AU2020202744A1 - A building panel - Google Patents
A building panel Download PDFInfo
- Publication number
- AU2020202744A1 AU2020202744A1 AU2020202744A AU2020202744A AU2020202744A1 AU 2020202744 A1 AU2020202744 A1 AU 2020202744A1 AU 2020202744 A AU2020202744 A AU 2020202744A AU 2020202744 A AU2020202744 A AU 2020202744A AU 2020202744 A1 AU2020202744 A1 AU 2020202744A1
- Authority
- AU
- Australia
- Prior art keywords
- coating
- panel
- polyurea
- building
- building panel
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Granted
Links
- 238000000576 coating method Methods 0.000 claims abstract description 88
- 239000011248 coating agent Substances 0.000 claims abstract description 83
- 229920002396 Polyurea Polymers 0.000 claims abstract description 41
- 239000004746 geotextile Substances 0.000 claims abstract description 9
- 239000004568 cement Substances 0.000 claims abstract description 8
- 238000000034 method Methods 0.000 claims description 35
- 238000004078 waterproofing Methods 0.000 claims description 14
- 239000003082 abrasive agent Substances 0.000 claims description 5
- 229920002635 polyurethane Polymers 0.000 description 8
- 239000004814 polyurethane Substances 0.000 description 8
- 230000035515 penetration Effects 0.000 description 3
- 239000007921 spray Substances 0.000 description 3
- DBAMUTGXJAWDEA-UHFFFAOYSA-N Butynol Chemical compound CCC#CO DBAMUTGXJAWDEA-UHFFFAOYSA-N 0.000 description 2
- 239000004593 Epoxy Substances 0.000 description 2
- 239000000428 dust Substances 0.000 description 2
- 239000004519 grease Substances 0.000 description 2
- 239000007788 liquid Substances 0.000 description 2
- 239000003921 oil Substances 0.000 description 2
- 239000011527 polyurethane coating Substances 0.000 description 2
- 239000004576 sand Substances 0.000 description 2
- 239000001993 wax Substances 0.000 description 2
- 102100029091 Exportin-2 Human genes 0.000 description 1
- 101710147878 Exportin-2 Proteins 0.000 description 1
- CTQNGGLPUBDAKN-UHFFFAOYSA-N O-Xylene Chemical compound CC1=CC=CC=C1C CTQNGGLPUBDAKN-UHFFFAOYSA-N 0.000 description 1
- 239000000853 adhesive Substances 0.000 description 1
- 239000002390 adhesive tape Substances 0.000 description 1
- 238000010420 art technique Methods 0.000 description 1
- 238000009435 building construction Methods 0.000 description 1
- 238000010276 construction Methods 0.000 description 1
- 239000000356 contaminant Substances 0.000 description 1
- 238000001035 drying Methods 0.000 description 1
- 238000005516 engineering process Methods 0.000 description 1
- 230000007717 exclusion Effects 0.000 description 1
- 239000004744 fabric Substances 0.000 description 1
- 238000009413 insulation Methods 0.000 description 1
- 239000000463 material Substances 0.000 description 1
- 238000002360 preparation method Methods 0.000 description 1
- 235000013580 sausages Nutrition 0.000 description 1
- 239000002904 solvent Substances 0.000 description 1
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 1
- 239000008096 xylene Substances 0.000 description 1
Classifications
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
- E04B1/00—Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
- E04B1/62—Insulation or other protection; Elements or use of specified material therefor
- E04B1/66—Sealings
-
- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B41/00—After-treatment of mortars, concrete, artificial stone or ceramics; Treatment of natural stone
- C04B41/45—Coating or impregnating, e.g. injection in masonry, partial coating of green or fired ceramics, organic coating compositions for adhering together two concrete elements
- C04B41/4505—Coating or impregnating, e.g. injection in masonry, partial coating of green or fired ceramics, organic coating compositions for adhering together two concrete elements characterised by the method of application
- C04B41/4535—Coating or impregnating, e.g. injection in masonry, partial coating of green or fired ceramics, organic coating compositions for adhering together two concrete elements characterised by the method of application applied as a solution, emulsion, dispersion or suspension
- C04B41/4543—Coating or impregnating, e.g. injection in masonry, partial coating of green or fired ceramics, organic coating compositions for adhering together two concrete elements characterised by the method of application applied as a solution, emulsion, dispersion or suspension by spraying, e.g. by atomising
-
- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B41/00—After-treatment of mortars, concrete, artificial stone or ceramics; Treatment of natural stone
- C04B41/45—Coating or impregnating, e.g. injection in masonry, partial coating of green or fired ceramics, organic coating compositions for adhering together two concrete elements
- C04B41/46—Coating or impregnating, e.g. injection in masonry, partial coating of green or fired ceramics, organic coating compositions for adhering together two concrete elements with organic materials
- C04B41/48—Macromolecular compounds
- C04B41/488—Other macromolecular compounds obtained otherwise than by reactions only involving unsaturated carbon-to-carbon bonds
- C04B41/4892—Polyamides
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
- E04C2/00—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
- E04C2/02—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials
- E04C2/26—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials composed of materials covered by two or more of groups E04C2/04, E04C2/08, E04C2/10 or of materials covered by one of these groups with a material not specified in one of the groups
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
- E04C2/00—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
- E04C2/44—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the purpose
- E04C2/52—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the purpose with special adaptations for auxiliary purposes, e.g. serving for locating conduits
- E04C2/526—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the purpose with special adaptations for auxiliary purposes, e.g. serving for locating conduits with adaptations not otherwise provided for, for connecting, transport; for making impervious or hermetic, e.g. sealings
- E04C2/528—Impervious or hermetic panels not otherwise provided for
Landscapes
- Engineering & Computer Science (AREA)
- Chemical & Material Sciences (AREA)
- Architecture (AREA)
- Structural Engineering (AREA)
- Ceramic Engineering (AREA)
- Civil Engineering (AREA)
- Materials Engineering (AREA)
- Organic Chemistry (AREA)
- Chemical Kinetics & Catalysis (AREA)
- Dispersion Chemistry (AREA)
- Physics & Mathematics (AREA)
- Electromagnetism (AREA)
- Building Environments (AREA)
- Application Of Or Painting With Fluid Materials (AREA)
- Finishing Walls (AREA)
Abstract
A building panel having a waterproof coating comprising polyurea. In preferred embodiments, the panel
is a plasterboard, a wallboard, a cement sheet, an insulated panel, or a geotextile. In further preferred
embodiments, the coating is a polyurea coating or a hybrid-polyurea coating. One or both faces of the
building panel is provided with the coating.
Description
A building panel
Field of the invention
[0001] Embodiments of the present invention relate to a building panel that is waterproofed. Other embodiments relate to a method of waterproofing a building panel and a method of waterproofing a building section.
Background
[0002] Waterproofing a room, for example a bathroom, is a time consuming process and would normally take at least five days to complete. As a result, waterproofing is typically an expensive process. Additionally, if the room is not waterproofed properly or if the waterproofing gets damaged during the course of laying the tiles, further time would need to be spent in re-waterproofing the room.
[00031 In this context, there is a need for an improved system for waterproofing a room.
[0004] The reference in this specification to any prior publication (or information derived from it), or to any matter which is known, is not, and should not be taken as an acknowledgment or admission or any form of suggestion that that prior publication (or information derived from it) or known matter forms part of the common general knowledge in the field of endeavor to which this specification relates.
Summary of the invention
[0005] According to an aspect of the present invention, there is provided a building panel having a waterproof coating comprising polyurea.
[00061 The panel may be a plasterboard, a wallboard, a cement sheet, an insulated panel, or a geotextile.
[00071 The coating may be a polyurea coating or a hybrid-polyurea coating.
[00081 The building panel preferably has at least one face with the coating. For example, the panel has a forward face and a rearward face with the coating being provided on the forward face. The coating may also be provided on the rearward face.
[0009] The coating preferably has a Shore A hardness of up to about 100 or a Shore D hardness of up to about 80. For example, the coating has a Shore A hardness of between about 70 and about 90 inclusive.
[0010] The coating preferably has an elongation of up to about 700%. For example, the coating has an elongation of between about 300% and about 600% inclusive.
[0011] The coating preferably has a tensile strength of up to about 30 MPa. For example, the coating has a tensile strength of between about 10 MPa and about 20 MPa inclusive.
[0012] The coating preferably has a tear strength of up to about 70kN/m. For example, the coating has a tear strength of between about 30 kN/m and about 60 kN/m inclusive.
[00131 The coating preferably has a thickness on the panel of up to about 5mm. For example, the thickness of the coating on the panel is about Imm.
[0014] According to an aspect of the present invention, there is provided a method of waterproofing a building panel, the method including applying a waterproof coating comprising polyurea on the panel.
[0015] The building panel is preferably the building panel of the aspect previously described above.
[00161 The method preferably includes allowing the coating of polyurea to substantially cure for up to about 15 minutes. For example, the polyurea may be cured within about 10 minutes, preferably within about 5 minutes.
[00171 The panel may be a plasterboard, a wallboard, a cement sheet, an insulated panel, or a geotextile.
[00181 The coating is preferably a polyurea coating or a hybrid-polyurea coating.
[0019] The method preferably includes coating at least one face of the panel with the coating. For example, the panel has a forward face and a rearward face with the method comprising applying the waterproof coating on the forward face of the panel. The method may include applying the waterproof coating on the rearward face of the panel.
[0020] The waterproof coating is preferably sprayed onto the building panel.
[0021] According to another aspect of the present invention, there is provided a building panel waterproofed according to the method of the aspect previously described above.
[00221 According to a further aspect, there is provided a method of waterproofing a building section, the method including installing a building panel with a coating comprising polyurea in the building section.
[00231 The panel is preferably the building panel of the aspects previously described above.
[0024] The method preferably includes applying the coating comprising polyurea to the building panel before it is installed in the building section. Alternatively, the method may include applying the coating of polyurea to the panel after the panel is installed.
[0025] The method preferably includes applying a coating of abrasive material on the panel. For example, the abrasive material may comprise sand.
Detailed description
[00261 An embodiment of the present invention relates to a building panel having a waterproof coating comprising polyurea.
[00271 The building panel is a plasterboard. In other embodiments, the panel may be a wallboard, a cement sheet, an insulated panel, or a geotextile. Non-limiting examples of plasterboard include a Gyprock plasterboard, a Gyprock Aqua check plasterboard, supplied by CSR Limited; or Sheetrock wallboard supplied by USG Boral. The plasterboard or wallboard may have a thickness of up to about mm, preferably either about 10mm or about 13mm. Non-limiting examples of cement sheet include a Villaboard@ sheet or the Scyon sheet range supplied by James Hardie Australia Pty Ltd. Non-limiting examples of insulated panels include Thermaroof TR27 panel or the XPS Styrozone insulation panel supplied by Kingspan Group, or the Fletcher® Insulboard panel. An example of the geotextile fabric includes the nonwover geotextile by BIDIM@.
[00281 Prior art techniques for waterproofing a panel (e.g. a plasterboard) involve applying a polyurethane coating to the panel. It would typically take at least a day for the polyurethane coating to cure. The long curing times would prolong the overall building construction time, which would have an impact on the construction cost.
[0029] The present inventor has discovered that these panels (e.g. plasterboard, cement sheet, insulated panels, and geotextiles) can be waterproofed with a coating comprising polyurea, and that waterproofing the panels with polyurea would result in a better product compared to panels that are waterproofed with polyurethane. Compared to polyurethane, polyurea has very fast curing times, has higher strength properties, and is more durable. Once the coating comprising polyurea has been applied to a panel, it could take up to at least about 5 minutes to substantially cure at which point the panel can be exposed to light foot traffic or can be transported without any risk, or with only very low risk, of damaging the coating. The coatings comprising polyurea include coatings that have a gel time of about minutes after being applied, coatings that have a gel time of about 20 seconds, coating that have a gel time of about 10 seconds, and coatings that have a gel time of about 5 seconds. The'gel time'is the time it takes for the coating to gel or become highly viscous that it is no longer workable or able to be handled. The curing time is the time it takes for the coating to substantially harden. The panel may be waterproofed before being delivered to site (i.e. the panel is waterproofed off-site).
[00301 The coating has a Shore A hardness of up to about 100 or a Shore D hardness of up to about 80, preferably a Shore A hardness of between about 70 and about 90 inclusive or a Shore D hardness of between 60 and 70. The coating has an elongation of up to about 700%, preferably between about 300% and about 600% inclusive. The coating has a tensile strength of up to about 30 MPa, preferably between about 10 MPa and about 20 MPa inclusive. The coating preferably has a tear strength of up to about 70kN/m, preferably between about 30 kN/m and about 60 kN/m inclusive.
[00311 The coating may be a polyurea coating or a hybrid-polyurea coating. The hybrid-polyurea coating comprises polyurea mixed with other materials (e.g. with polyurethane or an epoxy). Examples of coatings comprising polyurea include Tufflon D60, Tufflon P90, Tufflon P90AS, Tufflon P80, Tufflon JF90, Elaston W80, Elaston PL75, or Hybron W90 distributed by LiquiMix; Enviro HP1200, Enviro HP1200AC, Enviro HP1200PW, or Enviro HP1600 distributed by Enviro-Systems; or Chemspray 790LP or Silcor 780HI'LP Hybrid distributed by GCP Applied Technologies.
[0032] The building panel preferably has at least one face with the coating comprising polyurea. For example, the panel has a forward face and a rearward face with the coating being provided on the forward face. The coating may also be provided on the rearward face. The coating has a thickness on the panel of up to about 5mm, preferably about 1mm.
[00331 The building panels are preferably waterproofed before being delivered to site. The method of waterproofing the building panel includes:
* arranging one or more boards horizontally, evenly spaced apart from each neighbouring board
and preferably being arranged at an elevation;
• removing any dust, oil, wax, grease or other contaminants from the surface of the board(s);
• drying the board to substantially remove any moisture;
* applying a coating comprising polyurea, using a spray equipment with a consistent dry film
thickness of about 1mm to the face of the board; and
* allowing the coating to substantially cure (e.g. at least about 4 minutes) before moving and transporting the board to site.
[0034] The coating comprising polyurea is a two-part polyurea. The spray equipment used to apply the coating comprising polyurea to the panel may be a HP EXP2 machine supplied by Graco.
[00351 On site, before installing the waterproofed building panel at a section of the building, the section is prepared. The preparation of the building section involves:
* applying a two-part water based hydro-epoxy primer directly to the concrete areas to be
waterproofed (within 2 days after concrete has been poured);
* allowing the primer to substantially cure (at least about 9 hours);
* applying caulking, e.g. polyurethane caulking, to the puddle flanges, concrete set downs, any PVC pipes, and any penetrations through the slab; and
* applying a coating to waterproof the concrete, e.g. a polyurea two-part coating with a spray equipment, with a minimum dry film thickness of about 1.5mm including coating the puddle flange, any PVC pipes, and any penetrations through the slab.
[00361 Once the building section is prepared, the waterproofed building panel is installed.
[00371 Once the waterproofed building panel is installed, any debris, dust, oil, wax, grease or any other contaminates is removed from the surface of the panel. A xylene solvent can be applied to the panel, which would reactivate the polyurea.
[00381 Polyurethane caulking is then applied to all screw holes and any damaged areas within the area. The caulking can be performed using a sausage caulking gun and a broad knife to flatten out or to smoothen the caulking.
[00391 A self-adhesive butynol tape is subsequently applied to all junctions and joins of the building panel including the shower mixer, outlets and any penetrations through the building panel.
[0040] A polyurethane liquid is then applied, using a roller for example, to a dry thickness of about Inmm to the building panel. The polyurethane liquid is also applied to all polyurethane caulking and butynol self-adhesive tape.
[0041] An abrasive material is then applied into the top coat with a consistent coverage to provide tile adhesion. The abrasive material may comprise sand for example.
[00421 The surface can then be tiled in the usual manner.
[00431 While various embodiments of the present invention have been described above, it should be understood that they have been presented by way of example only, and not by way of limitation. It will be apparent to a person skilled in the relevant art that various changes in form and detail can be made therein without departing from the spirit and scope of the invention. Thus, the present invention should not be limited by any of the above described exemplary embodiments.
[0044] Throughout this specification and the claims which follow, unless the context requires otherwise, the word "comprise", and variations such as "comprises" and "comprising", will be understood to imply the inclusion of a stated integer or step or group of integers or steps but not the exclusion of any other integer or step or group of integers or steps.
Claims (21)
1. A building panel having a waterproof coating comprising polyurea.
2. The building panel of claim 1, wherein the panel is a plasterboard, a wallboard, a cement sheet, an insulated panel, or a geotextile.
3. The building panel of claim 1 or 2, wherein the coating is a polyurea coating or a hybrid polyurea coating.
4. The building panel of any one of claims 1 to 3, having at least one face with the coating.
5. The building panel of any one of claims 1 to 4, wherein the coating has a Shore A hardness of up to about 100 or a Shore D hardness of up to about 80.
6. The building panel of any one of claims 1 to 4, wherein the coating has an elongation of up to about 700%.
7. The building panel of any one of claims I to 4, wherein the coating has a tensile strength of up to about 30 MPa.
8. The building panel of any one of claims I to 5, wherein the coating has a tear strength of up to about 70 kN/m.
9. The building panel of any one of claims 1 to 6, wherein the coating has a thickness on the panel of up to about 5mm.
10. A method of waterproofing a building panel, the method including applying a waterproof coating comprising polyurea on the panel.
11. The method of claim 10, wherein the building panel is the building panel of any one of claims I to 9.
12. The method of claim 10, wherein the method includes allowing the coating of polyurea to substantially cure for up to about 15 minutes.
13. The method of claim 10 or 11, wherein the panel is a plasterboard, a wallboard, a cement sheet, an insulated panel, or a geotextile.
14. The method of any one of claims 10 to 13, wherein the coating is a polyurea coating or a hybrid polyurea coating.
15. The method of any one of claims 10 to 14, wherein the method includes coating at least one face of the panel with the coating.
16. The method of any one of claims 10 to 15, wherein the waterproof coating is sprayed onto the building panel.
17. A building panel waterproofed according to the method of any one of claims 10 to 16.
18. A method of waterproofing a building section, the method including installing a building panel with a coating comprising polyurea in the building section.
19. The method of claim 18, wherein the panel is the building panel of any one of claims 1 to 9 or claim 17.
20. The method of claim 18 or 19, wherein the method includes applying the coating comprising polyurea to the building panel before it is installed in the building section.
21. The method of any one of claims 18 to 20, wherein the method includes applying a coating of abrasive material on the panel.
Priority Applications (1)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
AU2021107533A AU2021107533A4 (en) | 2019-04-26 | 2021-08-31 | A building panel |
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
AU2019901415 | 2019-04-26 | ||
AU2019901415A AU2019901415A0 (en) | 2019-04-26 | A building panel |
Related Child Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
AU2021107533A Division AU2021107533A4 (en) | 2019-04-26 | 2021-08-31 | A building panel |
Publications (2)
Publication Number | Publication Date |
---|---|
AU2020202744A1 true AU2020202744A1 (en) | 2020-11-12 |
AU2020202744B2 AU2020202744B2 (en) | 2023-11-02 |
Family
ID=73048435
Family Applications (2)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
AU2020202744A Active AU2020202744B2 (en) | 2019-04-26 | 2020-04-24 | A building panel |
AU2021107533A Ceased AU2021107533A4 (en) | 2019-04-26 | 2021-08-31 | A building panel |
Family Applications After (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
AU2021107533A Ceased AU2021107533A4 (en) | 2019-04-26 | 2021-08-31 | A building panel |
Country Status (1)
Country | Link |
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AU (2) | AU2020202744B2 (en) |
Family Cites Families (12)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US5845347A (en) * | 1995-03-06 | 1998-12-08 | Young; David A. | Method of manufacturing shower foundation |
US8453404B2 (en) * | 2005-02-08 | 2013-06-04 | James Edward Cox | Composite building panel and method |
KR20120077213A (en) * | 2010-12-30 | 2012-07-10 | 최대호 | Floor for balcony or toilet |
DE202011005194U1 (en) * | 2011-04-13 | 2011-08-30 | Wedi Gmbh | Foreign soil element with wedge-shaped reinforcement in the edge area |
KR101112010B1 (en) * | 2011-05-06 | 2012-02-13 | 신계호 | Construction method of the outer wall for forming waterproof and insulation layer |
KR101368711B1 (en) * | 2012-09-27 | 2014-03-04 | 주식회사 테크닉스디앤씨 | Construction method of waterproof and root barrier for rooftop landscape architecture |
ES2393876B1 (en) * | 2012-10-23 | 2013-11-08 | Krypton Chemical S.L. | Surface isolation geomembrane arrangement and corresponding insulation procedure |
US20150259923A1 (en) * | 2014-03-13 | 2015-09-17 | William Sleeman | Roofing system with sensors |
KR20160137128A (en) * | 2015-05-22 | 2016-11-30 | 신계호 | Heat insulating and waterproofing method of constructure using tapering insulation board and Polyurea Waterproofing Sheet |
US9556615B1 (en) * | 2015-10-13 | 2017-01-31 | The Dragon Group, LLC | Encapsulated panel systems |
JP6852877B2 (en) * | 2017-01-30 | 2021-03-31 | 竹本 直文 | Foam panel and prefabricated house |
NZ735772A (en) * | 2017-09-22 | 2019-03-29 | Bree Charles | A Building Element |
-
2020
- 2020-04-24 AU AU2020202744A patent/AU2020202744B2/en active Active
-
2021
- 2021-08-31 AU AU2021107533A patent/AU2021107533A4/en not_active Ceased
Also Published As
Publication number | Publication date |
---|---|
AU2021107533A4 (en) | 2022-01-06 |
AU2020202744B2 (en) | 2023-11-02 |
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