US3372008A - Metal reflector and method of manufacturing such reflectors - Google Patents

Metal reflector and method of manufacturing such reflectors Download PDF

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Publication number
US3372008A
US3372008A US194217A US19421762A US3372008A US 3372008 A US3372008 A US 3372008A US 194217 A US194217 A US 194217A US 19421762 A US19421762 A US 19421762A US 3372008 A US3372008 A US 3372008A
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Prior art keywords
aluminum
silicon
alloy
reflectors
manganese
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US194217A
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Korver Cornelis
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US Philips Corp
North American Philips Co Inc
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US Philips Corp
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Classifications

    • GPHYSICS
    • G02OPTICS
    • G02BOPTICAL ELEMENTS, SYSTEMS OR APPARATUS
    • G02B5/00Optical elements other than lenses
    • G02B5/08Mirrors
    • G02B5/0816Multilayer mirrors, i.e. having two or more reflecting layers
    • G02B5/085Multilayer mirrors, i.e. having two or more reflecting layers at least one of the reflecting layers comprising metal
    • G02B5/0858Multilayer mirrors, i.e. having two or more reflecting layers at least one of the reflecting layers comprising metal the reflecting layers comprising a single metallic layer with one or more dielectric layers
    • CCHEMISTRY; METALLURGY
    • C22METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22CALLOYS
    • C22C21/00Alloys based on aluminium
    • C22C21/02Alloys based on aluminium with silicon as the next major constituent
    • CCHEMISTRY; METALLURGY
    • C22METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22CALLOYS
    • C22C21/00Alloys based on aluminium
    • C22C21/06Alloys based on aluminium with magnesium as the next major constituent
    • CCHEMISTRY; METALLURGY
    • C22METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22CALLOYS
    • C22C21/00Alloys based on aluminium
    • C22C21/06Alloys based on aluminium with magnesium as the next major constituent
    • C22C21/08Alloys based on aluminium with magnesium as the next major constituent with silicon
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10STECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10S428/00Stock material or miscellaneous articles
    • Y10S428/922Static electricity metal bleed-off metallic stock
    • Y10S428/923Physical dimension
    • Y10S428/924Composite
    • Y10S428/925Relative dimension specified
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10STECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10S428/00Stock material or miscellaneous articles
    • Y10S428/922Static electricity metal bleed-off metallic stock
    • Y10S428/9335Product by special process
    • Y10S428/938Vapor deposition or gas diffusion
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10TTECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00Stock material or miscellaneous articles
    • Y10T428/12All metal or with adjacent metals
    • Y10T428/12493Composite; i.e., plural, adjacent, spatially distinct metal components [e.g., layers, joint, etc.]
    • Y10T428/12535Composite; i.e., plural, adjacent, spatially distinct metal components [e.g., layers, joint, etc.] with additional, spatially distinct nonmetal component
    • Y10T428/12583Component contains compound of adjacent metal
    • Y10T428/1259Oxide
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10TTECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00Stock material or miscellaneous articles
    • Y10T428/12All metal or with adjacent metals
    • Y10T428/12493Composite; i.e., plural, adjacent, spatially distinct metal components [e.g., layers, joint, etc.]
    • Y10T428/12736Al-base component
    • Y10T428/12764Next to Al-base component
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10TTECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00Stock material or miscellaneous articles
    • Y10T428/12All metal or with adjacent metals
    • Y10T428/12993Surface feature [e.g., rough, mirror]

Definitions

  • the invention relates to metal reflectors and to a method of manufacturing such reflectors.
  • Metal reflectors for outdoor use and for use in damp spaces have to satisfy stringent requirements. They have to be capable of withstanding any type of climate and elevated temperatures while retaining their reflecting power.
  • Materials which might be particularly suitable for such use are aluminium casting alloys consisting mainly of aluminum with magnesium and/or silicon as main alloying element or elements.
  • satisfactory corrosion resistance which in some cases can be improved by the provision of an oxide film, for example by anodizing, and sufficient mechanical strength at the temperatures which may occur in practice
  • the use of an aluminium casting alloy has the advantage that the reflector, which frequently has a complicated shape, can be simply manufactured by casting in sand or a permanent mold.
  • the said alloys and many other alloys suffer from the disadvantage that articles manufactured from them cannot be polished so as to be highly reflecting.
  • the coefficient of reflection, expressed as a percentage, of a known aluminium alloy containing 1.0% of magnesium and 5% of silicon after polishing is at most about 60%, whereas the coeflicient of reflection of pure aluminium after polishing may be from 80 to 90%.
  • a further disadvantage consists in that an anodizing treatment of an aluminium alloy performed to increase the corrosion resistance reduces the coeificient of reflection by about one half, while some alloys do not form a continuous oxide film during this treatment.
  • reflectors comprising a support made of a material which itself cannot be polished so as to become highly reflecting when provided with a reflecting layer consisting of pure or substantially pure aluminium coated with a protective oxide film, are particularly suitable.
  • Mirrors and reflecting layers produced by deposition of pure or substantially pure aluminium from vapour are known. It is also known to anodize aluminium so as to grow an oxide film which imparts an increased corrosion resistance to the metal.
  • an oxide film having a thickness which does not reduce the reflectivity to an unserviceable value that is to say, a thickness of the order of magnitude of from 5 to microns, is not capable of withstanding temperatures exceeding about 150 C. for a prolonged period of time. Above the said temperature cracks are produced in the oxide film so that the protective action preventing further oxidation is lost and the reflecting power of the mirror is decreased.
  • reflectors in accordance with the invention can be heated to temperatures of up to about 300 C. for a prolonged period of time without the oxide film on the aluminium mirror losing its protective action against further oxidation and without the reflectivity deteriorating perceptibly.
  • Such a support is preferably made of an aluminium casting alloy containing magnesium and/ or silicon as main alloying element or elements.
  • Such alloys are 3,372,008 Patented Mar. 5, 1968 the aluminium alloys containing 3.0% of magnesium, less than 0.6% of manganese and less than 0.3% of silicon, or about 0.4% of managanese and from 12.0 to 13.5% of silicon, or 1.0% of magnesium, from 0.2 to 1.0% of manganese and 5% of silicon, and the like.
  • a parabolic reflector was made by casting a molten alloy having the composition 1.0% of magnesium, 0.6% of manganese, 5.0% of silicon and the remainder aluminium, in a suitable mold and cooling in the mold, after which the inner side was polished. The coeflicient of reflection of the material expressed as a percentage was 57%. Part of the reflector was anodized until an oxide film having a thickness of 1 micron was obtained. The coefficient of reflection now was 25%.
  • Another part of the reflector was degreased with the aid of an organic solvent, for example trichloroethane, and heated to a temperature of from 250 C. to 275 C., after which this part was treated in a vacuum with the aid of a glow discharge for 10 minutes. After cooling, aluminium was deposited from vapour so as to form a coating having a thickness of about 1.5 micron. This mirror had a coeflicient of reflection of 84%.
  • an organic solvent for example trichloroethane
  • This climate chamber test had been preceeded by a temperature test at 300 C. for 2 hours and at 250 C. for 24 hours.
  • the deterioration of the light reflectivity was only 2% compared with the initial value.
  • a metal reflector comprising a cast reflector body of aluminum and having alloys chosen from the group consisting of an alloy having 3.0% of magnesium, less than 0.6% of manganese, less than 3.0% of silicon and the remainder aluminum; an alloy having about 0.4% of manganese, from 12% to 13.5% of silicon and the remainder aluminum; an alloy having about 1.0% of magnesium, from 0.2% to 1.0% of manganese, about 5% of silicon, and the remainder aluminum; a reflecting layer of alumi num on said cast aluminum body and an oxide layer coating on said reflecting layer of aluminum.
  • a method of manufacturing a metal reflector comprising casting a metal reflector body from an alloy chosen from the group consisting of an alloy having 3.0% of magnesium, less than 0.6% of manganese, less than 3.0% of silicon and the remainder aluminum; an alloy having about 0.4% of manganese, from 12% to 13.5% of silicon and the remainder aluminum; an alloy having about 1.0% of magnesium, from 0.2% to 1.0% of manganese, about 5% of silicon, and the remainder aluminum, polishing the surface of said body which is desired to be reflecting, degreasing said surface, treating said surface with a glow discharge in a vacuum, vapor depositing aluminum upon said surface, and anodizing said polished aluminum reflective surface whereby said reflective surface is coated With an oxide layer.

Description

United States Patent F METAL REFLECTOR AND METHGD OF MANUFACTURING SUCH REFLECTORS Cornelis Korver, Eindhoven, Netherlands, assignor to North American Philips Company, Inc., New York,
N.Y., a corporation of Delaware No Drawing. Filed May 10, 1962, Ser. No. 194,217 Claims priority, application lgletherlands, May 29, 1961, 2 5, 87 3 Claims. (Cl. 29183.5)
The invention relates to metal reflectors and to a method of manufacturing such reflectors.
Metal reflectors for outdoor use and for use in damp spaces have to satisfy stringent requirements. They have to be capable of withstanding any type of climate and elevated temperatures while retaining their reflecting power. Materials which might be particularly suitable for such use are aluminium casting alloys consisting mainly of aluminum with magnesium and/or silicon as main alloying element or elements. In addition to satisfactory machinability, satisfactory corrosion resistance, which in some cases can be improved by the provision of an oxide film, for example by anodizing, and sufficient mechanical strength at the temperatures which may occur in practice, the use of an aluminium casting alloy has the advantage that the reflector, which frequently has a complicated shape, can be simply manufactured by casting in sand or a permanent mold.
However, the said alloys and many other alloys, such as brass, V A-steel, cast iron, and similar materials suffer from the disadvantage that articles manufactured from them cannot be polished so as to be highly reflecting. For example, the coefficient of reflection, expressed as a percentage, of a known aluminium alloy containing 1.0% of magnesium and 5% of silicon after polishing is at most about 60%, whereas the coeflicient of reflection of pure aluminium after polishing may be from 80 to 90%.
A further disadvantage consists in that an anodizing treatment of an aluminium alloy performed to increase the corrosion resistance reduces the coeificient of reflection by about one half, while some alloys do not form a continuous oxide film during this treatment.
It has now been found that reflectors comprising a support made of a material which itself cannot be polished so as to become highly reflecting when provided with a reflecting layer consisting of pure or substantially pure aluminium coated with a protective oxide film, are particularly suitable.
Mirrors and reflecting layers produced by deposition of pure or substantially pure aluminium from vapour are known. It is also known to anodize aluminium so as to grow an oxide film which imparts an increased corrosion resistance to the metal. However, in practice it has been found that such an oxide film having a thickness which does not reduce the reflectivity to an unserviceable value, that is to say, a thickness of the order of magnitude of from 5 to microns, is not capable of withstanding temperatures exceeding about 150 C. for a prolonged period of time. Above the said temperature cracks are produced in the oxide film so that the protective action preventing further oxidation is lost and the reflecting power of the mirror is decreased.
Surprisingly, it has now been found that reflectors in accordance with the invention can be heated to temperatures of up to about 300 C. for a prolonged period of time without the oxide film on the aluminium mirror losing its protective action against further oxidation and without the reflectivity deteriorating perceptibly.
Such a support is preferably made of an aluminium casting alloy containing magnesium and/ or silicon as main alloying element or elements. Examples of such alloys are 3,372,008 Patented Mar. 5, 1968 the aluminium alloys containing 3.0% of magnesium, less than 0.6% of manganese and less than 0.3% of silicon, or about 0.4% of managanese and from 12.0 to 13.5% of silicon, or 1.0% of magnesium, from 0.2 to 1.0% of manganese and 5% of silicon, and the like.
In order that the invention may readily be carried into effect, an embodiment thereof will now be described in detail in the following example.
A parabolic reflector was made by casting a molten alloy having the composition 1.0% of magnesium, 0.6% of manganese, 5.0% of silicon and the remainder aluminium, in a suitable mold and cooling in the mold, after which the inner side was polished. The coeflicient of reflection of the material expressed as a percentage was 57%. Part of the reflector was anodized until an oxide film having a thickness of 1 micron was obtained. The coefficient of reflection now was 25%.
Another part of the reflector was degreased with the aid of an organic solvent, for example trichloroethane, and heated to a temperature of from 250 C. to 275 C., after which this part was treated in a vacuum with the aid of a glow discharge for 10 minutes. After cooling, aluminium was deposited from vapour so as to form a coating having a thickness of about 1.5 micron. This mirror had a coeflicient of reflection of 84%. After anodizing in a solution of ammonium tartrate (pH 5.5) with a voltage of 110 volts (aluminium electrode) until an oxide film having a thickness of 1 micron was obtained, the coefficient of reflection still was In many cases an oxide layer having a thickness of 0.1 micron proves sufficient, as the following corrosion resistance tests show.
An anodized reflector surface provided with an oxide film of thickness 0.1 micron after an endurance test of 4 weeks in a climate chamber, in which the relative humidity was from to and the temperature was 42 C., did not exhibit measurable losses of light-reflecting properties. This climate chamber test had been preceeded by a temperature test at 300 C. for 2 hours and at 250 C. for 24 hours.
In case of pitting, that is to say, the occurrence of local points of attack owing to the porosity of the test casting, the rate of extension and expansion of the centers of attack was not increased. This was proved by immersing a test article in a solution containing 25 gms. of common salt, 15 mls. of glacial acetic acid, 7 mls. of 30% hydrogen peroxide and 1 gr. of crystallized copper sulphate per liter of distilled water, for 8 hours.
The deterioration of the light reflectivity was only 2% compared with the initial value.
Comparable results were obtained with reflectors the supports of which were made from other metals, for example brass.
What is claimed is:
1. A metal reflector comprising a cast reflector body of aluminum and having alloys chosen from the group consisting of an alloy having 3.0% of magnesium, less than 0.6% of manganese, less than 3.0% of silicon and the remainder aluminum; an alloy having about 0.4% of manganese, from 12% to 13.5% of silicon and the remainder aluminum; an alloy having about 1.0% of magnesium, from 0.2% to 1.0% of manganese, about 5% of silicon, and the remainder aluminum; a reflecting layer of alumi num on said cast aluminum body and an oxide layer coating on said reflecting layer of aluminum.
2. A metal reflector as claimed in claim 1 wherein the thickness of said oxide layer is approximately 0.1 micron.
3. A method of manufacturing a metal reflector comprising casting a metal reflector body from an alloy chosen from the group consisting of an alloy having 3.0% of magnesium, less than 0.6% of manganese, less than 3.0% of silicon and the remainder aluminum; an alloy having about 0.4% of manganese, from 12% to 13.5% of silicon and the remainder aluminum; an alloy having about 1.0% of magnesium, from 0.2% to 1.0% of manganese, about 5% of silicon, and the remainder aluminum, polishing the surface of said body which is desired to be reflecting, degreasing said surface, treating said surface with a glow discharge in a vacuum, vapor depositing aluminum upon said surface, and anodizing said polished aluminum reflective surface whereby said reflective surface is coated With an oxide layer.
References Cited UNITED STATES PATENTS 2,017,757 10/1935 Keller et al. 2,040,617 5/1936 Mason et al. 2,084,327 6/1937 Edwards 88-105 2 2,108,604 2/1938 Mason 88-105 2,443,196 6/1948 Raines et a1. 2,513,149 6/1950 Coutant et al 88-105 X FOREIGN PATENTS 337,558 11/1930 Great Britain. 1,03 6,081 4/1953 France.
OTHER REFERENCES Hass et al., On the Structure and Properties of Some Metal and Metal Oxide Films, article in Journal de Physique et le Radium, v01. 11, No. 7, July 1950, pp. 394402 cited.
15 HYLAND BIZOT, Primary Examiner.
DAVID L. RECK, RICHARD O. DEAN, DAVID H.
RUBIN, Examiners.

Claims (1)

1. A METAL REFLECTOR COMPRISING A CAST REFLECTOR BODY OF ALUMINUM AND HAVING ALLOYS CHOSEN FROM THE GROUP CONSISTING OF AN ALLOY HAVING 3.0% OF MAGNESIUM LESS THAN 0.6% OF MANGANESE, LESS THAN 3.0% OF SILICON AND THE REMAINDER ALUMINUM; AND ALLOY HAVING ABOUT 0.4% OF MANGANESE, FROM 12% TO 13.5% OF SILICON AND THE REMAINDER ALUMINUM; AN ALLOY HAVING ABOUT 1.0% OF MAGNESIUM, FROM 0.2% TO 1.0% OF MANGANESE, ABOUT 5% OF SILICON, AND THE REMAINDER ALUMINUM; A REFLECTING LAYER OF ALUMINUM ON SAID CAST ALUMINUM BODY AND AN OXIDE LAYER COATING ON SAID REFLECTING LAYER OF ALUMINUM.
US194217A 1961-05-29 1962-05-10 Metal reflector and method of manufacturing such reflectors Expired - Lifetime US3372008A (en)

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Cited By (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US5403657A (en) * 1991-01-11 1995-04-04 Alusuisse-Lonza Services Ltd. Aluminum surfaces
US5779871A (en) * 1994-11-24 1998-07-14 Alusuisse Technology & Management Ltd. Process of manufacturing aluminum surfaces for technical lighting purposes
CN102277520A (en) * 2010-06-08 2011-12-14 西安康博新材料科技有限公司 Aluminium-based material reflector and preparation method thereof

Families Citing this family (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB8302165D0 (en) * 1983-01-26 1983-03-02 Spafax Holdings Plc Producing optical component
US5009761A (en) * 1984-09-24 1991-04-23 Spafax Holdings Plc., Method of producing an optical component, and components formed thereby

Citations (8)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB337558A (en) * 1929-10-09 1930-11-06 Birmingham Aluminium Casting A new or improved light metal alloy
US2017757A (en) * 1933-10-20 1935-10-15 Aluminum Co Of America Duplex metal article
US2040617A (en) * 1934-02-10 1936-05-12 Aluminum Co Of America Method of producing bright surfaces on aluminum
US2084327A (en) * 1933-10-11 1937-06-22 Aluminum Co Of America Composite reflector
US2108604A (en) * 1933-08-02 1938-02-15 Aluminum Co Of America Aluminum reflector
US2443196A (en) * 1944-06-16 1948-06-15 Raines Arnold Process for making front-surface mirrors
US2513149A (en) * 1946-05-27 1950-06-27 Coutant Andre Clement Rotary reflecting element in a view finder for cinematographic cameras
FR1036081A (en) * 1950-04-26 1953-09-03 Aluminum reflectors manufacturing process

Patent Citations (8)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB337558A (en) * 1929-10-09 1930-11-06 Birmingham Aluminium Casting A new or improved light metal alloy
US2108604A (en) * 1933-08-02 1938-02-15 Aluminum Co Of America Aluminum reflector
US2084327A (en) * 1933-10-11 1937-06-22 Aluminum Co Of America Composite reflector
US2017757A (en) * 1933-10-20 1935-10-15 Aluminum Co Of America Duplex metal article
US2040617A (en) * 1934-02-10 1936-05-12 Aluminum Co Of America Method of producing bright surfaces on aluminum
US2443196A (en) * 1944-06-16 1948-06-15 Raines Arnold Process for making front-surface mirrors
US2513149A (en) * 1946-05-27 1950-06-27 Coutant Andre Clement Rotary reflecting element in a view finder for cinematographic cameras
FR1036081A (en) * 1950-04-26 1953-09-03 Aluminum reflectors manufacturing process

Cited By (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US5403657A (en) * 1991-01-11 1995-04-04 Alusuisse-Lonza Services Ltd. Aluminum surfaces
US5527572A (en) * 1991-01-11 1996-06-18 Alusuisse-Lonza Services Ltd. Aluminum surfaces
US5663001A (en) * 1991-01-11 1997-09-02 Alusuisse Technology & Management Ltd. Aluminum surfaces
US5779871A (en) * 1994-11-24 1998-07-14 Alusuisse Technology & Management Ltd. Process of manufacturing aluminum surfaces for technical lighting purposes
CN102277520A (en) * 2010-06-08 2011-12-14 西安康博新材料科技有限公司 Aluminium-based material reflector and preparation method thereof
CN102277520B (en) * 2010-06-08 2012-12-19 西安康博新材料科技有限公司 Aluminium-based material reflector and preparation method thereof

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DK103862C (en) 1966-02-28
CH439182A (en) 1967-07-15
GB1011977A (en) 1965-12-01

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