2 [0008] [0013] [0024] [0048] • US 5417841 A [0041]


• WO 2011073695 A [0011] [0021] • US 7153408 B [0041]
• US 4334966 A [0041] • WO 2011073659 A2 [0049]
• US 4781801 A [0041]

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