US20190201995A1 - Deposition of braze preform - Google Patents

Deposition of braze preform Download PDF

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Publication number
US20190201995A1
US20190201995A1 US16/297,944 US201916297944A US2019201995A1 US 20190201995 A1 US20190201995 A1 US 20190201995A1 US 201916297944 A US201916297944 A US 201916297944A US 2019201995 A1 US2019201995 A1 US 2019201995A1
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United States
Prior art keywords
braze
components
filler
void
component
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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.)
Abandoned
Application number
US16/297,944
Inventor
Lev Alexander Prociw
Jason A. Ryon
Steven J. Myers
Michael J. Bronson
Fouad T. Khairallah
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Delavan Inc
Original Assignee
Delavan Inc
Priority date (The priority date 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 date listed.)
Filing date
Publication date
Priority to US14/704,579 priority Critical patent/US20160325370A1/en
Priority to US15/630,313 priority patent/US10252365B2/en
Application filed by Delavan Inc filed Critical Delavan Inc
Priority to US16/297,944 priority patent/US20190201995A1/en
Publication of US20190201995A1 publication Critical patent/US20190201995A1/en
Assigned to DELAVAN INC reassignment DELAVAN INC ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: BRONSON, Michael J., MYERS, STEVEN J., KHAIRALLAH, Fouad, PROCIW, LEV A., Ryon, Jason A.
Abandoned legal-status Critical Current

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    • BPERFORMING OPERATIONS; TRANSPORTING
    • B23MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23KSOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K1/00Soldering, e.g. brazing, or unsoldering
    • B23K1/20Preliminary treatment of work or areas to be soldered, e.g. in respect of a galvanic coating
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B23MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23KSOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K3/00Tools, devices, or special appurtenances for soldering, e.g. brazing, or unsoldering, not specially adapted for particular methods
    • B23K3/06Solder feeding devices; Solder melting pans
    • B23K3/0607Solder feeding devices
    • B23K3/0623Solder feeding devices for shaped solder piece feeding, e.g. preforms, bumps, balls, pellets, droplets
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B23MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23KSOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K3/00Tools, devices, or special appurtenances for soldering, e.g. brazing, or unsoldering, not specially adapted for particular methods
    • B23K3/06Solder feeding devices; Solder melting pans
    • B23K3/0607Solder feeding devices
    • B23K3/0638Solder feeding devices for viscous material feeding, e.g. solder paste feeding
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B23MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23KSOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K35/00Rods, electrodes, materials, or media, for use in soldering, welding, or cutting
    • B23K35/02Rods, electrodes, materials, or media, for use in soldering, welding, or cutting characterised by mechanical features, e.g. shape
    • B23K35/0222Rods, electrodes, materials, or media, for use in soldering, welding, or cutting characterised by mechanical features, e.g. shape for use in soldering, brazing
    • B23K35/0244Powders, particles or spheres; Preforms made therefrom
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B23MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23KSOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K35/00Rods, electrodes, materials, or media, for use in soldering, welding, or cutting
    • B23K35/22Rods, electrodes, materials, or media, for use in soldering, welding, or cutting characterised by the composition or nature of the material
    • B23K35/24Selection of soldering or welding materials proper
    • B23K35/30Selection of soldering or welding materials proper with the principal constituent melting at less than 1550 degrees C
    • B23K35/3006Ag as the principal constituent
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B23MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23KSOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K35/00Rods, electrodes, materials, or media, for use in soldering, welding, or cutting
    • B23K35/22Rods, electrodes, materials, or media, for use in soldering, welding, or cutting characterised by the composition or nature of the material
    • B23K35/24Selection of soldering or welding materials proper
    • B23K35/30Selection of soldering or welding materials proper with the principal constituent melting at less than 1550 degrees C
    • B23K35/3013Au as the principal constituent
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B23MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23KSOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K35/00Rods, electrodes, materials, or media, for use in soldering, welding, or cutting
    • B23K35/22Rods, electrodes, materials, or media, for use in soldering, welding, or cutting characterised by the composition or nature of the material
    • B23K35/24Selection of soldering or welding materials proper
    • B23K35/30Selection of soldering or welding materials proper with the principal constituent melting at less than 1550 degrees C
    • B23K35/302Cu as the principal constituent
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B23MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23KSOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K35/00Rods, electrodes, materials, or media, for use in soldering, welding, or cutting
    • B23K35/22Rods, electrodes, materials, or media, for use in soldering, welding, or cutting characterised by the composition or nature of the material
    • B23K35/24Selection of soldering or welding materials proper
    • B23K35/30Selection of soldering or welding materials proper with the principal constituent melting at less than 1550 degrees C
    • B23K35/3033Ni as the principal constituent
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B23MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23KSOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K35/00Rods, electrodes, materials, or media, for use in soldering, welding, or cutting
    • B23K35/22Rods, electrodes, materials, or media, for use in soldering, welding, or cutting characterised by the composition or nature of the material
    • B23K35/24Selection of soldering or welding materials proper
    • B23K35/30Selection of soldering or welding materials proper with the principal constituent melting at less than 1550 degrees C
    • B23K35/3053Fe as the principal constituent
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B23MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23KSOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K35/00Rods, electrodes, materials, or media, for use in soldering, welding, or cutting
    • B23K35/22Rods, electrodes, materials, or media, for use in soldering, welding, or cutting characterised by the composition or nature of the material
    • B23K35/24Selection of soldering or welding materials proper
    • B23K35/32Selection of soldering or welding materials proper with the principal constituent melting at more than 1550 degrees C
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B23MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23KSOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K35/00Rods, electrodes, materials, or media, for use in soldering, welding, or cutting
    • B23K35/22Rods, electrodes, materials, or media, for use in soldering, welding, or cutting characterised by the composition or nature of the material
    • B23K35/24Selection of soldering or welding materials proper
    • B23K35/32Selection of soldering or welding materials proper with the principal constituent melting at more than 1550 degrees C
    • B23K35/322Selection of soldering or welding materials proper with the principal constituent melting at more than 1550 degrees C a Pt-group metal as principal constituent

Abstract

A method of manufacturing includes depositing a braze filler adjacent to a void between a first component and a second component thus holding the components in position before brazing. The first and second components are heated to melt and flow the braze filler into the void. A braze joint is formed between the first and second components by cooling the braze filler. Depositing the braze filler can include laser cladding the braze filler to the first and/or second components adjacent the void. The method also optionally includes welding the first and second components in position with the braze filler adjacent to the void. The braze filler may be deposited as a powder, cold spray, melted brazed filament, spherical ball or any other suitable form.

Description

    CROSS-REFERENCE TO RELATED APPLICATION
  • This application is a divisional of U.S. patent application Ser. No. 15/630,313, filed Jun. 22, 2017, which application is a divisional of U.S. patent application Ser. No. 14/704,579 filed May 5, 2015, the contents of each of which are incorporated herein by reference in their entirety.
  • BACKGROUND OF THE INVENTION 1. Field of the Invention
  • The present disclosure relates to manufacturing and, more particularly, to brazing components during manufacturing.
  • 2. Description of Related Art
  • Conventional construction of components which undergo high heat during operation, such as fuel injectors, nozzles, atomizers and heat exchangers, include the components bonded together with braze. The components are typically nested within one another or stacked and form a narrow gap which is filled with a braze alloy. Typically, the braze alloy is applied as a braze paste, wire ring, or as a thin sheet shim on the external surfaces or within pockets inside the assembly. Applying braze paste is a very manual process and often can be inconsistent. Braze rings are an improvement but still must be manually positioned and are sensitive to placement. Braze plating requires masking. The use of conventional weld balls for tack welding components for braze fixturing presents the extra process of removal of these weld balls after brazing is complete. All of these challenges can lead to high scrap rates and increased process time. Too little braze creates holes and leakage in the assembly and too much braze results in excess material, e.g., that can block intended fuel or air passages in atomizers and the like. There is a need in the art to more accurately apply a specific amount of braze material to the correct locations. The present disclosure provides a solution for this need.
  • SUMMARY OF THE INVENTION
  • A method of manufacturing includes depositing a braze filler adjacent to a void between a first component and a second component thus holding the components in position before brazing. The first and second components are heated to melt the braze filler and draw the braze filler into the void. A braze joint is formed between the first and second components by cooling the braze filler.
  • Depositing the braze filler can include laser cladding the braze filler to the first and/or second components adjacent the void. The method also optionally includes welding the first and second components in position with the braze filler adjacent to the void. The braze filler may be deposited as a powder, cold spray, melted brazed filament, spherical ball, or any suitable form. The braze material can include at least one material chosen from the group consisting of bronze-based matrix materials containing nickel, steel-based matrix materials containing nickel, and steel alloys containing chromium, nickel, molybdenum, silicon, vanadium, carbon, gold, silver, copper, platinum and/or palladium, or the like.
  • The method can include depositing the braze filler as a braze ball located and/or tack welded to the first and/or second components. The braze ball can be of a predetermined size. These and other features of the systems and methods of the subject disclosure will become more readily apparent to those skilled in the art from the following detailed description of the preferred embodiments taken in conjunction with the drawings.
  • BRIEF DESCRIPTION OF THE DRAWINGS
  • So that those skilled in the art to which the subject disclosure appertains will readily understand how to make and use the devices and methods of the subject disclosure without undue experimentation, preferred embodiments thereof will be described in detail herein below with reference to certain figures, wherein:
  • FIG. 1 is a schematic view of an exemplary embodiment of a brazed assembly constructed in accordance with the present disclosure, showing a braze material laser cladded to a first and second component adjacent a void;
  • FIG. 2 is a schematic view of the braze assembly of FIG. 1, showing the braze material forming a braze joint between the first and second components;
  • FIG. 3 is a schematic view of another exemplary embodiment of a brazed assembly constructed in accordance with the present disclosure, showing a braze ball crimped into a pocket feature prior to forming a braze joint between the first and second components;
  • FIG. 4 is a schematic view of the braze assembly of FIG. 3, showing the braze material forming a braze joint between the first and second components;
  • FIG. 5 is a schematic view of another exemplary embodiment of a brazed assembly constructed in accordance with the present disclosure, showing a preformed braze ball to tack welded in place prior to brazing; and
  • FIG. 6 is a schematic view of the braze assembly of FIG. 5, showing the braze ball consumed between the first and second components to provide a braze joint therebetween.
  • DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
  • Reference will now be made to the drawings wherein like reference numerals identify similar structural features or aspects of the subject disclosure. For purposes of explanation and illustration, and not limitation, a partial view of an exemplary embodiment of a method for manufacturing in accordance with the disclosure is shown in FIG. 1 and is designated generally by reference character 100. Other embodiments of methods of manufacturing in accordance with the disclosure, or aspects thereof, are provided in FIGS. 2-3, as will be described.
  • With reference to FIGS. 1 and 2 an example of a first component 112 and a second component 114 with a braze filler 110 is shown adjacent a void 116 is shown. First and second components 112, 114 are dimensioned to fit together. For example, first and second components 112, 114 can be nozzle components of a fuel injector. The first and second components 112, 114 are each welded in position with the braze filler 110 laser cladded adjacent the void 116. The components 112, 114 are heated during which the braze 110 melts flows into the void 116. A braze joint 118, as shown in FIG. 2 is formed between the first and second components after the braze 110 is cooled. In other words, first and second components 112, 114 and braze filler 110 are assembled with a laser cladding process prior to heating the components 112, 114 and braze filler 110 to form the braze joint 118. In this manner, the entire assembly, including the first and second components 112, 114 and braze filler, are kept in position to allow the braze filler 110 to melt and flow directly into the void 116 thereby increasing the ability to control the location, amount, and flow of the braze filler 110. Typical brazing techniques rely on capillary forces, etc. to provide a relatively uncontrolled flow of braze through or between components to a desired braze joint location. Thus components formed of typical braze techniques are prone to braze fillets and even braze blockages as well as incomplete sealing of various internal passages from one another. Depositing the braze filler 110 directly adjacent the void 116 prior to heating the components 112, 114 ensures the braze 110 will flow directly into the void 116, precisely where it is intended to flow and thereby avoid the challenges of traditional brazing techniques. The braze material 110 can include at least one material including bronze-based matrix materials containing nickel, steel-based matrix materials containing nickel, and steel alloys containing chromium, nickel, molybdenum, silicon, vanadium, carbon, gold, silver, copper, platinum, palladium, or the like.
  • The braze material 110 is applied to the first component 112 and/or the second component 114 using laser cladding. The braze material 110 can also be laser cladded to only one of the first component 112 or the second component 114. The non-joined component can be held in position by some other means such as clamping or a jig to maintain the void.
  • Laser cladding is a process in which an alloy of cladding material (in the form of a wire, powder, etc.) is applied to a surface to permit accurate, consistent application of material. A concentrated laser beam moves relative to the surface to melt the applied alloy and a thin layer of the surface material to form a cladding that is metallurgically bonded. Laser cladding is similar to thermal spraying in that an energy source is used to melt the alloy that is being applied to a substrate. However, unlike thermal spraying, laser cladding also melts a thin layer of the surface that the alloy is being applied to. This process results in a fused metal and strong metallurgical bond between the cladding and the surface the alloy is applied to. Typically, laser cladding results in an interface with superior bond strength over thermal spraying. Since a concentrated laser beam is used as the heat source, the heat affected zone will be minimal. Any suitable known laser cladding process may be used to deposit the braze material to the joint location without departing from the scope of this disclosure.
  • FIGS. 3 and 4 illustrate another embodiment of the present disclosure where the braze filler is a braze ball 110 that is located into a void 116. In this embodiment, the braze ball 110 is melted into the two structural components 112, 114 to be joined together by a braze joint 118. It will be understood by those skilled in the art the braze is shown as a braze ball for ease of illustration and description, however the braze can be any shape/form that fits within a desired void without departing from the scope of the present invention. FIGS. 5 and 6 illustrate another embodiment of the present disclosure where the braze filler is a braze ball 110 that is used to tack weld and locate the two structural components 112, 114 in place prior to braze operation. In this embodiment, the braze ball 110 is melted into the two structural components 112, 114 to be joined together by a braze joint 118.
  • As shown in FIGS. 3-6, the components 112, 114 and braze ball 110 are shown as a general assembly. It will be understood by those skilled in the art that the braze ball can be used on any suitable assembly requiring a braze joint, for example, pump motors, fuel assemblies, turbine engines, or the like. This embodiment allows to control the quantity of the braze material by selecting the proper size of the braze ball 110. Further, the proper size of the braze ball 110 allows for additional control over the applied heat quantity based on the operating conditions of the assembly. Thus, the supply of excess heat can be avoided. More specifically, oxidation, discoloration, warping and undesirable stresses are avoided. Due to the precise measuring of the braze material in the form of balls of predetermined size, any waste of braze material is also avoided. As shown in FIG. 3, as the first and second components 112, 114 and braze ball 110 are heated the braze ball 110 melts and flows into void 116 to a braze joint between components 112, 114.
  • The methods and systems of the present disclosure, as described above and shown in the drawings, provide for a method of manufacturing with superior properties including improved precision in brazing. While the apparatus and methods of the subject disclosure have been shown and described with reference to preferred embodiments, those skilled in the art will readily appreciate that changes and/or modifications may be made thereto without departing from the scope of the subject disclosure.

Claims (4)

What is claimed is:
1. A method of manufacturing, comprising:
depositing a braze filler adjacent to a void between a first component and a second component thus holding the components in position before brazing, wherein depositing the braze filler includes locating and/or tack welding the braze filler as a braze ball to the first and second components;
heating the first and second components to melt the braze filler and draw the braze filler into the void; and
forming a braze joint between the first and second components by cooling the braze filler.
2. The method of claim 1, wherein the braze ball is a predetermined size.
3. The method of claim 1, wherein depositing includes locating and/or tack welding the braze ball to the first component and clamping the first component to the second component.
4. The method of claim 1, wherein the braze material includes at least one material chosen from the group consisting of bronze-based matrix materials containing nickel, steel-based matrix materials containing nickel, and steel alloys containing chromium, nickel, molybdenum, silicon, vanadium, carbon, gold, silver, copper, platinum and/or palladium.
US16/297,944 2015-05-05 2019-03-11 Deposition of braze preform Abandoned US20190201995A1 (en)

Priority Applications (3)

Application Number Priority Date Filing Date Title
US14/704,579 US20160325370A1 (en) 2015-05-05 2015-05-05 Deposition of braze preform
US15/630,313 US10252365B2 (en) 2015-05-05 2017-06-22 Deposition of braze preform
US16/297,944 US20190201995A1 (en) 2015-05-05 2019-03-11 Deposition of braze preform

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
US16/297,944 US20190201995A1 (en) 2015-05-05 2019-03-11 Deposition of braze preform

Related Parent Applications (1)

Application Number Title Priority Date Filing Date
US15/630,313 Division US10252365B2 (en) 2015-05-05 2017-06-22 Deposition of braze preform

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US20190201995A1 true US20190201995A1 (en) 2019-07-04

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US14/704,579 Abandoned US20160325370A1 (en) 2015-05-05 2015-05-05 Deposition of braze preform
US15/630,313 Active US10252365B2 (en) 2015-05-05 2017-06-22 Deposition of braze preform
US16/297,944 Abandoned US20190201995A1 (en) 2015-05-05 2019-03-11 Deposition of braze preform

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US14/704,579 Abandoned US20160325370A1 (en) 2015-05-05 2015-05-05 Deposition of braze preform
US15/630,313 Active US10252365B2 (en) 2015-05-05 2017-06-22 Deposition of braze preform

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US10879211B2 (en) * 2016-06-30 2020-12-29 R.S.M. Electron Power, Inc. Method of joining a surface-mount component to a substrate with solder that has been temporarily secured
CN108941976B (en) * 2018-09-26 2020-02-14 西安理工大学 Welding wire for TA1-Q345 middle layer welding and preparation and welding method

Citations (2)

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US20040228036A1 (en) * 2003-03-03 2004-11-18 Sae Magnetics (H.K.) Ltd. Manufacturing method and apparatus of magnetic head device, and magnetic head device
US20060221501A1 (en) * 2005-04-05 2006-10-05 Alps Electric Co., Ltd. Slider, magnetic head assembly and manufacturing the same

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US3222774A (en) * 1961-03-01 1965-12-14 Curtiss Wright Corp Method of brazing porous materials
US20080099538A1 (en) * 2006-10-27 2008-05-01 United Technologies Corporation & Pratt & Whitney Canada Corp. Braze pre-placement using cold spray deposition
AU2009329094B2 (en) * 2008-12-18 2013-09-12 Csir Method of repairing a metallic artefact

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Publication number Priority date Publication date Assignee Title
US20040228036A1 (en) * 2003-03-03 2004-11-18 Sae Magnetics (H.K.) Ltd. Manufacturing method and apparatus of magnetic head device, and magnetic head device
US20060221501A1 (en) * 2005-04-05 2006-10-05 Alps Electric Co., Ltd. Slider, magnetic head assembly and manufacturing the same

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Title
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US10252365B2 (en) 2019-04-09
EP3090826A1 (en) 2016-11-09
US20160325370A1 (en) 2016-11-10
US20170282273A1 (en) 2017-10-05

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