WO2010039929A1 - Multilayer laminate footwear insole - Google Patents
Multilayer laminate footwear insole Download PDFInfo
- Publication number
- WO2010039929A1 WO2010039929A1 PCT/US2009/059186 US2009059186W WO2010039929A1 WO 2010039929 A1 WO2010039929 A1 WO 2010039929A1 US 2009059186 W US2009059186 W US 2009059186W WO 2010039929 A1 WO2010039929 A1 WO 2010039929A1
- Authority
- WO
- WIPO (PCT)
- Prior art keywords
- insole
- layer
- channel
- multilayer laminate
- footwear insole
- Prior art date
Links
Classifications
-
- A—HUMAN NECESSITIES
- A43—FOOTWEAR
- A43B—CHARACTERISTIC FEATURES OF FOOTWEAR; PARTS OF FOOTWEAR
- A43B3/00—Footwear characterised by the shape or the use
- A43B3/26—Footwear characterised by the shape or the use adjustable as to length or size
-
- A—HUMAN NECESSITIES
- A43—FOOTWEAR
- A43B—CHARACTERISTIC FEATURES OF FOOTWEAR; PARTS OF FOOTWEAR
- A43B17/00—Insoles for insertion, e.g. footbeds or inlays, for attachment to the shoe after the upper has been joined
Definitions
- the present invention relates to multilayer laminate footwear insoles, methods for manufacturing the insoles and methods for sizing the insoles.
- Removable insoles are general! inserted into shoes, in order to provide added cushioning and support for the wearer of the shoes.
- These insoles are typically made as a one-size-f ⁇ ts-all product, and the consumer purchasing the insoles must trim them to an appropriate size using scissors or similar means to cut through the material of the insoles.
- An insole is generally constructed of multiple layers of material, many of which are not easily cut with scissors by consumers. To cut through the material, the consumer must carefully follow a trim pattern that is printed on, molded in or applied to the insole. Consumers typically do not like to trim ⁇ nsoies v ⁇ th scissors for fear of misaligning the pattern while cutting or not cutting the correct mark on the pattern.
- U.S. Patent No. 4,864,740 describes a disposable hygienic shoe insole having three layers: a top layer of spunbonded polypropylene material, a composite layer of pulp fibers and polypropylene fibers mekblown onto the top layer, and a bottom iayer of pol> ethylene vinyl acetate meltblown onto the composite layer.
- the insole includes line perforations at the front and inner arch portions of the insole to allow a user to reduce the length and width of the insole.
- the insole includes lines of perforation across an arch area of the inso ⁇ e. These latter lines of perforation allow the length of the insole to be shortened by tearing off a portion of the arch area of the insoie and subsequent!) reattaching ioe and heel sections of the insoie.
- U.S. Patent No. 6,526,676 describes a disposable vandal formed of a piece of sheet materia! including a fabric laminated to polyurethane foam. A perforations are provided at the heel and/or toe portions of the sole of the sandal to allow the sandals to be sized to a user ' s foot.
- U.S. Patent No. 3,925,914 describes a sandal, whose sole member may be made of a laminate having a bottom layer of thermoplastic material and a top layer of fibrous material. The sole member may be provided with rows of holes at the toe and heel ends, in order to allow the sandal to be shortened by breaking away a portion of the sole member at the holes. The holes do not go through the entire sole, but instead, a break-away or tear-away portion is left at the bottom of each hole.
- a multilayer laminate footwear insole comprising a top layer having a top surface, a bottom layer having a bottom surface, wherein the bottom layer includes at least one cushioning layer, a channel in the insole, wherein the channel transects the top layer of the insole, and one or more punctuations in the channel, wherein the punctuation transects the bottom layer of the insole.
- the channel completely transects the top layer.
- the punctuation in the channel transects the bottom surface of the bottom layer.
- the channel penetrates at least part of the bottom layer.
- the channel traverses the top surface of the top layer from opposing edges of the insole.
- the at least one cushioning layer is a foam layer.
- the foam layer comprises at least one of polyurethane, ethylene vinyl acetate copolymer and styrene- ethylene-butadiene-styrene.
- the at least one cushioning layer is a gel layer.
- the gel layer comprises at least one of polyurethane, styrene-ethylene-butadiene-styrene, silicone or hydrogel.
- the top layer includes at least one fabric layer.
- At least one fabric layer comprises at least one of a polymer or natural fiber.
- the channel is laser cut.
- the punctuation is made in predetermined patterns.
- a method for manufacturing a multilayer laminate footwear insole having a top layer with a top surface, a bottom layer with a bottom surface, wherein the bottom layer includes at least one cushioning layer comprises the steps of cutting a channel in the top surface of the top layer of the insole, wherein the channel transects the top layer of the insole, and punctuating the bottom layer in the channel.
- the punctuation transects the bottom surface of the bottom layer of the insole.
- the cutting includes cutting two or more channels.
- the top layer is partially transected by the channel.
- the channel is cut using a laser.
- a method of reducing a dimension of a multilayer laminate footwear insole for altering a size of an insole having a predetermined punctuated channel comprises the step of tearing the insole by hand along the predetermined punctuated channel.
- FIG. 1 is a schematic plan view of an embodiment of an exemplary footwear insole.
- FIG. 2 is a schematic cross-sectional view, along line A-A', of the embodiment of the exemplary footwear insole of FIG. 1.
- FIG. 3 A is a schematic view of a laser cutter cutting a channel into a footwear insole, according to a non-limiting embodiment of the present invention.
- FIG. 3B is a schematic cross-sectional view of the embodiment of a footwear insole of FIG. 3 A, having a channel produced by the laser cutter of FIG. 3 A.
- FIG. 3C is a detail of the schematic cross-sectional view shown in FIG. 3B.
- FIG. 3D is a schematic cross-sectional view of an alternative, non-limiting embodiment of the present invention of a footwear insole of FIG. 3 A, having a channel produced by the laser cutter of FIG. 3 A, partially transecting the top layer.
- FIG. 3E is a detail of the schematic cross-sectional view shown in FIG. 3D.
- FIG. 4A is a schematic plan view of a footwear insole, according to a non- limiting embodiment of the present invention having a plurality of channels.
- FIG. 4B is a schematic cross-sectional view, along line B-B', of the non- limiting embodiment of a footwear insole of FIG. 4A, completely transecting the top layer.
- FIG. 5 A is a schematic plan view of a footwear insole, according to another non-limiting embodiment of the present invention, illustrated with six channels that traverse the top layer.
- FIG. 5B is a schematic cross-sectional view, along line D-D', of the non- limiting embodiment of a footwear insole of FIG. 5 A.
- FIG. 5C is a schematic cross-sectional view, along line C-C, of the non- limiting embodiment of a footwear insole of FIG. 5 A.
- FIG. 5D is an alternative, schematic cross-sectional view along line C-C, of the non-limiting embodiment of a footwear insole of FIG. 5 A, wherein the punctuation does not transect the bottom surface of the bottom layer.
- FIG. 6 is a flow chart of a method for manufacturing a multilayer laminate footwear insole, according to a non-limiting embodiment of the present invention.
- FIG. 7 is a flow chart of a method for reducing a dimension of a multilayer laminate footwear insole, according to a non-limiting embodiment of the present invention.
- FIG. 1 is a schematic plan view
- FIG. 2 a schematic cross-sectional view along line A-A', of a non-limiting embodiment of an exemplary footwear insole 10.
- the footwear insole 10 includes a toe portion 20, a heel portion 30 and a medial arch portion 40 interconnecting the toe and heel portions 20, 30.
- the insole may also include a top layer 50 and a bottom layer 60 affixed to the top layer 50.
- the top layer 50 may include one or more fabric layers
- the bottom layer 60 may include one or more cushioning layers, such as foam layers and gel layers.
- the top layer 50 may also include foam and/or gel layers.
- the fabric layer 50 may include at least one polymer or natural fiber such as polyester, acetate, polyethene, acrylic, nylon, rayon, spandex, wool, cotton, silk, bamboo, linen, hemp, urethane, or any material that can be ablated by a laser.
- fabric layer 50 may include at least one film, such as polyethylene, polyurethane, or any other material that can be ablated by a laser.
- Any foam layer used as the bottom layer 60 may include at least one of polyurethane, ethylene vinyl acetate copolymer, styrene-ethylene-butadiene- styrene or other suitable materials for cushioning.
- Any gel layer used as the bottom layer 60 may include at least one of polyurethane, styrene-ethylene-butadiene-styrene, silicone, hydrogel or other suitable materials for cushioning.
- the footwear insole 10 may take any of a variety of shapes in order to fit within a variety of shoes. Also, the footwear insole 10 may have any of a variety of contoured, flat, curved, or other surfaces in order to fit within a variety of shoes. Further, the tear strength of the top layer may be greater than the tear strength of the bottom layer.
- FIG. 3 A is a schematic view of a laser cutter cutting a channel into a footwear insole 110, according to an embodiment of the present invention.
- the laser cutter 112 focuses a laser beam 114 onto the footwear insole 110 (shown in cross-section) and is moved across a surface of the footwear insole 110 so as to cut a depression or channel 116 into the footwear insole 110.
- the laser cutter can cut channels of varying width and depth.
- An example of a laser cutter used to cut the channel 116 is an Epilog Mini 24, 35 Watt laser, manufactured by Epilog Laser of Golden, Colorado.
- FIG. 3B is a schematic cross-sectional view of the non-limiting embodiment of the footwear insole 110 of FIG. 3 A, having a channel produced by the laser cutter of FIG. 3 A, and FIG.
- FIG. 3C is a detail of the schematic cross-sectional view shown in FIG. 3B, indicated by a dashed circle 118.
- the channel 116 may be cut completely through a top fabric layer 150 of the footwear insole 110.
- the channel 116 may extend partially into a bottom foam or gel layer 160.
- Examples of settings on the Epilog Mini 24 laser that allowed the laser to burn through essentially only the fabric layer 150 of an exemplary polyester knit lamination were 100% speed, 50% power, 400 DPI (dots per inch) and 500 Hz.
- This exemplary polyester knit lamination was comprised of a polyester knit fabric bonded to a urethane film using a hot melt urethane adhesive, in which the fabric laminate was molded to urethane foam using an open cast urethane molding technique.
- a person having ordinary skill in the art would be able to modify the settings of the laser depending upon the different material properties of the fabric layer, such as thickness, density, moisture content, and other properties. For example, for a thicker fabric layer, a person having ordinary skill in the art would be able to adjust the various settings, such as power, of the laser in order to cut through the fabric layer.
- FIG. 3D is an alternative schematic cross-sectional view of a non-limiting embodiment of a footwear insole 110, having a channel produced by the laser cutter of FIG. 3 A
- FIG. 3E is a detail of the alternative schematic cross-sectional view shown in FIG. 3D, indicated by a dashed circle 119.
- the channel 116 may be cut substantially into the top fabric layer 150 of the footwear insole 110, such that the channel 116 does not extend into a bottom foam or gel layer 160.
- the channel may be cut to other various depths (not illustrated) ranging from only partially cutting into a top fabric layer 150 to both completely cutting through a top fabric layer 150 and substantially cutting into a bottom foam or gel layer 160 of the footwear insole 110.
- a clean and neat tear line results when a consumer tears along the predetermined channel.
- FIG. 4 A is a schematic plan view of a footwear insole 210, according to a non- limiting embodiment of the present invention
- FIG. 4B is a schematic cross- sectional view, along line B-B', of the embodiment of a footwear insole 210 of FIG. 4 A.
- the footwear insole 210 includes a toe portion 220, a heel portion 230 and a medial arch portion 240 interconnecting the toe and heel portions 220, 230.
- the insole 210 includes a top layer 250 of fabric and a bottom layer 260 of cushioning material affixed to the top layer 250.
- the top layer 250 may also include multiple fabric layers
- the bottom layer 260 may include multiple cushioning material layers.
- FIG. 4 A illustrates three separate channel cuts 216 in the toe portion 220 of the insole 210.
- the channel 216 extends laterally and curvilinearly across the top surface of the insole 210 and is configured to correspond to a possible shoe size of a user.
- the channel 216 may extend approximately perpendicularly through the top layer 250 and partially into the bottom layer 260.
- a channel 226 cut by the laser cutter 112 is situated in the heel portion 230 of the insole 210.
- FIG. 4A illustrates separate channel cuts 226 in the heel portion 230 of the insole 210.
- the channel 226 extends laterally and curvilinearly across the top surface of the insole 210 with a direction of curvature opposite to a direction of curvature of channel 216.
- a channel 236 cut by the laser cutter 112 is situated in the medial arch portion 240 of the insole 210 and extends curvilinearly and longitudinally with respect to the insole 210.
- the insole 210 may include one or more channels 216 in the toe portion 220, one or more channels 226 in the heel portion 230, and/or one or more channels 236 in the medial arch portion 240.
- channels 216, 226, 236, cutting the channels 216, 226, 236 with the laser cutter 112 advantageously produces a clean cut line in the fabric layer 250.
- the fabric layer 250 includes a polymer fabric
- the laser beam 114 cauterizes the fabric layer 250, thereby preventing the fabric from fraying at the cut line.
- the bottom foam layer 260 may have a relatively low tear strength, e.g., less than 10 lbsf, for the user to tear the insole 210 cleanly and easily along the channels 216, 226, 236.
- the bottom foam layer 260 may also have a sufficiently high modulus of elasticity, or flexural modulus, in order to ensure that the insole 210 does not permanently bend or wrinkle along the channels 216, 226, 236 when slipped into an article of footwear.
- FIG. 5 A is a schematic plan view of a footwear insole 310, according to another non-limiting embodiment of the present invention.
- FIG. 5B is a schematic cross-sectional view of the non-limiting embodiment of a footwear insole 310 of FIG. 5 A along line D-D'.
- FIGS. 5C and 5D are alternative, schematic cross-sectional views of the non-limiting embodiment of a footwear insole 310 of FIG. 5 A along line C-C
- the footwear insole 310 includes a toe portion 320, a heel portion 330 and a medial arch portion 340 interconnecting the toe and heel portions 320, 330.
- the footwear insole 310 includes a top layer 350 of fabric and a bottom layer 360 made of a cushioning material.
- the insole 310 further includes a laser-cut channel 316, which is situated in the toe portion 320 of the insole 310 and runs laterally and curvilinearly across the top surface of the insole 310. As illustrated in FIG. 5B, the channel 316 may extend through the top layer 350 and partially into the bottom layer 360.
- FIG. 5 A illustrates three separate channel cuts 316 in the toe portion 320 of the insole 310.
- the insole 310 may further include a laser-cut channel 326, which is situated in the heel portion 330 of the insole 310 and runs laterally and curvilinearly across the top surface of the insole 310 with a direction of curvature opposite to a direction of curvature of channel 316.
- FIG. 5A illustrates two separate channel cuts 326 in the heel portion 330 of the insole 310.
- a laser-cut channel 336 is situated optionally in the medial arch portion 340 of the insole 310 and runs curvilinearly and longitudinally with respect to the insole 310. As discussed with respect to the embodiment shown in FIGS.
- the insole 310 may include one or more channels 316 in the toe portion 320, one or more channels 326 in the heel portion 330, and/or one or more channels 336 in the medial arch portion 340 of the insole 310.
- the insole 310 includes punctuations 317 in the bottom gel layer 360. These punctuations may be produced by a die (not shown). As illustrated in FIG. 5C, the punctuations 317 may extend completely through the bottom layer 360 and run along the channels 316, 326, 336. Alternatively, as illustrated in FIG. 5D, the punctuations 317 may extend substantially into but not completely through the bottom layer 360 and run along the channels 316, 326, 336. In addition, as shown in FIG. 5A, the punctuations 317 are separated from one another in the direction of the channels 316, 326, 336 by web elements 318.
- a spacing of the punctuations 317, and thus a thickness of the web elements 318, may be adjusted such that a user of the insole 310 may tear the insole 310 cleanly and easily along the channels 316, 326, 336, while, at the same time, the insole 310 does not bend or wrinkle along any intact channel in the insole 310 when the insole 310 is slipped into an article of footwear.
- the punctuations 317 and web elements 318 may be formed of a variety of patterns including, but not limited to, circular, square, rectangular, polygonal, and other shapes, and combinations thereof. Further, punctuations as described in the present invention include patterns that may otherwise be referred to as perforations, serrations, cuts, punctures, notches, holes, slots, etc., some of which are illustrated in FIG. 5 A.
- FIG. 6 is a flow chart of a method for manufacturing a multilayer laminate footwear insole, according to a non-limiting embodiment of the present invention.
- the method begins at step 400.
- a laminated footwear insole is assembled.
- the insole has at least a top layer and a bottom layer.
- the top layer may include one or more layers of fabric or film, and the bottom layer may include one or more layers of foam or gel.
- a channel is cut into the top layer of the insole, e.g., by a laser cutter.
- the channel corresponds to human foot sizes and extends through the top layer and may extend partially into the bottom layer.
- step 430 a query is made as to whether another channel is to be cut into the top layer of the insole, e.g., by a laser cutter. If yes, then the method repeats step 420. If no, then in method step 440, a query is made as to whether the bottom layer should be punctuated in the channels. If no, then the method ends at step 460. If yes, then the bottom layer is punctuated in the channel(s) in step 450. The method then ends at step 460.
- FIG. 7 is a flow chart of a method for reducing a dimension of a multilayer laminate footwear insole, according to a non-limiting embodiment of the present invention.
- the method begins at step 500.
- step 510 a query is made as to whether a toe region of the insole has a channel corresponding to a desired foot size. If no, then the method advances to step 530. If yes, in step 520, the insole is then torn by hand along the above-mentioned channel in the toe region, after which the method advances to step 530.
- step 530 a query is made as to whether a heel region of the insole has a channel corresponding to the desired foot size. If no, then the method advances to step 550.
- step 540 the insole is then torn by hand along the above-mentioned channel in the heel region, after which the method advances to step 550.
- step 550 a query is made as to whether a medial arch region of the insole has a channel corresponding to the desired foot size. If no, then the method ends at step 570. If yes, then, in step 560, the insole is torn by hand along the above-mentioned channel in the medial arch region. The method then ends at step 570.
- query 510 and step 520, query 530 and step 540, and query 550 and step 560 may be re-ordered, as desired by a consumer.
- a multilayer laminate footwear insole having a top layer having a top surface and a bottom layer having a bottom surface, the bottom layer including at least one cushioning layer comprises a channel in the insole, wherein the channel transects the top layer of the insole, and one or more punctuations in the channel, wherein the punctuation transects the bottom layer of the insole.
- the multilayer laminate footwear insole may be a single one-size-fits-all insole, which may be adjusted to various sizes according to predetermined punctuated channels. Each channel may have a preferred punctuation within the channel.
- consumers may tear along each predetermined punctuated channel by hand in order to adjust the insole size to fit within shoes.
Abstract
Description
Claims
Priority Applications (7)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
JP2011530214A JP2012513777A (en) | 2008-10-03 | 2009-10-01 | Multi-layer laminate footwear insole |
EP09793228A EP2339935A1 (en) | 2008-10-03 | 2009-10-01 | Multilayer laminate footwear insole |
CA2737919A CA2737919A1 (en) | 2008-10-03 | 2009-10-01 | Multilayer laminate footwear insole |
AU2009298485A AU2009298485A1 (en) | 2008-10-03 | 2009-10-01 | Multilayer laminate footwear insole |
BRPI0920685A BRPI0920685A2 (en) | 2008-10-03 | 2009-10-01 | multi-layer laminate shoe insole, and method for manufacturing a multi-layer laminate shoe insole |
MX2011003561A MX2011003561A (en) | 2008-10-03 | 2009-10-01 | Multilayer laminate footwear insole. |
CN200980139012XA CN102170802A (en) | 2008-10-03 | 2009-10-01 | Multilayer laminate footwear insole |
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US12/245,352 | 2008-10-03 | ||
US12/245,352 US20100083534A1 (en) | 2008-10-03 | 2008-10-03 | Multilayer laminate footwear insole |
Publications (1)
Publication Number | Publication Date |
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WO2010039929A1 true WO2010039929A1 (en) | 2010-04-08 |
Family
ID=41404427
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
PCT/US2009/059186 WO2010039929A1 (en) | 2008-10-03 | 2009-10-01 | Multilayer laminate footwear insole |
Country Status (10)
Country | Link |
---|---|
US (1) | US20100083534A1 (en) |
EP (1) | EP2339935A1 (en) |
JP (1) | JP2012513777A (en) |
CN (1) | CN102170802A (en) |
AU (1) | AU2009298485A1 (en) |
BR (1) | BRPI0920685A2 (en) |
CA (1) | CA2737919A1 (en) |
CO (1) | CO6361868A2 (en) |
MX (1) | MX2011003561A (en) |
WO (1) | WO2010039929A1 (en) |
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US11612215B1 (en) * | 2019-08-09 | 2023-03-28 | Diana Irving | Shoe insert assembly and related methods |
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US20220039516A1 (en) * | 2020-08-10 | 2022-02-10 | Ashley Miller | Footwear Insert and Method of Manufacture |
CN114391698A (en) * | 2022-02-24 | 2022-04-26 | 东莞市德胜服饰有限公司 | Silica gel insole |
CN114869020A (en) * | 2022-06-06 | 2022-08-09 | 泉州大洲鞋塑有限公司 | Insole and processing technology |
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- 2009-10-01 MX MX2011003561A patent/MX2011003561A/en not_active Application Discontinuation
- 2009-10-01 CN CN200980139012XA patent/CN102170802A/en active Pending
- 2009-10-01 AU AU2009298485A patent/AU2009298485A1/en not_active Abandoned
- 2009-10-01 EP EP09793228A patent/EP2339935A1/en not_active Withdrawn
- 2009-10-01 WO PCT/US2009/059186 patent/WO2010039929A1/en active Application Filing
- 2009-10-01 CA CA2737919A patent/CA2737919A1/en not_active Abandoned
- 2009-10-01 BR BRPI0920685A patent/BRPI0920685A2/en not_active Application Discontinuation
- 2009-10-01 JP JP2011530214A patent/JP2012513777A/en not_active Withdrawn
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US20060265903A1 (en) * | 2005-05-27 | 2006-11-30 | Strong Vonda M | Self-adhering pedicure footwear |
Cited By (11)
Publication number | Priority date | Publication date | Assignee | Title |
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WO2011146927A1 (en) | 2010-05-21 | 2011-11-24 | George Shrum | Insole for footwear |
EP2571390A1 (en) * | 2010-05-21 | 2013-03-27 | Schrum LLC Leiser | Insole for footwear |
EP2571390A4 (en) * | 2010-05-21 | 2013-10-23 | Soxsols Llc | Insole for footwear |
WO2012028348A1 (en) * | 2010-09-03 | 2012-03-08 | W. L. Gore & Associates Gmbh | Method for manufacturing at least one part of a sole assembly of a shoe, and sole assembly for a shoe |
JP2013536772A (en) * | 2010-09-03 | 2013-09-26 | ダブリュ.エル.ゴア アンド アソシエーツ,ゲゼルシャフト ミット ベシュレンクテル ハフツング | Method of manufacturing at least one element of a shoe sole assembly and a shoe sole assembly for a shoe |
US9560896B1 (en) | 2014-02-12 | 2017-02-07 | Soxsols, Llc | Insole for footwear |
US10045590B2 (en) | 2014-02-12 | 2018-08-14 | Soxsols, Llc | Insole for footwear |
TWI706737B (en) * | 2014-08-27 | 2020-10-11 | 荷蘭商耐基創新公司 | Article of footwear with soil-shedding performance |
USD903268S1 (en) | 2019-02-06 | 2020-12-01 | S. C. Johnson & Son, Inc. | Insole |
USD906658S1 (en) | 2019-02-19 | 2021-01-05 | S. C. Johnson & Son, Inc. | Insole |
USD935758S1 (en) | 2019-02-19 | 2021-11-16 | S. C. Johnson & Son, Inc. | Insole |
Also Published As
Publication number | Publication date |
---|---|
MX2011003561A (en) | 2011-05-02 |
AU2009298485A1 (en) | 2010-04-08 |
US20100083534A1 (en) | 2010-04-08 |
CO6361868A2 (en) | 2012-01-20 |
BRPI0920685A2 (en) | 2015-12-29 |
CN102170802A (en) | 2011-08-31 |
JP2012513777A (en) | 2012-06-21 |
EP2339935A1 (en) | 2011-07-06 |
CA2737919A1 (en) | 2010-04-08 |
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