WO2011081834A1 - Pinning and affixing nano-active material - Google Patents
Pinning and affixing nano-active material Download PDFInfo
- Publication number
- WO2011081834A1 WO2011081834A1 PCT/US2010/059763 US2010059763W WO2011081834A1 WO 2011081834 A1 WO2011081834 A1 WO 2011081834A1 US 2010059763 W US2010059763 W US 2010059763W WO 2011081834 A1 WO2011081834 A1 WO 2011081834A1
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- WO
- WIPO (PCT)
- Prior art keywords
- nano
- platinum
- support
- active material
- interface
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Classifications
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
- B01J23/00—Catalysts comprising metals or metal oxides or hydroxides, not provided for in group B01J21/00
- B01J23/70—Catalysts comprising metals or metal oxides or hydroxides, not provided for in group B01J21/00 of the iron group metals or copper
- B01J23/89—Catalysts comprising metals or metal oxides or hydroxides, not provided for in group B01J21/00 of the iron group metals or copper combined with noble metals
- B01J23/8926—Copper and noble metals
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
- B01J37/00—Processes, in general, for preparing catalysts; Processes, in general, for activation of catalysts
- B01J37/009—Preparation by separation, e.g. by filtration, decantation, screening
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
- B01J23/00—Catalysts comprising metals or metal oxides or hydroxides, not provided for in group B01J21/00
- B01J23/38—Catalysts comprising metals or metal oxides or hydroxides, not provided for in group B01J21/00 of noble metals
- B01J23/40—Catalysts comprising metals or metal oxides or hydroxides, not provided for in group B01J21/00 of noble metals of the platinum group metals
- B01J23/42—Platinum
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
- B01J35/00—Catalysts, in general, characterised by their form or physical properties
- B01J35/20—Catalysts, in general, characterised by their form or physical properties characterised by their non-solid state
- B01J35/23—Catalysts, in general, characterised by their form or physical properties characterised by their non-solid state in a colloidal state
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
- B01J35/00—Catalysts, in general, characterised by their form or physical properties
- B01J35/40—Catalysts, in general, characterised by their form or physical properties characterised by dimensions, e.g. grain size
- B01J35/45—Nanoparticles
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
- B01J37/00—Processes, in general, for preparing catalysts; Processes, in general, for activation of catalysts
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
- B01J37/00—Processes, in general, for preparing catalysts; Processes, in general, for activation of catalysts
- B01J37/02—Impregnation, coating or precipitation
- B01J37/0201—Impregnation
- B01J37/0211—Impregnation using a colloidal suspension
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
- B01J37/00—Processes, in general, for preparing catalysts; Processes, in general, for activation of catalysts
- B01J37/32—Freeze drying, i.e. lyophilisation
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
- B01J37/00—Processes, in general, for preparing catalysts; Processes, in general, for activation of catalysts
- B01J37/34—Irradiation by, or application of, electric, magnetic or wave energy, e.g. ultrasonic waves ; Ionic sputtering; Flame or plasma spraying; Particle radiation
- B01J37/349—Irradiation by, or application of, electric, magnetic or wave energy, e.g. ultrasonic waves ; Ionic sputtering; Flame or plasma spraying; Particle radiation making use of flames, plasmas or lasers
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B28—WORKING CEMENT, CLAY, OR STONE
- B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
- B28B23/00—Arrangements specially adapted for the production of shaped articles with elements wholly or partly embedded in the moulding material; Production of reinforced objects
- B28B23/0081—Embedding aggregates to obtain particular properties
- B28B23/0087—Lightweight aggregates for making lightweight articles
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
- B32B37/14—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B7/00—Layered products characterised by the relation between layers; Layered products characterised by the relative orientation of features between layers, or by the relative values of a measurable parameter between layers, i.e. products comprising layers having different physical, chemical or physicochemical properties; Layered products characterised by the interconnection of layers
- B32B7/04—Interconnection of layers
- B32B7/12—Interconnection of layers using interposed adhesives or interposed materials with bonding properties
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B82—NANOTECHNOLOGY
- B82Y—SPECIFIC USES OR APPLICATIONS OF NANOSTRUCTURES; MEASUREMENT OR ANALYSIS OF NANOSTRUCTURES; MANUFACTURE OR TREATMENT OF NANOSTRUCTURES
- B82Y30/00—Nanotechnology for materials or surface science, e.g. nanocomposites
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B82—NANOTECHNOLOGY
- B82Y—SPECIFIC USES OR APPLICATIONS OF NANOSTRUCTURES; MEASUREMENT OR ANALYSIS OF NANOSTRUCTURES; MANUFACTURE OR TREATMENT OF NANOSTRUCTURES
- B82Y40/00—Manufacture or treatment of nanostructures
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- C—CHEMISTRY; METALLURGY
- C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
- C23C4/00—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge
- C23C4/12—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge characterised by the method of spraying
- C23C4/134—Plasma spraying
Definitions
- the present invention relates to the field of catalysts. More specifically, the present invention relates to methods of pinning and affixing nano-active material to a nano-support.
- Catalysts are used to facilitate and speed up a reaction. For example, using well- known methods of wet chemistry to form a catalyst, extrudates are placed in
- an extrudate is a cylindrical pellet made by an extrusion process.
- An example of an extrudate 100 is shown in FIG. 1A.
- the extrudate 100 is made of or is coated with alumina (A1 2 0 3 ) and thus has available oxygen (O) atoms 105 on its surface.
- the platinum (Pt) atoms 115 of the hexachlorplatinic acid 110 are chemically absorbed onto the surface of the alumina. In particular, drying and calcining, such as in an oven, allows the platinum atoms 115 to bond to the oxygen atoms 105, with HCl molecules as byproduct.
- the platinum atoms 115 are not fixed to their bonded oxygen atoms 105 and are able to move around to other available oxygen atoms 105 as illustrated in FIGS. 1C-1D. As the platinum atoms 115 move, the platinum atoms 115 begin to coalesce with other platinum atoms resulting in larger particles 120, as shown in FIG. IE, and a more energetically favorable state. It is understood that as the platinum particles become larger, it detrimentally affects the ability of the material to act as a catalyst. In high temperature applications, such as in an aged catalytic converting testing, the movement of platinum atoms is magnified. What is needed is an interface and method to prevent the platinum atoms from coalescing.
- an interface for pinning a nano-active material to a nano-support includes a compound configured to limit movement of the nano-active material on a surface of the nano-support.
- the compound is formed by a reaction of the nano-active material and the surface of the nano-support.
- the nano-active material is platinum and the nano-support is alumina.
- the nano-support comprises a partially reduced alumina surface.
- the compound is a platinum alumina metallic compound.
- the compound is a platinum copper intermetallic compound.
- a pinning method to affix nano-active materials to nano-supports uses a high temperature condensation technology.
- the high temperature condensation technology is eBeam, microwave, RF or DC plasma.
- the nano-active materials and the nano- supports are gathered.
- starting materials including a quantity of catalyst material and a quantity of carrier material, are loaded into a chamber.
- the quantity of catalyst material and the quantity of carrier material are vaporized to create the nano-active materials and the nano-supports.
- working gas is supplied to the chamber and energy is delivered to the working gas to form a highly reactive and energetic mixture such that the quantity of catalyst material and the quantity of carrier material are vaporized.
- a quantity of copper is also loaded into the chamber to be vaporized.
- each of the plurality of nano-active materials is platinum. In some embodiments,
- each of the plurality of nano-supports is alumina. In some embodiments, each of the plurality of nano-supports comprises a partially reduce alumina surface. In other embodiments, the interface includes a platinum alumina metallic compound or a platinum copper intermetallic compound.
- FIGS. 1 A- IE illustrate a wet catalyst and its properties in the prior art.
- FIG. 2 illustrates a process 200 of pinning and affixing nano-active material to nano- support in accordance with the present invention.
- FIGS. 3A-3B illustrate a nanoparticle in accordance with the present invention.
- FIG.4 illustrates a graph of difference of activity of fresh and aged plasma catalysts versus a ratio of copper to platinum in the plasma catalyst.
- Embodiments of the present invention are directed to pinning and affixing nano-active material to nano-support using a high temperature condensation technology.
- the high temperature condensation technology is plasma.
- temperature condensation technology can be eBeam, microwave, RF or DC plasma, or any other high temperature condensation technology are possible.
- Plasma catalyst formed by using the methods described below advantageously has an interface between a nano-active material and a support. As explained in more detail below, the interface dramatically reduces the ability for the nano-active material to move around on the surface of the support, thereby prevent, or at least minimizing, agglomerations of the nano-active material.
- Fig. 2 illustrates a process 200 of pinning and affixing nano-active material to nano- support in accordance with an embodiment of the present invention.
- starting materials are introduced into a plasma gun.
- a quantity of a catalyst material 212 is loaded into a plasma gun 215.
- the catalyst material 212 comprises platinum (Pt), which has excellent catalytic properties.
- a quantity of carrier material 214 is also loaded into the plasma gun 215.
- the carrier material 214 is an oxide such as alumina (A1 2 0 3 ). Other useful oxides will be apparent to those of ordinary skill.
- the catalyst material 212 and the carrier material 214 are loaded manually into a hopper (not shown), which automatically loads the materials into the plasma gun 215.
- an automated system is able to load the catalyst material 212 and carrier material 214 into the plasma gun 215.
- the starting materials are in powder form when they are loaded into the plasma gun 215.
- the starting materials are loaded into the plasma gun 215 in other forms (e.g., wire, liquid and gas) are contemplated.
- the ratio of the catalyst material 212 to the carrier material 214 can be adjusted to meet particular demands of a given application. Typically, the quantity of the carrier material 214 is much greater than the quantity of the catalyst material 212.
- the resulting vapor cloud 225 is then put through a quenching step 230.
- the quenching step occurs in a highly turbulent quench chamber to facilitate rapid, even, consistent quenching of the vapor 225 into precipitate nanoparticles 300.
- the catalyst material 212 and carrier material 214 solidify into
- nanoparticles 300 are shown in FIG. 3 A.
- the nanoparticle 300 comprises a nano-active material 320 and a nano-support 310.
- the nano-active material 320 is a gaseous platinum atom
- the nano-support 310 is some form of alumina, such as aluminum (Al) plus oxygen (O).
- the vaporizing and quenching is performed in reducing conditions using plasma from argon H 2 .
- the catalyst material 212 starts to cool down to form nano-active material 320 during quenching.
- the carrier material 214 forms into a nano-support 310 with a partially reduced alumina surface, resulting in a more metallic and less oxygen-rich surface.
- the partially reduced alumina is of A1 2 0 3 .
- X wherein x is an integer that ranges from zero to three.
- the ratio of the nano-active materials 320 and the nano-supports 310 is determined by the ratio of the starting quantities of the catalyst material 212 and carrier material 214 in step 210 of FIG. 2. As such, there are many more nano-supports 310 than there are nano-active materials 320. Although nano-active materials 320 are able to collide with other nano-active materials 320, the chances are greater that the nano-supports 310 collide with other nano-supports 310. The next most likely occurrence are the nano-active materials 320 colliding with the nano-supports 310, resulting in nanoparticles 300.
- FIG. 3B illustrates a cross-sectional view of the nanoparticle 300. Since the surface of the nano-support 310 is partially reduced alumina, the nano-active material 320 reacts with the aluminum metal (more so than with the aluminum oxide). As such, when a nano-active material 320 attaches to the surface 315 of a nano-support 310, an interface 325 is formed by the reaction of the nano-active material 320 and the partially reduced alumina. In some embodiments, the interface 325 thereby comprises a platinum alumina metallic compound (Pt a Al b ). The platinum alumina metallic compound changes dramatically the ability for the nano-active material 320 to move around on the surface 315 of the nano-support 310.
- a platinum alumina metallic compound changes dramatically the ability for the nano-active material 320 to move around on the surface 315 of the nano-support 310.
- coalescing/conglomeration is of great benefit in high temperature applications such as in an aged catalytic converting testing.
- the effectiveness and activity of the plasma catalyst is further improved by adding a quantity of copper (Cu) into the plasma gun 215 along with the other starting materials 212, 214.
- FIG.4 illustrates a graph of difference of activity of fresh and aged plasma catalysts versus a ratio of copper to platinum in the plasma catalyst. With a certain copper to platinum ratio, typically 0.4, in the plasma catalyst, an increase in conglomeration is even lower, typically equivalent to only a 1°C to 5°C raise in the wet catalysts.
- the interface between the nano-active material 320 and the surface 315 of the nano-support 310 comprises a platinum copper intermetallic compound (IMC), which consequently provides a better bond than an interface containing a platinum alumina metallic compound since the tendency of platinum atoms to skip over to an available oxygen atom is further reduced.
- IMC platinum copper intermetallic compound
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Priority Applications (9)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| BR112012014464A BR112012014464A2 (pt) | 2009-12-15 | 2010-12-09 | imobilização e afixação de material nanoativo |
| MX2012006990A MX2012006990A (es) | 2009-12-15 | 2010-12-09 | Sujecion y fijacion de nano-material activo. |
| RU2012129996/04A RU2579144C2 (ru) | 2009-12-15 | 2010-12-09 | Нанесение и закрепление наноактивного материала |
| CA2784523A CA2784523A1 (en) | 2009-12-15 | 2010-12-09 | Pinning and affixing nano-active material |
| CN201080063592.1A CN102812536B (zh) | 2009-12-15 | 2010-12-09 | 固定和附加纳米活性材料 |
| EP10841474.9A EP2513951A4 (en) | 2009-12-15 | 2010-12-09 | MOUNTING AND ANCHORING A NANOACTIVE MATERIAL |
| JP2012544652A JP2013513484A (ja) | 2009-12-15 | 2010-12-09 | ナノ活性材料のピンニングおよび付着 |
| AU2010337189A AU2010337189B2 (en) | 2009-12-15 | 2010-12-09 | Pinning and affixing nano-active material |
| IL220390A IL220390A (en) | 2009-12-15 | 2012-06-13 | Nano-active material for attachment and methods for attaching it |
Applications Claiming Priority (4)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| US28432909P | 2009-12-15 | 2009-12-15 | |
| US61/284,329 | 2009-12-15 | ||
| US12/962,473 US8652992B2 (en) | 2009-12-15 | 2010-12-07 | Pinning and affixing nano-active material |
| US12/962,473 | 2010-12-07 |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| WO2011081834A1 true WO2011081834A1 (en) | 2011-07-07 |
Family
ID=51359824
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| PCT/US2010/059763 Ceased WO2011081834A1 (en) | 2009-12-15 | 2010-12-09 | Pinning and affixing nano-active material |
Country Status (12)
| Country | Link |
|---|---|
| US (2) | US8652992B2 (enExample) |
| EP (1) | EP2513951A4 (enExample) |
| JP (2) | JP2013513484A (enExample) |
| KR (1) | KR20120112565A (enExample) |
| CN (1) | CN102812536B (enExample) |
| AU (1) | AU2010337189B2 (enExample) |
| BR (1) | BR112012014464A2 (enExample) |
| CA (1) | CA2784523A1 (enExample) |
| IL (1) | IL220390A (enExample) |
| MX (1) | MX2012006990A (enExample) |
| RU (2) | RU2567859C2 (enExample) |
| WO (1) | WO2011081834A1 (enExample) |
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| WO2014081826A2 (en) | 2012-11-21 | 2014-05-30 | SDCmaterials, Inc. | Three-way catalytic converter using nanoparticles |
| WO2014138254A1 (en) | 2013-03-06 | 2014-09-12 | SDCmaterials, Inc. | Particle-based systems for removal of pollutants from gases and liquids |
| EP2512665A4 (en) * | 2009-12-15 | 2015-09-30 | Sdcmaterials Inc | HIGH-ENGINEERED CATALYSTS FOR CAR APPLICATIONS |
| US9302260B2 (en) | 2007-10-15 | 2016-04-05 | SDCmaterials, Inc. | Method and system for forming plug and play metal catalysts |
| US9308524B2 (en) | 2009-12-15 | 2016-04-12 | SDCmaterials, Inc. | Advanced catalysts for automotive applications |
| US9332636B2 (en) | 2009-12-15 | 2016-05-03 | SDCmaterials, Inc. | Sandwich of impact resistant material |
| JPWO2014030369A1 (ja) * | 2012-08-22 | 2016-07-28 | 日本エクス・クロン株式会社 | 超音速気流によるアルミナ、マグネシアの還元方法 |
| US9427732B2 (en) | 2013-10-22 | 2016-08-30 | SDCmaterials, Inc. | Catalyst design for heavy-duty diesel combustion engines |
| US9433938B2 (en) | 2011-02-23 | 2016-09-06 | SDCmaterials, Inc. | Wet chemical and plasma methods of forming stable PTPD catalysts |
| US9498751B2 (en) | 2011-08-19 | 2016-11-22 | SDCmaterials, Inc. | Coated substrates for use in catalysis and catalytic converters and methods of coating substrates with washcoat compositions |
| US9511352B2 (en) | 2012-11-21 | 2016-12-06 | SDCmaterials, Inc. | Three-way catalytic converter using nanoparticles |
| US9517448B2 (en) | 2013-10-22 | 2016-12-13 | SDCmaterials, Inc. | Compositions of lean NOx trap (LNT) systems and methods of making and using same |
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Also Published As
| Publication number | Publication date |
|---|---|
| EP2513951A1 (en) | 2012-10-24 |
| JP2016196005A (ja) | 2016-11-24 |
| MX2012006990A (es) | 2012-10-15 |
| JP2013513484A (ja) | 2013-04-22 |
| IL220390A (en) | 2016-04-21 |
| CN102812536B (zh) | 2016-04-20 |
| AU2010337189A1 (en) | 2012-07-26 |
| RU2012129996A (ru) | 2014-01-27 |
| US8652992B2 (en) | 2014-02-18 |
| CN102812536A (zh) | 2012-12-05 |
| US20110143915A1 (en) | 2011-06-16 |
| IL220390A0 (en) | 2012-08-30 |
| US20140128245A1 (en) | 2014-05-08 |
| US9522388B2 (en) | 2016-12-20 |
| RU2579144C2 (ru) | 2016-04-10 |
| EP2513951A4 (en) | 2013-06-05 |
| AU2010337189B2 (en) | 2015-04-23 |
| RU2012129984A (ru) | 2014-01-27 |
| CA2784523A1 (en) | 2011-07-07 |
| BR112012014464A2 (pt) | 2017-06-06 |
| KR20120112565A (ko) | 2012-10-11 |
| RU2567859C2 (ru) | 2015-11-10 |
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