WO2000044527A2 - High quality optically polished aluminum mirror and process for producing - Google Patents
High quality optically polished aluminum mirror and process for producing Download PDFInfo
- Publication number
- WO2000044527A2 WO2000044527A2 PCT/US2000/000508 US0000508W WO0044527A2 WO 2000044527 A2 WO2000044527 A2 WO 2000044527A2 US 0000508 W US0000508 W US 0000508W WO 0044527 A2 WO0044527 A2 WO 0044527A2
- Authority
- WO
- WIPO (PCT)
- Prior art keywords
- polishing
- polishing agent
- metallic monolith
- aluminum
- monolith
- Prior art date
Links
Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B24—GRINDING; POLISHING
- B24B—MACHINES, DEVICES, OR PROCESSES FOR GRINDING OR POLISHING; DRESSING OR CONDITIONING OF ABRADING SURFACES; FEEDING OF GRINDING, POLISHING, OR LAPPING AGENTS
- B24B37/00—Lapping machines or devices; Accessories
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B24—GRINDING; POLISHING
- B24B—MACHINES, DEVICES, OR PROCESSES FOR GRINDING OR POLISHING; DRESSING OR CONDITIONING OF ABRADING SURFACES; FEEDING OF GRINDING, POLISHING, OR LAPPING AGENTS
- B24B13/00—Machines or devices designed for grinding or polishing optical surfaces on lenses or surfaces of similar shape on other work; Accessories therefor
- B24B13/015—Machines or devices designed for grinding or polishing optical surfaces on lenses or surfaces of similar shape on other work; Accessories therefor of television picture tube viewing panels, headlight reflectors or the like
-
- G—PHYSICS
- G02—OPTICS
- G02B—OPTICAL ELEMENTS, SYSTEMS OR APPARATUS
- G02B5/00—Optical elements other than lenses
- G02B5/08—Mirrors
- G02B5/0808—Mirrors having a single reflecting layer
Definitions
- the present invention relates to polishing an optic surface and more particularly to polishing an optic surface on an aluminum monolith.
- Metallic mirrors have been widely used for instruments in space and military applications. System performance of the instruments is largely dependent upon the reflective surface of the mirror. Performance of the optical mount, and its thermal and mechanical characteristics also have effects on the performance of the optical component. In actuality the optical mount has a significant impact on performance of the optical system in achieving objectives of any scientific and engineering experiment. When both optical mount and mirror substrate are of the same material there is uniformity of thermal properties. Also the high thermal conductivity of a metal mirror helps decrease cooling time in cryogenic applications.
- Aluminum materials for structural components in cases of cold or cryogenic use. Aluminum materials may also be used for mirrors as aluminum offers numerous benefits because of its machinability, lightweight, and low cost.
- One prior technique has overcome such problems yet provides inferior optical performace to one proposed by the present invention. For example, see “Diamonds turn infrared mirrors smooth", by Daniel Vukobratovich, et al, Optoelectronics World, page S25-S28, October 1998.
- the prior technique plates an aluminum substrate with an amorphous layer of high-purity aluminum. Then the plated substrate is diamond-turned to produce a mirror with surface roughness of 30 angstroms rms with surface accuracy in terms of surface figure error of 0.380 wave peak-to- valley.
- This plated substrate is theoretically bimetallic and should experience the bimetallic deformation to some degree.
- the present invention provides an aluminum mirror of about 5 angstroms rms surface roughness with surface accuracy in terms of surface figure error as low as one-fifteenth of a wave peak-to-valley without any bimetallic deformations .
- this invention provides the following advantages by eliminating the electroless nickel plating from the aluminum mirrors : (1) Drastic cost savings during fabrication. (2) Reduced risk associated with polishing through nickel to the aluminum. This requires that the part be stripped of the remaining nickel and re-plated. To do so, the optical surface must again be prepared for plating because the stripping procedure etches the aluminum.
- the proposed innovation will eliminate many of the associated problems now common with current aluminum mirror technology, delivering aluminum optics with superior accuracy.
- This invention presents a high quality optically polished aluminum mirror and a novel method of optically polishing aluminum monolith in a conventional polishing manner by employing modern techniques with a combination of compatible ingredients.
- this invention combines diamond turning and conventional polishing along with newly adopted materials for the polishing to accomplish a significant improvement in surface precision of bare aluminum for optical purposes .
- This present invention provides an aluminum mirror of less than about 30 angstroms rms and preferably about 5 angstroms rms surface roughness with surface accuracy in terms of surface figure error as low as one-fifteenth of a wave peak-to-valley.
- the inventors used commercial grade aluminum, for example, 6061-T6 aluminum, to produce the aluminum mirror presented by this invention. Inventors believe that further polishing of the aluminum mirror mentioned above with the polishing process proposed by this invention can produce an aluminum mirror of higher quality.
- Step one of this innovative polishing method is pre- polishing to produce a pre-polished surface having a surface roughness of not more than about 100 angstroms rms with a surface accuracy in terms of surface figure error of not more than about one-half of a wave peak-to-valley.
- the pre-polishing of the surface of the metallic monolith may be effected by diamond turning.
- the process of diamond turning is a precision method of producing accurate mirrored surfaces of optical quality (for some wavelengths) on bare aluminum and other materials. It is successful because the turning or cutting action of the sharp diamond tool serves to peel thin layers of aluminum from the surfaces at such small portions as to produce a polished finish whereby other machining processes actually tear the material away from the substrate.
- the amount of material removed on the typical final cut is .0001 inch.
- the diamond turning process allows surface figure errors of approximately .5 of a wave peak-to-valley over components up to four inches in diameter and surface roughness of generally 100 angstroms. The precision degrades slightly as the size of the component grows beyond four inches.
- the polishing method proceeds with fabrication of a polisher.
- select grade of pitch used exclusively for optical fabrication is melted and poured onto a cast iron lap. The pitch is allowed to cool, and then shaped and grooved according to the optician's discretion.
- the polisher is installed on a machine spindle, which is a part of a polishing tool assembly.
- the polishing process continues with applying an appropriate amount of a polishing agent to the surface of the polisher and placing the optical monolith onto the polisher. A pivot pin is then lowered into a pre-drilled small hole in the back of the optical monolith, and the assembly is set to motion. This method of polishing is called random motion polishing.
- Geometry of the assembly is such that all points of the polisher and all points of the optical substrate see the same amount of surface feet per minute of contact ensuring even material removal from the optical component. This polishing continues until an acceptable surface figure error with surface roughness is achieved.
- the material used as a polishing agent is different from those of normal polishing materials.
- the polishing agent employed in the present invention comprises an aqueous dispersion of abrasive particles, a catalyst, and organic solvent.
- the best mode of this invention employs india ink as a polishing agent.
- India ink is a solvent based black ink, which is being used in fields other than printing.
- U.S. Patent No. 5,383,472 which is a biology related invention, utilizes the india ink to handle biopsy tissue specimen.
- the india ink comprises carbon black, ammonium hydroxide, phenol, ethylene glycol and water, all of which provide suitable interactions between the polisher and the surfaces of bare aluminum monolith to produce high quality optical surface thereon.
- the polishing agent may be replaced with a mixture of carbon black, ammonium hydroxide, phenol, ethylene glycol and water, the mixing proportions of the materials are 7-8%, 1-2%, 0.2-1%, 1-2%, and 85-90% by weight, respectively, based on the total weight of the polishing agent.
- the polishing process may be repeated with the polishing agent that is gradually diluted with water.
- the mixing proportions of the polishing agent and diluting water are 100-50% and 0-50% by weight, respectively, based on the total weight of the diluted polishing agent.
- this invention also employs diamond particles for refining the pre-polished surface of the metallic monolith.
- Diamond particles whose size is within the ranges of .25 to .5 microns for this invention, are sprinkled on the surface of the polisher, which is coated with the polishing agent. Then, for the refining process, random motion polishing is performed for about 15 minutes to get rid of diffraction (i.e. rainbow effect) on the aluminum monolith to be polished.
- the polishing process or the refining process with diamond particles and before measuring the surface of the metallic monolith for verifying whether predetermined values of surface roughness and surface accuracy have been obtained the aluminum monolith needs to be cleaned.
- This cleaning process removes any residue of the polishing agent and diamond particles from the aluminum monolith and the polisher.
- the cleaning process involves water, a cleaning liquid comprising ammonia and water, paper towels, and a solvent such as acetone.
- the cleaning process is performed in the following sequence: (1) deactivating the polishing tool assembly, (2) removing the aluminum monolith from the polisher, (3) spraying a cleaning liquid over entire surface of the aluminum monolith, (4) allowing the aluminum monolith to dry, (5) rinsing the aluminum monolith with a solvent, and, and (6) wiping the polisher using cold water and a paper towel .
- the polishing process with the polishing agent is repeated until the surface of the aluminum monolith has met predetermined values of surface roughness and surface accuracy.
- FIG. 1 is a view of the polishing tool assembly.
- FIG. 2 is a flow chart of one preferred process for producing high quality optically polished surface on an aluminum monolith according to the invention.
- FIG. 3 is a flow chart of another preferred process for producing high quality optically polished surface on an aluminum monolith according to the invention.
- the polishing operation is performed by the precise assembly of components to create a polishing tool assembly 100.
- a select grade of pitch used exclusively for optical fabrication is melted and poured on a cast iron lap 8. The pitch is allowed to cool and then shaped and grooved according to the optician's discretion. The pitch fabricated in this manner is referred to as a polisher 6.
- the polisher 6 is installed on the machine spindle 10. The optician then applies the appropriate amount of a polishing agent to the surface of the polisher 6, and places the aluminum monolith 4 onto the polisher 6.
- Step 210 it is one of the preferred embodiments of producing high quality optically polished surface on an aluminum monolith according to the invention.
- Pre-polishing (Step 210) is performed until the surface of the aluminum monolith obtains a surface accuracy of 0.5 of a wave peak-to-valley and surface roughness of 100 angstroms rms .
- Diamond turning is one of the methods that can accomplish the surface accuracy and the surface roughness .
- a polishing agent is applied to the surface the polisher 6 of the polishing tool assembly 100 (Step 216) .
- the polishing agent provides lubrication for the aluminum monolith to be polished.
- the polisher 6 should be maintained to be wet with the polishing agent.
- the aluminum monolith 4 is placed on the polisher. Then the pivot pin 2 is lowered into a small pre-drilled hole in the back of the monolith 4, and the assembly 100 is set to motion. As the machine spindle 10 rotates, the polisher 6 and the metal substrate 4 also rotate while the pivot pin 2 passes back and forth over the polisher 6 at a predetermined distance. The geometry is such that all points of the polisher 6 and all points of the metal substrate 4 see the same amount of surface feet per minute of contact resulting in event material removal . This method of polishing is called random motion polishing. The polishing operation (Step 220) is performed for a predetermined duration. The aluminum monolith 4 is inspected (Step 224) to determine if acceptable surface figure and roughness are achieved.
- the aluminum monolith After the polishing operation (Step 220) and before the measuring operation (step 224) , which is to measure the surface of the metallic monolith for verifying whether predetermined values of surface roughness and surface accuracy have been obtained, the aluminum monolith must be cleaned (Step 224) to remove the polishing agent from the aluminum monolith 4 and the polisher 6. This cleaning process (Step 224) removes any residue of the polishing agent which might degrade on the aluminum monolith 4 and the polisher 6.
- the cleaning process involves water, a cleaning liquid comprising ammonia and water, paper towels, and a solvent such as acetone, and is performed in the following sequence: (1) deactivating the polishing tool assembly 100, (2) removing the aluminum monolith 6 from the polishing tool assembly 100, (3) spraying a cleaning liquid over entire surface of the aluminum monolith 4, (4) allowing the aluminum monolith 4 to dry, (5) rinsing the aluminum monolith 4 with a solvent, and (6) wiping the polisher 6 using cold water and a paper towel.
- a cleaning liquid comprising ammonia and water, paper towels, and a solvent such as acetone
- polishing process with the polishing agent (step 216 through 224) is repeated until the surface of the aluminum monolith has met predetermined values of surface roughness and surface accuracy.
- Step 310 it is another preferred embodiment of producing high quality optically polished surface an aluminum monolith according to the invention.
- Pre-polishing (Step 310) is performed until the surface of said metal substrate is of surface accuracy of .5 of a wave peak-to- valley and surface roughness of 100 angstroms rms.
- Diamond turning is one of the methods that can accomplish the surface accuracy and the surface roughness .
- a polishing agent is applied to surface the polisher 6 of the polishing tool assembly 100 (Step 316) .
- the polishing agent provides lubrication for the aluminum monolith to be polished.
- the polisher 6 should be covered with the polishing agent.
- Diamond particles are sprinkled (Step 318) on the surface of the polisher 6, which is coated with the polishing agent in step 316. Then the aluminum substrate 4 is placed on the polisher 6 (Step 320) . Next the pivot pin 2 is lowered into a small pre-drilled hole in the back of the substrate 4, and the assembly 100 is set to motion (Step 322) for about 15 minutes.
- Step 324 To remove the diamond particles and the polishing agent from the metal substrate 4 and the polisher 6, cleaning (Step 324) is performed in the following sequence: (1) deactivating the polishing tool 100, (2)removing the metal substrate 6 from the polishing tool 100, (3) spraying a cleaning liquid over entire surface of the metal substrate 4, (4) allowing the metal substrate 4 to dry, (5) rinsing the metal substrate 4 with a solvent, and (6) wiping the polishing tool 100 using cold water and a paper towel.
- polishing agent is applied to surface the polisher 6 of the polishing tool 100 (Step 316) .
- polisher 6 should be maintained to be wet with the polishing agent.
- the aluminum monolith 4 is placed on the polisher 6. Then the pivot pin 2 is lowered into a small pre-drilled hole in the back of the aluminum monolith 4, and the assembly 100 is set to motion. As the machine spindle 10 rotates, the polisher 6 and the metal substrate 4 also rotate while the pivot pin 2 passes back and forth over the polisher 6 at a pre-determined distance. The geometry is such that all points of the polisher 6 and all points of the metal substrate 4 see the same amount of surface feet per minute of contact resulting in event material removal. The polishing operation (Step 330) is performed for a predetermined duration. The aluminum monolith 4 is inspected (Step 332) to determine if acceptable surface figure and roughness are achieved.
- the aluminum monolith needs to be cleaned (Step 332) to remove the polishing agent from the aluminum monolith 4 and the polisher 6.
- This cleaning process removes any residue of the polishing agent which might degrade on the aluminum monolith rate 4 and the polisher 6.
- the cleaning process involves water, a cleaning liquid comprising ammonia and water, paper towels, and a solvent such as acetone, and is performed in the following sequence: (1) deactivating the polishing tool assembly 100, (2) removing the aluminum monolith 6 from the polishing tool assembly 100, (3) spraying a cleaning liquid over entire surface of the aluminum monolith 4, (4) allowing the aluminum monolith 4 to dry, (5) rinsing the aluminum monolith 4 with a solvent, and (6) wiping the polisher 6 using cold water and a paper towel.
- a cleaning liquid comprising ammonia and water, paper towels, and a solvent such as acetone
- polishing process with the polishing agent (step 326 through 334) is repeated until the surface of the aluminum monolith has met predetermined values of surface roughness and surface accuracy.
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- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- Physics & Mathematics (AREA)
- General Physics & Mathematics (AREA)
- Optics & Photonics (AREA)
- Grinding And Polishing Of Tertiary Curved Surfaces And Surfaces With Complex Shapes (AREA)
- Optical Elements Other Than Lenses (AREA)
- Finish Polishing, Edge Sharpening, And Grinding By Specific Grinding Devices (AREA)
Abstract
Description
Claims
Priority Applications (1)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
AU33447/00A AU3344700A (en) | 1999-02-01 | 2000-01-31 | High quality optically polished aluminum mirror and process for producing |
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US12251999P | 1999-02-01 | 1999-02-01 | |
US60/122,519 | 1999-02-01 |
Publications (2)
Publication Number | Publication Date |
---|---|
WO2000044527A2 true WO2000044527A2 (en) | 2000-08-03 |
WO2000044527A3 WO2000044527A3 (en) | 2001-02-15 |
Family
ID=22403174
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
PCT/US2000/000508 WO2000044527A2 (en) | 1999-02-01 | 2000-01-31 | High quality optically polished aluminum mirror and process for producing |
Country Status (2)
Country | Link |
---|---|
AU (1) | AU3344700A (en) |
WO (1) | WO2000044527A2 (en) |
Cited By (1)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US11466356B2 (en) * | 2019-08-16 | 2022-10-11 | Fraunhofer-Gesellschaft zur Förderung der angewandten Forschung e. V. | Optical element having metallic seed layer and aluminum layer, and method for producing same |
Citations (7)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US4115177A (en) * | 1976-11-22 | 1978-09-19 | Homer Van Dyke | Manufacture of solar reflectors |
US4431268A (en) * | 1980-06-26 | 1984-02-14 | Nhk Spring Co., Ltd. | Reflector and method for manufacturing the same |
US4457587A (en) * | 1981-12-22 | 1984-07-03 | Nhk Spring Co., Ltd. | Reflector and method for manufacturing the same |
US4482209A (en) * | 1981-02-27 | 1984-11-13 | Siemens Aktiengesellschaft | Mirror structure |
US4599827A (en) * | 1985-06-24 | 1986-07-15 | The United States Of America As Represented By The Secretary Of The Army | Metallographic preparation of particulate filled aluminum metal matrix composite material |
US5640282A (en) * | 1991-03-30 | 1997-06-17 | Shin-Etsu Quartz Co., Ltd. | Base body of reflecting mirror and method for preparing the same |
US5978133A (en) * | 1996-06-28 | 1999-11-02 | Alusuisse Technology & Management Ltd. | Aluminium reflector with composite reflectivity-enhancing surface layer |
-
2000
- 2000-01-31 AU AU33447/00A patent/AU3344700A/en not_active Abandoned
- 2000-01-31 WO PCT/US2000/000508 patent/WO2000044527A2/en active Application Filing
Patent Citations (7)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US4115177A (en) * | 1976-11-22 | 1978-09-19 | Homer Van Dyke | Manufacture of solar reflectors |
US4431268A (en) * | 1980-06-26 | 1984-02-14 | Nhk Spring Co., Ltd. | Reflector and method for manufacturing the same |
US4482209A (en) * | 1981-02-27 | 1984-11-13 | Siemens Aktiengesellschaft | Mirror structure |
US4457587A (en) * | 1981-12-22 | 1984-07-03 | Nhk Spring Co., Ltd. | Reflector and method for manufacturing the same |
US4599827A (en) * | 1985-06-24 | 1986-07-15 | The United States Of America As Represented By The Secretary Of The Army | Metallographic preparation of particulate filled aluminum metal matrix composite material |
US5640282A (en) * | 1991-03-30 | 1997-06-17 | Shin-Etsu Quartz Co., Ltd. | Base body of reflecting mirror and method for preparing the same |
US5978133A (en) * | 1996-06-28 | 1999-11-02 | Alusuisse Technology & Management Ltd. | Aluminium reflector with composite reflectivity-enhancing surface layer |
Cited By (1)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US11466356B2 (en) * | 2019-08-16 | 2022-10-11 | Fraunhofer-Gesellschaft zur Förderung der angewandten Forschung e. V. | Optical element having metallic seed layer and aluminum layer, and method for producing same |
Also Published As
Publication number | Publication date |
---|---|
AU3344700A (en) | 2000-08-18 |
WO2000044527A3 (en) | 2001-02-15 |
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