JP5681184B2 - AlおよびTiを含む溶融酸化物粒子およびその粒子を含むセラミック材料 - Google Patents
AlおよびTiを含む溶融酸化物粒子およびその粒子を含むセラミック材料 Download PDFInfo
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- JP5681184B2 JP5681184B2 JP2012522221A JP2012522221A JP5681184B2 JP 5681184 B2 JP5681184 B2 JP 5681184B2 JP 2012522221 A JP2012522221 A JP 2012522221A JP 2012522221 A JP2012522221 A JP 2012522221A JP 5681184 B2 JP5681184 B2 JP 5681184B2
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Description
− 15%を超えるが55%未満のAl2O3;
− 25%を超えるが60%未満のTiO2;
− 全体が20%未満の、MgOおよびCoOから選択される、元素M1の少なくとも1種の酸化物;
− 全体が0.7%を超えるが20%未満の、Fe2O3、Cr2O3、MnO2、La2O3、Y2O3およびGa2O3によって形成される群から選択される、元素M2の少なくとも1種の酸化物;
− 全体が20%未満の、ZrO2、Ce2O3およびHfO2によって形成される群から選択される、元素M3の少なくとも1種の酸化物;および、
− 30%未満のSiO2。
− aは、Al2O3のモルパーセントであり;
− sは、SiO2のモルパーセントであり;
− a’=a−0.37sであり;
− tは、TiO2のモルパーセントであり;
− m1は、M1の酸化物の全モルパーセントであり;そして、
− m2は、M2の酸化物の全モルパーセントである。
− 45%を超えるが55%未満のAl2O3;
− 30%を超えるが50%未満のTiO2;
− 1%を超えるが10%未満のFe2O3;
− 5%未満のSiO2;そして、
− 5%未満のZrO2。
− Al2O3は、48wt%と54wt%との間であってもよく;
− TiO2は、35wt%と48wt%との間、たとえば、38wt%と45wt%との間であってもよく;
− Fe2O3は、1wt%と8wt%との間、たとえば、2wt%と6wt%との間であってもよく;
− SiO2は、1wt%未満、または0.5wt%未満の割合で存在し、さらに上記相に存在せず;そして、
− ZrO2は、3wt%未満であり、さらに上記相に存在しない。
− 15%を超えるが55%未満のAl2O3;
− 25%を超えるが60%未満のTiO2;
− 全体が20%未満の、MgOおよびCoOから選択される、元素M1の少なくとも1種の酸化物;
− 全体が0.7%を超えるが20%未満の、Fe2O3、Cr2O3、MnO2、La2O3、Y2O3およびGa2O3によって形成される群から選択される、元素M2の少なくとも1種の酸化物;
− 全体が20%未満の、ZrO2、Ce2O3およびHfO2によって形成される群から選択される、元素M3の少なくとも1種の酸化物;および、
− 30%未満のSiO2。
− 45%を超えるが55%未満のAl2O3;
− 30%を超えるが50%未満のTiO2;
− 1%を超えるが10%未満のFe2O3;
− 5%未満のSiO2;および
− 5%未満のZrO2。
− Al2O3は48wt%と54wt%との間であってもよく;
− TiO2は35wt%と48wt%との間、たとえば38wt%と45wt%との間であってもよく;
− Fe2O3は1wt%と8wt%との間、たとえば2wt%と6wt%との間であってもよく;
− SiO2は、1wt%未満、さらに0.5wt%未満の割合で存在し、または上記相にはSiがまったくなく;そして、
− ZrO2は、3wt%未満であり、さらに上記相にはZrがまったくない。
− 35%を超えるが51%未満のAl2O3、たとえば、38%と50%との間のAl2O3;
− 25%を超えるが45%未満のTiO2;
− 0.7%を超えるが20%未満のFe2O3、たとえば、1%と10%との間のFe2O3;
− 所望により、0.1%を超えるが20%未満のSiO2;
− 2%未満のMgO、さらに1%未満のMgO;
− 所望により、0.3%を超えるが10%未満のZrO2;および、
− 所望により、全体が2%を超えるが13%未満の、CaO、Na2O、K2O、SrOおよびBaOによって形成される群から選択される少なくとも1種の酸化物。
a)原料を混合し、出発供給原料を作製する工程;
b)溶融液が得られるまで、出発供給原料を溶融する工程;
c)上記溶融液が完全に固体化するように、上記溶融液を、たとえば3分未満の時間で冷却する工程;および
d)溶融粒子の混合物が得られるように、溶融固体の塊を粉砕する工程。
最初に、本発明による溶融粒子を上述のように混合する。たとえば、溶融粒子は、粒子が50ミクロン未満、たとえば約0.1〜40ミクロンのメジアン径を有するような方法で粉砕される。製造方法は、粒子、メチルセルロースタイプの有機バインダおよび気孔形成剤を含む最初の混合物を混合し、その後、以下の押し出し成形の工程に望ましい可塑性が得られるまで水を加える工程を概して含む。
− 少なくとも5%、たとえば、少なくとも50%、または少なくとも90%、さらに100%の本発明による粒子。混合物の残りは、他の材料、またはAl、Ti、M1、M2またはM3の元素の単純な酸化物、またはそれらの酸化物の前駆物質、たとえば、炭酸塩、水酸化物、または上記元素の他の有機金属の形態の粉末または粒子からなり得る。;
− 所望により、所望の気孔のサイズにしたがって選択される1〜30重量%の少なくとも1種の気孔形成剤;
− 少なくとも1種の有機可塑剤および/または少なくとも1種の有機バインダ;および
− 製品に成形させるための一定量の水。
− 98%を超えるAl2O3を含み、「Alcan」社によって販売されている、約85μmのメジアン径d50を有するAR75アルミナ;
− 98%を超えるTiO2を含み、「Altichem」社から販売されているアナターゼ、または95%を超えるTiO2を含み、約120μmのメジアン径d50を有し、「Europe Minerals」社から販売されているルチル;
− 99.5%よりも高い純度を有し、メジアン径d50は208μmであり、「Sifraco」社から販売されているSiO2;
− 98%を超える純度を有し、0.25mmと1mmとの間の粒径を有する粒子が80%を超え、「Nedmag」社から販売されているMgO;
− 99%を超える純度を有するFe2O3;
− 98.5%を超えるSrCO3を含み、「Societe des Produits Chimiques Harbonnieres」社から販売されている炭酸ストロンチウム;
− 99.5%を超えるK2CO3を含み、「Albemarle」社から販売され、0.25mmと1mmとの間の直径を有する粒子が80%を超える炭酸カリウム;
− 98.5%を超える純度を有し、メジアン径d50が3.5μmであり、「CC10」の参照符号の下、「Saint-Gobain ZirPro」社から販売されているジルコニア;そして、
− 99%を超える純度を有する酸化ランタンLa2O3。
1)酸化物に基づいてwt%で示される化学組成は、蛍光X線によって測定された。
2)耐火生成物中に存在する結晶相は、X線回折によってキャラクタリゼーションされた。表1および2では、ATXは、酸化物(主相)の固溶体であり、PSは、ケイ酸塩相の存在を示し、1種または2種以上の他の相は、少なくとも1種の他の副相P2の存在を示し、一方、「〜」は、微量の形態の1つの相または複数の相が存在することを意味する。
3)存在する結晶相の安定性は、最初に存在する結晶相と1100℃で100時間熱処理した後に存在する結晶相とをX線回折によって比較することからなる試験によって評価された。この熱処理後のコランダム(Al2O3)の出現を示すメインピークの最大強度がATX相の3つのメインピークのそれぞれの最大強度の平均の50%未満のままである場合、製品は安定しているとみなされた。表1に示される値は、ATX相の3つのメインピークのそれぞれの最大強度の平均に対するルチル相のメインピークの最大強度の割合としての比率に対応し、以下の式による。
4)熱膨張係数(TEC)は、メジアン径d50が50μm未満であり、同じ粒子サイズ分布を有する粉末から作製された円盤で、25℃から1000℃までの熱膨張率測定によって従来の方法で得られた値の平均に対応し、円盤は、加圧し次いで表1に示される温度で空気中で4時間焼結することによって得られた。
− 比較例1および4によれば、溶融粒子は、金属源M2(Fe)を最初の反応物に導入することなく合成された。
− 比較例3によれば、溶融粒子は、本発明の文脈では不十分な量の金属M2(Fe)を最初の反応物に導入することによって合成された。そして、
− 比較例2によれば、試料は、溶融粒子を焼結することによっては粒子から合成されなかった。すなわち、上述の原料の混合物を溶融する工程の前によって得られた粒子から合成され、試料は、以下の原料の粉末混合物の反応焼結から直接合成された。
− 99.8%のAl2O3を含み、約5.2μmのメジアン径d50を有する「Almatis CL4400FG」アルミナ;
− 99.5%のTiO2を含み、約0.3μmの直径を有する「TRONOX T-R」酸化チタン;
− 99.7%の純度を有する「971U grade Elkem microsilicia」SiO2;
− 98.5%を超えるSrCO3を含み、「Societe des Produits Chimiques Harbonnieres」社から販売されている炭酸ストロンチウム;
− 約97%のCaOを含み、80μm未満の直径を有する粒子が80%を超える石灰;そして、
− 98%の純度を有するFe2O3。
− 同様の組成および同じ焼結温度の場合、本発明による溶融粒子から得られた材料または製品(例1)は、比較例2により示される反応焼結タイプの従来の方法によって得られた材料の熱膨張係数と実質的に等しい熱膨張係数を有することが観察される。しかし、(本発明による)例1に対応する試料と比較例2に対応する試料との間の腐食深さEの比較により、本発明による材料についてより良好な耐腐食性が示される。そして、
− 密度に関して、本発明による材料から得られた密度は、高く、結晶材料の理論的密度の80%を超えることがわかり得る。そのような特性は、とりわけ材料の非常に高い密度を要する用途、たとえば、製品が(たとえば、スラグまたは溶融金属タイプの)腐食性媒体と接触するところの用途において明確な結果をもたらすことをとくに証明することができる。気孔率がより小さくなると、耐浸透性が改善され得る。また、これは、材料の非常に高い機械強度をとりわけ要する用途において、たとえば鋳造濾過の分野で、有益である。
− 予め溶融された粒子から得られた本発明による第1の試料は、上述のようにして得られた。蛍光X線によって分析された、この第1の試料の化学組成は、対応する単純な酸化物の対応するwt%として、以下であった。
− 45.5%Al2O3;34.3%TiO2;6.37%Fe2O3;7.41%SiO2;5.17%SrO;0.6%CaO;0.13%Na2O;0.39% ZrO2。本発明に対応するa’−t+2m1+m2パラメータは1.0であった。
− 本発明によらない第2の試料は、第1のものと同じ酸化物組成物を使用したが、このとき、比較例2で上述した方法と同様の作製方法にしたがって原料を混ぜて直接反応焼結させることによって作製された。
Claims (17)
- 溶融粒子であって、
前記溶融粒子は、
− 15%を超えるが55%未満のAl2O3;
− 25%を超えるが60%未満のTiO2;
− 全体が20%未満の、MgOおよびCoOから選択される、元素M1の少なくとも1種の酸化物;
− 全体が2%を超えるが20%未満の、Fe2O3、Cr2O3、MnO2、La2O3、Y2O3およびGa2O3によって形成される群から選択される、元素M2の少なくとも1種の酸化物;
− 全体が10%未満の、ZrO2、Ce2O3およびHfO2によって形成される群から選択される、元素M3の少なくとも1種の酸化物;および、
− 30%未満のSiO2;
の化学組成を、酸化物に基づく重量パーセントとして有し、
前記溶融粒子は、a’−t+2m1+m2が−15と15との間であるような、前記溶融粒子に存在するすべての酸化物に基づくmol%の組成にさらに対応し、ここで、
− aは、Al2O3のモルパーセントであり;
− sは、SiO2のモルパーセントであり;
− a’=a−0.37sであり;
− tは、TiO2のモルパーセントであり;
− m1は、M1の酸化物の全モルパーセントであり;そして、
− m2は、M2の酸化物の全モルパーセントである、
溶融粒子。 - 前記組成は、a’−t+2m1+m2が、−10と10との間であるような組成である、請求項1に記載の溶融粒子。
- Al2O3は、重量%として、25%を超える化学組成であるが52%未満の化学組成である、請求項1または2に記載の溶融粒子。
- TiO2は、重量%として、26%を超える化学組成であるが55%未満の化学組成である、請求項1〜3のいずれか1項に記載の溶融粒子。
- 前記組成に存在する前記元素M1の1種または2種以上の酸化物は、重量%として、全体で、0.7%を超える化学組成であるが10%未満の化学組成である、請求項1〜4のいずれか1項に記載の溶融粒子。
- 前記組成に存在する前記元素M2の1種または2種以上の酸化物は、全体で、重量%として、1%を超える化学組成であるが10%未満の化学組成である、請求項1〜5のいずれか1項に記載の溶融粒子。
- 前記組成に存在する前記元素M3の1種または2種以上の酸化物は、重量%として、全体で、0.7%を超える化学組成である、請求項1〜6のいずれか1項に記載の溶融粒子。
- 対応する酸化物SiO2に基づいて、0.1重量%と20重量%との間の割合で、ケイ素をさらに含む、請求項1〜7のいずれか1項に記載の溶融粒子。
- M1はマグネシウムのみである、請求項1〜8のいずれか1項に記載の溶融粒子。
- M2は鉄のみである、請求項1〜9のいずれか1項に記載の溶融粒子。
- M2は鉄とランタンとの組み合わせによって形成される、請求項1〜9のいずれか1項に記載の溶融粒子。
- M3はジルコニウムのみである、請求項1〜11のいずれか1項に記載の溶融粒子。
- − 45%を超えるが55%未満のAl2O3;
− 30%を超えるが50%未満のTiO2;
− 1%を超えるが10%未満のFe2O3;
− 5%未満のSiO2;および
− 5%未満のZrO2;
の化学組成を、酸化物に基づくwt%で有するチタン酸アルミニウムタイプ酸化物主相を含む、請求項1〜12のいずれか1項に記載の溶融粒子。 - 請求項1〜13のいずれか1項に記載の粒子を焼結することによって得られ、チタン酸アルミニウムタイプの酸化物相を主に含むか、またはそれらの相によって形成される、セラミック製品または材料。
- − 15%を超えるが55%未満のAl2O3;
− 25%を超えるが60%未満のTiO2;
− 全体が20%未満の、MgOおよびCoOから選択される、元素M1の少なくとも1種の酸化物;
− 全体が2%を超えるが20%未満の、Fe2O3、Cr2O3、MnO2、La2O3、Y2O3およびGa2O3によって形成される群から選択される、元素M2の少なくとも1種の酸化物;
− 全体が10%未満の、ZrO2、Ce2O3およびHfO2によって形成される群から選択される、元素M3の少なくとも1種の酸化物;および、
− 30%未満のSiO2;
の化学組成を、酸化物に基づくwt%で有する、請求項14に記載のセラミック製品または材料。 - − 45%を超えるが55%未満のAl2O3;
− 30%を超えるが50%未満のTiO2;
− 1%を超えるが10%未満のFe2O3;
− 5%未満のSiO2;および
− 5%未満のZrO2;
の化学組成を、酸化物に基づくwt%で有するチタン酸アルミニウムタイプの酸化物主相を含む、請求項14または15に記載のセラミック製品または材料。 - 請求項14〜16のいずれか1項に記載のセラミック材料で作製される、または請求項1〜13のいずれか1項に記載の粒子を焼結することによって得られる、自動車の排気ライン中の触媒担体または微粒子フィルタとしての用途のためのハニカム構造体。
Applications Claiming Priority (3)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
FR0955282 | 2009-07-28 | ||
FR0955282A FR2948657B1 (fr) | 2009-07-28 | 2009-07-28 | Grains fondus d'oxydes comprenant al, ti et produits ceramiques comportant de tels grains |
PCT/FR2010/051586 WO2011015766A1 (fr) | 2009-07-28 | 2010-07-27 | Grains fondus d'oxydes comprenant al, ti et produits ceramiques comportant de tels grains |
Publications (2)
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JP2013500232A JP2013500232A (ja) | 2013-01-07 |
JP5681184B2 true JP5681184B2 (ja) | 2015-03-04 |
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JP2012522221A Expired - Fee Related JP5681184B2 (ja) | 2009-07-28 | 2010-07-27 | AlおよびTiを含む溶融酸化物粒子およびその粒子を含むセラミック材料 |
Country Status (6)
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US (1) | US8557012B2 (ja) |
EP (1) | EP2459498B1 (ja) |
JP (1) | JP5681184B2 (ja) |
CN (1) | CN102574744B (ja) |
FR (1) | FR2948657B1 (ja) |
WO (1) | WO2011015766A1 (ja) |
Families Citing this family (13)
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PL2221287T3 (pl) * | 2007-11-14 | 2015-12-31 | Hitachi Metals Ltd | Ceramiczna struktura typu plastra miodu, oparta na tytanianie glinu, sposób jej wytwarzania i sproszkowany materiał wyjściowy do jej wytwarzania |
KR20120083349A (ko) * | 2009-09-22 | 2012-07-25 | 생-고뱅 생트레 드 레체르체 에 데투드 유로삐엔 | 알루미나 티타네이트 다공성 구조물 |
FR2950340B1 (fr) * | 2009-09-22 | 2015-07-17 | Saint Gobain Ct Recherches | Structure poreuse du type titanate d'alumine |
US8709120B2 (en) * | 2010-12-22 | 2014-04-29 | Hollingsworth & Vose Company | Filter media including glass fibers |
DE102011087147B4 (de) * | 2011-11-25 | 2015-02-26 | C.A.R.R.D. Gmbh | Titanoxidhaltige Aluminiumoxidpartikel auf Basis von im elektrischen Lichtbogenofen aus kalzinierter Tonerde geschmolzenem Korund sowie ein Verfahren zu deren Herstellung und ihre Verwendung |
US9908260B2 (en) | 2013-05-20 | 2018-03-06 | Corning Incorporated | Porous ceramic article and method of manufacturing the same |
US9623360B2 (en) | 2013-05-20 | 2017-04-18 | Corning Incorporated | Porous ceramic article and method of manufacturing the same |
US9376347B2 (en) | 2013-05-20 | 2016-06-28 | Corning Incorporated | Porous ceramic article and method of manufacturing the same |
US9988311B2 (en) | 2013-11-27 | 2018-06-05 | Corning Incorporated | Aluminum titanate compositions, ceramic articles comprising same, and methods of manufacturing same |
FR3047733B1 (fr) * | 2016-02-12 | 2018-03-02 | Saint-Gobain Centre De Recherches Et D'etudes Europeen | Grains d'alumine-zircone fondus |
MX2018014812A (es) | 2016-05-31 | 2019-03-14 | Corning Inc | Articulo poroso y metodo para la fabricacion del mismo. |
CN111527054B (zh) | 2017-10-31 | 2023-09-01 | 康宁股份有限公司 | 包含球形预反应过的无机颗粒和球形造孔剂的批料组合物及由其制造蜂窝体的方法 |
WO2020101968A1 (en) * | 2018-11-16 | 2020-05-22 | Corning Incorporated | Cordierite-containing ceramic bodies, batch composition mixtures, and methods of manufacturing cordierite-containing ceramic bodies |
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US3993119A (en) | 1974-11-08 | 1976-11-23 | Norton Company | Progressively or continuously cycled mold for forming and discharging a fine crystalline material |
US4042403A (en) * | 1975-05-19 | 1977-08-16 | Corning Glass Works | Thermally stable glass-ceramic articles |
JPS5919068B2 (ja) * | 1980-03-26 | 1984-05-02 | 日本碍子株式会社 | 低膨脹性セラミックス |
US4483944A (en) * | 1983-07-27 | 1984-11-20 | Corning Glass Works | Aluminum titanate-mullite ceramic articles |
JPS60141668A (ja) * | 1983-12-28 | 1985-07-26 | 日本碍子株式会社 | セラミックハニカム構造体を接合若しくはコーティングまたは封着するためのセラミック材料組成物 |
US4528275A (en) * | 1984-06-04 | 1985-07-09 | General Electric Company | Mullite-cordierite composite ceramic and method for preparation |
JPS6221756A (ja) | 1985-07-22 | 1987-01-30 | 日本碍子株式会社 | チタン酸アルミニウム―ムライト系セラミック体の製造方法 |
DE3644664A1 (de) * | 1986-12-30 | 1988-07-14 | Didier Werke Ag | Aluminiumtitanatkeramik und ihre verwendung |
DE3707396A1 (de) * | 1987-03-09 | 1988-09-22 | Kalawrytinos Georg | Verfahren zur herstellung eines keramischen werkstoffes und verfahren zur beschichtung von werkstuecken mit diesem werkstoff |
US5914187A (en) | 1996-01-12 | 1999-06-22 | Ibiden Co., Ltd. | Ceramic structural body |
US6375910B1 (en) * | 1999-04-02 | 2002-04-23 | Engelhard Corporation | Multi-zoned catalytic trap and methods of making and using the same |
EP1775009A1 (en) | 1999-09-29 | 2007-04-18 | Ibiden Co., Ltd. | Honeycomb filter and ceramic filter assembly |
FR2833857B1 (fr) | 2001-12-20 | 2004-10-15 | Saint Gobain Ct Recherches | Corps filtrant comportant une pluralite de blocs filtrants, notamment destine a un filtre a particules |
US6849181B2 (en) | 2002-07-31 | 2005-02-01 | Corning Incorporated | Mullite-aluminum titanate diesel exhaust filter |
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JP4723173B2 (ja) | 2003-01-20 | 2011-07-13 | 日本碍子株式会社 | ハニカム構造体の製造方法 |
FR2853256B1 (fr) | 2003-04-01 | 2005-10-21 | Saint Gobain Ct Recherches | Structure de filtration, notamment filtre a particules pour les gaz d'echappement d'un moteur a combustion interne. |
US20060021308A1 (en) * | 2004-07-29 | 2006-02-02 | Merkel Gregory A | Mullite-aluminum titanate body and method for making same |
EP1890983B1 (en) * | 2005-05-31 | 2012-12-12 | Corning Incorporated | Aluminum titanate ceramic forming batch mixtures and green bodies including pore former combinations and methods of manufacturing and firing same |
FR2897612B1 (fr) * | 2006-02-17 | 2008-05-16 | Saint Gobain Ct Recherches | Grain fondu d'alumine-oxyde de titane-zircone |
US8394167B2 (en) * | 2006-06-30 | 2013-03-12 | Corning Incorporated | Cordierite aluminum magnesium titanate compositions and ceramic articles comprising same |
US7855163B2 (en) * | 2007-05-14 | 2010-12-21 | Geo2 Technologies, Inc. | Low coefficient of thermal expansion bonding system for a high porosity ceramic body and methods of manufacture |
US20100257829A1 (en) * | 2007-09-28 | 2010-10-14 | Kyocera Corporation | Honeycomb Structure and Purifying Apparatus Using the Same |
PL2221287T3 (pl) * | 2007-11-14 | 2015-12-31 | Hitachi Metals Ltd | Ceramiczna struktura typu plastra miodu, oparta na tytanianie glinu, sposób jej wytwarzania i sproszkowany materiał wyjściowy do jej wytwarzania |
FR2933400B1 (fr) * | 2008-07-04 | 2010-08-20 | Saint Gobain Ct Recherches | Grains fondus d'oxydes comprenant al, ti, mg et zr et produits ceramiques comportant de tels grains |
-
2009
- 2009-07-28 FR FR0955282A patent/FR2948657B1/fr not_active Expired - Fee Related
-
2010
- 2010-07-27 CN CN201080033765.5A patent/CN102574744B/zh not_active Expired - Fee Related
- 2010-07-27 WO PCT/FR2010/051586 patent/WO2011015766A1/fr active Application Filing
- 2010-07-27 US US13/386,755 patent/US8557012B2/en not_active Expired - Fee Related
- 2010-07-27 EP EP10754358.9A patent/EP2459498B1/fr not_active Not-in-force
- 2010-07-27 JP JP2012522221A patent/JP5681184B2/ja not_active Expired - Fee Related
Also Published As
Publication number | Publication date |
---|---|
US8557012B2 (en) | 2013-10-15 |
FR2948657B1 (fr) | 2013-01-04 |
EP2459498A1 (fr) | 2012-06-06 |
US20120124953A1 (en) | 2012-05-24 |
JP2013500232A (ja) | 2013-01-07 |
EP2459498B1 (fr) | 2014-01-08 |
WO2011015766A1 (fr) | 2011-02-10 |
CN102574744A (zh) | 2012-07-11 |
CN102574744B (zh) | 2015-09-09 |
FR2948657A1 (fr) | 2011-02-04 |
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